GD825A 2 Workshop PDF

SEBM002308
GD825A- 2
MACHINE MODEL SERIAL No.
GD825A-2 11001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• GD825A-2 mount the S6D140-1 and S6D140E-2 engine.

For details of the engine, see the 6D140-1 and 6D140-2 Series Engine Shop Manual.
© 2011 1
All Rights Reserved 00-1
Printed in Japan 02-11(01) (8)
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary actions Mark Indication Action required
be taken to these pages according to the table below.
fi Page to be newly added Add
‡ Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGE
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
‡ 00- 1 (8) 00-24 (7) 10- 1 (2) 10-26 10-34 (2)

00- 2 (2) 00-25 (7) 10- 2 10-27 10-35 (2)
‡ 00- 2-1 (8) 00-26 (7) 10- 3 (2) 10-28 10-36 (2)
‡ 00- 2-2 (8) 00-27 (7) 10- 4 10-29 10-37 (2)
023502
‡ 00- 2-3 (8) 00-28 (7) 10- 5 10-29-1 (2) 10-39 (6)
‡ 00- 2-4 (8) 00-29 (7) 10- 6 (2) 10-29-2 (4) 10-40 (6)
fi 00- 2-5 (8) 00-30 (7) 10- 7 (2) 10-29-3 (2) 10-41 (2)
00- 3 (7) 00-31 (7) 10- 7-1 (2) 10-29-4 (2) 10-42
00- 4 (7) 00-32 (7) 10- 7-2 (2) 10-29-5 (2) 10-43
00- 5 (7) 00-33 (7) 10- 8 10-29-6 (2) 10-44 (2)
00- 6 (7) 00-34 (7) 10-10 (2) 10-29-7 (2) 10-45 (2)
00- 7 (7) 00-35 (7) 10-11 (4) 10-29-8 (2) 10-46 (2)
00- 8 (7) 00-36 (7) 10-11-1 (4) 10-29-9 (2) 10-47 (2)
00- 9 (7) 00-37 (7) 10-11-2 (2) 10-29-10 (2) 10-48
00-10 (7) 00-38 (7) 10-12 (6) 10-29-11 (2) 10-49
00-11 (7) 00-39 (7) 10-13 (4) 10-29-12 (2) 10-50
00-12 (7) 00-40 (7) 10-14 (6) 10-29-13 (2) 10-51 (2)
00-13 (7) 00-41 (7) 10-15 (4) 10-29-14 (2) 10-51-1 (4)
00-14 (7) 10-16 (2) 10-30 (2) 10-51-2 (6)
00-15 (7) 01- 1 (2) 10-17 10-31 (2) 10-51-3 (6)
00-16 (7) 01- 2 (2) 10-18 10-31-1 (2) 10-52 (2)
00-17 (7) 01- 3 (2) 10-19 10-31-2 (2) 10-52-1 (2)
00-18 (7) 01- 4 (2) 10-20 10-31-3 (4) 10-53
00-19 (7) 01- 5 (2) 10-21 10-31-4 (2) 10-54
00-20 (7) 01- 6 (2) 10-22 10-31-5 (4) 10-55
00-21 (7) 01- 7 (2) 10-23 10-31-6 (4) 10-57 (2)
00-22 (7) 01- 8 (2) 10-24 10-32 10-58
00-23 (7) 01- 9 (2) 10-25 10-33 10-59 (2)
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10-60 10-85 10-115 (2) 10-146-9 (6) 20- 4 (3)

10-61 10-86 10-116 (2) 10-146-11 (6) 20- 5 (3)
10-62 (4) 10-87 10-117 (2) 10-147 (2) 20- 6 (3)
10-63 (4) 10-88 10-118 (2) 10-148 (2) 20- 7 (3)
10-64 10-89 (2) 10-119 (2) 10-149 (2) 20- 7-1 (3)
10-65 10-90 10-120 (6) 10-150 (2) 20- 8 (5)
10-66 10-91 10-120-1 (6) 10-151 (2) 20- 9 (5)
10-67 10-92 10-120-2 (6) 10-152 (2) 20-10 (2)
10-68 10-93 10-120-3 (6) 10-153 (4) 20-11 (2)
10-69 10-94 10-120-4 (6) 10-154 (2) 20-12 (2)
10-70 10-95 10-121 (6) 10-155 (2) 20-13 (2)
10-71 10-96 (2) 10-122 (6) 10-155-1 (4) 20-13-1 (2)
10-72 10-97 (2) 10-123 (6) 10-155-2 (4) 20-14
10-73 10-97-1 (2) 10-123-1 (6) 10-155-3 (4) 20-15 (5)
10-74 10-97-2 (2) 10-124 (2) 10-156 (6) 20-16
10-75 (2) 10-98 (2) 10-125 (2) 10-156-1 (6) 20-17
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10-76 (2) 10-99 10-126 (2) 10-157 (2) 20-18
10-77 (2) 10-100 10-128 (2) 10-158 (2) 20-19 (2)
10-78 (2) 10-100-1 (2) 10-129 (2) 10-159 (2) 20-19-1 (2)
10-79 (2) 10-100-2 (2) 10-130 (2) 10-160 (2) 20-20
10-79-1 (2) 10-100-3 (2) 10-131 (2) 10-161 (2) 20-21
10-79-2 (2) 10-100-4 (2) 10-132 (2) 10-162 (2) 20-22 (2)
10-79-3 (2) 10-101 (2) 10-134 (4) 10-163 (2) 20-23 (5)
10-79-4 (2) 10-102 10-135 (4) 10-164 (2) 20-23-1 (5)
10-80 (2) 10-103 10-136 (6) 10-165 (2) 20-24 (5)
10-80-2 (2) 10-104 10-136-1 (6) 10-166 (4) 20-25
10-80-3 (2) 10-105 (2) 10-137 (2) 10-166-1 (6) 20-26
10-80-4 (2) 10-106 (2) 10-138 (2) 10-166-2 (6) 20-27 (6)
10-80-6 (2) 10-107 10-140 (4) 10-167 (2) 20-28 (6)
10-80-7 (2) 10-108 (2) 10-141 (2) 10-168 (2) 20-29
10-80-8 (2) 10-109 (2) 10-141-2 (6) 10-169 (2) 20-30
10-80-10 (2) 10-110 (2) 10-142 (4) 10-170 (4) 20-31 (5)
10-80-11 (2) 10-111 (2) 10-142-1 (6) 10-171 (6) 20-32
10-80-12 (2) 10-112 (2) 10-143 (6) 10-172 (6) 20-33
10-81-1 (1) 10-113 (2) 10-144 (6) 10-173 (6) 20-34 (2)
10-81-2 (1) 10-113-1 (2) 10-145 (2) 20-35
10-81-3 (1) 10-113-2 (2) 10-146-1 (6) 20- 1 20-36 (2)
10-82 (2) 10-113-3 (2) 10-146-3 (6) 20- 2 20-37 (2)
10-83 10-113-4 (2) 10-146-5 (6) 20- 3 (2) 20-38 (2)
10-84 10-114 10-146-7 (6) 20- 3-1 (3) 20-39 (2)
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20-40 (2) 20-60-57 (6) 20-60-98 (7) 20-90-1 (4) 20-159 (2)
20-41 (6) 20-60-59 (6) 20-60-99 (7) 20-91 20-160 (2)
20-42 (2) 20-60-60 (6) 20-60-100 (7) 20-92 (4) 20-161 (2)
20-43 (2) 20-60-61 (6) 20-60-101 (7) 20-92-1 (4) 20-162 (2)
20-45 (5) 20-60-62 (6) 20-60-102 (5) 20-93 20-163 (2)
20-46 (2) 20-60-63 (7) 20-60-103 (5) 20-94 20-164 (2)
20-47 (2) 20-60-64 (7) 20-60-104 (5) 20-95 20-165 (2)
20-48 (5) 20-60-65 (7) 20-60-105 (5) 20-96 20-166 (2)
20-49 (5) 20-60-66 (7) 20-60-106 (5) 20-97 20-167 (2)
20-50 (5) 20-60-67 (7) 20-60-107 (5) 20-98 20-168 (2)
20-51 (5) 20-60-68 (7) 20-61 (2) 20-99 (4) 20-169 (2)
20-52 (5) 20-60-69 (7) 20-62 20-101 (2) 20-170 (2)
20-53 (5) 20-60-70 (7) 20-63 20-102 (2) 20-171 (2)
20-54 (5) 20-60-71 (7) 20-64 20-103 (2) 20-172 (2)
20-55 (5) 20-60-72 (7) 20-65 20-104 (2) 20-173 (4)
20-55-1 (5) 20-60-73 (7) 20-66 20-105 (4) 20-174 (4)
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20-56 (2) 20-60-74 (7) 20-67 20-105-1 (4) 20-175 (4)

20-57 (2) 20-60-75 (7) 20-68 20-106 (2) 20-175-1 (4)
20-58 (4) 20-60-76 (7) 20-69 20-107 (4) 20-176 (2)
20-59 (2) 20-60-77 (7) 20-70 20-108 (4) 20-177 (4)
20-59-1 (4) 20-60-78 (7) 20-71 20-109 (2) 20-178 (4)
20-59-2 (4) 20-60-79 (7) 20-72 20-110 (4) 20-179 (4)
20-60 (2) 20-60-80 (7) 20-73 20-110-1 (4) 20-180 (4)
20-60-1 (2) 20-60-81 (7) 20-74 20-111 (2) 20-181 (4)
20-60-2 (2) 20-60-82 (7) 20-75 20-112 (4) 20-182 (4)
20-60-3 (2) 20-60-83 (7) 20-76 20-112-1 (4) 20-183 (4)
20-60-4 (4) 20-60-84 (7) 20-77 20-113 (2) 20-184 (4)
20-60-5 (2) 20-60-85 (7) 20-78 20-114 (2) 20-185 (4)
20-60-6 (2) 20-60-86 (7) 20-79 20-115 (2) 20-186 (4)
20-60-8 (4) 20-60-87 (7) 20-81 (2) 20-116 (2) 20-187 (4)
20-60-9 (4) 20-60-88 (7) 20-82 ‡ 20-151 (8) 20-188 (4)
20-60-10 (4) 20-60-89 (7) 20-83 ‡ 20-152 (8) 20-189 (4)
20-60-49 (4) 20-60-90 (7) 20-84 20-153 (2) 20-190 (4)
20-60-50 (4) 20-60-91 (7) 20-85 (4) fi 20-153-1 (8) 20-191 (4)
20-60-51 (4) 20-60-92 (7) 20-85-1 (4) fi 20-153-2 (8) 20-192 (4)
20-60-52 (6) 20-60-93 (7) 20-86 20-154 (2) 20-193 (4)
20-60-53 (4) 20-60-94 (7) 20-87 (4) ‡ 20-155 (8) fi 20-194 (8)
20-60-54 (4) 20-60-95 (7) 20-88 20-156 (2) fi 20-195 (8)
20-60-55 (6) 20-60-96 (7) 20-89 (4) 20-157 (2) fi 20-196 (8)
20-60-56 (6) 20-60-97 (7) 20-90 (4) 20-158 (2) fi 20-197 (8)
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fi 20-198 (8) 30-19 (1) 30-50 (1) 30-90 (1) 30-129 (1)
20-201 (2) 30-20 (1) 30-51 (1) 30-91 (1) 30-130 (1)
20-202 (2) 30-21 (1) 30-52 (1) 30-92 (1) 30-131 (1)
20-204 (2) 30-22 (1) 30-53 (1) 30-93 (1) 30-132 (1)
20-205 (2) 30-23 (1) 30-54 (1) 30-94 (1) 30-133 (1)
20-206 (2) 30-24 (1) 30-55 (1) 30-95 (1) 30-134 (1)
20-207 (2) 30-25 (1) 30-56 (1) 30-96 (1) 30-135 (1)
20-208 (2) 30-26 (1) 30-57 (1) 30-97 (1) 30-136 (1)
20-209 (2) 30-27 (1) 30-58 (1) 30-98 (1) 30-137 (2)
20-210 (2) 30-28 (2) 30-59 (4) 30-99 (1) 30-138 (1)
20-211 (2) 30-28-1 (2) 30-60 (4) 30-100 (1) 30-139 (1)
20-212 (2) 30-29 (1) 30-61 (4) 30-101 (1) 30-140 (2)
30-30 (1) 30-62 (1) 30-102 (1) 30-141 (1)
30- 1 (6) 30-31 (1) 30-63 (1) 30-103 (1) 30-142 (1)
30- 1-1 (6) 30-32 (1) 30-64 (1) 30-104 (1) 30-143 (1)
30- 1-2 (7) 30-33 (1) 30-65 (1) 30-105 (1) 30-144 (1)
023502
30- 1-3 (7) 30-34 (1) 30-66 (1) 30-106 (1) 30-145 (1)
30- 1-4 (6) 30-35 (2) 30-67 (1) 30-107 (1) 30-146 (1)
30- 1-5 (6) 30-36 (1) 30-68 (1) 30-108 (1) 30-147 (1)
30- 1-6 (6) 30-37 (1) 30-69 (1) 30-109 (1) 30-148 (1)
30- 2 (6) 30-38 (1) 30-70 (1) 30-110 (1) 30-149 (1)
30- 3 (6) 30-39 (1) 30-71 (1) 30-111 (1) 30-150 (1)
30- 4 (2) 30-40 (1) 30-72 (4) 30-112 (1) 30-151 (1)
30- 4-1 (2) 30-41 (1) 30-73 (4) 30-113 (1) 30-152 (1)
30- 4-2 (2) 30-42 (1) 30-74 (4) 30-114 (1) 30-153 (1)
30- 5 (2) 30-43 (1) 30-75 (4) 30-115 (1) 30-154 (1)
30- 6 (2) 30-44 (1) 30-76 (1) 30-116 (1) 30-155 (1)
30- 7 (2) 30-45 (1) 30-77 (1) 30-117 (1) 30-156 (1)
30- 8 (1) 30-45-1 (2) 30-78 (1) 30-118 (1) 30-157 (1)
30- 9 (1) 30-45-2 (2) 30-79 (4) 30-119 (1) 30-158 (1)
30-10 (1) 30-45-3 (2) 30-80 (1) 30-120 (1) 30-159 (1)
30-11 (1) 30-45-4 (2) 30-81 (1) 30-121 (1) 30-160 (1)
30-12 (1) 30-45-5 (2) 30-82 (1) 30-122 (6) 30-161 (1)
30-13 (1) 30-45-6 (2) 30-83 (1) 30-123 (6) 30-162 (1)
30-14 (1) 30-45-7 (2) 30-84 (1) 30-124 (6) 30-163 (1)
30-15 (1) 30-45-8 (2) 30-85 (1) 30-124-1 (6) 30-164 (1)
30-16 (1) 30-46 (1) 30-86 (1) 30-125 (1) 30-165 (1)
30-17 (1) 30-47 (1) 30-87 (1) 30-126 (1) 30-166 (1)
30-18 (2) 30-48 (1) 30-88 (1) 30-127 (1) 30-167 (1)
30-18-1 (2) 30-49 (1) 30-89 (1) 30-128 (1) 30-168 (1)
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30-169 (1) 30-199 (1) 30-220 (1) 40- 5 (6)

30-170 (1) 30-200 (1) 30-221 (2) 40- 6
30-171 (1) 30-201 (6) 30-222 (2) 40- 7 (4)
30-172 (1) 30-202 (6) 30-223 (2) 40- 8 (2)
30-173 (1) 30-203 (6) 30-223-1 (2) 40- 9
30-174 (1) 30-204 (6) 30-223-2 (2) 40- 9-1 (2)
30-175 (1) 30-205 (6) 30-223-3 (2) 40- 9-2 (2)
30-176 (1) 30-205-1 (6) 30-223-4 (6) 40-10 (2)
30-177 (1) 30-205-2 (6) 30-223-5 (2) 40-10-1 (2)
30-178 (1) 30-205-3 (6) 30-224 (2) 40-11
30-179 (2) 30-205-4 (6) 30-225 (1) 40-12 (2)
30-180 (1) 30-205-5 (6) 30-226 (1) 40-13 (6)
30-181 (1) 30-205-6 (6) 30-227 (1) 40-14 (4)
30-182 (1) 30-205-7 (6) 30-228 (1) 40-15
30-183 (1) 30-205-8 (6) 30-229 (2) 40-15-1 (6)
30-184 (1) 30-206 (2) 30-230 (2) 40-15-2 (6)
30-185 (1) 30-207 (2) 30-231 (2) 40-16
023502
30-186 (2) 30-207-1 (2) 30-232 (2) 40-17

30-187 (1) 30-207-2 (2) 30-233 (2) 40-18
30-188 (1) 30-208 (2) 30-234 (2) 40-19 (2)
30-189 (2) 30-209 (1) 30-235 (2) 40-20 (2)
30-190 (1) 30-210 (1) 30-236 (2) 40-21 (2)
30-191 (1) 30-211 (2) 30-237 (2) 40-21-1 (2)
30-192 (1) 30-212 (2) 30-238 (6) 40-21-2 (2)
30-193 (1) 30-213 (2) 30-239 (5) 40-22 (2)
30-194 (1) 30-214 (2) 30-240 (5) 40-23 (2)
30-194-1 (2) 30-214-1 (6) 30-241 (6) 40-23-1 (2)
30-194-2 (2) 30-214-2 (2) 30-242 (6) 40-23-2 (2)
30-194-3 (2) 30-214-3 (2) 30-243 (6) 40-24 (2)
30-194-4 (2) 30-214-4 (2) 30-244 (6) 40-26 (2)
30-194-5 (2) 30-214-5 (2) 30-245 (6) 40-27 (2)
30-194-6 (2) 30-214-6 (2) 30-246 (6) 40-27-1 (2)
30-194-7 (2) 30-214-7 (2) 30-247 (6) 40-27-2 (2)
30-194-8 (2) 30-214-8 (2) 40-28 (2)
30-194-9 (2) 30-215 (2) 40- 1 (2) 40-29 (2)
30-194-10 (2) 30-215-1 (2) 40- 2 (4) 40-29-1 (2)
30-195 (1) 30-216 (2) 40- 3 40-29-2 (2)
30-196 (1) 30-217 (2) 40- 3-1 (4) 40-30 (2)
30-197 (1) 30-218 (1) 40- 3-2 (6) 40-31 (6)
30-198 (1) 30-219 (2) 40- 4 (4)
00-2-5
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Safety notice (Rev. 2008/08)1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before welding work, alw ays wear welding
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
00- 3
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2. Preparations for work 6) When removing a cover which is under
1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. larly careful to check that they are
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
00- 4
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4. Precautions for sling work and making
signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
00- 5
(7)
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
00- 6
(7)
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
00- 7
(7)
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
00- 8
(7)
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
00- 9
(7)
Explanation of terms for maintenance standard 1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
00- 10
(7)
2. Standard clearance and standard value 5. Clearance limit
q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
00- 11
(7)
Handling of electric equipment and hydraulic component 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly 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, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted 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.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
00- 12
(7)
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. 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, if water should get into
the connector, the pins will be short-
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face 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 it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
00- 13
(7)
3. Removing, installing, and drying connec-
tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. 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 connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
00- 14
(7)
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a 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.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
00- 15
(7)
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
00- 16
(7)
4) Drying wiring harness
If there is any oil or dirt on the wiring har-
ness, 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 fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a 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
o i l an d w at e r f r o m t h e c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a 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.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
00- 17
(7)
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
00- 18
(7)
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
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 check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked 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 danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
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
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
00- 19
(7)
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 equip-
ment, 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 cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
00- 20
(7)
Handling of connectors newly used for engines 1
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
00- 21
(7)
3. Push lock type
q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
00- 22
(7)
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00- 23
(7)
How to read electric wire code 1
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
00- 24
(7)
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
00- 25
(7)
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
00- 26
(7)
Precautions when carrying out operation 1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
00- 27
(7)
2. Precautions when carrying out installation work
q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a 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 idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
00- 28
(7)
4) Checking muffler and exhaust pipe for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
00- 29
(7)
Method of disassembling and connecting push-pull type coupler 1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
00- 30
(7)
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
00- 31
(7)
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
00- 32
(7)
Standard tightening torque table 1
1. Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
00- 33
(7)
2. Table of tightening torques for split flange bolts
a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00- 34
(7)
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
00- 35
(7)
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
00- 36
(7)
Conversion table 1
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 (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00- 37
(7)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
00- 38
(7)
Liters to U.K. Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00- 39
(7)
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
00- 40
(7)
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00- 41
(7)
01 GENERAL
Specification dimension drawings ............... 01-2

Specifications.. ................................................ 01-4
Weight table .................................................. 01-7
Fuel, coolant and lubricants ........................ 01-8
01-l
0
GENERAL SPECIFICATION DIMENSION DRAWINGS
SPECIFICATION DIMENSION DRAWINGS

Serial No.: 11001 - 12050 Unit: mm
-I
c
0
c
0
-
SWG00332
01-2
0
GENERAL SPECIFICATION DIMENSION DRAWINGS
Serial No.: 12051 and up Unit: mm
c
0
c
a
-
P
01-3
0
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model G D825A-2
Serial No. f 11001 - 12000 12001- 12050 12051 and up
Overall weight kg 29,680 29,680 29,680
Load on front wheel kN {kg1 78.9 {8,040) 78.9 (8,040) 78.9 (8,040)
Load on rear wheel kN (kg1 212.2 121,640) 212.2 (21,640) 212.2 (21,640)
Overall length mm 11,470 11,470 11,470
Overall width mm 3,310 3,310 3,310
Overall height (to top of cab) mm 3,550 3,550 3,550
Overall height (to tip of muffler) mm 2,605 2,605 2,605
Wheelbase mm 7,100 7,100 7,100
Distance between centers of mm 1,840 1,840 1,840

tandem wheels
Tread (front) mm 2,620 2,620 2,620
(rear) mm 2,620 2,620 2,620
Ground clearance mm 440 440 440
Forward 1st km/h 4.0 4.0 4.0

2nd km/h 5.4 5.4 5.4
3rd km/h 8.0 8.0 8.0
4th km/h 11.5 11.5 11.5
5th km/h 15.8 15.8 15.8
6th km/h 21.4 21.4 21.4
7th km/h 31.3 31.3 31.3
8th km/h 44.9 44.9 44.9
Reverse 1st km/h 4.3 4.3 4.3

2nd km/h 5.8 5.8 5.8
t
3rd km/h 8.5 8.5 8.5

4th km/h 12.2 12.2 12.2
5th km/h 16.9 16.9 16.9
6th km/h 22.8 22.8 22.8
7th km/h 33.4 33.4 33.4
8th km/h 47.9 47.9 47.9
Drawbar pull tN {kg) 169.85 {17,320) 169.85 {17,320} 169.85 (17,320)
Gradeability deg 24 24 24
Min. turning radius m 7.9 7.9 7.9
Static stability deg 35 35 35
01-4
0
Machine
Serial
model
No.
1 G D825A-2
Model 3
Type 4-cycle, water-cooled, in-line,

vertical, direct injection type,
ith turbocharger
No. of cylinders - Bore x stroke mm 6-140x165 6-140x165 6-140x 165
Piston displacement .Q{cc1 15.24 {I 5,240I 15.24 {I 5,240) 15.24 {I 5,240)
Flywheel horsepower :W/rprr 209/2,100 209/2,100 209/2,100

-iP/rpm {280/2,100) ~280/2,1001 {280/2,100)
Max. torque lm/rpn 1,255/l ,400 1,255/l ,400 1,255/l ,400
:gm/rprr {128/1,4001 {I 28/l ,400) {128/l ,400}
Low idling rpm 2,350 2,350 2,350
High idling rpm 650 650 650
Min. fuel consumption ratio g/kWh 201 208 208
g/HPhl {I501 11551 {I 551
Starting motor 24V, 11 kW
Alternator 24V, 50A
Battery 12V, 160Ahx2
Planetary gear type, power shift type,

multiple disc clutch, hydraulically
Transmission actuated, lubrication gear pump
force feed, forward 8 speeds,
reverse 8 speeds
deduction gear Spiral bevel gear and planetary gear

2-stage reduction
3ear axle Fullv floating, tandem tvoe
Tandem device Chain transmission type
U Reverse Elliott type angle

Type
3
_ Leaning Hydraulic type
z
5
2 Max. leaning angle deg 14.5 I 14.5 I 14.5
q
5 Type Fully hydraulic type (Orbit-roll)
ij
t Steering angle
z deg 50 50 50
q
ii
Max. articulating angle deg 25 25 25
Y
01-5
0
Machine model G D825A-2
Serial No. 11001 - 12000 12001- 12050 12051 and up
Size (front) 18.00-25-12PR 23.5-25-l 2PR 23.5-25-l 2PR
(rear) 18.00-25-i 2PR 23.5-25-l 2PR 23.5-25-l 2PR
Inflation pressure (front, rear kPa 240 240 240

:kg/cm? (2.45) (2.45) {2.45}
Rear 4-wheel braking

Main brake Wet type, multiple disc
Air actuated
Transmission output shaft braking

Parking brake Dry-type, disc type, spring actuated,
released bv air
Dimensions (length x height mm 4,928 x 800 4,928 x 800 4,877 x a60

(arc height) x thickness) (695) x 25 (695) x 25 (750) x 25
Dimensions of cutting edge mm 2,438 x 203 x 19 i 1,438 x 203 x 19 i !,438 x 254 x 25

- 2 pieces - 2 pieces - 2 pieces
Max. lifting height mm 490 420 450

(from ground)
Max. lowering depth mm 680 680 950

(from ground)
Max. side shift distance (left) mm 1,920 1,920 1,920
Max. side shift distance (right mm 2,070 2,070 2,070
Turning angle deg 360 360 360
Digging angle (max.) deg a4 a4 115
(min.) deg 25 25 63
Type Parallelogram type
Shank Standard 3 (possible to install 7)
Weight of ripper kN {kg1 149 {15,200) 1 149 {15,2001 / 149 {15,2001
Ripping width mm 2,978 2,978 2,978
Max. lifting height mm 675 615 615

(from ground)
Max. lowering depth mm 480 I 480

(from ground)
- Ripping angle deg 42.3 52 52
01-6
0
GENERAL WEIGHT TABLE
WEIGHT TABLE
a Thus
. weight table is for use when handling components or when transporting the machine.
Unit: kg
Machine model GD825A-2
Serial No. 11001 - 12000 12001-12050 12051 and up
Engine assembly (dry) 1,360 1,360 1,360
Radiator assembly (dry) 183 183 183
Fuel tank assembly (dry) 298 298 298
Transmission assembly (dry) 1,147 1,147 1,147
Final drive assembly 1,802 1,802 1,802
Tandem drive assembly (each) 1,242 1,242 1,242
Front axle assembly 1,024 1,024 1,085

(except leaning cylinder and steering cylinder)
Front frame assembly 2,982 2,982 2,982
Rear frame assembly 2,093 2,093 2,093
Operator’s compartment assembly

300 300 300
(incl. control)
ROPS cab assembly 1,000 1,040 1,040

(OPT, High ROPS cab assembly) 1,125 1,090 1,090
Drawbar assembly 1,160 1,160 1,320
Blade assembly 1,540 1,540 1,600
Circle rotation assembly 278 278 300
Wheel assembly 530 530 530
Power tilt cylinder assembly 83 83 83
Leaning cylinder assembly 26 26 26
Blade lift cylinder assembly 158x2 158 x 2 160 x2
Drawbar shift cylinder assembly 72 72 74
Blade shift cylinder assembly 106 106 105
Steering cylinder 15 x2 15 x 2 15 x2
Articulate cylinder 72 72 72
Ripper cylinder (dry) 130 130 130
Hydraulic tank (dry) 53 53 53
Hydraulic pump 106 106 106
Transmission pump 12 12 12
Circle rotation motor 55 55 15
Ripper assembly 2,025 2,025 2,025
01-7
0
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
Serial No.: 11001 - 12050
AMBIENT TEMPERATURE CAPACITY (J?)

UND OF
RESERVOIR -22 -4 14 32 50 68 86 104 122°F
FLUID Specified Refill
.30 -20 -10 0 10 20 30 40 50°C
Engine oil pan 34 (36)
+
Transmission case 25
Engine
Final drive case oil 63 57
Tandem case (each) 95
Front axle housing

t
Hydraulic system 80
Circle rotation gear case -

0.18
(Brake case)
Circle rotation gear case Gear
16
(Gear case) oil
Diesel
Fuel tank 500
fuel
Cooling system Coolant Add antifreeze j8 (78.5) -
z ASTM D975 No.1 ( 1: Serial No. 12001 - 12050
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than O‘C, be sure to
tenance hours described in this manual. use engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table SAE15W-40, even though an atmospheric
if fuel sulphur content is above 0.5%. temperature goes up to 10°C more or less in
the day time.
Change interval of oil in (3) Use API classification CD as engine oil and if
Fuel sulphur content API classification CC, reduce the engine oil
engine oil pan
change interval to half.
0.5 to 1.0% l/2 of regular interval
Above 1.0% l/4 of regular interval
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-8
0
GENERAL FUEL, COOLANT AND LUBRICANTS
Serial No.: 12051 and up
AMBIENT TEMPERATURE CAPACITY (k?)

<IND OF
RESERVOIR -22 -4 14 32 50 68 86 104 122°F
FLUID Specifiec Refill
Engine oil pan 40 36
Transmission case 35 25
Engine
Final drive case oil 63 57
c
Tandem case (each) 120 95
Front axle housing 0.9

L
Hydraulic system 140 80
+ +
Circle rotation gear cast Gear
10 8
l Brake case oil
Fuel tank
Cooling system
Diesel
fuel
Coolant Add antifreeze 1

I 500
78.5
t
L
s ASTM D975 No.1
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than OX, be sure to
tenance hours described in this manual. use engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table SAE15W-40, even though an atmospheric
if fuel sulphur content is above 0.5%. temperature goes up to 10°C more or less in
the day time.
Change interval of oil in (3) Use API classification CD as engine oil and if
Fuel sulphur content API classification CC, reduce the engine oil
engine oil pan
change interval to half.
)
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
10 STRUCTURE AND FUNCTION
General .......................................................... IO- 2 Parking brake system ................................ IO- 72

Power train diagram .................................... IO- 3 Parking brake solenoid valve.. .................. IO- 72
Joint ............................................................... IO- 4 Exhaust valve ............................................. IO- 74
HYDROSHIFT transmission and transfer Spring cylinder ........................................... IO- 75
piping ...................................................... IO- 5 Hydraulic control piping ............................ IO- 76
Hydraulic circuit for power train ................ IO- 6 Hydraulic circuit system ............................ IO- 80
Hydraulic circuit diagram for Hydraulic circuit diagram ........................ 10-80-2
power train ............................................. IO- 7 Closed center load sensing system
PTO (Power Take Off) .................................. IO- 8 (CLSS) .................................................. 10-81-I
HYDROSHIFT transmission and Hydraulic pump.. ........................................ IO- 82
transfer .................................................... IO-I 0 Priority flow divider valve ......................... IO- 87
Transmission control valve ......................... IO-16 Surge pressure absorbing valve .............. IO- 93
Transmission control ................................... 1O-30 Hydraulic control valve.. ............................ IO- 96
inching control ............................................. IO-32 Pressure compensating mechanism
Drive shaft ....................................................
. 1o-33 of hydraulic control valve ................... IO- 98
Final drive, differential lock and Blade lift speed adjustment
unlock piping.. ........................................ IO-34 mechanism ........................................ 10-100-4
Final drive ..................................................... 1O-36 Pilot check valve ......................................... IO-102
Tandem drive ............................................... 1o-39 Pilot check valve (with safety valve). ..... ..lO-10 4
Steering piping ............................................. IO-41 Circle rotation motor ................................. IO-106
Steering circuit system ................................ IO-42 Blade accumulator system ........................ IO-109
Steering circuit diagram.. ............................ 1o-43 Blade float system ..................................... IO-I 11
Steering valve.. ............................................. IO-44 Drawbar and lifter ...................................... IO-I 12
Double relief valve ....................................... 1O-48 Blade ......................................................... 1 O-l 13-3
Check valve.. ................................................. IO-49 Lifter bracket control piping.. .................... IO-I 14
Emergency steering system ........................ IO-50 Circle rotation gear .................................... IO-I 15
Front axle ...................................................... IO-51 Rear mount ripper ...................................... IO-I 17
Wheel ............................................................ 1O-52 Hydraulic control linkage .......................... IO-I 18
Disc brake ..................................................... IO-53 Main frame ................................................. IO-120
Parking brake.. .............................................. 1o-55 Air conditioner ......................................... 10-120-1
Brake air piping ............................................ 1 O-56 Electrical wiring diagram .......................... IO-121
Brake air circuit system ............................... 1O-58 Monitor panel, cluster gauge and
Brake air circuit diagram ............................. 1o-59 pilot lamp ............................................. IO-125
Air drier ......................................................... 1O-60 Electrical circuit diagram ........................... IO-128
Air governor ................................................. 1 O-62 Electronic vehicle monitoring system
Air tank .......................................................... 1 O-64 (EVMS) .................................................. IO-147
Safety valve .................................................. 1O-64 Transmission control system .................... IO-153
Automatic drain valve ............................... IO- 65 Sensors ....................................................... IO-156
Check valve.. ............................................... IO- 67 Engine starting circuit ................................ IO-162
Brake valve ................................................. IO- 68 Engine stopping circuit .............................. IO-168
10-l
0
GENERAL
4 5 El
F23507003
The power produced by diesel engine (I) goes to HY- 1. Engine

DROSHIFT transmission (3) through joint (2). 2. Joint
Transmission (31, with a planetary gear mechanism 3. HYDROSHIFT transmission
and a hydraulic control unit combined, allows an easy 4. Drive shaft
selection of eight forward speeds and eight reverse 5. Final drive
speeds. Through drive shaft (41, the power is trans- 6. Tandem drive
mitted from the transmission to the final drive (5).
Here, final drive (5) directs the power to the right and
left, and the power is transmitted to the left and right
tandem drives (6).
Tandem drive (6) transmits the power to the wheel
by a chain and the machine travels.
1o-2
POWER TRAIN DIAGRAM
F23501004
1. Engine
2. Joint
3. PTO (Power Take Off)
4. HYDROSHIFT transmission
5. Transfer
6. Parking brake
7. Drive shaft
8. Final drive
9. Tandem drive
10. Tire
P, Hydraulic pump
P, Transmission pump
P, Differential lock pump
1o-3
0
JOINT
Engine
f
-..
T
---2
13
F23501007
1. Engine flywheel
2. Plate
3. Tube
4. PTO input shaft
1o-4
c----q r-n
I YI
_-_--_$ 2 r-.
- - _.- - __i--i_~.-=&
f /l- - - *_-,-y_
1. Transfer
2. HYDROSHIFT transmission
3. Transmission control valve
4. Transmission filter
5. Transmission pump
6. Engine
7. Radiator
8. Oil cooler
. The oil in transmission (2) is sucked by trans-

mission pump (5) through the strainer.
. The oil from transmission pump (5) flows to trans-
mission filter (4), and transmission control valve
235CD02001 (3).
Then the oil flows to oil cooler (8) in radiator (7) to
be cooled and to the transmission to lubricate it.
1o-5
HYDRAULIC CIRCUIT FOR POWER TRAIN
Engine running, gear shift lever in NEUTRAL
Serial No.: 11001 - 12012, 12016 - 12018
R F 4th 3rd 2nd 1st L H
235FO2001
1O-6
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN

Serial No.: 11001 - 12012, 12016 - 12018
0. 29-3 04HPa
13-3lks/cm'l
t----t-------
6
4th
1. OGMPa 3rd
(10. Bka/cm'i
II
I
!________
i
)I(
LL
0 29HPa
_ ,;!
1. Transmission case 9. Pilot reducing valve 17. 3rd clutch spool

2. Strainer 10. Transmission lubrication relief valve 18. 2nd clutch spool
3. Transmission pump 11. Oil cooler 19. 1st clutch spool
4. Transmission filter 12. Transmission lubrication 20. High clutch spool
5. Priority valve 13. Oil cooler bypass valve 21. Low clutch spool
6. Modulating valve 14. Inching valve 22. Emergency spool
7. Quick return valve 15. F-R clutch spool 23. Solenoid valve
8. Pilot oil filter 16. 4th clutch spool
1o-7
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT FOR POWER TRAIN

Engine running, gear shift lever in NEUTRAL
Serial No.: 12013 - 12015, 12019 and up
SWG00336
1o-7- 1
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN

Serial No.: 12013 - 12015, 12019 and up
0.29-3.04HPa
13-3lka/cm'l
1 47HPa
&
il5ks/cm'l
L--J t--j
I.OGMPa
(IO Bkefcm'l
-___p~-~-~-----------__
9 I--_-dI II
)I(
LL
0 49MPa
15ks/cm'l
SWG00335
1. Transmission case 9. Pilot reducing valve 17. 3rd clutch spool

2. Strainer 10. Transmission lubrication relief valve 18. 2nd clutch spool
3. Transmission pump 11. Oil cooler 19. 1st clutch spool
4. Transmission filter 12. Transmission lubrication 20. High clutch spool
5. Priority valve 13. Oil cooler bypass valve 21. Low clutch spool
6. Modulating valve 14. Inching valve 22. Emergency spool
7. Quick return valve 15. F-R clutch spool 23. Solenoid valve
8. Pilot oil filter 16. 4th clutch spool
10-7-2
0
PTO (Power Take Off)
2
B-B
235FO2003
1, 1. Input shaft
2. Idler gear
3. Pump drive gear
4. Transmission pump
A-A F2350 1008-2
1 O-8
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION AND TRANSFER
HYDROSHIFT TRANSMISSION AND TRANSFER

Serial No.: 11001 - 12012,12016 - 112018
B-B
A-A
c-c
235FO2004
2
l The oil in the transmission is sucked by the trans- 1. Breather

mission pump through strainer (3). 2. Transmission control valve
The oil from the transmission pump flows to the 3. Strainer
transmission filter, and transmission control valve 4. Drain plug
(2).
10-10
0
023502
10-12
(6)
023502
10-14
(6)
TRANSMISSION CONTROL VALVE
Serial No.:11001 - 12012,12016-12018
235coo2039
1. Connector A. Inching pressure pick-up

2. Lower valve B. Main pressure pick-up
3. Upper valve C. Priority pressure pick-up
D. Oil cooler bypass pressure pick-up
E. Lubricating pressure pick-up
10-16
0
UPPER VALVE
r-71 -iid
1. Housing
2. Inching valve
3. . huick return valve
4. Modulating valve
235CDO2040
5. Priority valve \
1 4
6. Oil cooler bypass valve Y-Y
OUTLINE
l The oil from the transmission pump enters port A, l The other oil line flows to modulating valve (4)
and passes through priority valve (5). It is then and quick return valve (3). The action of modulat-
divided into two lines: one to the clutch pistons, ing valve (4) and quick return valve (3) raises the
and the other to pilot reducing valve (12). Priority clutch pressure smoothly. This reduces the shock
valve (5) acts to control the two lines so that pilot when actuating the FORWARD, REVERSE and Ist,
reducing valve (12) is the priority circuit. 2nd, 3rd, 4th, High and Low speed clutches to
l The oil flowing to pilot reducing valve (12) con- change gear.
trols the pilot pressure used to actuate the direc- . Lubrication valve (14) controls the lubrication oil
tional and speed spools. The oil regulated by pilot inside the transmission.
reducing valve (12) presses through the orifice in
each spool and fills the spool.
10-17
LOWER VALVE
235CD02041
7. High clutch spool

8. 2nd spool
9. Low clutch spool
10. 4th spool
11. 1st spool
12. Pilot reducing valve
13. F-R spool
14. Lubrication valve
15. 3rd wool
lo-18
SOLENOID VALVE
\ I I
6 7 8 9
\
1‘1 Section X-X
10
F23501302
STRUCTURE 1. Valve body

l The transmission solenoid valve is installed to 2. 2nd solenoid valve
the transmission together with the transmission 3. 4th solenoid valve
control valve. When the gear shift lever is operat- 4. 1 st solenoid valve
ed, the solenoid valve is actuated and moves the 5. L solenoid valve
spool inside the transmission valve. 6. H solenoid valve
7. 3rd solenoid valve
8. F solenoid valve
9. R solenoid valve
10. Emergency manual spool
1 1. Connector
10-19
PRIORITY VALVE
Function
. Priority valve (1) ensures the minimum oil press-
ure required for pilot reducing valve (2) and sends
oil to pilot reducing valve (2) with priority over
any other circuit.
Operation
To modulating valve To each transmission spool
l When the oil pressure is below 1.47 MPa (15 kg/
cm2), the oil from pump flows to port A on the
priority valve and also into port B on the pilot re-
ducing valve. Since the oil pressure on port A is
lower, the priority valve moves to the left, causing
the flow to ports A and C to be shut off. As a re-
sult, the oil from the pump is delivered only to the
pilot reducing valve circuit.
423FO33
l When the oil pressure is more than 1.47 MPa (15 To modulating valve To each transmission spool
kg/cm2), the hydraulic pressure and force of pop-
pet spring (3) push back spring (4) and move
priority valve (1) to the right. When this happens,
port A and port C are connected,
from port C to the clutch spool.
and the oil flows
-
Pi lot
oil filter
423FO34
1O-20
PILOT REDUCING VALVE
Function
l The pilot reducing valve acts to control the press-
ure needed to actuate the transmission spools.
Operation
l The oil from the pump passes through the pilot fil-
ter and enters port A of pilot reducing valve (1).
The oil passes through port B and enters through
the orifice of transmission spool (2) to fill the in-
side of port C.
’ valve
423 FO30
l When the pressure inside port C rises, press-

urized oil flows from orifice “a” of pilot reducing
valve (1) and goes to port D.
As a result, pilot reducing valve (I) moves to the
right, and ports A and B are shut off, so the press-
urized oil at port C is maintained at the same
pressure.
423FO29
10-21
Function of pilot circuit drain
This pilot valve functions as a reducing valve primary
pressure: 1.47 MPa (15 kg/cm*); secondary pressure:
1.06 MPa (10.8 kg/cm2). If the reducing valve does not
have drain port a at the secondary side, it is im-
possible to obtain the specified reducing pressure.
For example, at the Neutral position, if there is no sec-
ondary pressure at drain port a, theoretically the
pressure generated at the secondary side is the same
pressure as the primary pressure. (Actually, it is not as
high as the primary side because of leakage from the
valve spool.)
F23501306
1o-22
MODULATING VALVE AND QUICK RETURN VALVE
Function
l The modulating valve and quick return valve act (kg/cm”) C
together to raise the transmission clutch pressure Shifting gear I
smoothly. In this way. they reduce the shock
when shifting speed range, and prevent the gen-
eration of peak torque in the power train. As a
result, operator fatigue is reduced, and at the
same time, operator comfort and the durability
of the power train are increased.
Time (Set)
423FO35
11 Immediately after shifting gear (Point A on Fig. 423FO35)
erection and speed spool
To pilot reducing
F23501303
Operation
l The oil sent from the pump flows from priority difference in pressure between port B and port
valve (I) through port A, passes through C. The quick return valve moves to the right and
modulating valve (21, and enters port B of quick the oil flows to clutch (5). In addition, when quick
return valve (3). The oil passes through orifice return valve (3) moves to the right, drain port D
“a” of quick return valve (3) and flows to the is opened, and the pressurized oil at the rear of
clutch pistion, which has been actuated. Howev- piston (4) flows to the drain circuit.
er when it passes through orifice “a” it creates a
1 O-23
2) Clutch pressure rising (Point B on Fig. 423FO35)
Direction and Speed SpOOl
pilot reducing
Ive
To oil cooler
F23501304
Operation
l As the pressure at the clutch piston rises, the At the same time, pressurized oil also passes
pressure at port C also rises. Quick return valve through the orifice and enters poppet (7) of
(3) is pushed back to the left and drain port D is modulating valve (2). It moves modulating valve
closed. The oil from the pump flows from port C (2) to the left and some of the oil at port A flows
to the clutch piston, and at the same time it to port G.
flows from orifice “b” through quick return valve
(3) and enters port E.
The oil at port E acts on the modulating piston
(4). It pushes back spring (61 and moves piston
(4) to the rig ht.
1 O-24
3) Completion of rise in clutch pressure (Point C on Fig. 423FO35)
Direction and speed spool
pilot reducing
Ive
To oil cooler ’
To inching valve
235FO2005
Operation
l The oil entering port E continues to push piston
(4). When the piston reaches the end of its stroke,
the rise in pressure stops. When this happens, the
pressure reaches the set pressure of the modulat-
ing valve. In addition, port F and port G are closed
by piston (4), so the oil at port A passes through
port G and flows to the oil cooler.
l The oil at port E is connected to the inching valve
through the throttle (the modulating valve is inter-
connected with the inching valve).
1 o-25
OIL COOLER BYPASS VALVE
FUNCTION
l The oil cooler bypass valve acts to maintain the To each transmission spool
pressure of the oil entering the oil cooler at a con-
stant pressure. It drains the oil if it goes above
the specified pressure.
OPERATION
l The oil from the pump passes through priority
valve (I) and actuates modulating valve (2). It
then enters port A and flows to the oil cooler. -2
-1
To transmission From pump

lubrication
F7.3501307
l If the oil at port A goes above the specified To each transmission spool
pressure, it passes through orifice “a” of oil
cooler bypass valve (3) and enters port B. It then
moves oil cooler bypass valve (3) to the left. As a
result, the oil from port A is drained, and the oil
flowing to the oil cooler is maintained at the
specified pressure.

lubrication
F23501308
1 O-26
TRANSMISSION SOLENOID VALVE
Function
. There is one solenoid valve installed for each
directional and speed spool in the transmission
valve.
When the gear shift lever in the operator’s com-
partment is operated, the solenoid valve is
actuated, and oil is drained to actuate the direc-
tional and speed spools.
Operation
1) Solenoid valve OFF
The oil of spool (1) enters port A. However, valve
(2) shuts off the oil, so directional and speed
spool (I ) does not move.
423FO31
8
4
8
2) Solenoid valve ON
When the gear shift lever is operated, the sole-
noid valve is pulled up.
The oil from directional and speed spool (I)
enters port A and flows from port B to the drain
circuit. Therefore, port A becomes the low pres-
sure circuit, and directional and speed spool (1)
is moved to the right. As a result, the oil from
quick return valve flows to the piston.
Fr
reducing valve
423 F032
1 O-27
Function
l If there is any failure in the electrical circuit of the
transmission control system, and the solenoid
valve does not work, the emergency spool is
used. This spool is attached to each directional
and speed spool and is used to operate the trans-
mission valve mechanically. (It is used to drive
the machine to a place where it can be repaired.)
* Particular attention must be paid for when
using this spool.
Operation
1. When solenoid valve is normal:
(Emergency spool is at normal position)
When the solenoid valve is working normally, the
spool is maintained in this position.
Oil from directional and speed spool (I) enters
port A, but it is shut off by solenoid valve (2).
From. ~
reducing valve 423 F044
2. When solenoid valve is abnormal:

a. Clutch in disengaged position
(Emergency manual spool is pushed to the From quick
return valve
left (at normal position))
Emergency spool (3) is pushed to the left,
and the oil at port A is shut off regardless of
the action of solenoid valve (2). The oil
cannot flow to port B, so the clutch is not
actuated.
reducing valve
423 F045
b. Clutch in engaged position

From quick
(Emergency spool is pulled to the right (at return valve
actual position))
When emergency spool (3) is pulled to the
right, the oil at port A is drained to port B
regardless of the operation of solenoid valve
(2). As a result, the clutch is actuated.
From
reducing valve 423 F046
1 O-28
INCHING VALVE (INCHING VALVE WITH MODULATING VALVE)
l An inching valve with modulation is employed to

reduce the shock when the inching pedal is oper- From
ated.
OPERATION
1. When inching valve is not depressed;
The oil from the pump passes through ports A
and B, goes through the F-R spool and is sent to
the F-R clutch.
The return spring of the inching pedal pushes To quick return
valve spool (2) and collar (3). These push valve (1)
to the right. The oil passing through orifice D en- Modulating
valve
ters chamber C, and produces force to push valve
(I) to the left. However, the tension of the return
spring prevents valve (1) from moving.
The oil in chamber E of the modulating valve is To oil cooler From pump
shut off by spool (2), so it does not flow to drain bypass valve
port F.
2. When inching valve is slightly depressed;

Drain From pump
When the inching pedal is slightly depressed,
valve spool (2) moves to the left, so the oil press- 4 F 6 5A, 1 n_:_ 4 1
ure in chamber C pushes valve (I) to the left to a
position where it balances with the tension of
springs
ber C becomes
(5) and (6), and the oil pressure
the F-R clutch pressure.
in cham-
In other
u
Inch
words, the passage to port B is throttled and the
pressure of the F-R clutch is reduced, so the
clutch is partially engaged. In addition, the pas-
sage between drain port F and chamber E of Modulating
modulating valve (7) is opened by spool (2), so valve
the oil in chamber E passes through the throttle

and is drained. Modulating valve (7) moves to
drain hole G, and the main pressure is kept re-
To oil cooler From pump
duced.
bypass valve
235FO2007
3. When inching valve is fully depressed;
Valve spool (2) moves completely to the left, so
the tension of spring (5) is further reduced. As a 2 F ‘zin 5 From pump
result, the hydraulic pressure of the F-R clutch
drops to 39 kPa - 49 kPa (0:4 - 0.5 kg/cm2), and
the clutch is completely disengaged.
The oil at port E of modulating valve (7) is con-
nected to drain circuit F, so the main pressure is
kept reduced.
4. Inching valve (closed -r open)

If spool (2) closes drain circuit F, the oil entering Modulating
valve
port E continues to push modulating valve (7) to
the end of its stroke, and the pressure in the main
circuit rises and returns to the set pressure.
When this happens, modulation is applied, so the
F-R clutch is engaged smoothly. bypass valve
235FO2008
1 O-29
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
Serial No.: 12013 - 12015, 12019 and up
SWG00338
1. 2nd connector A. Inching pressure pick-up

2. 4th connector B. Main pressure pick-up
3. 1st connector C. Priority pressure pick-up
4. L connector D. Lubricating pressure pick-up
5. H connector E. Oil cooler bypass pressure pick-up
6. 3rd connector
7. F connector
8. R connector
9. Lower valve
10. Upper valve
10-29-l
0
LOWER VALVE
z-z SWG00339
7. High clutch spool

8. 2nd spool
9. Low clutch spool
10. 4th spool
11. 1st spool
12. Pilot reducing valve
13. F-R spool
14. Lubrication valve
15. 3rd spool
1O-29-3
SOLENOID VALVE
II 12 13 I4 15 Ifi 17 18
A-A SWG00340
STRUCTURE 1. Valve body

. The transmission solenoid valve is installed 2. 2nd solenoid valve
to the transmission together with the trans- 3. 4th solenoid valve
mission control valve. When the gear shift 4. 1st solenoid valve
lever is operated, the solenoid valve is actu- 5. L solenoid valve
ated and moves the spool inside transmis- 6. H solenoid valve
sion valve. 7. 3rd solenoid valve
8. F solenoid valve
9. R solenoid valve
10. Emergency manual spool
II. 2nd connector
12. 4th connector
13. 1st connector
14. L connector
15. H connector
16. 3rd connector
17. F connector
18. R connector
10-29-4
0
PRIORITY VALVE
Function
. Priority valve (1) ensures the minimum oil press-
ure required for pilot reducing valve (2) and sends
oil to pilot reducing valve (2) with priority over
any other circuit.
Operation To modulating valve To each transmission spool

l When the oil pressure is below 1.47 MPa (15 kg/
cm’), the oil from pump flows to port A on the
priority valve and also into port B on the pilot re-
ducing valve. Since the oil pressure on port A is
lower, the priority valve moves to the left, causing
the flow to ports A and C to be shut off. As a re-
sult, the oil from the pump is delivered only to the
pilot reducing valve circuit. oil filter
423FO33
. When the oil pressure is more than 1.47 MPa (15 To modulating valve To each transmission spool
kg/cm’), the hydraulic pressure and force of pop-
pet spring (3) push back spring (4) and move
priority valve (1) to the right. When this happens,
port A and port C are connected, and the oil flows
from port C to the clutch spool.
Pilot
oil filter
423FO34
1 O-29-5
0
PILOT REDUCING VALVE
Function
. The pilot reducing valve acts to control the
pressure needed to actuate the transmission
spools.
Operation
. The oil from the pump passes through the
pilot filter and enters port A of pilot reduc-
ing valve (I). The oil passes through port B
and enters through the orifice of transmis-
sion spool (2) to fill the inside of port C.
* To Priority valve
SWG00421
. When the pressure inside port C rises, pres-

surized oil flows from orifice “a” of pilot
reducing valve (I) and goes to port D.
As a result, pilot reducing valve (I) moves
to the right, and ports A and B are shut off,
so the pressurized oil at port C is maintained
at the same pressure.
The pressure at this point is 1.06 MPa (IO.8
kg/cm2).
To Priority valve
SWG00422
10-29-6
0
Function of pilot circuit drain

This pilot valve functions as a reducing valve
primary pressure: 1.47 MPa {I5 kg/cm*}; second-
ary pressure: 1.06 MPa I10.8 kg/cm*}. If the re-
ducing valve does not have drain port a at the
secondary side, it is impossible to obtain the
specified reducing pressure.
For example, at the Neutral position, if there is
no secondary pressure at drain port a, theoreti-
cally the pressure generated at the secondary
side is the same pressure as the primary pres-
sure. (Actually, it is not as high as the primary
side because of leakage from the valve spool.)
1 O-29-7
0
MODULATING VALVE AND QUICK RETURN VALVE
Function
. The modulating valve and quick return valve act (kg/cm*)
together to raise the transmission clutch pressure 40 - Shlftlng gear
smoothly. In this way, they reduce the shock
when shifting speed range, and prevent the gen-
30 -
eration of peak torque in the power train. As a F
5
result, operator fatigue is reduced, and at the Z
k 20-
same time, operator comfort and the durability .=
of the power train are increased. 0
Trne (Set)
1) Immediately after shifting gear (Point A on Fig. 423FO35) 423FO35
F23501303
Operation
l The oil sent from the pump flows from priority difference in pressure between port B and port
valve (1) through port A, passes through C. The quick return valve moves to the right and
modulating valve (21, and enters port B of quick the oil flows to clutch (5). In addition, when quick
return valve (3). The oil passes through orifice return valve (3) moves to the right, drain port D
“a” of quick return valve (3) and flows to the is opened, and the pressurized oil at the rear of
clutch pistion, which has been actuated. Howev- piston (4) flows to the drain circuit.
er when it passes through orifice “a” it creates a
10-29-8
0
2) Clutch pressure rising (Point Bon Fig. 423FO35)
Dir&m and speed spool
pilot reducing
lve
F23501304
Operation
l As the pressure at the clutch piston rises, the At the same time, pressurized oil also passes
pressure at port C also rises. Quick return valve through the orifice and enters poppet (7) of
(3) is pushed back to the left and drain port D is modulating valve (2). It moves modulating valve
closed. The oil from the pump flows from port C (2) to the left and some of the oil at port A flows
to the clutch piston, and at the same time it to port G.
flows from orifice “b” through quick return valve
(3) and enters port E.
The oil at port E acts on the modulating piston
(4). It pushes back spring (61 and moves piston
(4) to the right.
1 O-29-9
0
3) Completion of rise in clutch pressure (Point C on Fig. 423FO35)
irection and speed spool
It reducing
To inching valve
235FO2005
Operation
The oil entering port E continues to push
piston (4). When the piston reaches the end
of its stroke, the rise in pressure stops. When
this happens, the pressure reaches 3.04 MPa
I31 kg/cm’) as a set pressure of the modulat-
ing valve. In addition, port F and port G are
closed by piston (4), so the oil at port A
passes through port G and flows to the oil
cooler.
The oil at port E is connected to the inching
valve through the throttle (the modulating
valve is interconnected with the inching
valve).
10-29-10
0
OIL COOLER BYPASS VALVE
FUNCTION
l The oil cooler bypass valve acts to maintain the To each transmission spool
pressure of the oil entering the oil cooler at a con-

L
stant pressure. It drains the oil if it goes above
the specified pressure.
OPERATION
l The oil from the pump passes through priority
valve (1) and actuates modulating valve (2). It
then enters port A and flows to the oil cooler.

2
lubrication
%
F23501307
z
l If the oil at port A goes above the specified To each transmission spool
pressure, it passes through orifice “a” of oil

cooler bypass valve (3) and enters port B. It then
moves oil cooler bypass valve (3) to the left. As a
result, the oil from port A is drained, and the oil
flowing to the oil cooler is maintained at the
specified pressure of 0.49 MPa I5 kg/cm21.

lubrication
F23501308
10-29-11
0
Function
l There is one solenoid valve installed for each From quick
return valve
directional and speed spool in the transmis-
sion valve.
When the gear shift lever in the operator’s
compartment is operated, the solenoid valve
is actuated, and oil is drained to actuate the
directional and speed spools.
Operation
I) Solenoid valve OFF From pilot
reducing valve SWG00423
The oil of spool (I) enters port A. However,
valve (2) shuts off the oil, so directional and
speed spool (I) does not move.
2) Solenoid valve ON
When the gear shift lever is operated, the From quick
return valve
solenoid valve is pulled up.
-8
The oil from directional and speed spool (I)
enters port A and flows from port B to the
drain circuit. Therefore, port A becomes the
low pressure circuit, and directional and
speed spool (I) is moved to the right.
As a result, the oil from quick return valve
flows to the piston.
2?
From oilot
reducing valve
10-29-12
0
EMERGENCY SPOOL
Function
. If there is any failure in the electrical circuit
of the transmission control system, and the
solenoid valve does not work, the emergency
spool is used. This spool is attached to each
directional and speed spool and is used to
operate the transmission valve mechanically.
(It is used to drive the machine to a place
where it can be repaired.)
* Particular attention must be paid for
when using this spool.
Operation
1. When solenoid valve is normal:
From quick
(Emergency spool is at normal position) return valve
When the solenoid valve is working normally,
the spool is maintained in this position.
Oil from directional and speed spool (1) en-
ters port A, but it is shut off by solenoid
valve (2).
5/t,
:
Kh : A
% 3
From Pilot
reducing valve
SWG00425
2. When solenoid valve is abnormal:

a. Clutch in disengaged position From quick
return valve
(Emergency manual spool is pushed to
the left (at normal position))
Emergency spool (3) is pushed to the
left, and the oil at port A is shut off re-
gardless of the action of solenoid valve
(2). The oil cannot flow to port B, so the ,
clutch is not actuated. :,,, :
:
KL : A B
b\
% 3
From Pilot
reducing valve
SWG00426
b. Clutch in engaged position

From quick
(Emergency spool is pulled to the right return valve
(at actual position))
When emergency spool (3) is pulled to
the right, the oil at port A is drained to
port B regardless of the operation of so-
lenoid valve (2). As a result, the clutch is
actuated.
From oilot
reducina valve SWG00427
10-29-13
0
INCHING VALVE (INCHING VALVE WITH MODULATING VALVE)
l An inching valve with modulation is employed to

reduce the shock when the inching pedal is oper- From
Drain
ated.
OPERATION
1. When inching valve is not depressed;
The oil from the pump passes through ports A
and B, goes through the F-R spool and is sent to
the F-R clutch.
The return spring of the inching pedal pushes
valve spool (2) and collar (3). These push valve (1)
Modulating
to the right. The oil passing through orifice D en-
valve
ters chamber C, and produces force to push valve
(1) to the left. However, the tension of the return
spring prevents valve (I) from moving.
The oil in chamber E of the modulating valve is To oil cooler From pump
shut off by spool (2), so it does not flow to drain bypass valve
port F.
235FO2006
2. When inching valve is slightly depressed;

Drain From pump
When the inching pedal is slightly depressed,
valve spool (2) moves to the left, so the oil press-
ure in chamber C pushes valve (1) to the left to a
position where it balances with the tension of
springs (5) and (6), and the oil pressure in cham-
ber C becomes the F-R clutch pressure. In other
words, the passage to port B is throttled and the
pressure of the F-R clutch is reduced, so the
clutch is partially engaged. In addition, the pas-
sage between drain port F and chamber E of
modulating valve (7) is opened by spool (2), so
the oil in chamber E passes through the throttle
and is drained. Modulating valve (7) moves to
drain hole G, and the main pressure is kept re- c
duced.
’ To oil cooler From pump
bypass valve
235FO200:
3. When inching valve is fully depressed;
Valve spool (2) moves completely to the left, so
the tension of spring (5) is further reduced. As a 2 F D:i” 5 From pump
result, the hydraulic pressure of the F-R clutch

drops to 39 - 49 kPa (0.4 - 0.5 kg/cm2}, and the clutch
is completely disengaged.
The oil at port E of modulating valve (7) is con-
nected to drain circuit F, so the main pressure is
kept reduced.
4. Inching valve (closed -+ open)

If spool (2) closes drain circuit F, the oil entering Modulating
valve
port E continues to push modulating valve (7) to
the end of its stroke, and the pressure in the main
circuit rises and returns to the set pressure.
When this happens, modulation is applied, so the
F-R clutch is engaged smoothly. bypass valve
235FO2008
10-29-14
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL
Serial No.: 11001 - 11030
lIn
II
I..l
r-
d
235COO2002
1. Bolt 6. Gear shift lever

2. Shift lock lever 7. Rotary switch
3. Reverse switch 8. Connector
4. Forward switch 9. Interlock
5. Button switch 10. Interlock lever
1O-30
0
l-l
A-A 6-B lJ
235CD02003
Outline
l The control system of this machine is used the . Press button switch (5) on the gear shift lever only
electrical type. So, the operation is easy and the when moving the gear shift lever 5 .+ 6 or 6 + 7
operating force and stroke are small. (for both forward and reverse).
l When operating gear shift lever (6), the F-R If gear shift lever (6) is placed at the N position
switching is used F-R switch (3), (4) and the speed and shift lock lever (2) is placed at the LOCK posi-
range is used rotary switch (7), and the current tion, bolt (1) holds gear shift lever (6) and keeps
signal is sent to each solenoid valve so that the the gear shift lever in the N position.
transmission control valve operates.
10-31
0
TRANSMISSION CONTROL
STRUCTURE AND FUNCTION
Serial No.: 11031 - 12012, 12016 - 12018
1. Bolt 6. Gear shift lever

2. Shift lock lever 7. Rotary switch
3. Reverse switch 8. Connector
4. Forward switch 9. Interlock
5. Button switch 10. Interlock lever
10-31-l
0
A-A c-c
SDGOOOO
1
Outline
l The transmission control is an electrical type. l When shift lever (6) is at the N or P position,
When the shift lever is operated, an electri- and shift lock lever (2) is set to the LOCK
cal signal is sent to the transmission sole- position, bolt (I) holds shift lever (6) and
noid valve from F and R switches (4) and (3) prevents it from moving back from the N
when switching direction, and from rotary position (1st and other drive positions).
switch (7) for the gear ranges, and the con-
trol valve is actuated.
. To prevent mistaken operation, when the
shift lever is operated 5 + 6 or 6 + 7 (both
forward and reverse) and when it is oper-
ated N tf P, button (5) installed to shift lever
(6) must be pressed to move the shift lever.
10-31-2
0
SWG00350
Outline
. The transmission control is an electrical type.
When shift lever (1) is operated, an electrical
signal is sent to the transmission controller
from F and R switches (3) and (2) when
switching direction, and from potentiometer
(5) for the gear ranges.
The drive for the transmission solenoid valve
is carried out by the transmission controller
to protect the transmission from mistaken
operation or failure in the control system.
l To prevent mistaken operation, when shift
lever (1) is operated N ++ P, button (4) in-
stalled to the shift lever must be pressed to
move the shift lever.
10-31-4
0
INCHING CONTROL
_--_I@ !! e !
:I ^ :
2-
A-A
T
D
l-
“F’
---
235CDO2004
1. Inching pedal
2. Brake pedal
3. Brake valve
1 O-32
DRIVE SHAFT
-I6 -
-
-
-
p
:::
d-
----.
“\
_
h
:- F23501019
P -
1. Drive shaft
1o-33
STRUCTURE AND FUNCTION FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING
FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING
c
A=========3 ii
II I
SWG00351 +
1o-34
0
STRUCTURE AND FUNCTION FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING
SWG00352
[A
SWG00353
1. Differential lock pump (LAL 12)

2. Relief valve
Set pressure: 2.5 MPa (25 kg/cm*}
A-A
3. Solenoid valve
4. Differential lock piston
5. Bearing lubrication
1o-35
0
FINAL DRIVE
i
16 15 14 13 12 11
A-A 235COO2006
1. Shaft 7. Case 13. Gear (20 teeth)

2. Sprocket (21 teeth) 8. Bevel gear (59 teeth) 14. Ring gear (78 teeth)
3. Side case 9. Coupling 15. Gear (28 teeth)
4. Flange IO. Bevel pinion (16 teeth) 16. Pin
5. Shaft 11. Disc
6. Gear (21 teeth) 12. Plate
1O-36
0
235CD02007
17. Filler tube

18. Oil level gauge
19. Breather
20. support
Outline
When motor graders carry out operations with
the blade angled to the front or the chassis at
an angle, there is a reaction to this. It applies a
force in a sideways direction from the front, and
the machine tries to turn to the left or right.
It is necessary to give the machine the ability to
resist this and travel in a straight line, so gener-
ally speaking, motor graders are not designed
to be equipped with a differential.
However, the GD825A is an articulated type, so
when the machine is articulated, the rear wheels
tend to slip to the side. For this reason, the
machine is equipped with a differential to im-
prove the wear resistance of the rear tires. Con-
trol of the differential can be carried out simply
by pressing a switch in the operator’s compart-
ment.
Operation
The power transmitted from the engine to the
whee
transmission is then transmitted by the mesh-
To front wheel
ing of bevel pinion (IO) and bevel gear (7), and
is sent from shaft (6) -+ (I) + sprocket (2). \
The differential and differential lock are switched

hydraulically by the contact between disc (11)
and plate (12).
1o-37
0
Serial No.: 11001 – 12021
023502
1. Chain 8. Gear (105 teeth)

2. Breather 9. Plate (138 teeth)
3. Shaft 10. Disc
4. Sprocket 11. Tandem case
5. Cage 12. Sprocket
6. Piston 13. Oil level gauge
7. Spring 14. Drain plug
10-39
(6)
023502
1. Chain 8. Gear (105 teeth)

2. Breather 9. Plate (138 teeth)
3. Shaft 10. Disc
4. Sprocket 11. Tandem case
5. Cage 12. Sprocket
6. Piston 13. Oil level gauge
7. Spring 14. Drain plug
10-40
(6)
STEERING PIPING SWING CIRCLE
STEERING PIPING
1. Steering cylinder (R.H.)

2. Steering cylinder (L.H.)
3. Double relief valve
4. Steering valve
5. Check valve
6. Check valve
10-41
0
STEERING CIRCUIT SYSTEM
L ,
I
235FO2011
1. Pump 7. Check valve

Servo piston 8. Priority flow devider valve
2.
Servo valve 9. Hydraulic control valve (R.H.)
3.
10. Hydraulic control valve (L.H.)
4. Check valve
valve 11. Surge pressure absorbing valve
5. Steering
6. Steering cylinder
1 O-42
STEERING CIRCUIT DIAGRAM
From hydraulic
-c--
control valve
To hydraulic
control valve
235FO2012
1. Hydraulic tank 8. Steering valve

2. Strainer 9. Double relief valve
3. Hydraulic pump IO. Steering cylinder
4. Priority flow devider valve 11. Breather
5. Check valve 12. Surge pressure absorbing valve
6. Last chance filter 13. Pressure switch
7. Check valve 14. Emergency pump
1o-43
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
ORBIT-ROLL
A-A
10
11
SEW01234
1. Needle bearing 5. Rotor 9. Spool

2. Center spring 6. Cover 10. Stator
3. Drive shaft 7. Center pin 11. Lower cover
4. Valve body 8. Sleeve 12. Check valve
1o-44
0
Outline
l The steering valve is connected directly to
the shaft of the steering wheel. It switches
the flow of oil from the steering pump to the
left and right steering cylinders to determine
the direction of travel of the machine.
. The orbit-roil valve, broadly speaking, con-
sists of the following components: rotary
type spool (9) and sleeve (81, which have the
function of selecting the direction, and the
Girotor set (a combination of rotor (5) and
stator (IO)), which acts as a hydraulic motor
during normal steering operations, and as a
hand pump (in fact, the operating force of
the steering wheel is too high, so it cannot
be operated) when the steering pump or
engine have failed and the supply of oil has
stopped.
SLWO1980
Structure
l Spool (9) is directly connected to the drive
shaft of the steering wheel, and is connected
to sleeve (8) by center pin (7) (it does not
Connected to
contact the spool when the steering wheel steerlnu
is at neutral) and centering spring (2). wheel shaft
l The top of drive shaft (3) is meshed with

center pin (7), and forms one unit with sleeve
(81, while the bottom of the drive shaft is
meshed with the spline of rotor (5) of the
Girotor.
l There are four ports in valve body (41, 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 di- Groove for meshins
rectly from the tank by this check valve. with center Pin
1o-45
0
CONNECTION BETWEEN HAND PUMP AND SLEEVE
SBWOO725
SBWW726
. The diagrams above show the connections Suction /

diTrge port
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 I are connected to the head end of
the left steering cylinder in the same way.
In the condition in diagram above left, ports
1, 2, and 3 are the discharge ports of the
SBWGO727
Girotor set. They are connected to ports I, b,
and d, so the 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”, the con-
dition changes to the condition shown in
diagram above right. In this case, ports 1, 2,
and 3 are the suction ports, and are con-
nected to ports i, k, and c. Ports 5, 6, and 7
are the discharge ports, and are connected
to ports d, f, and h. SBWCQ728
1O-46
0
. In this way, the ports of the Girotor acting

as delivery ports are connected to ports
which are connected to the end of the steer-
ing valve spool. The ports acting as suction
ports are connected to the pump circuit.
. Adjusting delivery in accordance with angle
of steering wheel:
For every Ii7 turn of the steering wheel, the
inner teeth of the Girotor gear advance 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 pro-
portional 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 turn-
ing, so no more oil is sent to the cylinder
and the oil pressure rises.
To prevent this, when the turning of the
Angle
steering wheel is stopped, the action of the variation
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.
sow0230 I
1o-47
0
DOUBLE RELIEF VALVE
(For Steering)
1. Relief valve
2. Body
3. Poppet(B)
4. Sleeve
5. Relief valve
6. Poppet (A)
7. Sleeve
FL?3501389
ll4-n
F238098
The check valve with safety valve protects the cylin-

der from abnormal pressure inside the cylinder
caused by external force.
OPERATION
In the hydraulic circuit diagram above, oil from cham-

ber A, enters. When there is abnormal pressure of
over 210 kg/cm2, it pushes poppet (A) and flows to
chamber A,. In the same way, when there is abnormal
pressure of over 210 kg/cm2, oil from chamber Bz
pushes poppet (B) and flows to chamber B 1.
F23BOSS
1 O-48
CHECK VALVE
1 1. Nipple
2. Joint
3. Spring
4. Valve
235FO2013
235FO2014
--
8
FJJ
__-
I
1.
2.
3.
4.
Joint
Spring
Valve
Nipple
*I
ZJ
I
I
I I 1
I I
@
+-
+---~\,L-__--------
f I
1 rX- A ---------
x 1
LI
1
‘,
_‘Jk
,
*
235FO2015
F23501391
1o-49
EMERGENCY STEERING SYSTEM
235FO2017
235FO2016
OUTLINE 1. Emergency pump

. If the oil pressure in the hydraulic circuit drops to 2. Speed sensor
0.7 MPa (7 kg/cm2) because of a failure in the en- 3. Pressure switch
gine or the pump, pressure switch (3) is switched 4. Relay
ON, and emergency pump (1) is actuated to make 5. E.S.C controller
it possible to steer the machine. 6. Buzzer
* If the travel speed is below 1 km/h or the ma- 7. Select switch
chine is stopped, the emergency steering sys- 8. Starting motor
tem is not actuated.
* The emergency pump is an electric pump, so
do not continue to operate it for more than 30
seconds.
1O-50
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
Serial No,: 11001 - 12050
A-A B-B c-c D-D
235CDO2009
1. Steering cylinder 6. Housing

2. Tie rod 7. Bracket
3. Front axle 8. Leaning rod
4. Leaning cylinder 9. King pin
5. Hub shaft 10. Hub nut
1o-51
0
Serial No.: 12099 – 12502

023502
10-51-2
(6)
023502
10-51-3
(6)
WHEEL
Serial No.: 11001 - 12000
FRONT WHEEL (OPT)
*\
1’
3A 1.
2.
Side
Rim
ring
3. Tire
F23501039 F23501040
Tire size 18.00-25-I 2PR Tire size I 23.5-25-12PR
Rim size 13.00 x 25TB Rim size 19.5 x 25WTB
Air pressure 0.25 MPa (2.60 kg/cm*} Air pressure 2

0.24 MPa 12.46 kg/cm*}
FJ
g
REAR WHEEL (OPT)
=23501041 042
Tire size 18.00-25-l 2PR Tire size I 23.5-25-l 2PR
Rim size I 13.00 x 25TB Rim size I 19.5 x 25WlB
Air pressure 0.25 MPa i2.60 kg/cm21 Air pressure 0.24 MPa 12.46 kg/cm21
1o-52
0
FRONT WHEEL (OPT)
*\
l-----
1. Side ring 8H
2. Rim
3. Tire
F23501040 :23501039
Tire size 23.5-25-12PR Tire size 18.00-25-12PR

I
Rim size 19.5 x 25WTB Rim size 13.00 x 25TB
Air pressure 0.24 MPa f2.46 kg/cm*} Air pressure 0.25 MPa t2.60 kg/cm3
REAR WHEEL (OPT)
F23501042 F2350 1041
Tire size 23.5-25-12PR Tire size I 18.00-25-I 2PR
Rim size 19.5 x 25WTB Rim size I 13.00 x 25TB
Air pressure 1 0.24 MPa 12.46 kg/cm? Air pressure 1 0.25 MPa I2.60 kg/cm?
10-52-l
0
DISC BRAKE
STRUCTURE OF DISC BRAKE
1234 5
Final drive
I II
F23501056
Disc brakes are fitted on the four rear wheels and are 1. Hub shaft
actuated by air pressure. 2. Gear
The motive force from the final drive rotates hub 3. support
shaft (I), gear (2) and disc (4). This rotation is trans- 4. Disc
mitted to the tires which are fixed to the hub. 5. Plate
Each brake consists of discs (4) which are meshed 6. Spring
with gear (2). plates (5) which are meshed with cage 7. Cage
(7) and piston (8). The discs are cooled by the oil 8. Piston
inside the tandem case. 9. Nut
IO. Bolt
1o-53
OPERATION
1. Brake applied
When the brake pedal is depressed, the air circuit
is connected to chamber A of the disc brake.
When the air pressure is greater than the pushing
force of spring (6), piston (8) moves to the left,
and pushes discs (41 and plates (5). Friction is
generated between the discs (meshed with gear
(2)) and the plates (meshed with cage (7)). This
slows down the rotation of the discs and finally
stops it. In other words, the brake is applied.
From air tank
* 8
F23501057
2 Brake released
When the brake pedal is released, the air in
chamber A is released. Spring (6) moves piston
4 5 8
(8) back to the right, so the pushing force is
reduced. This removes the friction between
discs (4) and plates (5), and allows them to
rotate freely. In other words, the brake is
released.
To air tank
F23501058
1o-54
PARKING BRAKE
Section A -A
F23501061
Outline 1. Disc
l The parking brake is a disc type and is installed 2. Plate
on the transmission output shaft. 3. Disc
l The force of the spring inside the spring cylinder 4. Piston
(7) is used to apply the brake mechanically; it is 5. Shaft
released by air pressure. 6. Adjuster
l When spring cylinder (7) yoke is moved out, ad- 7. Spring cylinder
juster (6) and shaft (5) turn and piston (4)
moves. So discs (3) and plate (2) are forced in
contact and the parking brake is applied.
1o-55
STRUCTURE AND FUNCTION BRAKE AIR PIPING
BRAKE AIR PIPING
II
1. Brake valve
2. Disc brake housing 7. Parking brake valve
3. Safety valve 8. Air tank
4. Air governor 9. Air drier
5. Check valve 10. Air compressor
6. Parking brake 11. Automatic drain valve
1o-57
0
BRAKE AIR CIRCUIT SYSTEM
235FO2018
1. Air compressor 11. Stop lamp switch

2. Air drier 12. Disc brake
3. Air governor 13. Tire charger socket
4. Check valve 14. Horn valve
5. Air tank 15. Horn
6. Safety valve 16. Parking brake valve
7. Low pressure switch 17. Exhaust valve
8. Pressure gauge 18. Parking brake
9. Automatic drain valve 19. Bank-lock valve
10. Brake valve 20. Bank-lock cylinder
1 O-58
BRAKE AIR CIRCUIT DIAGRAM
SllG00003
1. Air compressor 11. Stop lamp switch

2. Air drier 12. Disc brake
3. Air governor 13. Tire charger socket
4. Check valve 14. Horn valve
5. Air tank 15. Horn
6. Safety valve 16. Parking brake valve
7. Low pressure switch 17. Exhaust valve
8. Pressure gauge 18. Parking brake
9. Automatic drain valve 19. Bank-lock valve
10. Brake valve 20. Bank-lock cylinder
1o-59
0
AIR DRIER
F23501047
The function of the air drier is to remove the moisture 1. Purge tank
from the compressed air in the circuit. In this way it 2. Check valve
protects the components of the equipment and pre- 3. Spring
vents problems with operation in cold areas. 4. Drier cylinder
5. Drying agent
6. Body
To Brakevalve 7. Valve body
8. Valve
9. Oil filter
A. Air compressor
8. Air drier
C. Air governor
D. Air tank
235FO2019
lo-60
OPERATION
1. Drying
When the compressor is working, air from the
compressor enters port A of the air drier. It is
then cooled by the outside of drier cylinder (4). To air tank
and water and oil collect in the bottom of body
(6). The air then passes through oil filter (9)
which is fitted with an oil mist separator. Here
the fine drops of oil and particles of dust are re-
moved before the air enters drier cylinder (4).
Any water still included in the air is removed by
drying agent (5). When the air reaches the top of
drier cylinder (4). it is completely dry. This dry air
From air compressor
then passes through check valve (2) and purge
tank (1) to the air tank.
F23501048
2. Restoring drying agent

When the air pressure inside the circuit reaches
the set pressure, the air governor switches the
compressor to unloading. The governor is also
received by the control ports of the air drier.
Valve (8) opens and the air inside drier cylinder
(4) is released to the atmosphere. This drops the
air pressure in purge tank (I 1, and the dried air in
purge tank (I) passes through orifice ‘a’. Be-
cause of the drop in pressure, the dry air expands
and becomes dry more. As the air flows back
through drier cylinder (41, it picks up water from
drying agent (5) and the water is carried out to
the atmosphere. This completely dries out drying
agent (5) and prepares it for further use.
When the loading cycle starts again, valve (8)
closes, and the air drier returns to the drying
action.
From air 9overnor
F23501049
10-61
AIR TANK
1. Plate
2. Plate
3. Plate
4. Boss
Section A-A 238FO66
The air tank acts to store the compressed air pro-

duced by the air compressor.
Maximum pressure: 0.93 MPa (9.5 kg/cm*)
(Capacity 17.5 P x 2)
SAFETY VALVE
1. Valve seat
2. Ball
3. Release pin
4. Spring
5. Spring cage
6. Lock nut
7. Adjusting screw
238FO67
The safety valve is installed in the air tank and acts to

maintain safety in the air circuit. When the pressure
inside the air tank exceeds 0.93 f 0.04 MPa (9.5 + 0.4
kg/cm’) the safety valve releases compressed air to
the atmosphere.
1 O-64
AUTOMATIC DRAIN VALVE
! 2 3
I. Retainer
2. Filter
3. Body
4. Plug
5. Valve guide
6. Inlet-Exhaust valve
7. Cover
238FO72
The automatic drain valve is installed at the bottom

of the air tank. It acts to automatically drain any
water which forms when the compressed air is
cooled.
OPERATION
1. When there is no air pressure inside the air tank,
inlet-exhaust valve (6) is closed.
238FO73
1O-65
2. When air pressure enters the air tank, inlet-
exhaust valve 16) opens even when the pressure
is low. Air and water then enter chamber A. The
inlet-exhaust valve stops open until the pressure
inside the air tank reaches the maximum pressure
(until the governor is cut off).
238FO74
3. When the pressure in the air tank and the pres-

sure in chamber A are equal, the spring action of
valve guide (5) closes inlet-exhaust valve (6).
238FO75
4. When the pressure in the air tank drops, and the

pressure in chamber A is about 0.03 MPa (0.3 kg/
cm2), inlet exhaust valve (6) exhausts the air and
water.
238FO78
1O-66
CHECK VALVE
1 2 3 4
1. Body
PI PZ 2. Disc valve
3. Spring
4. Screw cap
238FO64
The check valve acts to prevent air in the air tank

from flowing back to the air compressor when the air
compressor is stopped.
OPERATION
When air flows into the check valve from the left,
valve (2) leaks its seat and the air flows freely to the
various ports.
When air flows into the check valve from the right,
valve (2) is pushed back into its seat by spring (3)
and the air pressure. This shuts off the air flow.
238FO65
1 O-67
BRAKE VALVE
--. /ix
4L
1, ,I--‘, I
/i’ / :
\ 0, ii
l’\ 0 i
\__,’ ‘._.’ (
l--r---___--_____r_~_
I
F23501050
1. Brake pedal
2. Plunger
3. Piston
4. Inlet valve
5. Piston
t 6. Inlet valve
7. Rubber spring
A. From air tank

B. From air tank
C. To R.H. relay valve
D. To L.H. relay valve
235FO2020
1O-68
OPERATION
1. Brake operating
Upper part
l When brake pedal (1) is depressed, the
operating force pushes plunger (2) and
rubber spring (71, and these transmit the
operating force to piston (3).
l When piston (3) moves down, it closes ex-
haust outlet (9). At the same time, it pushes
down inlet valve (4) and air flows from air
tank A to right relay valve C.
Lower part
l When inlet valve (4) opens, air flows to
chamber ‘a’ of piston (5).
l The air pressure pushes piston (5) down and
this closes exhaust outlet (I 0). At the same
time, it pushes down.inlet valve (6) and air
flows from air tank B to left relay valve D to
actuate the brake.
l Only a small amount of air pressure is
needed to move piston (51, so the movement
of the lower valve occurs at almost the same
time as the movement of the upper valve.
F23501051
2. Brake operation when lower side breakes

down
If there is any leakage of air at the lower side, the
upper side operates normally but the lower side
does not actuate the brake.
F23501052
lo-69
3. Brake operation when upper side breaks down
. If there is any leakage of air at the upper
side, piston (5) is pushed down mechanically
when the brake pedal is depressed. Because
of this, the lower side operates normally but
the upper side does not actuate the brake.
F23501053
4. Balancing operation
Upper part
. If the air pressure in relay valve C and the
space below piston (3) becomes high, piston
(3) will push rubber spring (7) and move up
to close inlet valve (4).
l When this happens, exhaust outlet (9) re-
mains closed, so the air pressure in the relay
valve is maintained. As a result, the brake re-
mains applied. 3
Lower part
l When the air pressure at the top and bottom
of piston (5) becomes the same, the piston 4
moves down slightly under the force of the
spring at the top of the piston and closes
inlet valve (6). The exhaust valve is closed so
the air pressure is maintained. As a result,
9
the brake remains applied. 5
l The pressure in the space in the upper part
balances with the operating force of the
pedal, and the pressure in the space in the
lower part balances with the air pressure in
t-i
the space in the upper part.
F23501054
1O-70
l When piston (3) and (5) move their whole
stroke inlet valves (4) and (6) are completely
opened. As a result, the air pressure in the
spaces in the upper part and lower part, and
in the right and left relay valves is the same
as the air pressure in the air reservoir.
l Therefore, until the piston its full stroke
down, the braking effect is controlled by the
amount the brake pedal is depressed.
5. Pedal released
Upper part
l If the pressure on the pedal is reduced, and
the operating pressure is removed from the
top of the piston, the piston moves up be-
cause of the air pressure at the bottom of
the piston and the force of the piston return
spring. As a result, the passage to exhaust
port (9) is opened and the compressed air in
the relay valve is released to the atmosphere.
Lower part
l If the pressure on the pedal is reduced, and
the compressed air at the top of piston (5) is
released, the air pressure at the bottom of
piston (5) pushes piston (5) up. Exhaust port
(10) is opened and the compressed air in the
relay valve is released to the atmosphere.
F23501055
10-71
PARKING BRAKE SYSTEM
235CD02012
From air tank
235FO2022
235FO2021
OUTLINE 1. Parking brake solenoid valve

. If the parking brake switch is placed at the RE- 2. Exhaust valve
LEASE position, solenoid valve (1) is opened and 3. Spring cylinder
the air pressure from the air tank pushes spring
cylinder (3) to release the parking brake.
l If the parking brake switch is placed at the PARK-
ING position, solenoid valve (1) is closed and the
air pressure from the air tank is shut off, so the air
in spring cylinder (3) is discharged from exhaust
valve (2), and the spring cylinder is pushed back
by the force of the spring to apply the parki_ng
brake.
1 O-72
PARKING BRAKE SOLENOID VALVE
1. Coil
2. Body
3. Inlet valve
4. Outlet valve
A. Inlet port
B. Outlet port
C. From air tank
423F119
Function
l The parking brake solenoid valve is a valve to
switch air to the parking brake spring cylinder.
l Parking brake operated

Spring
When the shift lever is moved to the PARKING
position, the solenoid valve is switched OFF (no
current flows), and the air from the tank enters
port C. However, port C is sealed by valve (4). so
no air flows out. The air in the parking brake
spring cylinder is drained through the exhaust Exhaust Gz!
valve. The air from the exhaust valve enters port From are
A, passes around valve (5) and is drained from tank
4
port E. Therefore, the spring force of the parking
brake spring cylinder applies the parking brake. 235F239-1
. Parking brake released

If the shift lever is at any position other then
PARKING, solenoid valve is ON (current flows),
and valve (5) moves down. Valve (4) is connect-
ed to valve (5) by a rod, so valve (41 also moves
down.
The air from the tank enters port C, and valve (4)
has moved down, so the air passes around valve
From air
(4). It then flows from port A through the exhaust tank
valve to the parking brake spring cylinder to
release the brake. 235F240-1
1o-73
EXHAUST VALVE
Section A-A
z
4
2
F23501060
1. Body
2. Rubber valve
3. Valve
4. Cap
A. To spring cylinder
B. Exhaust port
C. From solenoid valve
l When the compressed air flows to port C

through the solenoid valve, rubber valve (2) is
moved and opens the circuit between ports C
and A and then the air flows to spring cylinder.
When this happens, the parking brake is released.
l When no air flows to port C, the air from the
spring cylinder is sent to port A so that valve (3)
moves to the right and the air is released to ex-
haust port B. When this happens, the parking
brake is applied.
1o-74
SPRING CYLINDER
423F I 24
1. Rod OUTLINE
2. Boot l The air pressure from the parking brake so-
3. Cylinder lenoid valve pushes spring (4) and com-
4. Spring presses it to release the parking brake.
5. Piston Usually the parking brake is kept applied by
spring (4), so the machine is prevented from
moving.
1o-75
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL PIPING
HYDRAULIC CONTROL PIPING

LOW AND HIGH PRESSURE PIPING
A-A
1O-76
0
1. L.H. hydraulic control valve

2. R.H. hydraulic control valve
3. Main relief valve
4. Priority flow divider valve
5. Hydraulic pump
6. Hydraulic tank
1o-77
0
HIGH PRESSURE PIPING

Serial No.: 11001 - 12050
4 -___
: :
y I i
--__-
Z
1. Pilot check valve (for articulate) 6. R.H. hydraulic control valve

2. Articulate cylinder 7. Blade lift cylinder
3. L.H. hydraulic control valve 8. Pilot check valve (for leaning)
4. Pilot check valve (for blade lift) L.H. 9. Pilot check valve (For drawbar shift)
5. Pilot check valve (for power tilt) 10. Leaning cylinder
1 O-78
0
Ii SWGOO
359
11. Pilot check valve (for blade lift) R.H. 16. Swivel joint
12. Shuttle valve 17. Drawbar side shift cylinder
13. Circle rotation motor 18. Blade side shift cylinder
14. Power tilt cylinder
15. Circle rotation gear
1o-79
0
II IO
SWGOO 1360
1. Pilot check valve (for articulate) 6. R.H. hydraulic control valve

2. Articulate cylinder 7. Blade lift cylinder
3. L.H. hydraulic control valve 8. Pilot check valve (for leaning)
4. Pilot check valve (for blade lift) L.H. 9. Pilot check valve (for drambar shift)
5. Pilot check valve (for power tilt) 10. Leaning cylinder
10-79-l
0
18 SWG00361
11. Relief valve (for leaning) 16. Swivel joint

12. Pilot check valve (for blade lift) R.H. 17. Drawbar side shift cylinder
13. Circle rotation motor 18. Blade side shift cylinder
14. Circle rotation gear
10-79-2
0
HYDRAULIC TANK PIPING
i i i i ii ii
235COO2013
1. Return filter
2. Suction filter
3. Hydraulic pump
1o-79-3
0
RIPPER PIPING
I :
__----
235COO2016
1. Ripper cylinder
2. Pilot check valve
1o-79-4
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT SYSTEM
HYDRAULIC CIRCUIT SYSTEM

Engine running, work equipment control lever in HOLD
I 1x1 x3 1x4
235FO2023
1. Servo valve 5. Steering valve

2. Servo piston 6. Hydraulic control valve (L.H.)
3. Pump 7. Surge pressure absorbing valve
4. Priority flow divider valve 8. Hydraulic control valve (R.H.)
1O-80
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

Serial No.: 11001 - 12022
27.4MPa 27.4MPa 27.4MPa

IO
_______ ~280kdcm~l (280wcm~t (280Wcmzl
L.lI!ii
I/ 12 113
L___ _-
I
----II--
II
-1
I
t-- 1---1p
2
2:
r
1 O-80-2
0
II II II II I
3 -7+Q
4
I
I
I
------------7
!I
i
I / ,
5I < i I
/
I 24.5MPa
I i250ko/cm*i
I I
; ---------------~~~_____-----__~_~--------_--------______---_________
I
SWG00363
10-80-3
0
1. Hydraulic tank
2. Breather
3. Strainer
4. Hydraulic pump (VXD70-IF)
6. Surge pressure absorbing valve
7. L.H. hydraulic control valve (5-spool)
7A. Blade lift (L.H.) control spool
7B. Ripper control spool
7C. Blade side shift control spool
7D. Power tilt control spool
7E. Circle rotation control spool
7F. Relief valve
8. R.H. hydraulic control valve (5-spool)
8A. Drawbar shift spool
8B. Articulate control spool
8C. Leaning spool
8D. Service spool
8E. Blade lift (R.H.) control spool
8F. Relief valve
9. Blade lift cylinder (L.H.)
10. Accumulator
11. Blade float solenoid valve
12. Ripper cylinder
13. Blade side shift cylinder
15. Swivel joint
16. Circle rotation motor
17. Drawbar shift cylinder
18. Articulate cylinder
19. Leaning cylinder
20. Blade lift cylinder (R.H.)
22. Check valve
23. Steering valve
26. Pressure switch
27. Filter
28. Hydraulic filter
29. Emergency pump
1 O-80-4
0
Serial No.: 12023 - 12050
27.4MPa 27.4MPa 27.4MPa

~280ks/cm~l
14 16
rl
24.5MPa
(250Wcm~l
2
--i-___ 3
I ! / I
4
---i---.__.i..-.__.i.._..__i--__-_~j
ILS
.*+-m-------
22 27
1 O-80-6
0
24.5MPa
3------
4
5 Il
SWG00365
10-80-7
0
1. Hydraulic tank
2. Breather
3. Strainer
78. Ripper control spool
8C. Leaning spool
8D. Service spool
10. Accumulator
12. Ripper cylinder
15. Swivel joint
22. Check valve
23. Steering valve
26. Pressure switch
27. Filter
29. Emergency pump
30. Relief valve
1O-80-8
0
27.4MPa 27.4MPa 27.4MPa

(28Ok/cm'l (280kP/cmzl
24.5MPa
A4 -_83 -.__-____
A3 82 -._______
A2 Bl _
7; > I
25
_-
r i P
As
!*-@L------- _,
L
22 27 :--
10-80-10
0
L_
24.5MPa
,-
; ----------- ----yq+_____ ____________________----_---------~
id27
27
i
IO
, , __-------_j@_
12
10-80-11
0
1. Hydraulic tank
2. Breather
3. Strainer
7B. Ripper control spool
8C. Leaning spool
8D. Service spool
10. Accumulator
12. Ripper cylinder
15. Swivel joint
22. Check valve
23. Steering valve
26. Pressure switch
27. Filter
29. Emergency pump
30. Relief valve
31. Relief valve
10-80-12
CLOSED CENTER LOAD SENSING SYSTEM (CLSS)
This machine uses the CLSS in the hydraulic system This system consists of the following components.
to supply an oil flow to each actuator to match the l Variable displacement piston pump with
characteristics of the work equipment at a pressure servo-valve
corresponding to the actuating load. l Selector valve with proportional flow control
This increases the working performance and saves function
the fuel consumption. l Reducing type pressure compensating valve
Advantages
(I 1 Constant of work equipment

speed not influenced by
engine speed.
Increase of operating
performance
(2) Extension and retraction Reducing type pressure
speeds of cylinder the
same.
(3) Excellent fine control

performance
Selector valve with
proportional flow
control function
(4) Excellent control for
compound operations
(6) Saves energy Fine control loss saving

I Y/
I
- I ’ /
i Relief loss saving
(I) Constant of work equipment speed not in-

fluenced by engine speed.
(2) Extension and retraction speeds of cylinder the
same.
The flow control is decided by the area of restric-
tion and the difference in pressure on either side
of the throttle. Even if the engine speed rises, the
difference in pressure is equal and the swash
plate angle of the variable displacement piston
pump is constant, so the delivery of the pump re-
mains the same.
1o-:‘-1
(3) Excellent fine control performance
The oil flow to each actuator is proportional to
area E of the gap between the valve body and
the selector spool of the control valve. It is not in-
fluenced by the load, so the fine control range is
a large 60 - 70%. Therefore, it is possible to
move each part of the work equipment at a
medium speed to enable more precise
operations.
F23501073
(4) Excellent control for compound operations.

During compound operations, the hydraulic
servo detects the larger actuating force and con-
trols the pump delivery pressure. The reducing
Work equipment control lever travel
type pressure compensating valve on the IoW
load (actuating pressure) side controls the pres- F23501074
sure difference on both sides of the selector

valve to a constant value, so the operation is the
same as for independent operations.
- To actuator
Reducing type pressure Selector valve with
compensating valve proportional flow
Variable displacement control function
piston pump - From actuator
++
Pump delivery pressure
I
I t
I
_-_-__c---- A f
Actuating pressure
Return
_ Oil flow
- -w Control flow F23501075
(5) Flow control to match each part of work

equipment
The power needed (pressure x oil flow) when
operating the blade lift cylinder, which needs pre-
cise movement, and when rotating the circle,
which needs speed and rotation torque, is ob-
viously different. With the CLSS, if the ‘area of
the gap explained in (3) Fine control is increased,
a large flow of oil can be supplied. Or, the oil flow
(cylinder speed) can be set in the same way for
12) Extension and retraction speed of cylinder.
(6) Saves energy
The CLSS is a system in which the pump delivers
the necessary oil flow at the necessary pressure.
Compared to the hydraulic circuit used with gear
pumps, the loss of hydraulic power and hydraulic
energy is extremely small.
c
CLSS Gear pump CLSS Gear pump
In neutral Pump delivery amount During fine

control
Only an oil flow to replace The pump is always Both the pump delivery The pressure corresponds
the oil which leaks from delivering oil, and pressure pressure and delivery to the load, but only part c
the high pressure circuits is caused by the resistance amount are controlled, so the delivery amount is
of the valve and pump to in the piping circuit, so the the power loss is small. used, so the power loss is
the lower pressure circuit is power loss is large. large.
needed. In addition, the
delivery pressure is the
standby pressure, so the
power loss is small.
F
(1
Uunderno load)
The pump delivery The pump delivery The hydraulic servo acts to All the oil delivered from
pressure is kept low, so the pressure depends on the prevent the pump delivery the pump is wasted, so the
power loss is small. load, so the power loss is pressure from going above power loss is extremely
small. the relief pressure, so the large.
oil flow is reduced and the
power loss is imall.
P: Pressure
0: Oil quantity
m Power loss
HYDRAULIC PUMP
VXD70-1 F
!
\
Suction port
Section A-A
Detail of pump assembly
Section B-B 21, I Detail of servo valve

/ \ \
17 ii 18 19 F23501077A
t
1. Servo valve assembly 6. Swash plate 11. Coupling 16. Dummy spool
2. Pump assembly 7. Front shaft 12. Housing 17. Yoke
3. Cylinder block 8. Front cover 13. Swash plate 18. Servo piston
4. Piston 9. Housing 14. Rear shaft 19. Guide
5. Shoe 10. Center section 15. Rear cover 20. Stopper pin
1O-82
0
PRINCIPLE OF OPERATION OF PISTON PUMP
FUNCTION
. It converts the rotation torque transmitted by the
pump shaft into hydraulic energy, and discharges
pressurized oil corresponding to the load.
. It is possible to vary the amount of oil discharged
by changing the angle of the swash plate.
OPERATION
Input shaft (2) is fitted with a spline and rotates cylin-
der block (I ). The nine pistons (4) contained inside
the cylinder block move in a reciprocal motion. The
distance moved in and out by the pistons is controlled
by the angle of swash plate (3) of the pump. This
swash plate is supported by trunnion (5). The only
parts that rotate are the input shaft and the cylinder
block. The input shaft does not contact the swash
plate of the pump. Therefore, when the directional
lever is at the Neutral position, and the sliding surface
of the pump swash plate is flat and vertical, there is 262F0 I6
no movement of oil to the motor, so no rotation is
given to the motor. The transmission speed can be
controlled steplessly by changing the angle of the
swash plate with the pump control lever.
When control lever (8) is moved to the left, the

swash plate is angled to the left and cylinder block
(I) rotates. Oil passes through port B (71, and is
sucked in through the piston hole. By carrying out
continuous rotation, the oil passes through port A
Input
(6). and is discharged to the motor to rotate the
Output
motor.
262F0 IS
When control lever (8) is moved to the right, the

swash plate is angled to the right and cylinder block
(I) rotates. Oil passes through port A (61, and is
sucked in through the piston hole. By carrying out
continuous rotation, the oil passes through port B
Output
(71, and is discharged to the motor to rotate the
motor in the opposite direction. Input
262FO20
1 O-83
OPERATION OF HYDRAULIC PUMP
FUNCTION
l This is a variable displacement swash plate type
piston pump with servo which can control the
amount discharged to match the pressure and oil
flow needed for the work equipment and steering
circuit.
l The pump assembly consists of the pump and
servo portion (servo valve and servo piston).
OPERATION
1. When engine is stopped
l No hydraulic pressure is generated, so servo
piston (1) is pushed fully to the left by the
force of spring (2).
l Swash plate (3) of the pump is interconnected
with servo piston (I), so it is at the maximum
swash plate angle.
235FO2024
2. Immediately after engine starts (work equipment
control lever, steering not operated)
1) The pump rotates at the maximum swash
plate angle, and oil is discharged from dis-
charge port P. The oil discharged from P is
sent to the main control valve and steering
valve, but the valves are closed, so the press-
ure in the circuit rises.
This circuit is connected with servo valve
chamber A, and the hydraulic pressure that is
generated overcomes the force of spring (5),
so spool (4) moves to the right.
When spool (4) moves to the right, servo
valve chamber A and servo piston chamber B
are connected, and servo piston (1) is pushed
to the right.
In addition, discharge port P is also connected
with servo piston chamber C, but the area of
chamber B is larger than the area of chamber
C, so servo piston (1) overcomes the force of
spring (2) and the pushing force of chamber
C, and moves to the right. This pushes back
swash plate (3) to a position where the dis-
charge amount is 0. (Servo piston chamber C
is a feedback pressure chamber. It is used to
improve the response and stabilize the oper-
ation of the servo piston, regardless of the 235FO2025
pressure in the circuit.)
1 O-84
2) In the condition in Section I), if the pressure
in the circuit drops, spool (4) of the servo
valve is pushed back to the left by spring (5),
and the oil in servo piston chamber B passes
through chamber E and is drained to the
case.
The pressure in chamber B drops, and the
force pushing servo piston (1) to the right is
removed, so servo piston (1) is moved to the
left by spring (2), and the angle of swash
plate (3) is changed to increase the discharge
of oil from the pump. The pump pressure
rises again, and piston (4) moves to the right
to a position where it balances with the push-
ing force of spring (5), and it then stays in this
position.
When this happens, the difference in balance
pressure is determined by the force of spring
(5), and is approx. 2.0 MPa (20 kg/cm2). In
other words, the pump is at the maximum
swash plate angle before the engine is
started, and provides the maximum discharge
immediately after the engine is started, but
the swash plate angle is immediately returned
235FO2026
to reduce the discharge amount to nearly the
minimum.
3. Work equipment lever, steering operated

If the work equipment levers or steering are oper-
ated, the load pressure of the actuator passes
through the LS line and goes to chamber D of the
servo valve (when the work equipment control
lever and steering are operated at the same time,
shuttle valve (6) inside the surge pressure absorp-
tion valve sends the high pressure side to cham-
ber D). The balance at spool (4) of the servo valve
is lost and spool (4) moves to the left.
In this way, the pressure in chamber B goeS
down, and servo piston (1) moves to the left. As a
result, the angle of swash plate (3) becomes
larger and the discharge amount increases.
As the amount of oil discharge from the pump in-
creases, the pressure in the circuit rises. When
the actuator is filled with the necessary pressure
and oil flow, the circuit pressure enters port A of
the servo valve and pushes spool (4) to the right.
The control differential pressure is balanced by
spring (5) at approx. 2.0 MPa (20 kg/cm2). In other
words, the pump pressure at this point is bal-
anced by the control differential pressure of ap-
prox. 2.0 MPa (20 kg/cm2) + load pressure Pz sent
from the actuator through the LS line.
235FO2027
1 O-85
4. When work equipment and steering are relieved
When the cylinder reaches the end of its stroke,
the relief pressure transmitted through the LS line
is sent to chamber D of the servo valve.
The servo valve is balanced by control differential
pressure approx. 2.0 MPa (20 kg/cm2) + load
pressure P2 of the LS line. Therefore, the pump
pressure is equal to the relief pressure + approx.
2.0 MPa (20 kg/cm2).
The cylinder has reached the end of its stroke and
the flow of the oil has stopped, so if the swash
plate is kept at the same angle, the pump press-
ure will rise further. If the pump pressure rises
further, the balance of the servo valve will be lost
and the pressure in servo piston chamber B will
rise. This pushes servo piston (I) to the right and
reduces the amount discharged by the pump.
In other words, at relief, the relief pressure is
maintained while the discharge amount is re-
duced (minimization of power loss).
235FO2028 8
4
8
1O-86
PRIORITY FLOW DIVIDER VALVE
8 7 6 235FO2029
1. Relief valve
2. Strainer
3. Spool
4. Body
5. PLUG, damping orifice
6. PLUG, flow control orifice
7. Orifice (for high response actuation)
, 17.2MPa
8. Spring
235FO2030
1 O-87
FUNCTION
l When the hydraulic systems for both the work
equipment and steering are covered by one
pump, if the work equipment and steering are
operated at the same time, there is danger that
the flow of oil to the steering circuit may be insuf-
ficient, making it impossible to operate the steer-
ing. This condition is extremely dangerous, so to
prevent this, the oil flow to the steering circuit is
given priority and is maintained by this priority
valve.
l This valve is a load sensing type and ensures only
the necessary flow of oil to the steering when the
steering is operated. When the steering is at neu-
tral, if a large amount of oil flows to the steering
circuit, the flow of oil to the work equipment cir-
cuit will drop, and the operating efficiency will
become poor. To prevent this and to ensure quick
response when the steering is operated, the flow
of oil to the steeering circuit is kept to the mini-
mum when the steering at neutral (approx. 1 Q/
min), and all the rest of the oil flows to the work
equipment circuit.
l The relief pressure of the steering circuit is set as
a different relief pressure from the relief pressure
for the work equipment circuit. It also has the
function of preventing any abnormal pressure in
the circuits.
OPERATION
1. When engine is stopped
Spool (1) is pushed to the right by spring (2).
In this condition, port CF is opened to the maxi-
mum and port EF is closed.
235FO2031
1O-88
2. When engine is started (steering and main con-
trol valves at neutral)
The oil from the pump flows to the steering valve,
but the steering valve is closed, so the pressure in
steering circuit CF rises.
The oil from the pump passes through orifice “a”
in spool (I), enters chamber B, and pushes spool
(1) to the left. At the same time, the oil passing
through orifice “b” of spool (1) enters chamber C,
passes from orifice “c” to the LS circuit, and is
drained to the’tank through the steering valve (the
flow in the LS circuit is normally 1 Urnin.)
When this flow passes through orifice ‘lb”, a dif-
ference in pressure of approx. 1.0 MPa (IO kg/
cm*) is formed on both sides of orifice “b”. The
pressure in chamber B is the pressure in chamber
C + 1.0 MPa (10 kg/cm2), so spool (1) is pushed
to the left and tries to close portion “d” of spool
(1). If the area of the opening at portion “d”
becomes smaller, the oil flow in the drain circuit
passing through orifice “b” becomes smaller, SO 235FO2032
the differential pressure on both sides of orifice

“b” becomes smaller and the force pushing spool
(1) to the left becomes weaker. Spool (1) is
pushed to the right by spring (2), and the flow of
oil through the opening at portion “d” again
becomes larger. When the oil flow becomes
larger, the opening at portion “d” again tries to
close. This is repeated until a balance is reached.
The forces acting on chamber B and chamber C
are as follows:
. Force in left direction (converted to hydraulic
force): PB [- 1.6 MPa (16 kg/cm2)]
. Force in right direction:
PC + 1 .O MPa (10 kg/cm’)
[= 1.6 MPa (16 kg/cm2)]
[I.0 MPa (10 kg/cm2) is the hydraulic force
converted for spring (2)]
1 O-89
0
3. Steering operated (main control valve at neu-
tral)
When the steering wheel is turned, the steering
valve is switched, and port CF and port LS are
connected to the steering cylinder. When this
happens, the pressure in chamber C becomes
higher, and spool (1) is pushed to the right by
spring (2). The area of the opening of portion “d”
of spool (1) becomes larger, so the oil from the
pump passes through port CF when the steering
wheel is being turned, and the necessary oil flow
goes from the steering valve to the steering cylin-
der.
If the steering wheel is turned quickly, and the
area of the variable throttle in the steering valve
becomes larger, the difference in pressure on
both sides of the variable throttle inside the steer-
ing valve becomes smaller, and the pressure in
the LS circuit rises. (The pressure in chamber 6
drops)
At the same time, the oil pressure in chamber C 235FO2033
also rises, so.spool (1) is moved further to the
right, and the area of the opening of portion “d”
also becomes larger. This sends a large oil flow to
the steering cylinder. On the other hand, if the
steering wheel is turned slowly, the differential
pressure on both sides of the variable throttle in-
side the steering valve becomes larger, and the
pressure in chamber B becomes larger than the
pressure in chamber C, so spool (1) is pushed to
the left, and the area of the opening of portion “d”
becomes smaller to match the flow of oil needed
for the steering valve. It becomes balanced in this
position.
In other words, spool (1) moves in accordance
with the flow of oil needed for port CF to maintain
the differential pressure between chamber B and
chamber C at 1.0 MPa (10 kg/cm2), and adjusts
the opening of portion ‘Id”. (In this way, all the oil
not needed for the steering can be used at port
EF.)
When the oil from port CF enters the steering cy-
linder and load is applied, the pressure in the cir-
cuit rises. This signal forms the PLS circuit and is
fed back to the pump servo valve. The angle of
the swash plate in the pump changed to increase
the discharge amount, and to increase the press-
ure in the circuit. In this way, the EL circuit acts to
detect the hydraulic load on the steering and
feeds back this information to the pump.
1O-90
4. Steering cylinder at end of stroke
When the steering cylinder reaches the end of its
stroke, and the operator continues to turn the
steering wheel, the flow of oil to the cylinder is
stopped regardless of the opening of the steering
valve.
There is no flow of oil, so the CF and LS press-
ures rise together with the pressure at pump port
P, and at the same time, pressures PB and PC
also rise, and spool (I) is moved to the right.
If pressure PC goes above 17.2 MPa (175 kg/cm2),
relief valve (3), which is being pushed to the right
by spring (4), opens and drains the oil in chamber
C.
Because of this flow of oil, a difference in press-
ure on both sides of orifice “b” is created, and
pressure PC becomes lower than pressure PB. As
a result, spool (1) moves to the left to a position
where the oil flow inside the spool is 1 Q/min.
Spool (1) remains at a position where portion “d”
of the spool is throttled, and this prevents the 235FO2034
large loss when the oil is drained if the circuit is
relieved.
If spool (1) moves too far to the left, portion “d” is
closed and the oil stops flowing. The flow of oil
through orifice “b” stops, so pressure PC and
pressure PB become the same, and spool (I) is
moved again to the right by spring (2) to open
portion “d”. Because of this repeated action, the
pressure in the steering circuit is maintained at a
maximum of 17.2 MPa (175 kg/cm2).
5. Steering valve at neutral, work equipment con-

trol lever operated
If the work equipment control levers are operated,
pressure PA of the pump port changes to 2.0 -
24.5 MPa (20 - 250 kg/cm2). However, the steer-
ing valve is at neutral, so the condition is the
same as when the engine is started (steering,
main control valve at neutral), and the force oper-
ating spool (1) is constant regardless of pressure
PA. If pressure PA rises, the pressure at port CF
also rises momentarily, and the amount of oil
flowing through orifice “b” increases.
A large difference in pressure is created, so spool
(1) is pushed to the right, and the area of the
opening of portion “d” becomes larger. However,
the area of the opening of portion “d” again
becomes smaller and is balanced. In this condi-
tion, the oil flow is automatically adjusted so that
only 1 Q/min flows to the steering valve.
235FO2035
10-91
6. Steering, work equipment operated simulta-
neously
1) When load on steering circuit is higher than
load on work
The actuation
as in Section
equipment
condition
3 “When
circuit.
is basically
steering
the same
is operated
e 63
A 1
(main control valve at neutral).

Port CF is at the same pressure as pump port
chamber A, and port EF is throttled by portion
“e” of spool (I) until it balances at the same
pressure as the pressure needed for the work
equipment. In other words, the main circuit
pressure for the pump is sent to the steering
To steering
circuit.
cylinder
235FO2036
2) When load on steering circuit is less than load

on work equipment circuit
Circuit CF satisfies the demand for the
amount of oil and oil pressure for the steering
circuit, but compared with port CF, when the
pressure at port EF is higher, the flow of oil
through portion “d” of spool (1) increases and
the pressure in chamber B rises.
As a result, spool (I) moves to the left, and
the area of the opening at portion “d”
becomes smaller. It balances so that the
pressure and oil flow matches the needs of
port CF. In other words, the pressure and oil
flow needed for the steering circuit is sup-
plied to the steering circuit by priority regard-
less of the pressure in the work equipment
circuit.
235FO2037
1 O-92
SURGE PRESSURE ABSORBING VALVE
B-B
A-A 235FO2038
1. Cover P. From hydraulic pump

2. Body T. To hydraulic tank
3. Spool Xl. From hydraulic control valve R.H.
4. Valve X3. From steering valve
5. Shuttle valve plug X4. From hydraulic control valve L.H.
6. Shuttle valve YI. From servo valve
1o-93
FUNCTION
. If the control lever is moved from an operating
position to neutral, the circuit between the pump
and the control valve is closed, but the pump
swash plate is prevented from returning to the
minimum swash plate angle by the inertia, so the
pump continues to discharge oil. As a result,
there is high pressure in the pump circuit (surge
pressure). This valve is installed to prevent this
high pressure.
. In order to obtain the necessary amount of oil dis-
charged from the pump when the work equip-
ment or steering are operated, it is necessary to
detect the highest pressure from the three inde-
pendent valves (left, right, main control valve,
steering valve), and to send this information to
the pump servo valve.
This valve also has the function of detecting the
highest pressure.
OPERATION
I. Control lever or steering operated
If we take the comparative size of the pressures
of the right control valve, left control valve, and
steering valve as PXI > PX3 > PX4, hydraulic
pressure PXI, which is the highest pressure, is
sent to chamber B by two shuttle valves (3) and
(4). At the same time, the pump discharge press-
ure is connected to port A.
The following forces are acting on spool (1).
Pressure to right from chamber A:
PXI + 2.0 MPa (20 kg/cm*)
[2.0 MPa (20 kg/cm*) is the differential press-
ure of the pump control pressure for the
valve.]
Pressure to left from chamber B:
PXI i- 2.4 MPa (24 kg/cm2) A. 1
[2.4 MPa (24 kg/cm2) is the converted hy-
draulic pressure for spring (2)]
The pressure in chamber B is larger, so valve (I)
is at the left and closes the drain port.
TO
priority flow 6
divider valve
235FO2039
1o-94
2. When operation of control lever or steering is
stopped
The moment the operation of the control lever or
steering is stopped, the circuit between the pump
and the valve is closed. However, because of iner-
tia, the pump swash plate does not return im-
mediately to the minimum swash plate angle, and
the pump continues to discharge oil, so there is
high pressure in the pump discharge circuit.
As a result, the pressure in chamber A rises
momentarily, and when it exceeds the pressure in
port B, valve (1) is moved to the right. This re-
leases the pressure in chamber A to the drain cir-
cuit and prevents the generation of surge press-
ure.
divider valve
235FO2040
1o-95
STRUCTURE AND FUNCTION HYDRAULIC CONTROL VALVE
HYDRAULIC CONTROL VALVE

Serial No.: 11001 - 12022
L.H. VALVE
(Left blade lift, Ripper, Blade side shift, Power tilt and Circle rotation)
12345
1-G H - H, J - J
K-K,L-L
F-F
B-B C-C.D--D
A-A
\
io
1. Blade lift spool (L.H.)

2. Ripper spool
3. Blade side shift spool
4. Power tilt spool
5. Circle rotation spool
6. Pilot relief valve
7. Shuttle valve
8. Body
9. Pressure compensating valve
10. Flow control valve
P. From hydraulic pump

T. To hydraulic tank
E-E
235FO2041
1O-96
0
R.H. VALVE
(Right blade lift, Leaning, Articulate, Drawbar and Service)
G-G
l--G H-H,J-J, K-K

F-F
8 9
J
A-A,B-B,C-C D-D E-E
\
10
235FO2042
1. Drawbar shift spool

2. Articulate spool
3. Leaning spool
4. Service spool
5. Blade lift spool (R.H.)
6. Pilot relief valve
7. Shuttle valve
8. Body
9. Pressure compensating valve
10. Flow control valve
P. From hydraulic pump

T. To hydraulic tank
1o-97
0

L.H. VALVE
A-A. B-B E-E

c-c. D-D
H-H
G-G SWG00366
1. Blade lift spool (L.H.)

2. Ripper spool
3. Blade side shift spool
4. Power tilt spool
5. Circle rotation spool
6. Pressure compensating valve spool
7. Shuttle valve
P: From hydraulic pump

T: To hydraulic tank
10-97-l
0
R.H. VALVE
(Right blade lift, Leaning, Articulate, Drawbar shift and Service)
I 2 3 4 5
F-F
A-A, E-0
c-c. D-D
E-E
7
H-H
G-G SWG00369
1. Drawbar shift spool

2. Articulate spool
3. Leaning spool
4. Service spool
5. Blade lift spool (R.H.)
6. Pressure compensating valve spool
7. Shuttle valve
P: From hydraulic pump

T: To hydraulic tank
10-97-2
0
PRESSURE COMPENSATING MECHANISM OF
Serial No.: 11001 - 12022
The control valve acts to start, accelerate, decelerate,

and stop the actuators.
A feature which is typical of these functions is the
metering function (the relationship between the con-
trol flow of the valve and the spool stroke of the se-
lector valve). This feature is obtained by controlling
the throttle installed in the selector valve by the
amount the lever is controlled. However, it has the
disadvantage that it is influenced by the load press-
ure, so even if the valve stroke is the same, it is fast
when the load pressure is low and slow when the
load pressure is high.
To overcome this problem, it is necessary to keep the
pressure difference on either side of the control
(throttle) constant to obtain a constant control flow re-
gardless of the load pressure. The pressure compen-
sating mechanism is used to perform this function.
OPERATION
1. Control lever at neutral (immediately after en-
gine is started)
The oil discharged from the pump enters .cham-
C b B A 2
ber B from chamber A of pressure compensation
spool (2), and enters chamber C through orifice
“b”. The pressure in chamber C becomes greater
than the force of spring (3), so pressure compen-
sation spool (2) moves to the right.
When pressure compensation spool (2) moves to
the right, chamber A and chamber B are closed,
and control pressure 0.6 MPa (6 kg/cm2), which
balances with the force of spring (3), is supplied
to chamber B.
The hydraulic pressure from the pump does not
flow to the work equipment because the work
equipment circuit is closed by work equipment
spool (1).
235FO2043
1 O-98
0
2. When control lever is operated.
1) If the control lever is operated and work
equipment spool (1) moves to the left, the oil
from the pump enters chamber F from cham-
ber E of work equipment spool (I), passes
through chamber G, and is sent to the work
equipment.
The pressure in chamber G is transmitted to
spring chamber D through orifice “a”, and is
applied to the right end of pressure compen-
sation spool (2). When the pressure in cham-
ber D rises, pressure compensation spool (2)
moves to the left, pump circuit chamber A is
connected to chamber B, and the pressure in
chamber B rises.
The pump pressure passes through orifice “b”
and is applied to the left end of pressure com-
pensation spool (2), so the pressure in cham-
ber C rises. As the pressure rises, the force in
the left direction becomes greater, and when
it overcomes the sum of the pressure in
chamber D (load pressure) + the force of 235FO2044
spring (3), pressure compensation spool (2) is
pushed back to the right. At this point, the
force acting on pressure compensation spool
(2) is as follows.
Force in right direction = pump pressure
Force in left direction = load force f
force of spring (3)
In this condition, pressure compensation
spool (2) is balanced,,so the pressure on the
left and right sides is equal.
Pump pressure = load pressure + force of
spring (3)
The differential pressure on both sides of por-
tion H (chamber F, chamber G), which con-
trols the flow of oil for work equipment spool
(1) is determined and kept constant by the
force of spring (3) (approx. 0.6 MPa (6 kg/
cm2)).
1o-99
2) When the pressure for the work equipment
rises, the pressure in chamber G goes to
chamber D through orifice “a”, and the bal-
ance at pressure compensation spool (2) is
lost. Pressure compensation spool (2) is
pushed to the left and opens control corner
“J” at the bypass end, so the oil from the
pump passes from chamber A through cham-
ber B and flows to chamber G of work equip-
ment spool (1).
The pressure in chamber G rises, so the
pump pressure and the pressure in chamber
B also rise.
The pressure in chamber B passes to cham-
ber C through orifice “b”, so pressure com-
pensation spool (2) is pushed back to the
right, and pressure compensation spool (2)
again becomes balanced. The pressure dif-
ference on both sides of flow control portion
H (chamber F, chamber G) is taken as the
force of spring (3).
235FO2045
3) When the pressure in the work equipment

C b B J
goes down, the pressure in chamber G goes
to chamber D through orifice “a”, and the bal- \\\\ Lv/”
ance at pressure compensation spool (2) is

lost. Pressure compensation spool (2) is
pushed to the right and the flow of oil
through control corner “J” at the bypass end
is reduced.
Because of this, the pressure in chamber B
and chamber C goes down, so pressure com-
pensation spool (2) is pushed back to the left
and pressure compensation spool (2) again
becomes balanced. At the point where the
pressure difference on both sides of flow con-
trol portion H (chamber F, chamber G)
becomes the force of spring (3).
In this way, pressure difference AP on both
sides of flow control portion H is kept con-
stant [approx. 0.6 MPa (6 kg/cm2)], se if area
S of the opening of flow control portion H is
constant, oil flow Q which passes through it
235FO2046
remains constant regardless of the load.
0 m (proportional) S X JZF
10-100
OPERATION
The control valve acts to start, accelerate, decel- 1. Control lever at neutral (immediately after
erate, and stop actuators. engine is started)
A feature which is typical of these functions is The oil discharged from the pump enters
the metering function (the relationship between chamber B from chamber A. The pressure in
the control flow of the valve and the spool stroke chamber C becomes greater than the force
of the selector valve). This feature is obtained of spring (3), so pressure compensation spool
by controlling the throttle installed in the selec- (2) moves to the right.
tor valve by the amount the lever is controlled. When pressure compensation spool (2)
However, it has the disadvantage that it is the moves to the right, chamber A and chamber
influenced by the load pressure, so even if the B are closed, and control pressure, which
valve stroke is the same, it is fast when the load balances with the force of spring (31, is sup-
pressure is low and slow when the load pres- plied to chamber B.
sure is high. The hydraulic pressure form the pump does
To overcome this problem, it is necessary to not flow to the work equipment because the
keep the pressure difference on either side of work equipment circuit is closed by work
the control (throttle) constant to obtain a con- equipment spool (I ).
stant control flow regardless of the load pres-
sure. The pressure compensating mechanism is
used to perform this function.
- SWG00428
10-100-1
0
2. When work equipment lever is operated Pressure pushing to right = pump pressure
1) When work equipment spool (1) is The force pushing to the left = load pres-
moved up, the oil in chamber B passes sure + force of spring (31, so pressure
through chamber C of work equipment compensation spool (2) is kept in bal-
spool (1) and is sent to the actuator. ance in this condition.
At the same time, the pressure in cham- The forces to the left and right are equal.
ber C is transmitted from small hole a to Pump pressure = load pressure + force
spring chamber D and is applied to the of spring (31, so the difference in pres-
right side of pressure compensation sure at the front and rear sides of the
spool (2). flow control portion of work equipment
When the pressure in chamber D rises, spool (I) (chamber B and chamber C) is
spool (2) moves to the left. Pump circuit determined by the force of spring (3) and
chamber A is connected to chamber B, is kept constant.
and the pressure in chamber B rises. The
pressure in chamber B is applied to the
left end of pressure compensation spool
(2), so as the pressure in chamber B rises,
and the force to the right increases. When
it overcomes the combined force of the
pressure in chamber D (load pressure) +
force of spring (31, spool (2) moves to
the right. When this happens, the force
acting on pressure compensation spool
(2) is as follows:
1o- 100-2
0
2) When the pressure for the work equip- 3) When the pressure in the work equip-
ment rises, the pressure in chamber C ment goes down, the pressure in cham-
goes to chamber D through orifice “a”, ber C goes to chamber D through orifice
and the balance at pressure compensa- ” a I’, and the balance at pressure com-
tion spool (2) is lost. Pressure compen- pensation spool (2) is lost. Pressure com-
sation spool (2) is pushed to the left and pensation spool (2) is pushed to the right
opens control corner “E” at the bypass and flow of oil through control corner
end, so the oil from the pump passes “E” at the bypass end is reduced.
from chamber A through chamber B and Because of this, pressure in chamber B
flows to chamber C of work equipment and chamber C goes down, so pressure
spool (I). compensation spool (2) is pushed back
The pressure in chamber C rises, so the to the left and pressure compensation
pump puressure and the pressure in spool (2) again becomes balanced. At
chamber B also rise. the point where the pressure difference
The pressure in chamber B pushes back on both sides of flow control portion
pressure compensation spool (2) to the (chamber B, chamber C) becomes the
right, and pressure compensation spool force of spring (3).
(2) again becomes balanced. The pres- In this way, pressure differnce AP on both
sure difference on both sides of flow sides of flow control portion is kept con-
control portion (chamber B, chamber C) stant, so if area S of the opening of flow
is taken as the force of spring (3). control portion is constant, oil flow Q
which passes through it remains con-
stant regardless of the load.
-
QOC (proprotional) S X liAP
SWG00429
1o- 100-3
0
BLADE LIFT SPEED ADJUSTMENT MECHANISM
Serial No.: 11001 - 12022
OUTLINE
. If there is a great difference in the blade lift speed
on the left and right, or if it is desired to reduce
the left and right blade speeds, it is possible to
adjust with the adjustment bolt.
l The adjustment bolt has an adjustment range of
4.8 turns, and if the adjustment bolt is loosened,
the cylinder speed will become slower.
FUNCTION
l When adjustment bolt (1) is loosened, the force of 2 3 1
spring (3) is reduced, so the force in the left direc-
tion is also reduced.
. In this condition, the differential pressure AP on
both sides of flow control portion H (chamber F,
chamber G) is reduced to balance pressure con-
trol spool (2).
l Therefore, oil flow Q passing through oil flow con-
trol portion H is reduced, and the blade lift cylin-
der speed becomes slower.
l On the other hand, if adjustment bolt (1) is
screwed in, oil flow Q increases, and the speed of
the blade lift cylinder becomes faster.
Q CC (proportional) S X p
(S = Area of opening at portion H)
235FO2047
1o- 100-4
0
Outline
. If there is a great difference in the blade lift
speed on the left and right, or if it is desired
to reduce the left and right blade speeds, it
is possible to adjust with adjustment bolt
(I).
. If adjustment bolt (I) is loosened, the cylin-
der speed will become slower.
Operation
. When adjustment bolt (I) is loosened, the
force of spring (3) is reduced, so the force in
the left direction is also reduced.
In this condition, the differential pressure AP
on the front and rear sides of flow control
portion F (chamber B and chamber C) is re-
duced to balance pressure compensation
spool (2). Therefore, the oil flow passing
through oil flow control portion F is reduced,
and the blade lift cylinder speed becomes
slower. On the other hand, if adjustment bolt
(I) is screwed in, oil flow Q increases, and
the speed of the blade lift cylinder becomes
faster.
QOC (proprotional) S X m
(S = Area of opening at portion F)
SWG00431
PILOT CHECK VALVE
(For Blade lift R.H.)
1. Pilot valve
2. Check valve
F23501093
F23501092
OPERATION
When the control valve is operated to lower the
blade, pressure is generated at the bottom end of the
blade lift cylinder. This pressure passes through a
throttle and pushes pilot valve (1). This opens pilot
check valve (2), and the oil in chamber C at the
cylinder head returns to the tank. The blade hold
pressure is acting on the head end of the blade lift
cylinder. When it pushes open check valve (21, the oil
in chamber C suddenly escapes to chamber A, and
the pressure at the bottom drops.
When this happens, if there is no throttle at the pilot
valve, the check valve will always open and close ac-
cording to the changes in the pressure at the bottom
and head ends. This will cause blade chattering. To E
prevent this, a throttle is installed at E which acts as
a damper, so even if the pressure at the bottom end
drops, the check valve will not close immediately.
I F23501094
1o-1 02
PILOT CHECK VALVE
(For Articulate, Leaning and Drawbar)
1. Check valve
2. Piston
3. Body
4. Plug
,5
5. Plug
6. Check valve
Al A2
_ -
F23BH1115
F23BH1116
OPERATION
When the control valve is operated, the oil from the
pump enters port A,, opens check valve (61, and
flows into port B,. When a pressure is generated, the
oil from orifice E pushes up piston (2) and opens
check valve (1). so the oil connecting port B, and
port A, flows into the drain port.
Hunting occurs because check valve (1) opens and
closes in accordance with the fluctuations in pressure
at the bottom side and head side, but because of ori-
fice E, a damper effect is provided so that check
valve (1) will not close immediately even if the pres-
sure at port A, goes down.
F23BH1117
10-103
PILOT CHECK VALVE (WITH SAFETY VALVE)
(For Blade lift L.H.)
1. Check valve
2. Plug
3. Body
4. Piston
5. Relief valve
.-.
-----
.-.
'-1
The check valve with safety

drift of the
from abnormal
cylinder
valve prevents
and also protects
pressure caused by external
the
F23501098
hydraulic
cylinder
force.
R
I-
A2
L
Al
F23501099
When the blade lift is raised to the maximum position

and the drawbar is shifted to the side, the drawbar
stopper and lifter come into contact. The check valve
with safety valve installed to the blade lift cylinder
(left) acts to prevent damage to the work equipment
caused by this contact.
OPERATION
When the lever is operated to retract the cylinder, oil
from the pump enters chamber AI and pushes check
valve (1). It then passes through chamber BI and
flows to the chamber at the head of the cylinder to
push the cylinder piston. The oil at the cylinder
bottom end flows back through chamber Bz and
chamber AZ and returns to the tank.
When the lever is operated to extend the cylinder,
the oil from the pump enters chamber A2 and flows
through chamber B2 to the cylinder bottom end. As
the pressure in chambers A2 and B2 rises, piston (4)
is pushed. This pushes open check valve (I ), and the
oil at the cylinder head flows from chamber BI
through the throttle of check valve (1). It then flows
from chamber AI hack to the tank.
If there is any shock to the work equipment during
operations, and the pressure in chamber BI rises to
an abnormal pressure of 280 kg/cm2 or more, relief
valve (5) is pushed open and the oil flows to chamber
B2. This raises the work equipment and relieves the
shock. 235F247
10-104
(For Ripper and Power tilt)
1. Check valve
2. Piston
3. Body
4. Check valve
5. Relief valve
-5
The check valve with safety valve prevents hydraulic

drift of the cylinder and also protects the cylinder
from abnormal pressure caused by external force.
OPERATION
When the lever is.operated to extend the cylinder, oil
from the pump enters chamber A, and pushes piston
(2) and check valve (4). It then passes through cham-
ber B, and flows to the chamber at the bottom end
of the cylinder. The oil at the cylinder head flows
back through the chamber B, and chamber A,’ and
returns to the tank.
When the lever is operated to retract the cylinder, the
oil from the pump enters chamber A,. As the pres-
sure in chamber A, rises, check valve (I) is pushed.
This pushes open check valve (I), and the oil flows
to the cylinder head from chamber B,.
If shock causes abnormal pressure of over 280
kg/cm2 in chamber B,, it pushes open relief ,valve (5)
and oil flows to chamber B, to relieve the shock.
10-105
0
CIRCLE ROTATION MOTOR
Serial No.: 11001 - 12050
ME300-FTS
F23501104
1. Cover
2. Bearing
3. Thrust plate
4. Slipper retaining ring
5. Slipper
6. Spring
7. Piston
8. Bearing
9. Thrust retainer plate
10. Timing plate
1 1. Cylinder block
12. Shaft
13. Casing
ircle rotation gear
/ Circle rotatiol; motor

F23501071-1
lo-106
0
4
F23501105
When high pressure oil flows in from main port R, it

passes through timing plate (10) and enters cylinder
(1 1). This high pressure oil acts on piston (7). and the
movement of the piston in the axial direction causes
slipper (5) to push thrust retainer plate (9). Rotating
force is generated in cylinder block (1 11, and the
rotating force is transmitted to output shaft (I 2),
which forms one unit with cylinder block (1 1). When
this happens, the output shaft rotates in the direction
of the arrow 0 , and even at low speed, performs
interconnected operation smoothly. The low pressure
oil after actuating passes through timing plate (IO)
and flows out from main port L.
If the inlet and outlet ports are reversed, the direction
of rotation is also reversed.
1o-1 07
ME150203AAAA
1. Housing
2. Key
3. Coupling shaft
4. Drive shaft
5. Wear plate
6. Rotor set
7. Manifold
8. Commutator ring
9. Commutator
IO. End cover
lo-108
0
BLADE ACCUMULATOR SYSTEM
235FO2048
i Iii 3
1.
2.
3.
Solenoid
Solenoid
valve
valve
Pilot check valve
(for blade float)
(for accumulator)
---- 4. Accumulator
5. Blade lift cylinder
6. Blade lift control valve
235FO2049
10-109
0
ACCUMULATOR
1. Cap
2. Shell
3. Bladder
4. Valve
5. Plug
6. Slow return valve
A: Nitrogen gas
B: Pressure oil (from blade cylinder)
C: From solenoid valve
t
C
SWG00004
FUNCTION
When oil pressure is applied to the blade cylin- shell (2) sends to the blade cylinder until the oil
der, the pressure oil flows to the accumulator pressure in the shell balances to that in blade
through the solenoid valve and pushes valve cylinder circuit. At this time, valve (5) closes
(6). This pushes valve (4), and the oil flows into throttling the return oil. This prevents the oil in
shell (2). Thereby, bladder (3) is compressed. shell (2) from flowing out abruptly and prevents
Consequently, the shock imposed on the blade the bladder from striking against the inside of
cylinder is reduced by the compressible amount the shell.
of the bladder. When the oil pressure in the The flow of oil in the accumulator hydraulic cir-
blade cylinder drops, the bladder expands by cuit is repeated smoothly to reduce the shock
the gas pressure in bladder (31, and the oil in imposed on the blade.
10-110
0
BLADE FLOAT SYSTEM
235FO2050
OUTLINE
l When the blade lift lever is at the N position, and
blade float switch (6) is turned ON, solenoid valve
(1) is actuated, and the bottom and head ends of
blade lift cylinder (3) are connected to the drain
circuit. This sets the blade in a floating condition. 2
l When blade float switch (6) is ON, and the blade
lift lever is operated to the RAISE or LOWER posi-
tions, switch (5) turns blade float switch (6), and
the blade returns to the normal RAISE or LOWER
condition, and this condition is maintained.
If the blade lift lever is returned to the N position,
the blade is placed in a floating condition.
t If the blade float switch is turned ON with the
blade raised, the blade will suddenly drop.
235FO2051

4. Blade lift control valve
5. Switch
6. Blade float switch
10-111
0
STRUCTURE AND FUNCTION DRAWBAR AND LIFTER
DRAWBAR AND LIFTER

Serial No.: 11001 - 12050
==- -==
==v -_==
i
__--
235CD02018
OUTLINE 1. Circle
The drawbar is an important piece of equipment 2. Drawbar
which supports the circle and blade. If ball joint (6) is 3. Blade lift cylinder
worn, use shim (5) to adjust the clearance at the joint 4. Drawbar side shift cylinder
so that there is no excessive play. When adjusting the 5. Shim
clearance at the contact portions of guides (8) and 6. Ball joint
(II), adjust with shims (7) and (IO), and adjustment
bolt (9).
10-112
0
A-A B-B ii i2 D-D

c-c
114
F-F G-G
235CD02019
There are two cylinders installed in the lifter for mov- 7. Shim
ing the blade device. Brackets (14) and (16) are in- 8. Guide
stalled by the guide which is welded to the main 9. Adjustment bolt
frame. They can be revolved by revolving the guide 10. Shim

by extracting a pin (17) controlled from the operator’s 11. Guide
seat. There are two insertion holes altogether for the 12. Bolt
pin stopping revolution. Holes (b) and (c) are used for 13. Yoke
the blade to make a bank cut to left or right. At other 14. Lifter bracket (Upper)
times, holes (a) are used. 15. Shim

These (a) get used much more than other holes and a 16. Lifter bracket (Lower)
bushing (18) is used in it to make the clearance be- 17. Pin

tween the pin and the hole at a minimum. (This clear- 18. Bushing
ance amplifies the up and down movement of the 19. Bolt
blade.) Also, the clearance between the bracket and 20. Pin
the guide welded to the frame can be adjusted with
shims (15). Pin (20) combined with bolt (19) tightening
force prevents bracket up and down slippage.
10-113
0
OUTLINE 1. Circle
The drawbar is an important piece of equip- 2. Drawbar
ment which supports the circle and blade. If ball 3. Blade lift cylinder
joint (6) is worn, use shim (5) to adjust the clear- 4. Drawbar side shift cylinder
ance at the joint so that there is no excessive 5. Shim
play. 6. Ball joint
When adjusting the clearance at the contact por-
tions of guides (20) and (17), adjust with shims
(16) and (191, and adjustment bolt (15).
10-113-l
0
B-B
I8 5
G-G ”
17 F-F
SWG00376
There are two cylinders installed in the lifter for 7. Lifter bracket (Upper)
moving the blade device. Brackets (7) and (9) 8. Shim
are installed by the guide which is welded to 9. Lifter bracket (Lower)
the main frame. They can be revolved by re- 10. Yoke
volving the guide by extracting a pin (13) con- 11. Bolt
trolled from the operator’s seat. There are two 12. Pin
insertion holes altogether for the pin stopping 13. Pin
revolution. Holes b and c are used for the blade 14. Bushing
to make a bank cut to left or right. At other 15. Adjustment bolt
times, holes a are used. 16. Shim
These a get use much more than other holes 17. Guide
and bushing (14) is used in it to make the clear- 18. Bolt
ance between the pin and the hole at a mini- 19. Shim
mum. (This clearance amplifies the up and down 20. Guide
movement of the blade.) Also, the clearance
between the bracket and the guide welded to
the frame can be adjusted with shims (8). Pin
(12) combined with bolt (11) tightening force
prevents bracket up and down slippage.
10-113-Z
0
STRUCTURE AND FUNCTION BLADE
BLADE
Serial No.: 11001 - 12050
V
\ \
6 1
Y
235CO02020
FUNCTION 1. Bracket
Side edge (5) installed to the blade is designed so that 2. Blade shift cylinder
it can be used twice by turning it upside-down and 3. Support
moving it to the other (left or right) side. 4. Blade
A power tilt device is installed to adjust the cutting 5. End bit
angle of the blade. Adjustment can be made freely be- 6. Bolt
tween 25” and 84” using a single lever. 7. Nut
The guide acts as a bushing for the sliding parts when 8. Cutting edge
shifting the blade to the side. If the clearance from the 9. Adjuster
sliding parts is too large and the finishing accuracy 10. Shaft
cannot be obtained, replace the guide.
10-l 13-3
0
STRUCTURE AND FUNCTION BLADE
FUNCTION 1. Bracket
Side edge (5) installed to the blade is designed 2. Blade shift cylinder
so that it can used twice by turning it upside- 3. support
down and moving it to the other (left or right) 4. Blade
side. 5. Side edge
A power tilt device is installed to adjust the cut- 6. Bolt
ting angle of the blade. Adjustment can be made 7. Nut
freely between 25” and 84” using a single lever. 8. Cutting edge
The guide acts as a bushing for the sliding parts 9. Adjuster
when shifting the blade to the side. If the clear- 10. Shaft
ance from the sliding parts is too large and the
finishing accuracy cannot be obtained, replace
the guide.
10-113-4
0
LIFTER BRACKET CONTROL PIPING
235CD02021
Detail A
F23501114
The lifter bracket is fixed by pin (3). When setting in the 1. Air tube
bank cutting position, operate control lever. This uses 2. Bank-lock valve
compressed air to push piston (4). The pin can be 3. Pin
removed and the bracket can then be rotated. 4. Piston
5. Spring
6. Bushing
10-114
CIRCLE ROTATION GEAR,
Serial No.: 11001 - 12050
6 7 8
Circle rotation motor

li 16 13 14 1‘3
F23501400
Outline 1. Cover
The circle rotation gear is driven by an oil motor 2. Spring
connected to worm gear shaft (17). 3. Disc
When the control valve is operated, disc (14) and 4. Plate
plate (15) are separated by pressurized oil, and the 5. Shaft
motive force is transmitted to pinion gear (9). If the 6. Case
control valve is not operated, disc (14) and plate 7. Worm wheel
(15) are pressed together by spring (13) and act as 8. Plug
a brake. Pinion gear (9) has a clutch mechanism, 9. Pinion gear
and if an abnormal rotating force is transmitted 10. Shim
from the blade, disc (3) slips to prevent breakage 11. Nut
of the blade. 12. Bolt
The clutch pressure of this clutch mechanism is ad- 13. Spring
justed by the thickness of shim (IO). 14. Disc
15. Plate
16. Drain plug
17. Worm gear shaft
10-115
0
Outline 1. Flowting seal

The circle rotation gear is driven by an oil motor 2. Shaft
connected to worm gear shaft (13). 3. Case
Pinion gear shaft (2) has a clutch mechanism, 4. Worm wheel
and if an abnormal rotating force is transmitted 5. Plate
from the blade, disc (6) slips to prevent break- 6. Disc
age of the blade. 7. Plug
The clutch pressure of this clutch mechanism is 8. Spring
adjusted by the thickness of shim (IO). 9. Cover
10. Shim
11. Pinion gear
12. Drain plug
13. Worm gear shaft
14. Oil motor
lo-116
0
REAR MOUNT RIPPER
-7 III
Section A-A
Section B-B
Section G-G
Section E-E
Section F-F
Section C-C Section D-D
F23501118
Ripper lifting height and digging depth can be con- 1 Ripper cylinder
trolled with ripper cylinder (1). Since the point tips 2. Pin
cut into the ground under the load of the ripper’s 3. Bracket
heavy weight, the ripper easily performs heavy-duty 4. Shank pin
digging work which cannot be done by the scarifier. 5. Shank
Two kinds of points are selectively used: A short 6. Point
point for heavy-duty work and a long point for ordi-
nary work.
10-l 17
0
HYDRAULIC CONTROL LINKAGE
1234 7 8 9 10
235FO2052
l Steering wheel and instrument panel tilting mech- 1. Blade lift R.H. lever
anism: 2. Service lever
Rotate tilt lever (11) to loosen the lock, move to a 3. Leaning lever
suitable position, then tighten the lever. 4. Articulate lever
The tilting angle can be adjusted steplessly 20”. 5. Drawbar shift lever
l Console box tilting mechanism: 6. Circle rotation lever
Depress pedal (12) to remove the dowel pin, and 7. Power tilt lever
the console box can be adjusted in five stages. 8. Blade shift lever
In this way, the steering wheel and console box can 9. Ripper lever
be set to the optimum position for the operator. 10. Blade lift L.H. lever
11. Tilt lever
12. Pedal
lo-118
0
A-A
B-B
F-F
E-E
G-G
H-H 235FO2053
10-119
0
Serial No.: 11001 – 12502
023502
10-120
(6)
023502
1. Main frame
3. Center pin
4. Pin
5. Grease fitting
10-120-1
(6)
STRUCTURE AND FUNCTION AIR CONDITIONER
Serial No.: 11001 – 11013
023502
10-120-2
(6)

023502
10-120-3
(6)
MOUNT-ON CONDENSER OPERATOR CAB SPECIFICATION

AIR CONDITIONER PIPING
023502
SYSTEM DIAGRAM
1. Air conditioner unit
2. Receiver tank
3. Compressor
4. Condenser
5. Hot water heater
6. Evaporator
7. Blower unit
10-120-4
(6)
ELECTRICAL WIRING DIAGRAM
(1/3)
023502
1. Head lamp 6. Air horn valve

2. Front combination lamp 7. Battery
3. Front working lamp (front of blade) 8. Radiator coolant level sensor
4. Front working lamp (rear of blade) 9. Battery relay
5. Parking brake valve 10. Transmission solenoid valve pick-up
10-121
(6)
(2/3)
023502
1. Heater relay 10. Air pressure sensor

2. Fuel gauge pick-up 11. Hydraulic oil temperature sensor
3. Ground connection of engine 12. Hydraulic oil level sensor
4. Final drive oil temperature sensor 13. Air gauge sensor
5. Rear combination lamp 14. Engine oil level sensor
6. Rear working lamp 15. Engine oil pressure sensor
7. Back-up lamp 16. Speed sensor
8. Back-up alarm 17. Water temperature gauge pick-up
9. Differential lock valve 18. Coolant level sensor (if equipped)
10-122
(6)
(3/3)
Serial No.: 11001 – 12502
023502
10-123
(6)
(3/3)
023502
1. Cluster gauge and pilot lamp 9. Horn relay

2. Turn signal lamp switch 10. Emergency steering relay
3. Monitor panel 11. Engine stop motor relay
4. Fuse box 1 12. Emergency steering controller
5. Fuse box 2 13. Warning buzzer (for emergency steering)
6. Stop lamp switch 14. Engine oil pressure relay
7. Hazard relay 15. Warning buzzer
8. Flasher relay
10-123-1
(6)
Serial No.: 12013 - 12015, 12019 and up
1. R switch * This shows components that have been

2. F switch added because of the installation of the trans-
3. Caution lamp mission controller.
4. Potentiometer (for shift lever)
5. Alarm buzzer
6. Relay (for alarm buzzer)
7. Transmission controller
8. Engine speed sensor
9. Potentiometer (for inching)
10. Transmission oil temperature sensor
(transmission outlet port)
11. Transmission solenoid
12. Speed sensor
lo-124
0
MONITOR PANEL, CLUSTER GAUGE AND PILOT LAMP
Serial No.: 11001 - 11030
27 235CD0202B
23
1. Coolant temperature gauge 15. Front wiper switch (Upper)

2. Caution monitor group 16. Service meter
3. Speedometer 17. Front wiper switch (Lower)
4. Accumulator, blade float select switch 18. Rear wiper switch
5. Service meter 19. Air pressure gauge
6. Differential control switch 20. Door wiper switch
7. Differential control indicator lamp 21. Emergency steering select switch
8. Accumulator indicator lamp 22. Lift arm lock indicator lamp
9. Blade float indicator lamp 23. Bank cut switch
10. Parking blake indicator lamp 24. Cab head lamp switch
11. Warning lamp 25. Rear working lamp switch
12. Head lamp switch 26. Front working lamp switch
13. Fuel gauge 27. Starting switch
14. Dimmer switch 28. Parking brake switch
10-125
0
,22
‘23
27 26 25 24 SDG00009
1. Coolant temperature gauge 16. Service meter

2. Caution monitor group 17. Front wiper switch (Lower)
3. Speedometer 18. Rear wiper switch
4. Accumulator, blade float select switch 19. Air pressure gauge
5. Service meter 20. Door wiper switch
6. Differential control switch 21. Emergency steering select switch
7. Differential control indicator lamp 22. Lift arm lock indicator lamp
8. Accumulator indicator lamp 23. Bank cut switch
9. Blade float indicator lamp 24. Cab head lamp switch
10. Parking brake indicator lamp 25. Rear working lamp switch
11. Warning lamp 26. Front working lamp switch (rear of blade)
12. Head lamp switch 27. Front working lamp switch (front of blade)
13. Fuel gauge 28. Starting switch
14. Dimmer switch 29. Hazard switch
15. Front wiper switch (Upper)
10-126
0
(1/2)
Serial No.: 12013 – 12015, 12019 – 12098
023502
10-134
4
(2/2)
Serial No.: 12013 – 12015, 12019 – 12098
023502
10-135
4
(1/2)
Serial No.: 12099 – 12502
023502
10-136
(6)
(2/2)
Serial No.: 12099 – 12502
023502
10-136-1
(6)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
TRANSMISSION ELECTRICAL CIRCUIT
Serial No.: 11001 - 11030
CN-TO1 Rotary
Diode
______
I Transmission
; solenoid valve
SWG00437
10-137
0
Serial No.: 11031 - 12012, 12016 - 12018
CN-RPB
Relay
(parking
brake1
iJJ Diode
SWG00438
lo-138
0
FR detect
Caution buzzer Cautlan buzzer
CN-RDI
I
yifferential
ock relay
lamp
used)
Shift potentic meter I
Shift Potentlo meter 2
Inching
CN_TM,, Potentio mete
,.___________
#- SWG00440
Serial No.: 12099 – 12502
023502
10-141-2
(6)
Serial No.: 12001 – 12502

023502
10-142-1
(6)
EELCTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER

(Refrigerant for R-12)
Serial No.: 11001 – 11013
023502
10-143
(6)
(Refrigerant for R134a)
Serial No.: 11014 – 12502
023502
10-144
(6)
r-k
If--!
CN-A6
I
Damper ~ ComPressor
Air
“-
conditioner I 4
CN-A3 unit I-
”
CN-27
Pressure
II
From
Lisnt switch
Fuse box
CN-
SWG00443
10-145
0
ELECTRICAL CIRCUIT DIAGRAM (1/6)
023502
10-146-1
(6)
023502
10-146-3
(6)
023502
10-146-5
(6)
(Transmission)
023502
10-146-7
(6)
(Steel cab)
023502
10-146-9
(6)
(Air conditioner)
023502
10-146-11
(6)
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)

Serial No.: 11001 - 12000
-4A
2A
5A
ii 5c 5D 5E 5F 235COO2032
1. Gauge 5. Pilot indicator

IA. Coolant temperature 5A. Preheater monitor
IB. Fuel level 5B. Emergency steering
2. Check (Check before starting items) 5C. Parking
2A. Hydraulic tank oil level 5D. Float
2B. Engine oil level 5E. Accumulator
2C. Coolant level 5F. Differential lock
3. Caution (Emergency warning items) 6. Turn signal pilot lamp
3A. Differential oil temperature 7. Head lamp (High beam)
3B. Engine oil pressure 8. Speedometer
3C. Hydraulic tank oil level 9. Service meter indicator
3D. Coolant temperature 10. Service meter
3E. Air pressure 11. Warning lamp
4. Caution (Warning items)
4A. Coolant level
4B. Battery charge
4C. Hydraulic tank oil temperature
10-147
0
3E 30 3C 38 3A 6 7 6
4A
2A 48
9
IO
4c
‘5B
1. Gauge 5. Pilot indicator

IA. Coolant temperature 5A. Preheater monitor
IB. Fuel level 5B. Emergency steering
2. Check (Check before starting items) 5C. Parking
2A. Hydraulic tank oil level 5D. Float
2B. Engine oil level 5E. Accumulator
2C. Coolant level 5F. Differential lock
3. Caution (Emergency warning items) 6. Turn signal pilot lamp
3A. Differential oil temperature 7. Head lamp (High beam)
3B. Engine oil pressure 8. Speedometer
3C. Hydraulic tank oil level 9. Service meter indicator
3D. Coolant temperature 10. Service meter
3E. Air pressure 11. Warning lamp
4. Caution (Warning items)
4A. Coolant level
4B. Battery charge
4C. Hydraulic tank oil temperature
10-148
0
INDICATION ON MONITOR PANEL
Serial No.: 11001 - 12000
Cate-
Symbol Indication item Indication range Description
gory
Hydraulic tank oil level Below low mark
Displays when starting switch is turned

to ON with engine stopped.
Engine oil level Below low mark - Display goes out when normal
+ Display flashes when abnormal
Coolant level Below low mark
Displays when engine is running

When charging is . Display goes out when normal
Battery charge
defective . Display flashes when abnormal and
lamps flash at same time
Hydraulic tank oil At specified tem-
temperature perature or above
Differential oil At specified tem-

Below specified
Engine oil pressure
pressure
Displays when engine is running

. Display goes out when normal
Hydraulic oil level Below low mark
. Display flashes when abnormel;
buzzer and lamp actuated
Coolant temperature Above 105°C
Below specified
Air pressure
pressure
Speedometer 0- 100 km/h Digital display
--
-0 High beam When operated
Displays when starting switch is turned ON;
4D
Lights up when operated
Turn signals (right, left) When operated
0 - 99999/h Actuated when engine oil pressure is normal

Service meter
displayed Advances 1 for every hour of operation
0 Service meter indicator When operated Flashes when service meter is operating
10-149
0
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM IEVMS)
Cate-
gory

PREHEAT When preheating
lights up during preheating
Lights up when emergency steering is

Emergency steering When operated
operated
Red 115OC
102.3-C
97OC
Coolant temperature ;reen
90°C One lamp lights up to indicate level
80°C
67’C
White
FULL
Fuel level All lamps light up below indicated level
Red EMPTY
L
10-150
0
Cate-
gory
Hydraulic tank oil level Below low mark
Displays when starting switch is turned

to ON with engine stopped.
Engine oil level Below low mark
Display flashes when abnormal
al s0c000!8
e,.,, 1 Coolant level Below low mark
Displays when engine is running.

When charging is Display goes out when normal
Battery charge
defective Display flashes when abnormal and
SAP00522 / lamps flash at same time.
Hydraulic tank oil At specified tem-

Differential oil A specified tem-

Below specified
Engine oil pressure
pressure
Displays when engine is running.

Hydraulic oil level Below low mark . Display flashes when abnormal;
buzzer and lamp actuated.
@I~
SDP00957
Coolant temperature Above 105°C
Below specified
Air pressure
pressure
0 - 100 km/h Digital display
--
--
- High beam When operated

Lights up when operated.
4 D Turn signals (right, left) When operated

lDGOOOl4
0 - 99999/h Actuated when engine oil pressure is normal

Service meter
displayed Advances 1 for every hour of operation
SKD00631
Service meter indicator When operated Flashes when service meter is operating
0
SKD00632
10-151
0
Cate-
gory

PREHEAT When preheating
lights up during preheating.
Lights up when emergency steering is

Emergency steering When operated
operated
El
Red 115’c
lOZf3'C
97-c
al
SDP00957
Coolant temperature Green 90"c
80"c
One lamp lights up to indicate level
67°C
White
SWG00461
FULL
;reer
Fuel level All lamps light up below indicated level
SAD00712
led EMPTY
SWG00462
10-152
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL SYSTEM
TRANSMISSION CONTROLLER
1. Display window
2. Connector
cN3 CN4 cN6
CNl cN2
2 SWCOO388
Outline
The transmission controller controls the system, 2) Prevention of overrun of engine or trans-
and has a built-in computer. When the operator mission
operates the shift lever, this is transmitted to When the transmission is shifted down, it
the controller, and the controller observes the judges if there is overrun of the engine or
condition of the machine and shifts to the speci- transmission, and does not shift down until
fied speed range. In this way, it is possible to the travel speed will not cause any overrun.
prevent excessive load on the transmission and If the machine is accelerated with the clutch
engine caused by any failure or mistaken opera- still partially engaged (acceleration caused
tion by the operator. by the weight of the machine when traveling
down hill), it shifts up at above the travel
Protective functions of transmission speed that is dangerous for the speed range
1) Observing disconriections or short circuits for the lever position.
It judges if there is any abnormality in the 3) Observing excessive inching load
transmission switch signals and uses a dou- It calculates the temperature of the clutch
ble system to prevent damage to the trans- and plate from the length of time that the
mission clutches. clutch is partially engaged, and warns of
If there is any abnormality, it carries out con- overheating of the clutch.
trol to prevent the clutch for that speed range
from being meshed.
10-154
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL SYSTEM
Shift lever position and transmission controller output
Controller output (0: output)
F R 1 2 3 / 4 / L / H j ST 1 FB 1 DF 1 PB 1 PL 1
Parking lamp
Parking brake
Backup buzzer
Starting motor
Differential lock solenoid
Transmission H clutch solenoid
Transmission L clutch solenoid
Transmission 4 clutch solenoid
Transmission R clutch solenoid
Transmission F clutch solenoid
10-155
0
STRUCTURE AND FUNCTION SENSORS
SENSORS
Display (use) category
Machine monitor Transmission controller
Check before starting
Type of sensor Sensor method When normal When abnormal

Caution 1
Caution 2
Gauge
Q Q Coolant level (Sub-tank) Contact ON (Close) OFF (OPEN)

Q Q Coolant level (Radiator upper tank) (if equipped) Contact OFF (OPEN) ON (Close)
Q Engine oil pressure Contact OFF (OPEN) ON (Close)
Q Q Engine water temperature Resistance — —
Q Hydraulic oil temperature Resistance — —
Q Final drive oil temperature Resistance — —
Q Transmission oil temperature Resistance — —
Q Q Speedometer Pulse — —
Q Engine speed Pulse — —
Q Air pressure (for air pressure gauge) Resistance — —
Q Air pressure Contact ON (Close) OFF (OPEN)
023502
Q Engine oil level Contact ON (Close) OFF (OPEN)
Q Q Hydraulic oil level Contact ON (Close) OFF (OPEN)
Q Fuel level Resistance — —
Q Shift potentiometer Resistance — —
Q Inching potentiometer Resistance — —
10-156
(6)
COOLANT LEVEL SENSOR
1. Sub-tank
2. Float
3. Sensor
4. Connector
Function
• The coolant level sensor is
installed to the radiator
sub-tank. If the coolant
goes below the specified
level, the float goes down
and the switch is turned
OFF. The warning lamp
then flashes.
023502
COOLANT LEVEL SENSOR (IF EQUIPPED)
1. Float Function
2. Sensor • The coolant level sensor is installed to the radia-
3. Tube tor upper-tank. If the coolant goes below the
4. Wire specified level, the float goes down and the
5. Connector switch is turned OFF. The warning lamp then
flashes.
10-156-1
(6)
ENGINE OIL PRESSURE SWITCH
1 2 3 4 5 6
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Function
. The engine oil pressure switch is installed to
the engine cylinder block. It uses a dia-
phragm to detect the oil pressure, and when
it goes below the specified pressure, the
switch is turned ON. The engine oil pressure
indicator lamp lights up to warn of the ab-
normality.
ENGINE WATER TEMPERATURE SENSOR

TRANSMISSION OIL TEMPERATURE SENSOR
FINAL DRIVE OIL TEMPERATURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
@&- 1.
2.
3.
Connector
Plug
Thermistor
@%!I
Composition of circuit
SBPO0379
Function
. The engine water temperature sensor is in- the final drive case. They send a signal to
stalled to the right side of the engine. the monitor panel. If the temperature goes
Thermistor (3) detects the temperature and above the specified temperature, the warn-
sends a signal to the monitor panel. The ing lamp flashes and the alarm buzzer
monitor panel displays the water tempera- sounds to warn of the abnormality.
ture according to that signal. If the tempera- The transmission oil temperature sensor is
ture goes above the specified temperature, installed to the transmission oil piping and
the warning lamp flashes and the alarm sends a signal to the transmission control-
buzzer sounds to warn of the abnormality. ler. If the temperature goes above the speci-
. The hydraulic oil temperature sensor is in- fied temperature, the warning lamp flashes
stalled to the hydraulic tank and the final and the alarm buzzer sounds to warn of the
drive oil temperature sensor is installed to abnormality.
SPEEDOMETER SENSOR
ENGINE SPEED SENSOR
I c1
20 a
1 2 3 4
I --?
F9 5
ii 0.85fG 1
._. 0.85fG 2
0 c
b Structure of circuit
SEW00289
1. Magnet Function
2. Terminal . The speedometer sensor is installed to the
3. Case transmission output gear. A pulse voltage is
4. Boot generated by the rotation of the gear teeth,
5. Connector and the signal is sent to the machine moni-
tor to display the travel speed.
. The engine speed sensor is installed to the
ring gear portion of the flywheel housing.
A pulse voltage is generated by the rotation
of the gear teeth, and a signal is sent to the
transmission controller.
AIR PRESSURE SENSOR
Function
. The air pressure sensor is installed to the air
tank. Any change in the air pressure inside
the air tank is converted to a change in the
1. Connector resistance, and a signal is sent to the air
2. Frame pressure gauge to display the air pressure.
lo-158
0
AIR PRESSURE SWITCH
1. Plug
2. Diaphragm
3. Switch
4. Wire
5. Connector
Construction of circuit swcoo447
Function
. The air pressure switch is installed to the air
tank. The diaphragm detects the air pres-
sure, and when it goes below the specified
pressure, it shuts off the electric current from
the machine monitor. The warning lamp then
flashes, and the alarm buzzer sounds.
ENGINE OIL LEVEL SENSOR
1. Connector
2. Bracket
3. Sensor
4. Switch
Composition of
circuit
SBPOO376
10-159
0
HYDRAULIC OIL LEVEL SWITCH
1. Float
2. Switch
3. Plug
4. Connector
m
Construction of
1
circuit SWG00448
Function
. The hydraulic oil level switch is installed to
the hydraulic tank, and the float moves up
and down according to the oil level. If the oil
goes below the specified level, the switch is
turned OFF, the warning lamp flashes, and
the alarm buzzer sounds.
FUEL LEVEL SENSOR
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
Structure
of circuit
Function A-A SBD02295
. The fuel level sensor is installed to the
center of the front face of the fuel tank.
Float (2) moves up and down according
to the fuel level.
As the float moves up and down, arm (3)
actuates a variable resistance, and this
sends a signal to the sub monitor to dis-
play the fuel level.
10-160
0
SHIFT POTENTIOMETER
INCHING POTENTIOMETER
1. Lever
2. Sensor
3. Connector
Construction of circuit
//
!
ua
I
i,, SWG00449
Function
. The shift potentiometer is installed to the
shift lever, and sends a signal to the trans-
mission controller according to the amount
that the lever is operated. The transmission
controller controls the speed range of the
transmission according to this signal.
The inching potentiometer is installed to the
inching linkage at the transmission end, and
sends a signal to the transmission controller
according to the amount that the inching
pedal is depressed. It is used to detect inch-
ing overload.
lo-161
0
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT

Serial No.: 11001 - 11030
Engine
staD
lnator
relay
Monitor module
\
Non-continui
port ion
(hatched DO,
Parking End
brake lamp
_
start Ina Alternator
motor
Fuse box
Transmission
control box
CN-RST
Start ins
Rotary motor relay
switch
SWG00450
10-162
0
Function
Starting motor terminal E is separated from the
ground only when the shift lever is at the neu-
tral position, the parking switch is ON, and the
starting relay coil is energized. If it is not in this
condition, it is impossible to start the engine.
Operation
1. When the starting switch is turned to the 7. If the parking brake switch is turned to the
ON position, electricity flows from battery ON position, electricity flows from battery
+ starting switch terminals B - BR + en- relay + fuse + parking switch terminals 1 -
gine stop motor relay terminals 1 - 2 + 2 + starting motor relay (CN RST) terminals
ground, and the relay coil is energized. 1 - 2 + ground, and the relay coil is ener-
gized.
2. The electric current from the battery flows
from engine stop motor terminals A - B + 8. In this condition, if the starting switch is
relay terminals 5 - 3 + motor, and rotates turned to the START position, electric cur-
the motor. rent flows from starting switch terminals B -
C + starting motor terminal S + terminal E
3. When the motor rotates, terminal D also ro- + starting motor relay (CN RST) terminals 5
tates at the same time. When the non-con- - 3 + starting motor relay (CN RST) termi-
tinuous portion of terminal D reaches terminals 3 - 5 + ground.
nal B, the circuit from terminal A to B opens,
and the current from the battery to the mo- 9. A circuit is formed from the battery + bat-
tor is shut off. The motor attempts to con- tery relay + starting motor terminal B, so
tinue rotating under inertia, but when the the engine starts.
continuous portion of terminal D contacts
terminal B, both poles of the motor are con- If the shift lever is not at the N position,
nected to the ground, and the motor stops electricity is not supplied to terminal 1
rotating. of the starting motor relay (CN RST).
Terminals 3 and 5 of the relay remain
4. In this condition, the engine stop motor ca- open, so the circuit in Item 6 is not
ble is completely extended, and the fuel in- formed, and the engine does not start.
jection pump lever is set to the FULL posi-
tion to place it in the operating condition. In addition, if the parking switch is not
ON, electricity is not supplied to termi-
5. In addition, the current flows from starting nal 1 of the starting motor relay (CN
switch terminal BR + battery relay coil -+ RPST). Terminals 3 and 5 of the relay
ground, and the battery relay switch is remain open, so the circuit in Item 7 is
closed. not formed, and the engine does not
start.
6. Furthermore, if the shift lever is at the neu-
tral position, electric current flows from the
battery relay + fuse + starting motor relay
(CN RST) terminals 1 - 2 + rotary switch
terminals 2 - 11 + ground, and the relay
coil is energized.
10-163
0
Serial No.: 11031 - 12012, 12016 - 12018
Engine
stop
motor
relay
Monitor module II
I I
CN-25
- 4 I
CN-PL
Parkine
End
brake IamP
Service meter
StartIn Alternator
motor
Fuse box
Transmission
control box
Startin
Rotary motor rel
switch
Parklna
brake rel
SWG0045 I
lo-164
0
Function
ground only when the shift lever is at the park-
ing position and the starting relay coil is ener-
gized. If it is not at the parking position, it is
impossible to start the engine.
Operation
1. When the starting switch is turned to the 6. Furthermore, if the shift lever is at the park-
ON position, electricity flows from battery ing position, electric current flows from the
--f starting switch terminals B - BR + en- battery relay + fuse -+ starting motor relay
gine stop motor relay terminals 1 - 2 -+ terminals 1 - 2 + rotary switch terminals 1 -
ground, and the relay coil is energized. 11 + ground, and the relay coil is energized.
2. The electric current from the battery flows 7. In this condition, if the starting switch is
from engine stop motor terminals A - B + turned to the START position, electric cur-
relay terminals 5 - 3 + motor, and rotates rent flows from starting switch terminals B -
the motor. C -+ starting motor terminal S + terminal E
-+ starting motor relay terminals 3 - 5 +
3. When the motor rotates, terminal D also ro- ground.
tates at the same time. When the non-con-
tinuous portion of terminal D reaches termi- 8. A circuit is formed from the battery + bat-
nal B, the circuit from terminal A to B opens, tery relay + starting motor terminal B, so
and the current from the battery to the mo- the engine starts.
tor is shut off. The motor attempts to con-
tinue rotating under inertia, but when the . If the shift lever is not at the parking
continuous portion of terminal D contacts position, electricity is not supplied to ter-
terminal B, both poles of the motor are con- minal 1 of the starting motor relay. Ter-
nected to the ground, and the motor stops minals 3 and 5 of the relay remain open,
rotating. so the circuit in Item 6 is not formed,
and the engine does not start.
4. In this condition, the engine stop motor ca-
ble is completely extended, and the fuel in-
tion to place it in the operating condition.
5. In addition, the current flows from starting

switch terminal BR -+ battery relay coil +
ground, and the battery relay switch is
closed.
lo-165
0
Serial No.: 12099 – 12502

023502
10-166-1
(6)
023502
10-166-2
(6)
Function
ground only when the transmission controller
recognizes the parking command and the start-
ing relay coil is energized. If the shift lever is not
at the parking position, it is impossible to start
the engine.
Operation
1. When the starting switch is turned to the 6. Furthermore, if the shift lever is at the park-
ON position, electricity flows from battery ing position, electric current flows from the
+ starting switch terminals B - BR -+ en- transmission controller + starting motor re-
gine stop motor relay terminals 1 - 2 -+ Jay terminals 1 - 2 -+ ground, and the relay
ground, and the relay coil is energized. coil is energized.
2. The electric current from the battery flows 7. In this condition, if the starting switch is
from engine stop motor terminals A - B + turned to the START position, electric cur-
relay terminals 5 - 3 + motor, and rotates rent flows from starting switch terminals B -
the motor. C + starting motor terminal S + terminal E
+ starting motor relay terminals 3 - 5 +
3. When the motor rotates, terminal D also ro- ground.
tates at the same time. When the non-con-
tinuous portion of terminal D reaches termi- 8. A circuit is formed from the battery -+ bat-
nal B, the circuit from terminal A to B opens, tery relay + starting motor terminal B, so
and the current from the battery to the mo- the engine starts.
tor is shut off. The motor attempts to con-
tinue rotating under inertia, but when the . If the shift lever is not at the P position,
continuous portion of terminal D contacts electricity is not supplied to terminal 1
terminal B, both poles of the motor are con- of the starting motor relay. Terminals 3
nected to the ground, and the motor stops and 5 of the relay remain open, so the
rotating. circuit in Item 7 is not formed, and the
engine does not start.
4. In this condition, the engine stop motor ca-
ble is completely extended, and the fuel in-
tion to place it in the operating condition.
5. In addition, the current flows from starting

switch terminal BR -+ battery relay coil +
ground, and the battery relay switch is
closed.
lo-167
0
STRUCTURE AND FUNCTION ENGINE STOPPING CIRCUIT
ENGINE STOPPING CIRCUIT

Serial No.: 11001 - 11030
CN-53 CN-15
Engine
stop
motor
relay
Monitor module
I/I/ (hatched portion) ~

Parking
brake lamp
Service meter
CN-SH
w
StartIne Alternator
motor
t
______.._.__ ~__._ -.-..-.- ------ -~~ 7 _.__.__ ~_
Transmission
z
control box
CN-RST
Start ine
Rotary motor relay
switch
SWG00453
lo-168
0
Serial No.: 11031 - 12012, 12016 - 12018
CN-53 CN-15
Engine
stop
motor
relay
Monitor module
II
CN-25
ir Engine
stop motor
\
Non-continuity
port ion
(hatched portion)
Parking End
brake IamP
Startin
snitch
Service meter
Transmission
control box
Start ino
motor relay
Rotary
switch
Parking
brake relay
SWG00454
1O-l 69
0
Serial No.: 12099 – 12502

023502
10-171
(6)
023502
10-172
(6)
023502
10-173
(6)
20 TESTING AND ADJUSTING
Standard value table for engine ............... 20- 3

Standard value ...............
table for chassis 20- 4
Tool list for testing and adjusting .............. 20- 8
Testing and adjusting valve clearance ......... 20-10
Measuring compression pressure .............. 20-I 1
Testing and adjusting fuel injection timing ..... 20-I 2
Measuring blow-by pressure .................. 20-14
Measuring engine oil pressure ................. 20-15
Measuring exhaust gas color .................. 20-16
Measuring exhaust gas temperature ........... 20-17
Measuring intake air pressure
(boost pressure ) .......................... 20-18
Testing and adjusting belt tension ............. 20-19
Procedure for adjusting the engine stop
motor cable .............................. 20-20
Adjusting accelerator control .................. 20-21
Inching pedal travel and operating force ....... 20-22
HYDROSHIFT transmission .................... 20-23
Checking differential locking device
oil pressure ............................... 20-24
Steering system .............................. 20-25
Checking tire runout .......................... 20-26
Checking air pressure of tire ................... 20-26
Checking toe-in ............................... 20-27
Installation of articulate center pins ............ 20-28
Checking wear of brake disc ................... 20-29
Checking parking brake ....................... 20-29
Checking work equipment control lever
travel and operating force ................. 20-30
Checking hydraulic oil temperature ............ 20-30
Checking work equipment
hydraulic pressure ........................ 20-31
Adjusting work equipment
hydraulic pressure ........................ 20-31
Measuring hydraulic ......................
drift 20-32
Charging blade accumulator with gas .......... 20-33
Adjusting blade lift speed ..................... 20-34
Bleeding air from hydraulic pump ............. 20-35
Adjusting slip load of circle rotation clutch ..... 20-36
Adjusting speedometer module of
machine monitor .......................... 30-38
TROUBLESHOOTING . . _. 20-39
20-l
A When carrying
pins, block the wheels,
out testing
and apply
and adjusting,
the parking
or troubleshooting,
brake.
stop the machine on level ground, fit safety
A When
thorized
carrying
person
out operations
near the machine.
with two or more workers, always use signals, and do not allow any unau-
A When checking the water level, if the radiator cap is removed when the engine is hot, boiling water will
spurt out and may cause burns, so always wait for the engine to cool down before checking the water
level.
A Be extremely careful not to touch any hot parts.
A Be extremely careful not to get caught in the fan or any other rotating parts.
A When
release
removing
the internal
the plugs
pressure
or caps
first.
from
Fit the
places
measuring
under hydraulic
tools securely
pressure,
before
water
carrying
pressure,
out any
or air pressure,
testing, adjust-
ing, or troubleshooting.
* When using the standard values table for judgement in testing, adjusting, or troubleshooting, it is necessary to
be careful of the following points.
1. The standard values for the new machines in the standard values table are values given as reference from the
standards for new machines and machines shipped from the factory. They should be used as values for esti-
mating wear during operation or as target values when carrying out repairs.
2. The failure judgement standard values in the standard value table are values using estimated values based on
the results of various tests and standard values for machines shipped from the factory. Use these values for ref-
erence together with the repair and operation history of the machine when judging failures.
3. Do not use this standard values table as a standard for judging claims.
20-2
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Serial No.: 11001 - 12000
Engine I S6D140-1
Classifi
cation
Item Condition Unit Standard value Permissible value
High idling speed rpm 2,350 + 50 2,350 + 50

Engine
Low idling speed rpm 665 + 15 -
Quick acceleration
Bosch scale Max. 5.0 7.0
(Low idling + High idling)
Exhaust gas color
At high idling Bosch scale Max. 1.5 2.5
Intake pressure See “Measuring intake air

kPa ImmHgl Max. 54 (405) 43 13201
(Boost pressure) pressure (boost pressure)”
See “Measuring exhaust

Exhaust temperature “C Max. 400 600
gas temperature”
Valve clearance Intake valve mm 0.43 -

(When engine is hot
or cold) Exhaust valve mm 0.80 -
Compression Oil temperature: 40 - 60°C VlPa {kg/cm? Max. 3.1 I321 2.2 (22)
pressure
(SAE30 oil) (Engine speed) (rpm) (160 - 200) (160 - 200)
(Water temperature inside

Blow-by pressure operating range)
:Pa {mmH,OI Max. 0.98 11001 1.96 {200}
(SAE30 oil)
At rated output

operating range)
Oil pressure
(SAEBO pil) At high idling WPa {kg/cm2) 0.3 - 0.5 13.0 - 5.01 0.2 (2.01
At low idling WPa {kg/cm2) Min. 0.1 il.01 0.07 IO.71
Oil temperature All speed (Oil in oil pan) “C 80 - 110 120
Before top dead center

Fuel injection timing
(B.T.D.C.)
Deflects when pushed with

Fan belt tension
a force of 58.8 N 16 kg}
+ The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel infection pump.
20-3
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
Serial No.: 12001 and UD
Engine S6D140E-2
Classifi-
cation Item Condition Unit Standard value I‘ermissible value
ga,
PC
0 Engine
High idling speed mm 2,350 f 50 2,350 + 50
-
tm
a
Low idling speed mm 650 +;
Quick acceleration
Bosch scale Max. 4.0 6.0
(Low idling + High idling)
Exhaust gas color
At high idling Bosch scale Max. 1.0 2.0
Intake pressure See “Measuring intake air

kPa {mmHg) Min. 78.7 1590) 66.7 1500)
(Boost pressure) pressure (boost pressure)”
See “Measuring exhaust

Exhaust temperature “C Max. 700 700
gas temperature”
Valve clearance Intake valve mm 0.43 -

(When engine is hot
or cold) Exhaust valve mm 0.80
Compression Oil temperature: 40 - 60°C MPa {kg/cm? Max. 3.8 139) 2.7 f27)
pressure
(SAE30 oil) (Engine speed) (rpm) (160 - 200) (160 - 200) 8
z
zz
Blow-by pressure operating range)
tPa ImmH,O) Max. 0.98 UOO) 1.96 1200)
(SAEBO oil)
At rated output

operating range)
At high idling (SAE 30) MPa (kg/cm? 0.3 - 0.5 (3.0 - 5.0) 0.2 (2.0)
Oil pressure
(SAE30 oil) At high idling (SAE IOW) MPa Ikg/cm*) 3.25 - 0.44 (2.5 - 4.5)t 0.18 (1.8)
At low idling (SAE 30) MPa Ikg/crr+) 0.12 (1.2) 0.07 (0.7)
At low idling (SAE IOW) MPa {kg/cm? 0.10 (1.0) 0.07 (0.7)
Oil temperature All speed (Oil in oil pan) “C 80- 110 120
Before top dead center

Fuel injection timing degree 16 + 0.5 16 + 0.5
(B.T.D.C.)
Alternator belt
13- 16
tension
Deflects when pushed with
mm
a force of 58.8 N 16 kg)
Fan belt tension 17 - 19
* The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel infection pump.
20-3-l
STANDARD VALUE TABLE FOR TESTING AND
TESTING AND ADJUSTING ADJUSTING, FAILURE JUDGMENT OF CHASSIS
STANDARD VALUE TABLE FOR TESTING AND ADJUSTING,

FAILURE JUDGMENT OF CHASSIS
Compo
nent
Accelerator . Engine stopped

pedal . Up-down movement at joint
Fuel control
between pedal and pin
. Stroke from center of knob
mmI
lever I 160 + 10
I
160 f 20
Height H from floor to center

of pedal mounting bolt
mmL
-
- TOGO0001
Operating effort
. Engine stopped 127.5 5 19.6 127.5 f 49.0
. Max. value to just before end of travel {I3 rt 2) {13 + 51
Travel . Up-down movement of pedal mm 60 f 5 Max. 65

I
Operating effort
. Engine stopped
. Max. value to just before end of travel
&I 13.0
29.4 +f 0.51
4.9 13.0
29.4 *f 0.5)
4.9
. Engine stopped
Travel . Travel at tip of lever for each mm 27f 10 27+ 12
speed range
. Engine at full throttle

Slippage of
. Lock brake
transmission
. Set transmission at highest speed set Max. 3.0 Max. 3.0
range, then release inching pedal
and measure time until engine stalls
Main oil . Engine at full throttle

pressure . Oil temperature: 40 - 60°C
Lubrication oil
I 1.1 f 0.1
{II f I} I
-
. Engine at full throttle

+0.5
. Transmission: Neutral MPa
2.5 o
Oil pressure . Differential: Locked $01
g/cm’)
. l$a14$$e oil temperature: I25 +; 1
. Raise front tires 50 - 100 mm

from ground
Play of steering
. Turn steering wheel and mm ~ 25-45 1 Max.45
wheel
measure distance to point
where wheels start to turn to side
20-4
0
Compc)- Standard value

nent Item Measurement conditions Unit for new machine Service limit value
I I
. Raise front tires 50 - 100 mm
from ground, check point where
steering wheel starts to turn,
Turning angle
then turn steering wheel fully and - 5.7 + 0.5 turns 5.7 f 1.0 turns
(lock-to-lock)
measure distance to point where
steering wheel stops turning
Check distance to both IefI and right
Operating effort of . Engine at low idling Max. 49 Max. 59

steering wheel . When traveling in Fl {Max. 5) {Max. 61
. Put a dial gauge in contact with

Runout of tires side wall of both front and rear mm Max. 7 Max. 7
tires and measure runout 1 I
. 23.5-25-12PR Front tire MPa 0.24 0.24
. Serial No.12001 and up Rear tire {kg/cm21 12.451 i2.451
Tire inflation
pressure . 18.00-25-12PR Front tire MPa 0.25 0.25
. Serial N0.11001 - 12000 Rear tire {kg/cm3 12.61 12.61
Camber
I
-----I
Toe-in . Flat, paved road surface
Leaning angle
I I deg 19.5 + 1.5
I
19.5 rt 1.5
Priority flow 17.2 k 0.5 17.2 + 1.0

Engine at full throttle
divider relief valve 1175 + 51 I U75 f 101
. Engine at low idling I I I

Operating effort of . Measure at center of pedal 313.8 k 19.6 Max. 490
brake pedal . Measure when wheels are {32 * 21 {Max. 501
fully locked
$ Stopping . Stopping distance when brakes are Max. 16 Max. 22.8

I] g distance applied at travel speed of 32 km/h m
(SAE J 1473) (SAE J1473) (SAE J 1473)
SE
“Z
ot Parking brake holding . Tire slip limit when parking
Min. 20 Min. 15
$ performance brake is locked deg
MPa 0.41 - 0.93 Max. 0.36

Air pressure . Engine at full throttle
(kg/cm21 I4.2 - 9.51 {Min. 3.7)
N H Left
Leaning N H Right 30 + 5 30 f 10.0
N H Left
Articulating N H Right 35 + 5 35 + 10.0
Blade lift N ti RAISE

(left, right) N H LOWER 30 + 5 30 f 10.0
. Engine: N tf Left
F Blade side shift Stopped N tf Right 30 + 5 30 * 10.0
2 . . Measure at mm
I= Drawbar side tip of lever N tf Left
shift N ti Right 30 f 5 30 + 10.0
N ++ Left
Circle rotation N tf Right 30 * 5 30 + 10.0
N ti Tilt forward
Power tilt N H Tilt back 35 f 5 35 f 10.0
N t;, RAISE
Ripper N tj LOWER 35 f 5 35 * 10.0
20-5
0
T
-
Compc
Item Measurement conditions Standard value Service limit value
nent LJnit for new machine
Leaning
N t)
N t)
Left
Right I 19.6 - 34.3
{2 - 3.5) I
Max. 39.2
{Max. 4.0)
Articulating
N
N tf
H Left
Right I 14.7 - 29.4
{I .5 - 3.0) I
Max. 39.2
{Max. 4.0)
Blade lift N tj RAISE

(left, right) N t) LOWER
. Engine: N tf Left
Blade side shift
Stopped N H Right
. Max. value ~ -
Drawbar side to end of N tf Left 19.6 - 34.3 Max. 39.2
shift travel N tf Right {2 - 3.5) {Max. 4.0)
N tj Left 19.6 - 34.3 Max. 39.2

Circle rotation
N t) Right I2 - 3.51 {Max. 4.0)
N ++ Tilt forward 14.7 - 29.4 Max. 39.2

Power tilt
N tf Tilt back {I .5 - 3.0) {Max. 4.0)
N tf RAISE 14.7 - 29.4 Max. 39.2

Ripper
N tf LOWER 11.5 - 3.0) {Max. 4.0)
. Enaine: Rated soeed

. Hydraulic oil ’ RAISE 130 + 15 130 + 15
temoerature: 40 & 5°C
Blade lifting . Time taken to move
speed bottom edge of blade
between 50 and 100
LOWEf
mm from ground
. Engine: Rated speed

. Hydraulic oil
temperature: 40 & 5°C Left
Blade side shift . Set height of bottom
speed with edge of blade to 100
movement of mm with blade at center
circle as standard condition
. Side shift speed to left and Right
right when shifting 200 mm
horizontally with circle
Blade side shift

. Hydraulic oil
temperature:
. Set height of bottom
40 + 5°C Left I 130 * 15 I 130 + 15
speed edge of blade to 100

compared mm with blade at center
to circle as standard condition
. Side shift speed to left and Right
right when shifting 200 mm
horizontally with circle

. Hydraulic oil RAISE :::::
Ripper lifting temperature: 40 f 5°C
speed . Speed to raise tip of
center ripper shank LOWEf 100 * 15 100 * 15
between 50 and 150 mm
. Blade angle speed Serial No.

with engine at
11001 - 1205C
Blade rotation full throttle
speed . Hydraulic oil
Serial No.
temperature:
12051 and up
40 f 5°C
20-6
0
Compc Standard value

Item Measurement conditions Unit iervice limit value
nent for new machine

. Hydraulic oil temperature:
40 f 5°C
Hydraulic drift . Downward movement of
Max. 10 Max. 10
of blade cylinder when blade is
suspended at right angle to
chassis and equally extended
to left and right
. Engine: .Rated speed

Hydraulic drift . i$p5uF 011 temperature:
of chassis when 0
gc;;d up with . Downward movement of Max. 10 Max. IO
cylinder when blade is lowered I
to ground and used to raise
front wheels from ground ,

. Hydraulic oil temperature:
Hydraulic drift 40 * 5°C
Max. 20 Max. 20
of ripper . Downward movement of
cylinder when ripper is
suspended

Hydraulic drift . Hydraulic oil temperature:
of chassis when 40 I?z5°C
pushed up with . Downward movement of
Max. 20 Max. 20
ripper cylinder when ripper is lowerec 1
to ground and used to raise
and rear wheels from ground
Priority valve relief 24.5 f 1.0 24.5 + 1.5

pressure . Engine at full 1250 f 10) 1250 + 15)
throttle
. Hydraulic oil 24.5 f 1.0 24.5 f 1.5
Right valve
temoerature: {250 + IO} (250 I!C151
Main control valve
40 F 5°C
relief pressure 24.5 + 1.5
24.5 + 1.0
Left valve {250 + 101 {250 I!I 151
20-7
0
Standard value
Item Measurement conditions Unit for new machine Service limit value
1st 4.0 f 5 % 4.0 f 10 %
2nd 5.4 f 5 % 5.4 f 10 %
3rd 8.0 + 5 % 8.0 f 10 %
4th 11.5 f 5 % 11.5 + 10 %

Forward
5th 15.8 + 5 % 15.8 + 10 %
6th 21.4 + 5 % 21.4 rt 10 %
7th . Flat and dry road surface 31.3 * 5 % 31.3 * 10 %

. Oil temperature and pressure
8th in operating range 44.9 * 5 % 44.9 f 10 %
. Engine at rated speed km/h
1st . No load 4.3 + 5 % 4.3 f 10 %
. ~;;irressure of tire in specified
2nd 5.8 f 5 % 5.8 f 10 %
3rd 8.5 + 5 % 8.5 f 10 %
4th 12.2 * 5 % 12.2 L!z10 %

Reverse
5th 16.9 +z 5 % 16.9 f 10 %
6th 22.8 + 5 % 22.8 f 10 %
7th 33.4 XL5 % 33.4 f 10 %
8th 47.9 + 5 % 47.9 f 10 %
Engine
water
cooling
I Max.102
I
Max. 102
Engine oil
8 temperature . Oil and water levels are normal
E Transmission oil
. Air temperature 40°C
. Continuous traction IF-21
2 “C
. On a concrete road surface
z . Using thermistor
z! Performed with thermostat
open
Tandem case oil

temperature I
20-7-l
0
6 – 99999.9 rpm
799-205-1100 Tachometer kit
2.5, 6, 40, 60 MPa

{ }
60 MPa
790-261-1204
{600 kg/cm2}
{ }
799-201-9001 Bosch index : Level 0 – 9
799-401-2311 200 kPa {1,500 mmHg}
79A-264-0091 0 – 490 Nm {0 – 50 kg}
79A-264-0021 0 – 294 Nm {0 – 30 kg}
(5)
6 – 99999.9 rpm
Tachometer kit 799-205-1100
2.5, 6, 40, 60 MPa

{ }
79A-264-0021 0 – 294 Nm {0 – 30 kg}
0 – 1 MPa {0 – 10 kg/cm2}
0 – 1,080 Nm {0 – 110 kg}
(5)
TESTING AND ADJUSTING VALVE CLEARANCE
Ir Adjust clearance between rocker lever and top of

crosshead to following value.
Intake valve (at 20°C) Exhaust valve (at 20°C)
0.43 mm I 0.80 mm
1. Remove cylinder head cover (1).
2. Rotate the crankshaft in the normal direction to align

pointer (2) with the 1.6 TOP mark of crankshaft
pulley. When rotating, check the movement of the
intake valve of No. 1 cylinder and No. 6 cylinder. Set
with No. 1 cylinder at compression top dead center.
3. When No. 1 cylinder is at compression top dead

Valve arrangement
center, adjust the valves marked l . Then rotate the
crankshaft one turn in the normal direction, set No. 6
cylinder to compression top dead center, and adjust
the valves marked o.
I TDD00714
4. To adjust, insert tool F between rocker lever (3) and

crosshead (4) and turn adjustment screw (5) until
clearance is a sliding fit.
Tighten locknut (6) to hold adjustment screw in po-
sition.
w Locknut: 58.8 i 5.9 Nm (6.0 + 0.6 kgm)
20-l 0
0
5. Then rotate the crankshaft in the normal direction by
one turn and adjust the valve clearance for the re-
maining valves marked o.
* After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 120” each time and adjust the valve
clearance of each cylinder according to the firing
order.
l Firing order: 1 - 5 - 3 - 6 - 2 - 4
t After tightening the locknut, check the clearance

F621201068
again.
MEASURING COMPRESSION
PRESSURE
A When measuring the compression pressure, be

careful not to touch the exhaust manifold or
muffler, or to get caught in rotation parts.
1. Adjust valve clearance.

* For details, see TESTING AND ADJUSTING
Z
VALVE CLEARANCE.
%
2
2. Warm up engine (oil temperature 40 - 60°C).
3. Remove nozzle holder assembly.
4. Install tool 02 to the nozzle holder mount, then con-

nect pressure gauge DI.
5. Set engine tachometer in position.
6. Disconnect connector (2) of stop motor (I), set to

the NO INJECTION position, then crank the engine
and measure the compression pressure.
f Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
* When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
235FO2057
20-l 1
0
TESTING AND ADJUSTING FUEL INJECTION TIMING
Serial No.: 11001 - 12000
There are the following methods of testing and adjust-

ing the fuel injection timing of the injection pump.
. Aligning match mark when assembling the injection
pump to the original engine without repair.
. Delivery valve method when assembling the injec-
tion pump that has been repaired or replaced.
* When using the delivery valve method, always re-
place the copper gasket and O-ring of the delivery
valve with new parts. Prepare these parts before
starting the operation.
* Set the No. 1 cylinder at the compression top dead
center, then test and adjust.
For details, see TESTING AND ADJUSTING VALVE
CLEARANCE.
. Testing and adjusting by aligning match mark
1. Turn the crankshaft back 30” to 45” from No. 1 cylin-

der TOP.
2. Turn the crankshaft slowly in the normal direction,

and align the injection timing line on crankshaft
damper (1) with pointer (2).
3. Remove engine oil level gauge tube (3) and hose

flange (4), then remove guard (5) from the injection
pump.
t After removing the engine oil level gauge tube
and the hose flange, fit a blind plug to prevent
mud or dirt from getting in.
4. Check that line “a” on the injection pump and line

“b” on the coupling are aligned.
* If the lines are not aligned, loosen nut (6), move
the coupling to align the lines, then tighten the
nut.
D Nut: 58.8 f 4.9 Nm (6.0 I 0.5 kgm)
. Testing fuel injection timing by delivery valve

method
* Prepare new parts for the copper gasket and
O-ring of the delivery valve before starting the
.operation.
1. Disconnect fuel injection pipe (7) of the No. 1 cylin-

der.
2. Remove delivery valve holder (8).
20-12
0
3. Remove spring (9) and delivery valve (10) from the
delivery valve holder (8), and reassemble the de-
livery valve holder (8).
4. Remove engine oil level gauge tube (3) and hose

flange (4), then remove guard (5) from the injection
pump.
* After removing the engine oil level gauge tube
and the hose flange, fit a blind plug to prevent
mud or dirt from getting in.
5. With No. 1 cylinder piston at TOP position, rotate

I 423F302
the crankshaft 30” to 40” in the reverse direction.
6. Place the fuel control lever in FULL position, slowly

rotate the crankshaft in the normal direction while
operating the priming pump, and observe the posi-
tion when the fuel stops flowing out of the delivery
valve holder.
7. In the position where the outflow of fuel stops,

check the injection timing stamp line on crankshaft
damper (1) to see if it is aligned with pointer (2).
* If the injection timing stamp line passed through
the pointer: The injection timing is late.
8
z * If the injection timing stamp line did not reach
z the pointer: The injection timing is advanced.
* If the inspection shows that the injection timing is

out of adjustment, adjust the fuel injection timing in
the following manner.
* After the checking and adjusting, be sure to reas-
semble the spring and the delivery valve.
* Always replace the delivery valve copper gasket and
O-rings with new parts.
1) Rotate the crankshaft 30” to 40” in the reverse

direction, starting from TOP position in No. 1 cy-
linder.
2) Align the injection timing stamp line on damper
(I) with pointer (2) by slowly rotating the crank-
shaft in the normal direction.
3) Loosen nut (11) on the injection pump mounting
flange slot, and rotate the flange on the pump
side little by little by operating the priming
pump until no fuel flows out of the delivery
valve holder.
4) Tighten the nut on the injection pump mounting
flange slot.
* Recheck the injection timing to see if it is
properly adjusted.
5) If match marks a and b are not aligned, stamp
new one.
20-l 3
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
1. Testing
1) Procedure for fixing crankshaft in position
i) Pull out pin (I), and remove nut (2).
ii) Rotate the crankshaft in the normal di-
rection and align pointer (4) with the fuel
injection line on top of damper (3).
* When doing this, check that line (5)
on the injection pump camshaft is
near the line on the pump case. If it
cannot be seen, rotate the crankshaft
one more turn.
iii) Push in lock pin (7) towards the engine
and rotate the crankshaft to insert pin
(7) into the hole in gear (8).
2) In this position, check the position of line (5)
on the injection pump camshaft and line (6)
on the pump case.
Note: In this condition, do not start the engine
or try to crank it by force.
2. Adjusting
If the line in Step l-2) is not aligned, adjust as
follows.
I) Loosen coupling bolts (9) and nuts (IO) at
two places.
2) Rotate camshaft (11) to align line (5) on the EEP01138
camshaft completely with line (6) on the in-
jection pump case.
3) Tighten bolts (9) and nuts (IO).
w Nut :
61.25 + 2.45 Nm t6.25 f 0.25 kgm}
3. Procedure for releasing crankshaft

1) Remove lock pin (7) from the hole in gear
(8).
It If pin (7) is stiff, tighten nut (2) before
removing the pin.
* Pull the pin out completely toward this
side to a position where it does not
move. BEP01139
2) Tighten nut (2).
w Nut, bolt :
31.4 +_3.5 Nm 6.2 + 0.36 kgm1
3) Install pin (I).
BEPOll
20-13-l
0
MEASURING BLOW-BY PRESSURE
Measure the blowby pressure under the following

conditions.
. Temperature of cooling water: Within operating
range
. Temperature of hydraulic oil: 45 - 55°C
Set tool E4 and El to blowby hose (1).

Use tool E3 to connect tool El and Ez.
Run the engine at the rated output and measure the
blowby pressure as follows.
+ Blowby varies greatly according to the condition
of the engine. Therefore, if the blowby value is
considered abnormal, check for problems con-
nected with defective blowby, such as excessive
oil consumption, defective exhaust gas color,
and prematurely dirty or deteriorated oil.
A When taking measurements, be careful not

to touch any hot parts or rotating parts.
1) Before starting measurements, set the work

equipment to the following posture.
A: A When setting the work equipment in
position, be careful not to let the blade
hit the tire.
B: For the drawbar shift, take the center posi-
tion as the standard position.
c: Shift the blade fully to the right.
D: Rotate the circle to give a propulsion angle
of 50”.
E: Raise the blade fully on both the left and
right sides.
2) Pull right blade lift lever (1) back, and hold it at
the end of its stroke.
* Raise the right end of the blade, and relieve
the circuit.
3) In the condition in Step 2), operate blade left
shift lever (2) and circle left rotation lever (3) at
the same time to the front to move the work Front
equipment. Opeate at
* Use the blade left shift lever and the circle same time
left rotation lever to set the oil discharge
amount to the maximum.
;),8 -4:%/
2 3
235FO2059
20-14
MEASURING EXHAUST GAS COLOR
* For tests in the field where there is no air or elec-

tricity available, use handy smoke checker; for tests
in a repair shop, use smoke meter.
MEASURING WITH HANDY SMOKE CHECKER

A When measuring the exhaust color, be careful
not to touch the exhaust pipe.
* Measure the exhaust color when the engine is warm

(oil temperature is 60°C).
1) Fit the filter paper in tool GI.
2) Insert the exhaust gas suction port into the ex-
566FO6118
haust 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 with the
scale provided to judge the condition. Gl
MEASURING WITH SMOKE METER

A When measuring the exhaust color, be careful
not to touch the exhaust pipe.
* Measure the exhaust color when the engine is warm

(oil temperature is 60°C).
1) Insert the probe in the outlet of exhaust pipe
and secure it to the exhaust pipe with a clip.
2) Connect the probe hose, accelerator switch plug
and air hose to tool Gz.
* The pressure of the air supply should be
under 1.5 MPa (15 kg/cm*).
3) Connect the power cord to a power source
socket.
* Check that the power switch is OFF before
connecting the cord.
4) Loosen the cap nut of the suction pump and
insert the filter paper.
* Fit the filter paper securely so that the ex-
haust gas does not leak.
5) Turn the powr switch ON.
6) Accelerate the engine suddenly. At the same 566FO6120
time, depress the accelerator pedal, operate the
relief valve and catch the exhaust gas color on
the filter paper.
G2
7) Lay the filter paper used to catch the exhaust
gas color on top of unused filter papers (IO
sheets or more) inside the filter paper holder,
and read the indicated value.
Fl RM02216A-K
20-l 6
MEASURING EXHAUST GAS
A When removing
_
or installing measuring equip-
ment, be caretul not to touch any hot parts.
* Raise the cooling water temperature to the opera-

ting range before carrying out measurements.
1. Set tool 6 to exhaust temperature pickup connector

(1).
A When taking measurements, be careful not
to touch any hot parts or rotating parts.
2. Run the engine at rated output and measure the ex-
haust temperature as follows.
A: A Wh en setting the work equipment in
hit the tire.
C: Shift the blade fully to the right.
of 50”.
right sides.
8 2) Pull right blade lift lever (I) back, and hold it at
s the end of its stroke.
8 * Raise the right end of the blade, and relieve
the circuit.
shift lever (2) and circle left rotation lever (3) at
the same time to the front to move the work
equipment.
* Use the blade left shift lever and the circle
4) In the condition in Step 3). measure the blowby
pressure. Front
Opeate at
A The blade moves during the measurement,
so be careful to avoid the contact shown in
the diagram, and stop operation of the OsF{@J OoooJ
lever before there is any contact.
A: AB e careful not to let the work
equipment hit the main frame.
B: AB e careful not to let the blade hit
2 3 235FO2059
the tire.
235FO2060
20-17
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
A When removing or installing measuring equipment,

be careful not to touch any hot parts.
1. Install tool H to intake pressure measurement

coupler (1).
A When taking measurements, be careful not to

touch any hot parts or rotating parts.
Note:
Run the engine at a mid-range speed or above, then
use the self-seal portion of the gauge to remove oil
from inside the hose.
* Insert the gauge about half-way and repeat the
movement to open the self-seal and remove the
oil.
* If there is any oil inside the hose, the gauge will
not move, so always be sure to remove the oil.
2. Run the engine at rated output and measure the

boost pressure as follows.
A: A When setting the work equipment in
hit the tire.
c: Shift the blade fully to the right.
of 50”.
right sides.
2) Pull right blade lift lever (1) back, and hold it at
the end of its stroke.
* Raise the right end of the blade, and relieve
the circuit.
shift lever (2) and circle left rotation lever (3) at Front
the same time to the front to move the work
equipment.
* Use the blade left shift lever and the circle
235FO2059
20-l 8
4) In the condition in Step 3), measure the boost
pressure. I
A The blade moves during the measurement,
so be careful to avoid the contact shown in
the diagram, and stop operation of the
lever before there is any contact.
A: A Be careful not to let the work
equipment hit the main frame.
B: AB e careful not to let the blade hit
the tire.
AA BA
235FO2060
TESTING AND ADJUSTING BELT TENSION

Serial No.: 11001 - 12000
1. Fan belt
1) Testing
Check that the deflection of the belt is within
the standard range when central portion “a” be-
tween fan pulley (2) and belt tension adjustment
pulley (1) is pressed with a force of approx.
58.8 N (6 kg). If it is not within the standard
value, adjust the belt tension.
* Standard belt tension: 5 - 9 mm
2) Adjusting
Use adjustment bolt (3) to adjust the belt ten-
sion as follows.
If deflection is too LARGE, TIGHTEN bolt
b
If deflection is too SMALL, LOOSEN bolt
2. Alternator belt
1) Testing
Check that the deflection of the belt is wihin the
standard range when central portion “b” be-
tween alternator (4) and accessory pulley (5) is 235FO2062
pressed with a force of approx. 58.8 N (6 kg). If
it is not within the standard value, adjust the
belt tension.
2) Adjusting
i) Loosen belt tension adjustment bolt (6) and
mount bolt (7) of alternator (4).
ii) Using a bar, pull alternator (4) up to adjust
the belt tension’, then tighten adjustment bolt
(6) and mount bolt (7).
20-l 9
0
1. Fan belt
1) Testing
the standard range when central portion “a”
between fan pulley (2) and belt tension ad-
justment pulley (I) is pressed with a force of
approx. 98 N {IO kg}. If it is not within the
standard value, adjust the belt tension.
2) Adjusting
If the deflection of the belt is too loose, a
tighten adjustment bolt (3); if the tension is
too tight, loosen adjustment bolt (3).
TEGOOOOZ
2. Alternator belt
1) Testing
the standard range when central portion “a”
between alternator pulley (I) and accessory
pulley (2) is pressed with a force of approx.
98N {IO kg}. If it is not within the standard
value, adjust the belt tension.
Ir Standard belt tension: 13 - 16 mm
2) Adjusting
i) Loosen mounting bolt (3) of the alterna-
tor assembly and locknut (4) of the belt
tension adjustment bolt.
ii) Turn adjustment nut (5) to move the al-
ternator assembly and adjust the tension
of belt (6). After adjusting, tighten locknut
(41, adjustment nut (5), and alternator as-
sembly mounting bolt (3).
iii) After adjusting the belt tension, check
again that deflection “a” of the belt is
within the standard value.
TLD00026
20-19-l
0
PROCEDURE FOR ADJUSTING THE ENGINE STOP
MOTOR CABLE
1. Temporarily attach the ball joint connected to the in-

jection pump to cable (2) of engine stop motor (1).
2. Pull injection pump stop lever (3) to the ENGINE

STOP (fuel non-injection) position, temporarily attach
the ball joint to the stop lever, then fix the cable to
the bracket.
t The engine stop motor cable is housed in the
pulled condition.
t When the lever is free, the stop lever is in the
OPERATING position (built-in spring).
3. Turn the engine starting switch ON and OFF a few 23
times to confirm that the engine stop motor actu-

ated smoothly. Be especially sure to confirm that
there is a clearance between the stop lever and
stopper when the engine is stopped.
* The engine stop motor has built-in limit switches
on both sides of the cable stroke.
* When the engine is running, there is some slack
in the engine stop motor cable. A spring built
into the injection pump actuates to hold the
opening position.
. Engine stop motor stroke: 35 mm
. Injection pump stop lever stroke: 30 mm
20-20
ADJUSTING ACCELERATOR CONTROL
A-A
235FO2064
Procedure for adiustinq

_ - accelerator control
1. Fix stopper bolt (2) at the standard height from the 6. After starting the engine, set regulator lever (7) to
floor. the STOP position, and adjust the mounting angle of
l Standard height of stopper bolt: 56 mm spring hook plate (IO) so that the engine stops.
or If the regulator lever moves back because of the
2. Adjust so that the installed length of cable (6) at the vibration, tighten double nut (11) further to in-
engine end is dimension A. crease the holding power.
. Dimension A: 307 mm
3. Depress pedal (1) until it contacts stopper bolt (2),

then adjust cable mounting dimension B atthe oper-
ator’s compartment end so that throttle lever (5) at
the engine end is at the end of its stroke.
4. Adjust damper (8) and stopper bolt (9) so that regu-

lator lever (7) gives the engine STOP, idling, and full
speed positions.
l Standard length of damper: 346 mm
5. Adjust the height of the decelerator pedal so that at

the engine idling position the head of decelerator
pedal (3) is level with the top surface of the floor mat
(if there is no floor mat, level with the top surface of
the floor).
20-2 1
INCHING PEDAL TRAVEL AND OPERATING FORCE
INCHING PEDAL TRAVEL CHECK
Use convex rule 0 to measure the length of the

movement from up to down from beginning to the
end of depressing inching pedal (I).
i
235FO2065
INCHING PEDAL OPERATING FORCE CHECK
Use push-pull scale @ to measure the maximum

value in the travel to just before the inching pedal
travel end.
CHECKING HEIGHT OF INCHING PEDAL
Using a steel tape, measure height H of the center

of pedal mounting bolt (I) from the floor.
ADJUSTING HEIGHT OF INCHING PEDAL a k 235FO2066
Adjust the installed length using rod (3) and

yoke (2) at the pedal end so that installed height
6 I 4
H of the center of pedal mounting bolt (I) from
the floor is 98:: mm. When doing this, remove
pin (5) connecting the yoke and lever (4), then
turn the yoke to adjust the length.
t Check that portion A of the pedal does not
interfere with the floor.
Depress the pedal to the end of its travel, and
adjust stopper bolt (6) at this position. Then
screw in the stopper bolt a further one turn and
lock it in position. 5 2 3 2
* Check that portion B of the pedal does not I TOG00004
interfere with the floor.

After the completion of adjustment, start the
engine and run it at full throttle. Depress the
pedal and check that the machine does not move
when the gear shift lever is put into Fl.
Depress the service brake pedal and inching
pedal, and put the gear shift lever into F8. From
this position, release the inching quickly, and
check that the engine stalls within 3 seconds.
(Check with the engine running at full throttle.)
20-22
0
CHECKING STEERING WHEEL PLAY
When the play of the steering wheel is outside the stan-

dard value or vibrates abnormally or pulls, replace the
steering valve assembly.
CHECKING STEERING WHEEL OPERATING FORCE
Using push-pull scale 0, measure the operating force of

the steering wheel.
* Measure operating force of the steering wheel with
F23B01039
the engine idling and with the wheels on the ground.
20-25
CHECKING TIRE RUNOUT
FRONT WHEEL CHECK
1. Start the engine and raise the front wheels off the
ground, using the blade or scarifier as a jack.
2. Use dial gauge @ to measure the tire runout while
rotating the tire (I 1 by hand.
REAR WHEEL CHECK
1. Put jacks under the left and right tandem cases, and
raise the rear wheels off the ground.
2. Put stand @ under the tandem case.
3. Start the engine and lower the blade to the ground.
4. Use dial gauge @ to measure the tire runout while

rotating tire (2) by hand.
A Always stop the engine before measuring.
CHECKING AIR PRESSURE OF

TIRE
Use tire gauge @ to measure the air pressure of front

and rear wheels.
20-26
023502
20-27
(6)
INSTALLATION OF ARTICULATE CENTER PINS
1. Insert the front frame in the rear frame. Serial No.: 11001 – 12502
2. Insert center pins (1) and (2), adjust with bottom

nut (4) so that all clearance “A” are equal, then
tighten the unit.
a For serial No. 12503 and after, install O-rings (7)

to center pins (1) and (2).
3. Tighten top nut (3).
3 Nut (3)
(1st pass): 255 ± 9.8 Nm {26 ± 1 kgm}
(2nd pass): Loosen temporarily and then
tighten to
215 ± 9.8 Nm {22 ± 1 kgm}.
4. Set lock plates (5) to nuts (3) and (4) and secure
them with the bolts.
a For serial No. 12503 and after, install washer
(6) between lock plate (5) and frame.
023502
20-28
(6)
CHECKING WEAR OF BRAKE DISC
1. Remove plug (1) of checking hole and peep through

from direction above the checking hole.
2. Depress brake pedal to push piston (2) against plate

(3) and to compress disc 14).
3. Confirm that length A in the diagram at right is not 0.

In other words, confirm that a portion of the disc can
be seen through the checking hole.
Checking hole
F23EC030
CHECKING PARKING BRAKE
CHECKING PARKING BRAKE
1. Place the gear shift lever at the P position.
2. Check that slack adjuster (I) works smoothly.
3. Check that the angle between push rod (2) of the
brake chamber and slack adjuster (1) is greater than
90”.
ADJUSTING PARKING BRAKE

1. Rotate worm shaft (3) with a wrench to adjust the
clearance.
2. When adjusting, be careful to turn exactly one notch
at a time.
20-29
CHECKING WORK
EQUIPMENT CONTROL LEVER
TRAVEL AND OPERATING
FORCE
CHECK AND ADJUSTMENT OF WORK EQUIPMENT

CONTROL LEVER TRAVEL
Use a convex rule 0 and measure the operating length

from the center of the knob of lever (1).
* Measure with engine stopped.
t The stroke of work equipment control lever is deter-
mined by the spool travel of the control valve, but the
neutral position of each lever is adjusted by each rod.
CHECK AND ADJUSTMENT OF EACH WORK

EQUIPMENT CONTROL LEVER OPERATING FORCE
Use push-pull scale @ to measure maximum value from

the tip of lever (I) to just before the stroke end.
+ Measure with engine stopped.
* The operating force of the work equipment control
lever is determined by the spring load of the spool on
the control valve side. When the operating force is
outside standard value, check the movement of the
connecting rod. If it is normal disassemble the control
valve and check the movement of the spool.
CHECKING HYDRAULIC
OIL TEMPERATURE
Special tool
Part number Part name I Q’tY
A 1 799-101-I 502 1Thermistor I ’ 235FO2075
1. Remove hydraulic oil tank cap (1) and remove

strainer.
A When
slowly
removing
to release
cap, loosen the oil filler cap
the remaining’oil pressure
in the hydraulic tank.
2. Insert sensor into filling port and measure oil tem-

perature with thermistor gauge A.
20-30
MEASURING HYDRAULIC DRIFT
EXTENTION OF BLADE CYLINDER
Start engine and after the pressure test, bring hydrau-

lic oil temperature to the 40 & 5°C range.
Raise the blade 300 mm from the ground and at
right angles to the machine and equidistant to right
and left.
Stop the engine and leave for 10 minutes.
Use a convex rule @ to measure the amount the
cylinder piston rod has dropped.
RETRACTION OF BLADE CYLINDER
Start engine after the pressure test, bring hydraulic

oil temperature to the 40 & 5°C range.
Lower blade until its bottom edge touches the
ground, push the cylinder and float the front wheels
about 300 mm off the ground.
Stop the engine and leave for 10 minutes.
Use a convex rule @ to measure at the cylinder the
amount of sinkage.
EXTENTION OF RIPPER CYLINDER (If equipped)
1: Start the engine and test the pressure, then warm up

the hydraulic oil to 40 f 5°C.
2. Raise the ripper about 300 mm from the ground.
3. Stop the engine and wait for 10 minutes. Then using
steel tape 0, measure the distance the cylinder
piston rod has moved.
RETRACTION OF RIPPER CYLINDER (If equipped)
1. Start the engine and test the pressure, then warm up

the hydraulic oil to 40 f 5°C.
2. Lower the ripper to the ground, then extend the cylin-
der piston or raise the rear wheels about 300 mm.
3. Stop the engine and wait for 10 minutes. Then using
steel tape 0, measure the distance th,e cylinder
piston rod has moved.
20-32
CHARGING BLADE ACCUMULATOR WITH GAS
Special tool
Part number Part name Q’ty
A 792-61 O-l 700 Charging assemblv 1
A Always use nitrogen when charging the accumu-

lator with gas.
1. Remove plug (2) from the accumulator, then install

charging assembly A.
Size of joint for connecting accumulator: TV8
2. When installing the charging valve, tighten valve (3)

fully and open valve (4) fully.
3. After installing charging valve assembly A, tighten

valve (4) gradually and the charging pressure of the
gas in the accumulator will be shown on pressure
gauge (4).
A Charging pressure: 2.4 +z.’ MPa

(24 ‘A kg/cm*)
If pressure gauge (5) does not reach 2.4 MPa (24 kg/
SI
z cm*), loosen valve (3) gradually, and charge with
z gas from the cylinder until pressure gauge (5)
reaches 2.4 MPa (24 kg/cm*).
If the pressure gauge registers above 2.4 MPa (24
kg/cm*), remove hose (6). Then gradually loosen ,_______j”____,
valve (3) to release gas from the accumulator into I I ‘\.
the atmosphere and adjust to 2.4 MPa (24 kg/cm*).
Ii. Accu;;;;iator
A 234F114E
Accumulator joint
Gasket
\ r-i-
! t-7
5/8-18UNi /
TV8 234F1146
TESTING AND ADJUSTING ADJUSTING BLADE LIFT SPEED
ADJUSTING BLADE LIFT

SPEED
Serial No.: 11001 - 12022
If there is a difference between the left and right

blade lift speeds, or when reducing the lifting speed
on the left and right, adjust as follows.
1. Loosen the locknut and adjust with adjustment

bolt (1).
* If there is a difference between the left and
right balde lift speeds, adjust by loosening TWG002.49
the bolt on the fast side to reduce the speed.
* The adjustment bolt has an adjustment range
of 4.8 turns.
1. Loosen locknut (3) of the main control valve.

Adjust with adjustment screw (2).
* If there is a difference between the left and
right blade speeds, adjust by loosening the
adjustment bolt on the fast side to make it
slower.
m Locknut : 88.3 + 9.8 Nm 19 * 1 kgml TWG00250
20-34
0
BLEEDING AIR FROM HYDRAULIC PUMP
A Lower the work equipment completely to the

ground.
1. Remove hydraulic tank side cover.
2. Loosen air bleed plug (I) of the front pump.
3. Loosen air bleed plug (2) of the rear pump.
4. Disconnect drain hose (3) from elbow.
5. Add hydraylic oil from drain hose (3).

* Add oil until the hydraulic oil comes out from
the front and rear air bleed ports.
Qz Hydraulic oil: 3.5 - 4.0 Q
6. Tighten air bleed plugs (1) and (2).
7. Install drain hose (3) to elbow (4).
8. Install the side cover of the hydraulic tank.
9. Run the engine at low idling, and raise and lower

the left and right blade lift cylinders 2 - 3 times.
z
R 10. Run the engine at high idling, and raise and lower
8 the left and right blade lift cylinders 2 - 3 times.
1
11. Loosen air bleed plug (5).
12. Run the engine at low idling, and raise the left and
right blade lift cylinders to the end of their stroke.
* Relieve the hydraulic pressure and bleed the air
completely.
13. Tighten air bleed plug (5).

* Run the engine to circulate the oil through the
system. Then check the oil level in the hydraulic
tank and add hydraulic oil.
._-
I \ ii !\ 235CD0204E
20-35
TESTING AND ADJUSTING ADJUSTING SLIP LOAD OF CIRCLE ROTATION CLUTCH
ADJUSTING SLIP LOAD OF CIRCLE ROTATION CLUTCH

Serial No.: 11001 - 12050
INSPECTION
1. Remove plug (I).
2. Make a mark on holder (2) and lock plate (3)

from the plug hole.
‘1 F23501402
3. Make a mark on cover (4) that is on the same

line as the mark on lock plate (3).
I Mark
heck mark from

lug hole
F23501401
4. Push the blade against the ground surface so

that the circle does not rotate, lift the front wheels
off the ground or fix the end of the blade in
position.
Method of raising front wheels off ground
1) Lower the work equipment to the ground,
extend the blade lift cylinder further, and
raise the front wheels off the ground.
2) Apply the parking brake.
Front wheels raised off around
a When raising the front wheels off the
ground, put blocks under the frame at TWG00300
the center of the front axle to ensure

safety.
Edge of blade held in Position

TWG00301
20-36
0
5. Operate the circle rotation lever and check if the

clutch slips.
METHOD OF CHECKING FOR SLIPPAGE
1) If it slips, the sound of sliding can be heard,
so return the circle rotation lever to the neu-
tral position to stop the slippage.
2) Check if the slippage occurred because the
mark on the cover and lock plate were out
of alignment.
* However, if the angle of misalignment is
within 20”, consider that it is not slip-
Cover I
ping. F23501405
ADJUSTING
1. When clutch does not slip.
1) Loosen bolts (I) and add 0.2 mm shim (2).
2) Tighten bolts (1) in the order of tightening.
3) Refer to the procedure for inspection, and
repeat Steps 1) and 2) until there is slippage
to align to the slippage limit point.
2. When clutch slips.
1) Loosen bolts (I) and remove 0.2 mm shim (2).
2) Tighten bolts (I) in the order of tightening.
3) Refer to the procedure for inspection, and
repeat Steps I) and 2) until there is no more
slippage.
When the slippage stops, loosen bolt (I),
add one 0.2 mm shim (21, and align with the
\I F23501406
slippage limit.
* If a shim is added, the pushing force of
the belleville spring becomes smaller,
and it is easier for the clutch to slip. If a
shim is removed, the pushing force of
the belleville spring becomes larger, and
it is difficult for the clutch to slip.
BREAKING IN CLUTCH
. When the clutch disc is replaced with a new
part, break in the clutch as follows.
i) Adjust in Steps 1 and 2 above to align to the
slippage limit point.
2) Make the clutch slip for 3.5 - 4.0 seconds. [Order of tightening bolts] F23501407
. Run the engine at full throttle
. The clutch disc will rotate one turn when
it slips for 3.5 - 4.0 seconds. Shim thickness that slips
3) Repeat Step 2) 20 - 25 times at three min- (Slipoaae limit Point)
(Alien to this shim
utes intervals. c thickness)
* Precautions
a) If the clutch housing temperature ex-
ceeds 5O”C, stop the breaking-in opera-
tion until it cools down to the normal
temperature.
b) If the clutch stops slipping during the
operation, add one shim of 0.2 mm to Shim thickness
make the clutch slip.
Shim thickness that
4) Adjust again to the slippage limit point. does not slip TWG00243
* Wait for the clutch housing to cool down
to the normal temperature before adjust-
ing.
20-37
Testing
1. Remove bolt (I), then remove cover (2).
2. To prevent the circle from rotating, push the
blade against the ground and raise the front
wheels or secure the ends of the blade.
. Method of raising front wheels
I) Lower the work equipment to the ground,
then extend the blade lift cylinder fur-
ther to jack up the front wheels.
2) Apply the parking brake.
A Put a block under the frame at the center
of the front axle.
3. Operate the circle rotation lever and check that
the clutch slips.
. When it starts to slip, there will be a sliding
noise and the holder at the tip of the shaft
will rotate. After checking, return the circle
rotation lever to the neutral position.
However, if the slippage stops immediately,
judge that it is not slipping.
Front wheels raised off eround
I TWG00300
Adjusting
t Adjust the pushing force of belleville spring (6)
by adjusting the number of shims (5).
INCREASE shims to DECREASE pushing force
and make it EASY to slip
DECREASE shims to INCREASE pushing force
and make it DIFFICULT to slip
1. When clutch does not slit,

1) Remove bolt (3), then’remove holder (4) and
add shim (5) of 0.2 mm.
Edae of blade held in position
2) Install holder (4), then tighten bolt (3). TWG00301
w Mounting bolt :
110.5 f 12.5 Nm Ill.25 f 1.25 kgm)
3) Repeat the testing procedure to check if the
clutch slips. I + Shim
(Slivvaae
thickness
Ilmlt
that
Point)
slips
4) Repeat steps I) to 3) until the clutch slips to

align to the slippage limit point.
5) When the clutch slips, remove shim (5) of
0.2 mm.
l Set to the shim thickness where the
clutch does not slip.
Chim thickness
I
I
Shim
(Al
thickness
ian to this
that
shim
does
thickness)
not SIIP
TWG00302
I
20-38
0
2. When clutch slips Shim thickness that slips

1) Remove bolt (3), then remove holder (4) and 1 (SliPPage limit Paint)
0.2mm
take out shim (5) of 0.2 mm.
2) Install holder (4), then tighten bolt (3).
w Mounting bolt :
110.5 + 12.5 Nm ill.25 k 1.25 kgm1
3) Repeat the testing procedure to check if the
clutch slips.
4) Repeat steps I) to 3) until the clutch slips to
b
align to the slippage limit point. 0 Chim thickness

5) When the clutch slips, remove shim (5) of Shim thickness that does not slip
0.2 mm. (Alien to this shim thickness) TWG00302
. Set to the shim thickness where the
clutch does not slip.
Breaking in clutch
. When the clutch disc is replaced with a new
part, break in the clutch as follows.
1) Adjust in Steps 1 and 2 above to align to the
slippage limit point.
2) Make the clutch slip for 3.5 - 4.0 seconds.
. Run the engine at full throttle
. The clutch disc will rotate one turn when it
slips for 3.5 - 4.0 seconds.
z 3) Repeat Step 2) 20 - 25 times at three minutes
z intervals.
2 * Precautions
a) If the clutch housing temperature exceeds
5O”C, stop the breaking-in operation until it
cools down to the normal temperature.
b) If the clutch stops slipping during the opera-
tion, add one shim of 0.2 mm to make the
clutch slip.
4) Wait for clutch to cool down to normal tempera-

ture.
5) Adjust again to the slippage limit point.
. Set to shim thickness that does not slip
20-39
0
TESTING AND ADJUSTING ADJUSTING CLEARANCE OF F AND R SWITCHES
ADJUSTING CLEARANCE OF
F AND R SWITCHES
Adjusting
1. Set the shift lever to the neutral position and
operate to the REVERSE position.
2. Change the tightening position of nut (I) to ad-

just the clearance between shift lever plate (2)
and R switch (3).
* Clearance : 2 mm
3. Set the shift lever to the neutral position and

operate to the FORWARD position.
4. Change the tightening position of nut (I) to ad-

just the clearance between shift lever plate (2)
and R switch (4).
* Clearance : 2 mm
3
4
Checking actuation
. Check that the LEDs in the F switch and R switch
light up when the switch is ON. I I
l Turn the starting switch on and check that the F
switch (R switch) LED lights up when the shift
2
lever is operated to the F (RI position.
II TWG00255
20-40
0
TESTING AND ADJUSTING ADJUSTING SHIFT POTENTIOMETER
ADJUSTING SHIFT
POTENTIOMETER
Serial No.: 12013 – 12015, 12019 – 12098
023502
20-41
(6)
TESTING AND ADJUSTING ADJUSTING INCHING POTENTIOMETER
ADJUSTING INCHING POTENTIOMETER

Serial No.: 12013 - 12015, 12019 and up
Transmission control valve
From inchina Pedal

TWG00303
. Adjust the output voltage of the inching

potentiometer by adjusting the mounting angle
of potentiometer (2).
1. Remove cover (I).

2. Insert a T-adapter into connector TM1 1.
3. Turn the starting switch ON and adjust the volt-
age between terminals @ and @ of TMII.
. Adjust with the inching pedal not pressed.
Voltage: 0.53 f 0.08 V
. The voltage can be changed by loosening
screw (3) and changing the mounting angle TWG00260
of potentiometer (2).
& Portion A of potentiometer (2): LM-G
4. Turn the starting switch OFF and remove the T-
adapter.
. Connect connector TM1 1 to its original posi-
tion.
5. Reset the controller (0 drift).
1) Turn the starting switch ON.
2) Ground the OD terminal inside the right con-
sole box to the chassis.
20-42
0
ADJUSTING SPEEDOMETER MODULE OF MACHINE
MONITOR
The speedometer on the machine monitor is a

common part for all models, but depending on the
model, the input signal for the travel speed is
different, so it is necessary to adjust the speedometer
to match the model.
Adjustment procedure
Remove the machine monitor, and adjust at the back
of the speedometer.
1. Remove rubber caps II and Ill at the back of the
speedometer.
2. When the rubber caps are removed, a rotary
switch can be seen inside. Check the part
number of the speedometer, then turn this
switch with a screwdriver to adjust as shown in
the table below.
(Part No. 7831-85-6000)
Switch11 1 3 / 3 1 3 1 3 i 7
Screwdriver 423F336
Switch III 121213131E b
3. After completing adjustment, fit the rubber caps

securely and install the machine monitor.
423F337
20-43
0
TROUBLESHOOTING
Points to remember when troubleshooting ....................................................................................... 20- 46

Sequence of events in troubleshooting ............................................................................................. 20- 47
Handling of electric equipment and hydraulic component ............................................................. 20- 48
Checks before troubleshooting ........................................................................................................... 20- 56
Electrical circuit system diagram ........................................................................................................ 20- 57
Connector types and mounting locations ....................................................................................... 20-60-49
Electrical wiring diagram .................................................................................................................. 20-60-60
Connection table for connector pin numbers ................................................................................ 20-60-63
T-branch box and T-branch adapter table ........................................................................................ 20-60-99
Method of using troubleshooting charts ...................................................................................... 20-60-102
Details of troubleshooting and troubleshooting procedure ....................................................... 20-60-104
Troubleshooting of engine (S mode) ................................................................................................. 20- 61
Troubleshooting chart for electronic vehicle monitoring system (M mode) ................................. 20- 81
Troubleshooting chart for electronic (engine, parking brake,
023502
transmission control) (E mode) ..................................................................................................... 20-101

Troubleshooting chart for transmission controller (ET mode) ......................................................... 20-151
Troubleshooting chart for hydraulic system (H mode) ..................................................................... 20-201
20-45
(5)
2
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
a Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
AL When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
a If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
a Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
a When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
a When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- . Confirm the extent of the failure yourself,
sembled. and judge whether to handle it as a real fail-
. It will become impossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or * When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in . Use the results of the investigation and in-
accordance with the fixed procedure. spection in Items 2 - 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Was there anything strange about the ma- * The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? . Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred be- will occur again.
fore? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-46
0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop
TFWnOl RO &Q TFWII”II(I Jobsite
eP 1
IExamination, confirmation of symptoms 1
1) When a request for repairs is received, first ,, II
ask the following points. R ins! Ring!
* Name of customer
- Type, serial number of machine
- Details of jobsite, etc.
21 Ask questions to gain an outline of the prob-
Ien%
- Condition of failure
- Work being carried out at the time of the TEW00182
failure
. Operating environment
. Past history, details of maintenance, etc.
eP 2 TEP01348
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
1 Repair at jobsite / )
* Hydraulic pressure gauge kit, etc. Decide action to take

2) Look in the parts book end prepare the nec-
essary replacement parts. Before starting troubleshooting, locate and n
repair simple failures.
- Check before starting items
* Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
Step 6
&-enacting failure]
. Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
TEP01351
Was there anything strange about the ma-

chine before the failure occurred?
Did the failure occur suddenly?
- Had any repairs been carried out before the
TEWOOlB9
failure?
TEWOOl91
20-47
0
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly 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, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted 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.
2. Main failures occurring in wiring harness
023502
1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
20-48
(5)
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. 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, if water should get into
023502
the connector, the pins will be short-cir-

cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face 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 it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
20-49
(5)
3. Removing, installing, and drying connec-
tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. 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 connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
023502
q When removing a connector from a
clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
20-50
(5)
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a 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.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
023502
per clicks into position.

3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
20-51
(5)
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
023502
20-52
(5)
4) Drying wiring harness
If there is any oil or dirt on the wiring har-
ness, 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 fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a 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
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a 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
023502
parts too hot, as this will cause

deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
20-53
(5)
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
023502
5. Points to remember when troubleshooting
electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
20-54
(5)
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
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 check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
023502
openings should be sealed with caps, tapes, or

vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
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
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-55
(5)
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 equip-
ment, 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.
023502
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 cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
20-55-1
(5)
Other check items Item Checks before starting
Hydraulic. Electrical
Electrical components mechamcal Lubricating oil, cooling water
compo”e”tS equipment
8
A A A
P 0 13 .‘
023502
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM DIAGRAM
ELECTRICAL CIRCUIT SYSTEM DIAGRAM

ELECTRONIC VEHICLE MONITORING SYSTEM
Serial No.: 11001 - 12012, 12016 - 12018
Final drive oil

wllperature sensor
Engine oil
pressure switch
[r/i iii/i1 IF
Radiator water
level sensor
II/l Hydraulic oil level sensor
CN PL
DIFF +-.--J& (Right)
e *ensor
Accumulator
Fl0a1 (Left
Parking
To flasher relay
Warning To turn signal lamp
To head lamp
I watertemperature
II lllll Startina 62
I ST
Electrical Intake
Head lamp Hi-Low
u --- . ,-,
235FO2079
20-57
0
Y”’
PleSS”le
switch
Winker 125W)
Parking 13W)
Winker (25W)
w/- Parking (3Wl
Electrical intake
air heater
Head Iaav Winker Starting Alternator

snitch (2OW) motor
TWG00345
20-59
0
TRANSMISSION CONTROL SYSTEM

Serial No.: 11001 - 11030
Body 1Transmission control box ass’y
Proximity Proximity
switch(F) switch(R1 Relay
(XtYPe) IXtYPe) (Starting
PROCEDURE FOR TESTING

GEARSHIFT SIGNALS
(l)The Procedure for connecting to the
connectors is as shown in below.
GND
lWG00244
20-60
0
Relay Relay
(BAck-uD (Diffe-
buzzer) rent lall Relay (RI Relav(F)
Rotary
Print board circus CN-TO 1 switch
I
Diode
(3lThe actuation is as shown

in the table below.
(2)Connect the pi lot lamp (24V

specifications 1 to check each
load and siana
q iBack-uo buzzer
q :Startina motor
q iDifferential lock solenoid
q LTransmission R clutch solenoid
q :Transmisslon F clutch solenoid
on 4th clutch so enoid
on 3th clutch so enold
on 2th clutch so enoid
on lth clutch so enoid
on low clutch so enoid
on hIat clutch s 0 lenoid
TWG00245
20-60- 1
0
Serial No.: 11031 - 12012, 12016 - 12018
Body 1 Transmission control box ass’y

I
Transmission
-.._._-__-__-.._-.-._-___ solenoid valve
2nd
4th
1st
LO
Hi
3rd
F
R
PROCEDURE FOR TESTING

GEARSHIFT SIGNALS
(lIThe Procedure for connecting to the
Power source for
drivino rotary
switch relay
1 difierkniiai lock 1 +14v 1
TWG00246
20-60-2
0
Relay Relay Relay

(BAck-ue (Diffe- (Parking
buzzer) rential) Relar(R) Relay(F) brake)
Rotary
int board circuit CN-TO I sxich
(SWP type1 ISIP type1
! p 0. 68rR -m P
- Diode
(3)The actuation is as shown

in the table below.
(2) Connec t the Pilot lamp (24V
specif icationsi to check each
~oao and sianal.
q : Parking lamp
q : Parking brake
q iBack buzzer
q
r-Y
;Startino motor
:Different al lock solenoid
;Transmlss on R clutch solenoid
;Transmlss on F clutch solenoid
:Transmiss on 4th clutch solenoid
:Transmiss on Ith clutch solenoid
:Transmiss on low clutch solenoid
:Transmlss on hioh clutch solenoid
TWG00247
20-60-3
023502
CN-FRError memo,~
reset
0 drift
CN-SWF
a-n
-a
:a
--m
3-
m
CN-SWR :;I:
------1
(2/2)
Procedure for testing gearshift signals

(l)The Procedure for connecting to the
Power sollrce for
rI”l”g relay +24v
Transmission
Power SoUrce for cant rol
back-up buzzer +24V
box ass’ Y
Power source for
startlna motor +24V
I
Power source for
differential lock
1 CN-E2’ Transmission
controller
Power source far
transmission clutch +24V ----v
solenoid
Ground
(2) nect the oi IO t lamp (24V :3) The actuation is as shown

cificationsl to check eat h in the table below.
d and signal.
iParking lamp
:Parkino brake
:Back buzzer
:Starting mot0 r
iDifferential lock solenoid
:Transmission R clutch sole noid
:Transmission F clutch sole naid
;Transmission 4th clutch so lenoid
:Transmission 3th clutch so lenoid
:Transmission 2th clutch so lenoid
;Transmission lth clutch so lenoid
:Transmission low clutch so lenaid
iTransmission hioh clutch s olenoid

TWG00306
20-60-6
0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

Connector No. 1Connectortype 1No. of pins 1 Mounting location 1 Address 1
CNl SWP 8 Intermediate connector (articulate section) F9, A4
CN2 X 8 Intermediate connector (articulate section) F7, A3
CN3 X 4 Intermediate connector (below left side of floor frame) 12
CN4 SWP 12 Intermediate connector (below left side of floor frame) I2
CN5 SWP 14 Intermediate connector (below left side of floor frame) HI
1 CN6 1 KES2 1 8 1 Intermediate connector (inside of R.H. console box) / G3, J3 1
1 CN7 I SWP I 12 I Intermediate connector (left side of radiator) 1 E2, J7 1
CN8 SWP 16 Intermediate connector (inside of R.H. console box) 1 G2
CN9 SWP 12 Intermediate connector (inside of R.H. console box) G2
CNIO Relay 5 Engine oil pressure relay H4
CNII - 1 Buzzer (inside of R.H. console box) -
1 CN12 I - I - I Intermediate connector I2
1 CN13 I swp I 8 I Intermediate connector (below left side of floor frame) 1 Gl I
CN14 1 SWP 1 8 1 I ntermediate connector (inside of R.H. console box) 1A4. G9. 14.M51
CN15 SWP 12 Intermediate connector (next to L.H. battery) D2
CN16 KESl 2 Monitor module -
CN17 DLI 8 Monitor module -
I CN18 / DLI I 12 1 Monitor module ]~~~:I
CN19 I MIC I 5 I Speedometer module I - I

CN20 DLI 16 Speedometer module -
CN21 M 3 Intermediate connector (below monitor panel) J4
CN22 X 4 Intermediate connector (next to L.H. battery) c2
CN23 - - Intermediate connector H4
/ CN25 / SWP 1 14 I Intermediate connector (below left side of floor frame) / HI I

1 CN26 I SWP 1 12 I Intermediate connector (below left side of floor frame) I HI
CN27 1 SWP / 16 I Intermediate connector (below left side of floor frame) I G2
CN28 KESI 3 Head lamp Hi-Lo selector switch I4
CN29 YPC 2 Cab mount lamp switch -
CN30 SWP 2 Speed sensor 82, G7, 01
CN31 X 1 Final drive oil temperature sensor K7
CN32 I - I 1 I Engine oil pressure switch I J6
CN33 I x I 1 I Fuel gauge sensor 1 J7
CN34 X 2 Engine water temperature sensor J9
CN35 X 1 Engine oil level sensor J5
CN36 X 2 Hydraulic oil level switch L6
CN37 I x I 2 / Air pressure switch (L.H.) 1 H9, K6

CN38 I x I 2 I Air pressure switch (R.H.) / 19, K6
CN39 / KESI I 3 / Ra d’la t or coolant level sensor I D2
CN40 KESI 3 Turn signal switch I5
CN41 YPC 6 Hazard switch (OPT) -
20-60-7
0
TESTING AND ADJUSTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Serial No.: 12019 – 12502
023502
20-60-52
(6)

Connector No. Connector type No. of pins Mounting location Address
CN1 DT-T 8 Intermediate connector (articulate section) F9, A4
CN2 DT-T 8 Intermediate connector (articulate section) F7, A3
CN3 DT-T 12 Intermediate connector (below left side of floor frame) H1
CN6 KES2 8 Intermediate connector (inside of R.H. console box) G3, J3
CN7 DT-T 12 Intermediate connector (left side of radiator) E2, J7
CN10 Relay 5 Engine oil pressure relay H4
CN11 — 1 Buzzer (inside of R.H. console box) —
CN12 — — Intermediate connector —
CN13 DT-T 8 Intermediate connector (below left side of floor frame) G2
CN14 DT-T 8 Intermediate connector (inside of R.H. console box) A4, G9, I4, M5
CN15 SWP 12 Intermediate connector (next to L.H. battery) D2
CN16 KES1 2 Monitor module —
CN17 DLI 8 Monitor module —
023502
CN18 DLI 12 Monitor module —

CN19 MIC 5 Speedometer module —
CN20 DLI 16 Speedometer module —
CN21 M 3 Intermediate connector (below monitor panel) J4
CN22 DT-T 2 Intermediate connector (next to L.H. battery) C2
CN23 — — Intermediate connector H4
CN26 DT-T 12 Intermediate connector (below left side of floor frame) I3
CN27 DT-T 8 Intermediate connector (below left side of floor frame) J2
CN27A DT-T 8 Intermediate connector (below left side of floor frame) I1
CN28 KES1 3 Head lamp Hi-Lo selector switch I4
CN29 YPC 2 Cab mount lamp switch —
CN30 SWP 2 Speed sensor B2, G7, O1
CN31 X 1 Final drive oil temperature sensor K7
CN32 — 1 Engine oil pressure switch J6
CN33 X 1 Fuel gauge sensor J7
CN34 X 2 Engine water temperature sensor J9
CN35 X 1 Engine oil level sensor J5
CN36 X 2 Hydraulic oil level switch L6
CN37 X 2 Air pressure switch (L.H.) H9, K6
CN38 X 2 Air pressure switch (R.H.) I9, K6
CN39 KES1 3 Radiator coolant level sensor D2
CN40 KES1 3 Turn signal switch I5
20-60-55
(6)

CN41 YPC 6 Hazard switch (OPT) —
CN43 — 1 Intermediate connector (inside of R.H. console box) —
CN46 — 1 Intermediate connector (inside of R.H. console box) —
CN50 M 6 Intermediate connector (rear of operators seat) K4
CN51 SWP 8 Engine stop motor D5
CN53 (inside of R.H. console box) Relay 5 Engine stop motor relay H4, K6
CN53 (hydraulic oil tank) X 1 Hydraulic oil temperature sensor L6
CN55 DT-T 6 Intermediate connector (below left side of floor frame) G1
CN56 — 1 Back-up alarm —
CN57 KES0 4 Rear combination lamp (L.H.) —
CN58 KES0 4 Rear combination lamp (R.H.) —
CN59 — 1 Rear work lamp —
CN61 Relay 5 Emergency steering relay H4
CN63 X 1 Intermediate connector (below left side of floor frame) H2
CN64 KES2 4 ESC (emergency steering) (inside of R.H. console box) —
023502
CN65 KES2 2 ESC (emergency steering) (inside of R.H. console box) —
CN66 — 1 Intermediate connector (inside of R.H. console box) H4
CN67 DT-T 2 Intermediate connector (below left side of floor frame) —
CN67A DT-T 2 Intermediate connector (below left side of floor frame) I2, N2
CN67B DT-T 2 Intermediate connector (below left side of floor frame) I1, N2
CN68 M 2 Pressure switch (emergency steering) H1
CN69 — 1 Rear work lamp —
CN71 KES2 2 Differential lock solenoid K7
CN73 KES2 2 Parking brake solenoid B5
CN74 — 1 Air drier G9, K5
CN77 — 1 Starting switch —
CN79 SWP 16 Intermediate connector (rear of operator’s seat) K4
CN82 KES0 2 Air pressure sensor L5
CN86 X 3 R.H. sensor (blade float) (blade lift lever) —
CN87 X 3 L.H. sensor (blade float) (blade lift lever) —
CN88 — 1 Intermediate connector (blade float) (below left side of floor frame) —
CN89 Relay 5 Blade float relay (R.H.) —
CN90 Relay 5 Blade float relay (L.H.) —
CNA7 X 2 Intermediate connector (below air tank) —
CNA28 X 1 Intermediate connector (below air tank) —
CNAC X 1 Air conditioner compressor —
CNAG YPC 2 Air gauge —
20-60-56
(6)

CNE1 MIC 13 Transmission controller —
CNE3 (No.1 – 20) AMP040 20 Transmission controller —
CNE3 (No.21 – 36) AMP040 16 Transmission controller —
CNE4 AMP040 12 Transmission controller —
CNFBW YPC 2 Blade work lamp switch —
CNFR — 1 Error memory reset (inside of R.H. console box) M3
CNFW YPC 2 Front work lamp switch —
CNOD — 1 0 drift (inside of R.H. console box) M2
CNPL KES0 6 Pilot lamp —
CNPL — 1 Panel lamp J4
CNRBB Relay 5 Back-up buzzer relay M8
CNRCB Relay 5 Caution buzzer relay P8
CNRDI Relay 5 Differential lock relay N8
CNRIL Relay 5 Tail lamp (not used) O9
023502
CNRPB Relay 5 Parking brake relay G4

CNRPST Relay 5 Starting motor relay G4
CNRST Relay 5 Starting motor relay M7
CNRW YPC 2 Rear work lamp switch —
CNSM — 1 Service meter —
CNST AMP 3 Starting motor I7
CNSWF X 3 F switch M5
CNSWR X 3 R switch M6
CNT03 SWP 12 Transmission control switch —
CNTM3 X 4 For flash memory write (transmission controller) —
CNTM4 X 3 Shift potentiometer 1 M7
CNTM5 X 3 Shift potentiometer 2 N8
CNTM9 SWP 2 Engine speed sensor R7
CNTM10 SWP 2 Transmission oil temperature senor R3
CNTM11 X 3 Inching potentiometer R6
CNTM13 DT-T 12 Intermediate connector (inside of R.H. console box) M5
CNTM14 DT-T 12 Intermediate connector (inside of R.H. console box) M4
CNTM15 DT-T 12 Intermediate connector (below left of air tank installation table) R4
CNTM16 DT-T 12 Intermediate connector (below left of air tank installation table) R4
CNTM95 DT-T 3 Intermediate connector (engine speed sensor) R5
CNTMC — 1 Intermediate connector (below left side of floor frame) N2
E5 — 1 Intermediate connector (slow below fuse – fuse box) G2
E6 — 1 Intermediate connector (slow below fuse – fuse box) G2
20-60-57
(6)
TESTING AND ADJUSTING ELECTRICAL WIRING DIAGRAM
ELECTRICAL WIRING DIAGRAM (1/3)

023502
20-60-59
(6)
(2/3)
Serial No.: 11001 – 12502
023502
20-60-60
(6)
(2/3)
023502
20-60-61
(6)
(3/3)
023502
20-60-62
(6)
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
20-60 - 63
(7)
20-60 - 64
(7)
20-60 - 65
(7)
20-60 - 66
(7)
20-60 - 67
(7)
20-60 - 68
(7)
20-60 - 69
(7)
20-60 - 70
(7)
20-60 - 71
(7)
20-60 - 72
(7)
20-60 - 73
(7)
20-60 - 74
(7)
20-60 - 75
(7)
20-60 - 76
(7)
20-60 - 77
(7)
20-60 - 78
(7)
20-60 - 79
(7)
20-60 - 80
(7)
20-60 - 81
(7)
20-60 - 82
(7)
20-60 - 83
(7)
20-60 - 84
(7)
20-60 - 85
(7)
20-60 - 86
(7)
20-60 - 87
(7)
20-60 - 88
(7)
20-60 - 89
(7)
20-60 - 90
(7)
20-60 - 91
(7)
20-60 - 92
(7)
20-60 - 93
(7)
20-60 - 94
(7)
20-60 - 95
(7)
20-60 - 96
(7)
20-60 - 97
(7)
20-60 - 98
(7)
T- branch box and T- branch adapter table (Rev. 2009.03)1
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
20-60 - 99
(7)
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
20-60 - 100
(7)
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
20-60 - 101
(7)
TROUBLESHOOTING OF ENGINE
(S MODE)
S-l Starting performance is poor (Starting always takes time) .............................................................. 20-62
s-2 Engine does not start

@ Engine does not turn .............................................................................................................. 20-63
@ Engine turns but no exhaust gas comes out (Fuel is not being injected) ..................................... 20-64
@ Exhaust gas comes out but engine does not start (Fuel is being injected) ................................... 20-65
s-3 Engine does not pick up smoothly (Follow-up is poor) .................................................................... 20-66
s-4 Engine stops during operations ..................................................................................................... 20-67
s-5 Engine does not rotate smoothly (hunting) .................................................................................... 20-68
S-6 Engine lacks output (no power) ..................................................................................................... 20-69
s-7 Exhaust gas is black (incomplete combustion) ................................................................................ 20-70
S-8 Oil consumption is excessive (or exhaust gas is blue) ..................................................................... 20-71
s-9 Oil becomes contaminated quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
s-10 Fuel consumption is excessive ...................................................................................................... 20-73
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-74
s-12 Oil pressure lamp lights up (drop in oil pressure) ........................................................................... 20-75
S-l 3 Oil level rises ............................................................................................................................... 20-76
s-14 Water temperature becomes too high (overheating) ....................................................................... 20-77
S-l 5 Abnormal noise is made ............................................................................................................... 20-78
S-l 6 Vibration is excessive ................................................................................................................... 20-79
20-61
0
TROUBLESHOOTING TABLE
S-l Starting performance is poor (Starting always takes time)

General causes why starting performance is poor
- Defective electrical system
- Insufficient supply of fuel
- Insufficient intake of air
f Improper selection of fuel Legend
0 : Possible causes (judging from Questions and check items)
(At ambient temperature of -10°C or below, use Q : Most probable causes (judging from Questions and Check items1
ASTM D975 No. 1, and -10°C or above, use ASTM a : Possible causes due to length of use (used for a long period)
D975 No. 2 diesel fuel.) 0 : Items to confirm the cause.
t Battery charging rate.
. The specific gravity should exceed the value for the charging rate
of 70% in the above table.
. In cold weather the specific gravity must exceed the value for the
charging rate of 75% in the above table.
I measured. it IS found to be IoIo/ I I I I I I I I I I I I
20-62
S-2 Engine does not start
0 Engine does not turn
General causes why engine does not turn

. internal parts of engine seized
* If internal parts of the engine are seized, carry
out troubleshooting for “Engine stops during
operations”.
. Failure in power train
. Defective electrical system
Legend
0 : Possible causes (judging from Questions and check items]
G : Most probable causes (judging from Questions and Check items)
* : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
switch IS turned ON
turned to START, pinion
moves out, but
connect the cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are connected,
20-63
@ Engine turns but no exhaust gas comes out
(Fuel is not being injected)
General causes why engine turns but no exhaust gas

comes out
. Supply of fuel impossible
f Supply of fuel is extremely small
. Improper selection of fuel (particularly in winter)
Standards for use of fuel
Ambient temperature
Type of fuel -22 -4 ,4 32 50 68 86 104 122°F

-30 -20 -10 0 10 20 30 40 50°C
Diesel fuel
Legend
0 : Possible causes (judging from Questions and check items1
6,:) : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
1 Confirm recent reoair historv I I I I I I I I I I I
20-64
0 Exhaust gas comes out but engine does not
start
(Fuel is being injected)
General causes why exhaust gas comes out but

engine does not start
. Lack of rotating force due to defective electri-
cal system
. Insufficient supply of fuel
. Insufficient intake of air
. Improper selection of fuel
Legend
0 : Possible causes (judging from Ouestions and check items)
0 : Most probable causes (judging from Questions and Check items)
l : Items to confirm the cause.
When fuel filter is drained, no fuel comes out

S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up smoothly
. insufficient supply of fuel
* Improper condition of fuel injection
. Improper fuel used
Legend
length of use (used for a long period)
I Replacement of filters has not been carried out according to operation IllI I Ill III
When exhaust manifold is toLched Immediately after starting engine,
temperature of some cvlinders is low
When fuel cap is inspected directly, it is found to be clogged 0

When feed pump is operated, operation is too light or too heavy l
20-66
S-4 Engine stops during operations
General causes why engine stops during operations
. Seized parts inside engine
- Insufficient supply of fuel
. Overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
. Failure in power train
* If the engine stops because of a failure in
the power train, carry out troubleshooting
for the chassis.
:gend
a : Most probable causes (judging from Questions and Check items)
Confirm recent repair history
Deoree of use 1 Operated for long period

-_I .._:__ ..^^ .^___I
Condition when engine
stopped
Non-specified fuel is being used 0 0 0 0
When feed pump is operated, there is no response or it is heavy 0 0 d
Mud is stuck to fuel tank cap Q

Engine turns. but stops when transmission control lever is
Try to turn by hand using
Remove head cover and check directly
When qear train is inspected, it does not tL
Turns when pump auxiliary equipment is removed

I I I I t-1 I I I I I I I 5
1
When fuel filter,,strainer are inspected directly, they are found
l 2
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
Check feed pump directly
When control rack is pushed, it is found to be heavy or
I does not return /I III I III III I
20-67
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly
. Air in fuel system
. Defective governor mechanism
. Defective electric goyernor machanism (electric
governor type)
* If there is no hunting when the electric governor
rod is disconnected, carry out troubleshooting
for the electrical system.
Legend
Condition of hunting
epacemen 0
20-68
S-6 Engine lacks output (no power)
General causes why engine lacks output
. Insufficient supply of fuel
. Improper condition of fuel injection
. Improper fuel used
(if non-specified fuel is used, output drops)
. Lack of output due to overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
Legend
: Most probable causes (judging from Questions and Check items)
: Possible cau e to length of use (used for a long period)
Color of exhaust gas
en va ve c earance IS c
20-69
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black
. improper condition of fuel injection
* Excessive injection of fuel
Legend
@ : Most probable causes (judging from Ouestions and Check items)
a : Possible causes due to length of use (used for a long period)

;
.g
I
Fi
Power was lost
Non-specified fuel is being used
Noise of interference is heard from around turbocharger
V
Dust indicator is red \?
Blow-by gas is excessive c
Engine pickup is poor and combustion is irregular 0 :: 0 0 0 0
When exhaust manifold is touched immediately after starting engine,
standard value
When muffler is removed, exhaust gas color returns to normal 0
When control rack is pushed, it is found to be heavy, or does not return l
20-70
S-8 Oil consumption is excessive (or exhaust gas is blue)
* Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is excessive
. Abnormal combustion of oil
. External leakage of oil
. Wear of lubrication system
Legend
gth of use (used for a long period)
20-7 1
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper combustion
. Improper oil used
. Operation under excessive load
Legend
When oil filter is inspected, metal particles are found 0

2 _ UJ
0 h
When exhaust pipe is removed, inside is found to be dirty with oil E
Enoine oil temoerature rises auicklv ,,, :
c
When compression pressure is measured, It is found to be low l l ;

-0
When breather element is inspected directly, it is found to be clogged
l P
‘G
with dirty oil, or hose is broken
8
When oil filter is inspected directly. it is found to be clogged l 5
When oil cooler is inspected directly, it is found to be clogged l n
a
Turbocharger drain tube __
is cloqqed I I.1 I b
Excessive play of turbocharger shaft 0 %
When safety valve is directly inspected, spring is found to be catching t
. &
20-72
S-l 0 Fuel consumption is excessive
General causes why fuel consumption is excessive
. Leakage of fuel
. Improper condition of fuel injection
. Excessive injection of fuel
om Questions and check items)

: Most probable ca ging from Questions and Check items)
A : Possible causes d gth of use (used for a long period)
l : Items to confirm
of same model
Condition of fuel consumption
Injection pump test shows that injection amount is excessive l

Speed of some cylinders does not change when operatjng on reduced
l
cyltnders
When control rack is oushed. it is found to be heavv. or does not return l

When check IS made using delivery method, injection timng is found
to be incorrect
Remove head cover and check directly 1 1.1 j
Remove feed pump and check directlv I I I I I I /.I
20-73
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
* Internal leakage in lubrication system
. Internal leakage in cooling system
LegC!“O
ssible causes (judging from Questions and check items)
_____. , _
2 Oil level
0 Graduallv increased
Hard water is being used as cooling water 0 0
Engine oil level has risen. oil is cloudy white G 0 0

,”
li Excessive air bubbles inside radiator, spurts back Q Cz
.S
., Hvdraulic oil, torque converter, transmission oil is cloudv white I I I
I
I CC?
1
I I I
$ When hydraulic oil, torque converter, transmission oil is drained,
u 6
wilt07 ic fn,,nrl
Pressure-tightness test of oil cooler shows there is leakage
Pressure-tightness test of cylinder head shows there 1s leakage
Remove cylinder head and check directly
Remove 011 pan and check directly
20-74
S-12 Oil pressure lamp lights up (drop in oil pressure)
General causes why oil pressure lamp lights up
. Leakage, clogging, wear of lubricating system
* Defective oil pressure control
* Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
+ Standards for engine oil selection
Type of oil
I Selection of oil SAE number
to ambient temperature
according
I
-22 -4 14 32 50 68 86 104 122°F
-30 -20 -10 0 10 20 30 40 5o’c
!gend
: Possible causes (judging from Questions and check items)
gth of use (used for a long period1
Condition when oil pressure
When oil filter is inspected directly, it is found to be clogged a l F

‘Z
m Remove oil pan and check directly 0 l 0 8
.s f =m
Oil pump rotation is heavy, there is play 0 ‘=
8 + .e
f There is catching of relief valve or regulator valve, spring or eB
1_
20-75
S-13 Oil level rises
t If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
. Water in oil (cloudy white)
. Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
I I
Legend
20-76
S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes
too high
. Lack of cooling water (deformation, damage of
fan)
. Drop in heat dissipation efficiency I I
. Defective cooling circulation system
. Rise in oil temperature of power train
* Carry out troubleshooting for chassis.
Legend
0 : Possible causes (judging from Questions and check.items)
a : Possible causes due to length of use (used for a long period)
Degree of use 1 Operated for long period a 1a /A IA

E .,A^_,..^..^_L_^._A :\- 0 0
water temperature gauge
Temperature difference between top and bottom radiator tanks is
even at the cracking temperature
20-77
S-l 5 Abnormal noise is made
* Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
. Abnormal combustion noise
* Air sucked in from intake system
Legend
Q : Most probable causes (judging from Questions and Check items)
Confirm recent repair history
Degree of use
z 1 Gradual1 y occurred 0 0
Condition of abnormal noise
.g
Suddenly occurred 0 0 0
5
Non-specified fuel is being use ‘d 0 0
2
Engine oil must be added more __._.... 1-1 I, I, / I I I I I
1 Blue under liaht load @ I 1
Color or exhaust gas
Metal particles are found in oil
Blow-by gas is excesswe
Noise of interference is heard fl
Engine pickup is poor and coml
When exhaust manifold is touched immedjately after starting engrne.

62 0
temperature of some cylinders is low
g
C Seal on iniection our-no has come off
20-78
S-l 6 Vibration is excessive
* If there is abnormal noise together with the
vibration, carry out troubleshooting for “Abnor-
mal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)
* Improper alignment
* Abnormal combustion
Legend
: Possible causes due to length of use (used for a long period)
:: Vibration follows engine speed 0 0 0 0 0

_z Exhaust gas is black 0 0
0
Seal on injection pump has come off Q
1 Remove oil pan and check directly I.1 I I I I I I I I
Injection pump test shows that injection amount is incorrect
20-79
TROUBLESHOOTING CHART FOR ELECTRONIC
VEHICLE MONITORING SYSTEM
(M MODE)
M-l. When starting switch is turned ON, monitor panel display does not appear . . .. 20-82
M-2. When starting switch is turned ON, monitor panel display does not go out . . . 20-82
M-3. When starting switch is turned ON (engine stopped), check items flash . .. 20-83
M-4. Preheating operation is not being used but preheating display lights up . . . 20-85
M-5. When starting switch is turned ON and engine is started, caution items flash
(but there is no abnormality with engine or CHECK items ) . . . _. . 20-86
M-6. Buzzer does not sound for 1 minute when starting switch is turned ON (engine stopped) 20-91
M-7. There is no abnormality displayed on monitor, but buzzer sounds . _. . . . 20-91
M-8. Monitor panel lighting does not light up . . . . . 20-92
M-9. . Service meter does not move after engine is started
. Service meter continues to move when engine is stopped ..... 20-93
M-10. Coolant temperature gauge displays abnormally low temperature 20-94
M-l 1. Coolant temperature gauge does not give a display ............. 20-95
M-12. Fuel level gauge always displays FULL .......................... 20-96
M-13. Fuel gauge does not give any display ........................... 20-96
M-14. Speedometer display does not work normally ................... 20-97
M-15. Turn signal indicator pilot lamp does not light up ................ 20-98
M-16. High beam pilot lamp does not Ilight up ......................... . . 20-99
20-81
0
M-l WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL
DISPLAY DOES NOT APPEAR.
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch OFF.
* When connecting the T-adapter, connect the male and female to the socket specified in ( ).
* After checking, connect the disconnected connectors again immediately.
a) NONE OF MONITOR PANEL WORKS.

Cause Remedy
2 YES
Defective monitor module Replace
YES Is voltage behveen
, - CN18 (female) (I) - Defective contact, or discon-
and (2) 20 - 30 V? section in wiring harness After inspec-
Jetween CN18 (female) (1) tion, repair
Is voltage between
1) Connect T-adap- NO - CN25 (4) - CN13 (3) -fuse (clean) or re-
chassis ground and -
ter to CN18 (fe- 13, or between CN18 (fe- place
fuse 13 20 - 30 V?
male). male) (2) - chassis ground
2) Turn starting switch ON.
1) Turn starting 3lown fuse After finding
switch ON. case, check for
short circuit in
wiring harness
b) PART OF MONITOR PANEL DOES NOT WORK.
Defective monitor module. Replace
Tester
Troubleshooting
tools T-adapter or socket adapter
(for DLl)
M-l a) Related electrical circuit drawing
CNIE CN25 CNl3

Fuse 13
Monitor
module
Fl
2
235FO2088
M-2 WHEN STARTING SWITCH IS

TURNED ON, MONITOR PANEL
DISPLAY DOES NOT GO OUT.
defective monitor module. Replace
20-82
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),
CHECK ITEMS FLASH.
* When connecting the T-adapter, connect the male and female to the socket specified in ( 1.
a)
sl 8 (COOLANT LEVEL) FLASHES.
Cause Remedy
VFS Defective radiator coolant

Replace
level sensor
3 YES
YESI I
Disconnection in wiring
After inspec-
1) Connect CN39 harness, or defective con-
tion, repair
tact between CN39 (fe-
(clean)-or re-
male) (3) - CN25 (7) -
place
2) Connect - disconnect CN39 (female) (3) CN18 (female) (7).
2) Turn starting
After inspec-
harness, or defective con-
(or socket adapter) NO tion, repair
tact between CN39 (fe-
to CN39 (female). (clean) or re-
male) (2) - CN25 (3) -
place
chassis ground.
Table
CN39
Continuity
(3) - (2)
Connect 1 Yes
Disconnect 1 No
(ENGINE OIL LEVEL) FLASHES.
YES Defective engine oil level

Replace
1 sensor
Does q go out? - NO
2 YES
_ Is there continuity
1) Connect CN35 (fe- _ between CNI 8 (fe-
Defective contact, or dis-
male) (engine oil male) (6) - (Z)?
connection in wiring har- After inspec-
level sensor) to (See table)
ness between CN35 (fee- tion, repair
chassis ground. male) (1) - CN15 (1) - (clean) or re-
1) Connect T-adapter NO
2) Turn starting place
to CN18 (female). CN26 (2) - CN18 (female)
switch ON.
2) Connect - discon- Table (6).
nect CN35 (fe-
male) and chassis CN35 -
Continuity
ground. chassis ground
Connect Yes
Disconnect No
Tester Short socket adapter

Troubleshooting
tools T-adapter or socket adapter T-adapter or socket adapter
ifor DLl) ffor Econoseal)
20-83
cl
El b (hydraulic oil level) flashes.
Cause Remedy
‘ES Defective hydraulic oil sen-

-I Replace
1 SOT
Does @j go out
r-l
when short con-
nector is con-
nected?
1) Connect short con-

nector to CN36 (fe-
rl0
Is continuity be-
tween CN18 (fe-
male) (5) and (2)
2 YES
Defective monitor

connection in wiring har-
module Replace
After inspec-
male) (hydraulic as shown in table? ness between CN36 (fe-
, tion, repair
oil level sensor). male) (1) - CN25 (8) -
1) Connect T-adaoter NO (clean) or re-
2) Turn starting CN18 (female) (5). or be-
to CN18 (femaie). place
switch ON. tween CN36 (female) (2) -
2) Connect * discon- Table CN25 (3) - chassis ground
nect CN36 (fe- ^,. ,.
male) and short- anorr SOCKBT:
Continuity
connector. adapter
M-3 a) Related electrical circuit drawing
CN18 CN25 CN39
Monitor
module Coolant level sensor
235FO2089
M-3 b) Related electrical circuit drawing
CNl8 CN26 CN15 CN35

Monitor
module
Engine oil level sensor
235FO2090
M-3 c) Related electrical circuit drawing
CNl8 CN25 CN36
Monitor Hydraulic oil

module level sensor
235FO2091
20-84
M-9 l Service meter does not move after engine is started
l Service meter continues to move when engine is stopped
a) Service meter does not move after engine is started Remedy

Cause
YES
Go to M5 a)
1
Is engine oil press-

ure CAUTION lamp -
2 YES
lighted up? Defective service meter Replace
- Is voltage between
1) Turn starting - CN19 (female) (1) -
switch ON. NO and (4) 20 - 30 V?
Disconnection in wiring hap
After inspec-
2) Start engine. tion, repair
ness between CN19 (female)
1) Connect T-adapter NO (clean) or re-
(4) and CN25 (male) (5)
to CN19. place
2) Turn starting
switch ON.
3) Start engine.
b) Service meter continues to move when engine is stopped
2 YES Defective engine oil press-

ure sensor
Does service meter
YES stop when CN32 is Wiring harness between engtne
oil pressure relay (3) - CN13 (51
1 - connected to chas- -
- CN25 (5) - CN19 (female) (41 After inspec-
- sis ground? short circuiting with chassis tion, repair
ground, or defective relay, or
(clean) or re-
Does service meter _ 1) Connect CN32 to NO defective contact, or disconnec-
stop? tion in wiring harness between place
chassis ground.
2) Turn starting engine oil pressure relay (2) -
CN13 (8) - CN15 (4) - CN32
) Remove CN13.- switch ON.
Wiring harness between
) Turn starting NO CN13 (female) (5) - CN25 (5
switch ON.
- CN19 (female) (4) short
circuiting with chassis
ground
Tester
Troubleshooting
tools T-adapter or socket adapter
lfor DLI)
20-93
M-9 Related electrical circuit drawing
Engine oil
pressure relay
Monitor
module
Service meter
(speedometer
module)
CN32
A 0
”
Engine oil
* pressure sensor
235FO2101
8
R
M-IO COOLANT TEMPERATURE GAUGE DISPLAYS ABNORMALLY s1
LOW TEMPERATURE
t After checking, connect the disconnected connectors again immediately.
Cause Remedy
YES Defective coolant tempera-

Replace
ture sensor
connection in wiring har-
ness between CN34 (fe- After inspec-
male) (2) - CN15 (2) - tion, repair
CN25 (3) - chassis ground, (clean) or re-
1) Connect short con-
orspray go c or between CN34 (female) place
(male) - (1) - CN15 (3) - CN25 (9)
cted to - CN17 (1)
und?
switch ON. Defective monitor module Replace
to CN17.
2) Connect CN17 (1)
to chassis ground.
3) Turn starting
switch ON.
20-94
M-II COOLANT TEMPERATURE GAUGE DOES NOT GIVE A DISPLAY
* When connecting the T-adapter, connect the male and female to the socket specified in ( 1.
F
Cause Remedy
YES Defective coolant tempera-

Replace
ture sensor

when CN34 is dis- CN34 (female) (1) - CN15 After inspec-
connected (lowest 2. YES tion, repair
(3) - CN25 (9) - CN17 (1)
Does temperature (clean) or re-
short circuiting with chas-
“- -‘ty appear place
1) Disconnect CN34. sis ground
CN17 is dis- -
2) Turn starting .,.+*rl +#/est
switch ON.
II Defective monitor module IReplace
1) Disconnect CN17. NO
2) Turn starting
switch ON.
M-l 0, M-l 1 Related electrical circuit drawing
CN 17 CN25 CN15 CN34

Monitor
module @ Coolant
temperature
sensor
CNIE
235FO2094
20-95
M-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL
YES
Defective fuel level sensor Replace
1 I
After inspec-
CN17 (female) (3) - CN26
2 YES tion, repair
(4) - CN7 (9) - CN33 (1)
(clean) or re-
(female) short circuiting
Does fuel level place
1) Disconnect CN33 with chassis ground
(fuel level sensor). - ga”ge disp’av go -
out?
2) Turn starting
switch ON. Defective monitor module Replace
3) Wait for approx. 1 1) Disconnect CN17. NO
min. 2) Turn starting
switch ON.
3) Wait for approx. 1
min.
M-13 FUEL GAUGE DOES NOT GIVE ANY DISPLAY
ES
Defective fuel level sensor Replace
Does FULL display

appear? NO 2 YES
Defective monitor module Fieolace
Is there continuity
1) Disconnect CN33 between CN17 (fe-
(fuel level sensor). male) (3) and Defective contact, or dis-
After inspec-
2) Connect short con- chassis ground? connection in wiring har-
tion, repair
nector. ness between CN17 (fe-
(clean) or re-
3) Turn starting 1) Disconnect CN17. NO male) (3) - CN26 (4) - CN7
date
switch ON. 2) Connect short con- (9) - CN33 (I) (female)
4) Wait for approx. 1 nector.
min. 3) Connect T-adapter
to CN17 (female).
Tester Short socket adapter

Troubleshooting
(for DLI) (for Econoseal)
M-12, M-13 Related electrical circuit drawing
CNI? CN26 CN33

Monitor
module
Fuel level sensor
235FO2102
20-96
M-14 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY
Cause Remedy
4 YE! Defective speedometer

Replace
module
setting of speed
sensor 0.5 - 1.5
Defective speed sensor

Replace
mount
0
It It contacts
.,. _
turn.

After inspec-
tweclt bIYLV ,Ic- connection in wiring har-
tion, repair
male) (7) and (6) ness between CN20 (2).
(clean) or re-
300 R - 1 kR? NO (10) (female) and CN26
olace
(male) (61, (7)
Connect T-adapter
Is resistance be-
(socket adapter) to Defective contact, or dis-
tween CN30 (male) After inspec-
CN26 (female). connection in wiring har-
(I) and (2) 300 R - tion, repair
ness between CN26 (fe-
(clean) or re-
male) (6), (7) and CN30 (I),
gggi$gj (2)
Defective speed sensor

place
Replace
NO
sor) (male).
Troubleshooting
(for DLI) (for Econoseal)
M-14 Related electrical circuit drawing
CN20 CN 26 CN30
Monitor
3
Speedometer sensor
module
235FO2103
20-97
M-15 TURN SIGNAL INDICATOR PILOT LAMP DOES NOT LIGHT UP
t The turn signal indicator lamp itself lights up.
a) Right turn signal indicator pilot lamp Remedy
1 YES Defective speedometer

Replace
module
Is voltage between
CN20 (female) (3)
and chassis Defective contact, or dis- After inspec-
ground normal? connection in wiring har-
tion, repair
(clean) or re-
1) Connect T-adapter NO male) (3) and CN40 (fe-
place
to CN20. male) (3)
2) Turn starting
switch ON.
3) Turn right turn sig-
nal indicator
switch ON.
4) Switches between
20 -30 V and 0 V
in turn.
b) Left turn signal indicator pilot lamp

1 YES Defective speedometer Replace
module
Is voltage between
CN20 (female) (11)
and chassis Defective contact, or dis-
After inspec-
ground normal? Eonnection in wiring har-
tion, repair
(clean) or re-
1) Connect T-adapter NO nale) (11) and CN40 (fe-
to CN20. male) (2)
2) Turn starting
switch ON.
3) Turn left turn sig-
nal indicator
switch ON.
4) Switches between
20 - 30 V and 0 V
in turn.
Tester
Troubleshooting
tools T-adapter or socket adapter 1 I
I 1 (for Dil, I
M-l 5 Related electrical circuit drawing
CN40
Turn signal switch

Speedometer
module
To To
turn signal turn signal
lamp (L.H.) lamp (R.H.)
235FO2104
20-98
TROUBLESHOOTING CHART FOR ELECTRONIC
(ENGINE, PARKING BRAKE, TRANSMISSION CONTROL)
(E MODE)
E- 1 Engine does not start (starting motor works). ................................................................. 20-102

E- 2 Starting motor does not turn ............................................................................................ 20-I 02
E- 3 Parking brake does not work ............................................................................................. 20-I 06
E- 4 Parking brake cannot be released ................................................................................... 20-106
E- 5 Transmission does not shift when transmission lever is moved to
a position between Fl and F8, or RI and R8 .................................................................. 20-108
E- 6 Transmission does not shift to 1st (F and R) .................................................................. 20-I 14
E- 7 Transmission does not shift to 2nd (F and R) ................................................................ .20-l 14
E- 8 Transmission does not shift to 3rd (F and R) ................................................................. .20-l 14
E- 9 Transmission does not shift to 4th (F and R) ................................................................. .20-l 15
E-10 Transmission does not shift to 5th (F and R) .................................................................. 20-I 15
E-l 1 Transmission does not shift to 6th (F and R) ................................................................. .20-l 15
E-12 Transmission does not shift to 7th (F and R) ................................................................. .20-l 16
E-13 Transmission does not shift to 8th (F and RI .................................................................. 20-I 16
* If the controller displays an error on machines mounting a transmission controller (Serial No.:
12013 - 12015, 12019 and up), carry out troubleshooting for the transmission system first.
* When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or
when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
* When connecting T-adapter (or socket adapter), connect to the connector specified. (CNxx( 1)
* When disconnecting connectors or connecting T-adapters, return them to the original condition
immediately after checking, then go to the next check.
* If the diagnosis indicates a defect in the shift controller, replace the sensor assembly (a diode and
relay are assembled on the print board, so use the input from the rotary switch to output the signal
voltage to drive the solenoid valve inside the transmission), the F-R switch assembly and the
rotary switch assembly, do not disassemble the assemblies, otherwise dust or other impurities
may get inside and cause secondary failures.
20-101
0
TROUBLESHOOTING E-l
E-l Engine does not start (starting motor works).
Cause Remedy
2 YES
lefective engine stop qeplace
notor.
Sjg-jH-
Iefective relay, or ?epair or

* Turn starting NO lefective contact, or replace.
ES switch OFF. lisconnection in wiring
- Disconnect rarness.
CN51.
3 YES
1 Iefective engine stop ?eplace
notor.
Is voltage of
CN51 (4) 20 -
3OV? Iefective relay, or Repair or
. Turn starting NO lefective contact, or replace.
- Starting switch switch ON. lisconnection in wiring
at both ON and * Disconnect rarness.
OFF. CN51
Iefective contact, or Repair
U jisconnection in wiring
rarness between battery
elay and CN51 (4).
E-2 Starting motor does not turn.

Serial No. 11001 - 11030
, Disconnection of starting Repair or
3 YES motor START circuit, or replace.
defective contact.
t Defective starting motor.
Y
Iefective contact, or Reoair
lisconnection in wiring
jarness between ground
:onnection - CNTOl (11) -
switch ON. otary switch - CNTOI (2) -
YE s * Place shift lever at )rint board - CNT02 (2) -
between CN14 N position. itarter relay, CN RST 12)
(5) and starting * Turn parking nside transmission box.
1
- Defective contact, or Repair or
- Turn starting disconnection in wiring replace.
Is voltage switch ON. harness between start in
between CN14 * Turn parking 1 motor (E)_ - CN14 (5).
switch ON. . Defective relay or RPST.
s Connect T- Iefective contact, or Repair
adapter (or - Turn starting NO iisconnection in wiring
socket) to CN 14 switch ON. larness between parking
- Turn starting
(female) (male). rwitch and tarting motor
switch ON. * Turn parking
switch ON. clay.
. Turn parking
switch ON. i Defective fuse (No. 14), or Repair
. Connect T- NO fefective power circuit.
adapter (or
socket) to CN14
(female).
20-l 02
0
TROUBLESHOOTING E-2
Serial No. 11031 - 12012, 12016 - 12018
Cause Remedy
2 YES harness between starting
Repair
motor (E) and CN14 (5)
Is there continuity
YES between CN14 (5) _ Failure of starting motor Replace
and chassis relay or rotary switch or
ground? disconnection in wiring
harness between CN14 Repair
CN14 (famale) (1) I) Turn starting NO (male) (5) -starting
and chassis ground switch ON. motor relay- rotary
2) Place shift lever at P. switch -chassis ground
3) Connect T-adapter to CN14 (male) (female)
1) Turn starting
Defective power source -
switch ON. IO wiring
Serial No. 12013 - 12015, 12019 and up
Cause Remedy
Use error code display to

YES inspect location of -
abnormality
controller warning
3 YES harness between starting Repair
r
lamp flash and is Is there continuity motor(E) and CN14 (5)
Failure of starting motor Replace

relay or disconnection in
1) Turn starting
NL!Ft5&J
gg%_..
‘,p
wiring harness between
switch ON.
CN14 (male) (5) -starting Repair
motor relay -chassis
ground
3) Connect T-adapter to CN14 (male) (female Defective power source -
seconds after NO wiring
starting switch
is turned ON
20-l 03
0
TROUBLESHOOTING E-2
E-2 Related electrical circuit diagram
Serial No. 11001 - 11030
3
Cbj27 CN15
1 3
ctq55 Start ina
motor
3 CNST
Start ine CN8 73 0422 3
-3 I 3
From battery
CN9 CN14 Battery
relay
Rotary -
switch
TWCOO307
20-104
0
TROUBLESHOOTING E-5
4) Transmission shifts to 1st to 4th (F and RI but not to 5th to 8th Cause Remedy
(F and R).
Serial No.:11001 - 12012,12016- 12018
2 YES
Defective transmission Replace
Is voltage between high solenoid valve.
YES CNT03 (4) - CNTOI
- (11) -ground
1 connection 20 -
- 3OV?
* Defective contact, or Repair or
Is voltage
between CNTO3 - * Turn starting No disconnection in wiring replace.
switch ON. harness.
(1 j - (4) 20 - 3OV?
* Place shift lever - Defective print board
between 5th and 8th. circuit.
* Turn starting Iefective contact, or Repair
switch ON. NO iisconnection in wiring
- Place shift >arness between CNT03
lever between and transmission
5th and 8th. solenoid valve.
. Connect T-
adapter (or
socket) to
CNT03 (male).
5) Transmission shifts to 5th to 8th (F and R) but not to 1st to

4th (F and R).
SerialNo.:11001-12012,12016- 12018
2 YES
Iefective transmission Replace
Is voltage ow solenoid valve.
YES between CNT03
_ I3)-CNTOl (II)- _
1 ground
- connection 20 -
Is voltage 3OV?
Defective contact, or Repair or
between CNT03 NO disconnection in wiring replace.
(I) and (3) 20 - harness.
3OV? Defective print board
I circuit.
. Turn starting Reoair
Iefective contact, or
switch ON.
iisconnection in wiring
- Place shift iarness between CNT03
lever between
Ind transmission
1st and 4th.
solenoid valve.
* Connect T-
adapter (or
socket) to
CNT03 (male).
20-113
0
TROUBLESHOOTING E-6, E-7, E-8
E-6 Transmission does not shift to 1st (F and R).

Serial No.: 11001 - 12012, 12016 - 12018
Cause Remedy
2 YES
Defective inside rotary Repair or
Is voltage switch. reolace.
YES between CNTO~
1 - (3) and (11) 20- -
- 3OV?
Is voltage between
CNTOZ 14) and Defective contact, or
CNTOl 13). CNT02 - ’ Turn Starti”g No disconnection in siring
(6) and CNTOI (3) switch ON. harness of rotary switch.
20 - 3OV? * Place shift lever
at 1st.
* Turn starting 1 * Defective print board Replace
switch ON. NO circuit.
* Place shift lever - Defective contact, or
at 1st. Repair
disconnection in wiring
harness between print
board and connector.
E-7 Transmission does not shift to 2nd (F and R).
Serial No.: 11001 - 12012, 12016 - 12018

switch. replace.
Defective contact, or Repair

disconnection in siring
harness of rotary switch.
. Turn starting 1 * Defective p;int board Replace

* Place shift lever - Defective contact, or* Reoair
atr 2nd. disconnection in wiring
E-8 Transmission does not shift to 3rd (F and R).
Serial No.: 11001 - 12012, 12016 - 12018
2 YES
IIefective inside rotary Repair or
Is voltage switch. replace.
YES between CNTOI
1 - (5) and (11) 20 - -
3OV?
Is voltage between
CNTOZ (4) and Iefective contact, or
CNTOI (~),CNTOP - - Turn stafiiw No zlisconnection in siring
(8) and CNTOl (5) switch ON. larness of rotary switch.
20 - 3OV? * Place shift lever
3rd.
. Turn starting 1 . Defective print board Replace
- Place shift lever * Defective contact, or Repair
at 3rd.
20-114
0
TROUBLESHOOTING E-S, E-10, El1
E-9 Transmission does not shift to 4th (F and R).

Serial No.: 11001 - 12012, 12016 - 12018
2 YES
Defective inside rotary
Is voltage switch.
YES between CNTOI
1 - (6)and (11) ZO- -
- 3OV?
Is voltage
between CNTOZ ~ Defective contact, or
(4) and CNTOI (6), _ * Turn starting NO disconnection in wiring
CNT02 19) and switch ON. harness of rotary switch.
CNTOl (6) 20 -
3OV? - Place shift levr
at 4th.
. Turn starting 1 - Defective print board
- Place shift lever - Defective contact, or
at 4th. disconnection in wiring
E-lOTransmission does not shift to 5th (F and R). 1 boardandconnector’

Serial No.: 11001 - 12012, 12016 - 12018
2 YES
Defective inside rotary
Is voltage switch.
YES between CNTOI
1 - (7) and (11) 20 - -
~ 3OV?
Is voltage
between CNT02 Defective contact, or
(5) and CNTOI (7), * Turn starting NO disconnection in wiring
CNTOZ 16) and - switch ON. harness of rotary switch.
CNT02 (7) 20 -
3OV? * Place shift lever
at 5th.
. Turn starting 1 - Defective print board
* Place shift lever . Defective contact, or
at 5th. disconnection in wiring
E-l 1 Transmission does not shift to 6th (F and R).
Serial No.: 11001 - 12012, 12016 - 12018
20-115
0
TROUBLESHOOTING E-12, E-13
E-12Transmission does not shift to 7th (F and R).

Serial No.: 11001 - 12012, 12016 - 12018
Cause
,EiZ
switch. replace.
ES between CNTOl
i-------- Defective contact, or

CNTOl (9), CNTOS
NO disconnection in wiring
(8)and CNTOl (9) swtich ON. harness of rotary switch.
* Place shift lever
* Turn starting
*Defective print board Replace
switch ON.
circuit.
* Place shift lever - -Defectivecontact, or
at 7th. Repair
E-13Transmission does not shift to 8th (F and R).
Serial No.: 11001 - 12012, 12016 - 12018
2 YES
Iefective inside rotary Repair or
Is voltage switch. replace.
mz between CNTOI
1 (IO) and (11) 20- -
- 3OV?
Is voltage between
CNTOZ(5) and Iefective contact, or Repair
CNTOl(lO), CNTOP - ' Turn starting No disconnection in wiring
19)and CNTOI (IO) switch ON. larnss of rotary switch.
20-3OV? * Place shift lever
at 8th.
* Turn starting 1
switch ON. * Defective print board Replace
NO circuit.
- Place shift lever Repair
at 8th. * Defective contact, or
20-l16
0
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(ET MODE)
LED display for transmission controller .............................................................................................. 20-152

ET- 1 [A1] (Short circuit in 1st solenoid) is displayed .................................................................. 20-156
ET- 2 [A2] (Short circuit in 2nd solenoid) is displayed ................................................................. 20-157
ET- 3 [A3] (Short circuit in 3rd solenoid) is displayed .................................................................. 20-158
ET- 4 [A4] (Short circuit in 4th solenoid) is displayed .................................................................. 20-159
ET- 5 [A5] (Short circuit in High/Low solenoid) is displayed ....................................................... 20-160
ET- 6 [A7] (Short circuit in FORWARD/REVERSE solenoid) is displayed ....................................20-162
ET- 7 [b1] (Disconnection in 1st solenoid) is displayed ............................................................... 20-164
ET- 8 [b2] (Disconnection in 2nd solenoid) is displayed .............................................................. 20-165
ET- 9 [b3] (Disconnection in 3rd solenoid) is displayed .............................................................. 20-166
ET-10 [b4] (Disconnection in 4th solenoid) is displayed ............................................................... 20-167
ET-11 [b5] (Disconnection in Low solenoid) is displayed ............................................................. 20-168
ET-12 [b6] (Disconnection in High solenoid) is displayed ............................................................ 20-169
023502
ET-13 [b7] (Disconnection in FORWARD solenoid) is displayed .................................................. 20-170

ET-14 [b8] (Disconnection in REVERSE solenoid) is displayed .................................................... 20-171
ET-15 [c1] (Disconnection in inching potentiometer) is displayed .............................................. 20-172
ET-16 [c2] (Failure in shift potentiometer 1) is displayed ............................................................ 20-173
ET-17 [c3] (Failure in shift potentiometer 2) is displayed ............................................................ 20-174
ET-18 [d1] (Failure in F and R switches) is displayed ................................................................... 20-175
ET-19 [d4] (Disconnection in engine speed sensor) is displayed ................................................ 20-176
ET-20 [d5] (Disconnection in speed sensor) is displayed ............................................................. 20-177
ET-21 [d6] (Failure in transmission oil temperature sensor) is displayed .................................. 20-178
ET-22 [E0] (Drop in power source voltage) is displayed .............................................................. 20-179
ET-23 [E1] (Short circuit in parking brake) is displayed ................................................................ 20-181
ET-24 [E2] or [F2] (Short circuit, disconnection in parking brake lamp) is displayed .............. 20-182
ET-25 [E3] or [F3] (Short circuit, disconnection in differential lock relay) is displayed ........... 20-183
ET-26 [E4] or [F4] (Short circuit, disconnection in backup buzzer relay) is displayed ............. 20-185
ET-27 [E5] or [F5] (Short circuit, disconnection in caution lamp) is displayed ......................... 20-187
ET-28 [E6] or [F6] (Short circuit, disconnection in alarm buzzer relay) is displayed ................ 20-188
ET-29 [E7] or [F7] (Short circuit, disconnection in starting motor relay) is displayed ............. 20-190
ET-30 [F1] (Disconnection in parking brake) is displayed............................................................. 20-192
ET-31 [C4] (Disconnection in rotary switch photo-interrupter) is displayed .............................. 20-194
ET-32 [C5] (Abnormality in rotary switch photo-interrupter) is displayed .................................. 20-195
20-151
(8)
TROUBLESHOOTING LED DISPLAY FOR TRANSMISSION CONTROLLER
LED DISPLAY FOR TRANSMISSION CONTROLLER

Serial No. 12013 – 12015, 12019 – 12098
1) Self-diagnostic display
The error code is displayed by LEDs using a 2-digit code. If an abnormality is detected, the warning
lamp and alarm buzzer are actuated.
2) Method of displaying error codes and abnormal operation codes again
Turn the starting switch OFF Æ ON and the error code and abnormal operation code will be
displayed in the following order:
[CHECK.SUM] Æ [Past failures] Æ [Existing failures] Æ [Abnormal operation]
When the [Abnormal operation] display finishes, the [Existing failure] display is repeated.
Trouble-
Error Warning Alarm shooting
Abnormal system and content of abnormality lamp buzzer
code code
A1 Short circuit in 1st clutch solenoid output system fi fi ET-1
A2 Short circuit in 2nd clutch solenoid output system fi fi ET-2
A3 Short circuit in 3rd clutch solenoid output system fi fi ET-3
A4 Short circuit in 4th clutch solenoid output system fi fi ET-4
A5 Short circuit in High/Low clutch solenoid output system fi fi ET-5
A7 Short circuit in FORWARD/REVERSE clutch solenoid output system fi fi ET-6
b1 Disconnection in 1st clutch solenoid output system fi fi ET-7
023502
b2 Disconnection in 2nd clutch solenoid output system fi fi ET-8
b3 Disconnection in 3rd clutch solenoid output system fi fi ET-9
b4 Disconnection in 4th clutch solenoid output system fi fi ET-10
b5 Disconnection in Low clutch solenoid output system fi fi ET-11
b6 Disconnection in High clutch solenoid output system fi fi ET-12
b7 Disconnection in FORWARD clutch solenoid output system fi fi ET-13
b8 Disconnection in REVERSE clutch solenoid output system fi fi ET-14
c1 Disconnection in inching potentiometer system fi — ET-15
c2 Abnormality in voltage of shift potentiometer (1) signal fi — ET-16
c3 Abnormality in voltage of shift potentiometer (2) signal fi — ET-17
c4 Discrepancy in shift potentiometers (1), (2) signals fi — (ET-16·17)
c5 Abnormality in both shift potentiometer signal systems fi fi (ET-16·17)
d1 Both F and R switches are ON fi fi ET-18
d4 Disconnection in engine speed sensor system fi — ET-19
d5 Disconnection in speed sensor system fi — ET-20
d6 Failure in transmission oil temperature sensor — — ET-21
d7 Shift lever is not at P position when starting switch is ON fi fi —
20-152
(8)
Abnormal system and content of abnormality
2
z
2
16 Engine speed above 2350 rpm 0 0 -
17 Acceleration to dangerous speed with inching pedal depressed 0 0 -
Transmission lubricating oil temperature above 120°C
18 0 0 -
continued for more than 30 seconds
With transmission at neutral, travel speed above 4 km/h and - -
19
engine speed above 1400 rpm continued for more than 10 seconds -
With transmission in F or R and inching pedal depressed,
IA travel speed above 4 km/h and engine speed above - - -
1400 rpm continued for more than 10 seconds
Error Gearshifting pattern when there is abnormal operation

code
- i F Shifts N + F when travel speed is above 9 km/h
- i A Shifts N + R when travel speed is above 9 km/h
F i A Shifts F + R when travel speed is above 9 km/h
A i F Shifts R + F when travel speed is above 9 km/h
F i - Shifts to F4 or above when travel speed is below 2 km/h
A : - Shifts to R4 or above when travel speed is below 2 km/h
F i 0 Inching used for long time in F (FORWARD)

A i 0 Inching used for long time in R (REVERSE)
t
I------
0 : Clutch temperature below 200°C
1 : Clutch temperature 200 - 230°C
4 : Clutch temoerature above 290°C
20-153
0
Trouble-
Error Warning Alarm shooting
Abnormal system and content of abnormality lamp buzzer
code code
E0 Power source voltage below 18 V fi — ET-22
E1 Short circuit in parking brake solenoid system fi fi ET-23
E2 Short circuit in parking lamp system — — ET-24
E3 Short circuit in differential lock solenoid system fi fi ET-25
E4 Short circuit in backup buzzer system fi — ET-26
E5 Short circuit in caution lamp system — fi ET-27
E6 Short circuit in alarm buzzer system fi — ET-28
E7 Short circuit in starting motor relay system fi — ET-29
F1 Disconnection in parking brake solenoid system, short circuit fi — ET-30
F2 Disconnection in parking lamp system, short circuit fi — ET-24
F3 Disconnection in differential lock relay system, short circuit fi fi ET-25
F4 Disconnection in backup buzzer system, short circuit fi — ET-26
F5 Disconnection in caution lamp system, short circuit — fi ET-27
F6 Disconnection in alarm buzzer system, short circuit fi — ET-28
F7 Disconnection in starting motor relay system, short circuit fi — ET-29
10 Detection of overrun by deceleration fi fi —
Operation to switch between FORWARD and REVERSE
11
at above 9 km/h fi — —
12 Operation to shift to 4th or above at below 2 km/h fi fi —
13 Clutch plate temperature above 200°C — — —
fi
023502
14 Inching used continuously for more than 10 seconds — —

15 Inching used continuously for more than 30 seconds fi fi —
16 Engine speed above 2350 rpm fi fi —
17 Acceleration to dangerous speed with inching pedal depressed fi fi —
Transmission lubricating oil temperature above 120°C
18
continued for more than 30 seconds fi fi —
With transmission at neutral, travel speed above 4 km/h and
19 — — —
engine speed above 1400 rpm continued for more than 10 seconds
With transmission in F or R and inching pedal depressed,
1A travel speed above 4 km/h and engine speed above — — —
1400 rpm continued for more than 10 seconds
Error Gearshifting pattern when there is abnormal operation

code
............. ......................................
— F Shifts N Æ F when travel speed is above 9 km/h

— A Shifts N Æ R when travel speed is above 9 km/h
F A Shifts F Æ R when travel speed is above 9 km/h
A F Shifts R Æ F when travel speed is above 9 km/h
F — Shifts to F4 or above when travel speed is below 2 km/h
A — Shifts to R4 or above when travel speed is below 2 km/h
F 0 Inching used for long time in F (FORWARD)
A 0 Inching used for long time in R (REVERSE)
≠
0 : Clutch temperature below 200°C
1 : Clutch temperature 200 – 230°C
4 : Clutch temperature above 290°C
20-153-2
(8)
3) Saving error codes, abnormal operation codes

The transmission controller saves any error codes and abnormal operation codes that are gener-
ated, and keeps these in memory even after the starting switch is turned OFF.
As a result, when the starting switch is turned ON and the transmission controller power is turned
ON, it is possible to check the content of all the abnormalities that have occurred so far.
Display time
Display item (order of display) LED display
(se4
1) Transmission controller power ON Starting switch OFF + ON -
2) All segments of LED light up I-!

-.-. I-! 5
-
3) (No comment) .Y 0.5
4) CHECK.SUM display
5) Trouble data
Z .Y 0.5
5 6) Error codes
Z
2 d4: Abnormality in engine speed sensor
Y-J $ c( 3
I? 7) If there are any other failures in memory,
Steps 5) and 6) are repeated.
8) Existing failures
* If there are no existing failures, t3.E is f-u 0.5
Z
L
=I displayed for 3 seconds.
Z
2 9) Error codes
F4: Disconnection in backup buzzer F 1-i
.-P 3
Z system, short circuit in power source
‘X
LLI IO) If there are any other failures, Steps 8) and
9) are repeated.
11) Abnormal operations record u 0.5
g 12) Abnormal operation codes

0
‘E 14: Inching used continuously for more than P+ 3
B 10 seconds
x
0 13) Gearshift pattern code when there is
Z abnormal operation FE 3
E FO: FORWARD, clutch temperature below 200°C
Z
5 14) Number of times of operation of this
m
abnormal operation r:-- ,I 3
.-? 02: 2 times
2
ul 15) If there are any other abnormal operations
in memory, Steps 11) to 14) are repeated.
Z When the display of abnormal operations in

5
Z memory is completed, display returns again to
2 existing failures. - -
? * If there are no existing failures, fi.3 is
‘E
2 displayed.
i2
20-154
0
• Method of deleting error codes from memory

After carrying out troubleshooting and completing repairs of the failure, the self-diagnostic display
returns to the normal display. Always do as follows to delete the transmission controller error
codes from memory.
fl The abnormal operation items are deleted from memory at the same time.
(1) Turn the starting switch to the ON position, and after completing the display for all the past
failures in memory, check that the display returns to .
(2) Take the connector (color of wiring harness: green) connected to connector number [FR] inside the
right console box, and ground it to the chassis. (When doing this, make sure that the starting
switch is at the ON position.)
• After grounding the connector, install the blind connector to the FR connector in the original
way.
(3) Turn the starting switch OFF, then turn it ON again and check that the past error codes have been
deleted from memory.
• If the past error codes have been deleted from memory, CHECK.SUM is displayed, then
is displayed immediately.
023502
20-155
(8)
TROUBLESHOOTING ET-1
ET-1 [Al] (Short circuit in 1st 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 connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
display, the problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 YES
GotoA
1Is voltage
H
II
(female) (2) and Short circuit with power

When 1st is chassis normal? source in wiring harness
11[ZFn
y$ijiij!;;;g.
Repair or
between 1st (female) (2)
YES replace
and E2 (female) (17)
betwee”,st Short circuit in wiring

Is resistance harness between E2 (7) Repair or
and 1st (I) and wiring replace
(male) (1) and (2) - NO harness between E2 (17)
switch OFF.
normal? and 1st (2)
* Disconnect 1st
-5-20R and E2.
-Turn starting Defective 1st solenoid Replace
switch OFF. NO
* Disconnect 1st.
4 YES Defective transmission Repair or

controller replace
Aj$!jnL’JHP Short circuit with power

source in wiring harness Repair or
* Max. 0.1 V NO between 1st (female) (1)
* Turn starting and E2 (female) (7)
switch OFF.
* Disconnect 1st and E2.
* Turn starting switch ON.
ET-1 Related electrical circuit diagram
Transmission controller
I
E2 1st 1st solenoid
1st solenoid (+I
1st solenoid (-1
TWG00317
20-156
0
ET-2 [A21 (Short circuit in 2nd solenoid) is displayed
Ir This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
t Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 YES
GotoA
Is voltage
YES between 2nd
Short circuit with power
2 (female) (2) and
When 2nd is chassis normal? between 2nd (female) (2) replace
YE disconnected, is and E2 (female) (18)
* Max. 0.1 V NO
resistance between -
E2 (female) (81 and -Turn starting switch OFF. Short circuit in wiring
1
(18) normal? * Disconnect 2nd and E2. harness between E2
* Min. 1 MR - Turn starting switch ON. (female) (8) and 2nd Repair or
*Turn startina (female) (1) and wiring replace
hln
(male) (1) and (2) harness between E2
switch OFF.- ‘*”
(female) (18) and 2nd
. Disconnect 2nd (female) (2)
-5-20Q and E2.
-Turn starting Defective 2nd solenoid Replace
switch OFF. 0
- Disconnect 2nd.

controller replace
AjZHP Short circuit with power

I I I
- Max. 0.1 V NO between 2nd (female) (1) replace
*Turn starting and E2 (female) (8)
switch OFF.
* Disconnect 2nd and E2.
*Turn starting switch ON.
I I
E2 2nd 2nd solenoid
20-157
0
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 YES GotoA
Is voltage
YES between 3rd
2 - (female) (2) and -
When 3rd is chassis normal?
between 3rd (female) (2) replace
disconnected, is
YE * Max. 0.1 V NO and E2 (female) (19)
- resistance between -
* Turn starting switch OFF. Short circuit in wiring
1 E2 (female) (9) and
119) normal?
* Disconnect 3rd and E2. harness between E2
* Min. 1 MC2 *Turn starting switch ON. (female) (9) and 3rd Repair or
(female) (1) and wiring replace
* Turn starting NO
switch OFF.
(female) (19) and 3rd
* Disconnect 3rd (female) (2)
*5-20R and E2.
. Turn starting ,h Defective 3rd solenoid Replace
switch OFF. IV”
s Disconnect 3rd.

controller replace
+ZJgJH-- Short circuit with power

* Max. 0.1 V NO
between 3rd (female) (1) replace
* Turn starting and E2 (female) (9)
switch OFF.
* Disconnect 3rd and E2.
* Turn starting switch ON.
I
E2 3rd 3rd solenoid
3rd solenoid (+I 3
3rd solenoid (-1 3
TWG00319
20-l 58
0
ET-4 [A41 (Short circuit in 4th solenoid) is displayed
+ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Cause Remedy
3 YES GotoA
Is voltage
YES between 4th Short circuit with power
2 - (female) (2) and - source in wiring harness Repair or
I When 4th is chassis normal? between 4th (female) (2) replace
YES disconnected, is * Max. 0.1 V and E2 (female) (20)
NO
*Turn starting switch OFF. Short circuit in wiring
1 E2 (female) (101and
* Disconnect 4th and E2.
p (201normal? _ harness between E2
Is resistance *Turn starting switch ON. (female) (IO) and 4th Repair or
* Min. 1 MCI
between 4th (female) (I) and wiring replace
- *Turn starting NO
switch OFF. (female) (20) and 4th
normal?
* Disconnect 4th (female) (2)
-5-20R and E2.
* Turn starting Defective 4th solenoid Replace
switch OFF. NO
* Disconnect 4th.

controller replace
+GjjiJH-- Short circuit with power
* Max. 0.1 V
* Turn starting
NO
source in wiring harness
between 4th (female) (1)
Repair or
replace
switch OFF.
- Disconnect 4th and E2.
- Turn starting switch ON.
I
E2 4th 4th solenoid
4th solenoid (-1 3
TWC00320
20- 159
0
ET-5 [A51 (Short circuit in High/Low solenoid) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
Cause Remedy
GotoA

When Lo is between Lo (female) (2) replace
YES disconnected. is
* Max. 0.1 V NO and E2 (female) (13)
. Turn starting switch OFF.
1 E2 (female1 (2) and Short circuit in wiring
~ (13) normal? * Disconnect Lo and E2.
harness between E2
Is resistance *Turn starting switch ON. Repair or
* Min. 1 MR (female) (2) and Lo
between Lo (male) (female) (I) and wiring replace
- *Turn starting NO
(1) and (2) harness between E2
switch OFF.
normal? (female) (13) and Lo
* Disconnect Lo
(female) (2)
*5-20R and E2.
*Turn starting Defective Low solenoid Replace
switch OFF. NO
* Disconnect Lo.
6 YES
GotoB
When Hi is
YES disconnected, is
Short circuit in wiring
- resistance between - harness between E2
5
- E2 (female) 121and
(female) (2) and Lo
Is resistance (14) normal? Repair or
(female) (I) and wiring
YES between Hi (male) _ *Min. 1 MR NO harness between E2 replace
(1) and (2) *Turn starting switch (female) (13) and Lo
~ 4 normal? OFF. (female) (2)
Is voltage * Disconnect Hi and E2.
*5-20R
A between Lo Defective Hi solenoid Replace
- -Turn starting NO
(female) (1) and switch OFF.
chassis normal?
. * Disconnect Hi.
* Max. 0.1 V Short circuit with power
* Turn starting
NO between Lo (female) (1) replace
switch OFF.
and E2 (female) (2)
* Disconnect Lo and E2.
-Turn starting switch ON.
a YES Defective transmission Repair or
controller replace
(female) (2) and Short circuit with power

chassis normal? source in wiring harness Repair or
between Hi (female) (1) replace
B between Hi _ * Max. 0.1 V NO
and E2 (female) (3)
(female) (2) and -Turn starting switch OFF.
chassis normal? - Disconnect Hi and E2. Short circuit with power
* Max. 0.1 V * Turn starting switch ON. source in wiring harness Repair or
* Turn starting NO between Hi (female) (2) replace
switch OFF. and E2 (female) (14)
* Disconnect Hi
and E2.
. Turn starting
switch ON.
20-160
0
Lo solenoid
ransmission controller
Lo solenoid (+I
id
Hi solenoid (+I
Lo solenoid (+I
I I TWG00321
20-161
0
ET-6 [A71 (Short circuit in FORWARD/REVERSE solenoid) is displayed
-+ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Cause Remedy
3 YES
GotoA
YESI I Short circuit with power

2 (female) (2) and source in wiring harness Iepair or
1When FW is s-l chassis normal? l-l 2etween FW (female) (2) eplace
snd E2 (female) (15)
* Turn starting switch OFF. Short circuit in wiring
. Disconnect FW and E2. harness between E2
(female) (2) and FW Iepair or
(female) (1) and wiring eplace
NO
harness between E2
(female) (15) and FW
(female) (2)
-5-20R and E2.
-Turn starting defective FORWARD 3eplace
switch OFF. NO solenoid
- Disconnect FW.
6 YES
GotoB
Short circuit in wiring

jZ+Z&CJH-- narness between E2
:female) (5) and RE
Is resistance 3epair or
:female) (1) and wiring
YES between RE * Min. 1 MD NO narness between E2 eplace
(male) (1) and (2) *Turn starting switch ifemale) (16) and RE
4 OFF. :female) (2)
- normal?
Is voltage * Disconnect RE and E2.
*5-20R 3efective REVERSE
A between FW
(female) (1) and - * Turn starbng NO solenoid
switch OFF.
chassis normal?
* Disconnect RE.
- Max. 0.1 V
* Turn starting 1
between FW (female) (1) replace
switch OFF. NO
and E2 (female) (4)
* Disconnect FW and E2.
-Turn starting switch ON.
a YES Defective transmission Repair or
controller replace
YE
7 Short circuit with power
Is voltage
* source in wiring harness Repair or
L-t
between RE (female) (I) replace
B between RE Max. 0.1 V NO
and E2 (female) (5)
(female) (2) and * Turn starting switch OFF.
chassis normal? - Disconnect RE and E2. Short circuit with power
f Max. 0.1 V I *Turn starting switch ON. source in wiring harness Repair or
-Turn starting between RE (female) (2) replace
switch OFF. and E2 (female) (16)
* Disconnect RE
and E2.
* Turn starting
switch ON.
20- 162
0
FORWARD
solenoid
Transmlsslon controller
FORWARD solenoldlt) REVERSE

solenoid
REVERSE solenoid(t)
FORWARD solenold(-1
TWG00322
20-163
0
ET-7 [bll (Disconnection in 1st solenoid) is displayed
*
4YES1 Defective transmission Repair or
Is resistance between
controller replace
YES E2 (female) (17).1st
Short circuit with ground
3 ifemale) 12)and
in wiring harness Repair or
~ chassis normal?
When 1st (female) (2) between 1st (female) (2)
YES isgroundedto chassis, ~ - replace
* Min. 1 MR NO and E2 (female) (17)
- is resistance between -
* Turn starting
2 E2 (female)(17)and Defective contact or
~ chassis n~~m.g switch OFF. disconnection in wiring
When 1st(female) (1) . Disconnect 1st and E2. 1 harness between 1st
* Max. 1 R Repair or
YI ; Is groundedto chassis, replace
- ISresistancebetween - - Turn starting NO (female) (1) and E2
E2 (female1 (71 and switch OFF. (female) (17)
1 chassisnormal? - Disconnect 1st and E2.
- Max. 1 R Defective contact or
* Ground 1st (female) (2) to chassis. Repair or
-Turn starting disconnection in wiring
harness between 1st replace
(male) (I) and (2) switch OFF. NO
+ Disconnect 1st and E2. (female) (I) and E2
* Ground 1st (female) (1) (female) (7)
*5-20R
* Turn starting to chassis. Defective 1st solenoid Reolace
switch OFF. \I0 (internal disconnection)
* Disconnect 1st.
1
E2 1st 1st solenoid
1st solenoid C-t) 3
1st solenoid (-1 -3
TWG00317
20- 164
0
ET-8 [b2] (Disconnection in 2nd solenoid) is displayed
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Sr Always connect any disconnected connectors before going on to the next step.
I Cause Remedy
4YEA Defective transmission Repair or

controller replace
Isresistance between
YESE2 (female) 118). 2nd Short circuit with ground
3 (female) (2) and in wiring harness
-
When 2nd (female) 12) chassis normal? Repair or
between 2nd (female) (2)
YES is grounded tO chassis, ~* Min. 1 MR replace
NO and E2 (female) (18)
- is resistance between -
*Turn starting
2 E2 (female1 (18) and Defective contact or
p chassis normal? switch OFF. disconnection in wiring
When 2nd (female) (1)
is grounded to chassis, f Max. 1 - R * Disconnect 2nd and E2. harness between 2nd Repair or
YI replace
. is resistance between - . Turn starting NO (female) (2) and E2
E2(female) (8) and switch OFF. (female) (18)
1 chassisnormal? - Disconnect 2nd and E2.
Defective contact or
* Max. 1 R - Ground 2nd (female) (2) to chassis. Repair or
- Turn starting replace
NO harness between 2nd
switch OFF.
(female) (I) and E2
* Disconnect 2nd and E2.
* Ground 2nd (female) (1) (female) (8)
-5-20R
* Turn starting to chassis. Defective 2nd solenoid Replace
switch OFF. IO (internal disconnection)
- Disconnect 2nd.
I
E2 2nd 2nd solenoid
g)
I TWG00318
20- 165
0
ET-9 [b31 (Disconnection in 3rd solenoid) is displayed
Ir Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4YEI Defective transmission Repair or

controller replace

(female) (2) and
in wiring harness
chassis normal? Repair or
between 3rd (female) (2)
replace
*Turn startina Defective contact or
harness between 3rd Repair or
YE
(female) (2) and E2 replace
(female) (19)
* Ground 3rd (female) (2) to chassis. Repair or
harness between 3rd replace
* Disconnect 3rd and E2. (female) (1) and E2
* Ground 3rd (female) (1) (female) (9)
*5-20n
. Turn starting to chassis. Defective 3rd solenoid Replace
switch OFF. JO (internal disconnection)
* Disconnect 3rd.
I
E2 3rd 3rd solenoid
3rd solenoid (+) 3
3rd solenoid (-) 3
TWG00319
20-166
0
ET-10 [b41 (Disconnection in 4th solenoid) is displayed
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective transmission Repair or

controller replace

in wiring harness
1 When 4th (female) (2)
1chassis normal? 1 /_ between 4th (female) (2)
Repair or
replace
- Min. 1 MR NI and E2 (female) (20)
is resistance between
-Turn starting Defective contact or
E2 (female) (20) and
Is
harness between 4th Repair or
YE replace
(female) (2) and E2
(female) (20)
1
1 chassis normal?
* Disconnect 4th and E2.
resistance * Max. 1 R Defective contact or
* Ground 4th (female) (2) to chassis. Repair or
between 4th * Turn starting disconnection in wiring
harness between 4th replace
normal? * Disconnect 4th and E2. (female) (I) and E2
. Ground 4th (female) (1) (female) (IO)
5-20R
* Turn starting to chassis. Defective 4th solenoid Replace
switch OFF. 0 (internal disconnection)
* Disconnect 4th.
E2 4th 4th solenoid
I TWG00320
20-167
0
TROUBLESHOOTING ET-l 1
ET-11 [b51 (Disconnection in Low solenoid) is displayed
Ir Before carrying out troubleshooting, check that ail the related connectors are properly inserted.
Cause Remedy
4YES Defective transmission Repair or

Is resistance between controller replace
YES E2 (female) (131, Lo
3 - Ifemale) (2) and
- chassis normal?
When Lo (female) (21 is
between Lo (female) (2)
YES grounded to chassis, is 1 - replace
- resistance between E2 -
* Min. 1 MR NO and E2 (female) (13)
* Turn starting
2 (female)113) and Defective contact or
~ chassisnormal? switch OFF.
When Lo (femaleI (1) ~ disconnection in wiring
* Max. 1 R * Disconnect Lo and E2. Repair or
is groundedto chassis, harness between Lo
YE
is resistance between - * Turn starting NO (female) (2) and E2 replace
E2 (female)(2) and switch OFF. (female) (13)
1
chassisnormal? . * Disconnect Lo and E2.
* Max. 1 R * Ground Lo (female) (2) to chassis. Defective contact or
between Lo (male) disconnection in wiring Repair or
* Turn starting
NO harness between Lo replace
switch OFF.
* Disconnect Lo and E2. (female) (I) and E2
* Ground Lo (female) (1) (female) (2)
-5-20R
* Turn starting Defective Low solenoid Replace
switch OFF. NO (internal disconnection)
- Disconnect Lo.
I
E2 Lo Lo solenoid
Lo solenoid (+I 3
Lo solenoid (-1 3
TWG00323
20-168
0
ET-12 [b6] (Disconnection in High solenoid) is displayed
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
I Cause Remedy
Defective transmission Repair or

controller replace

(female) (2) and
in wiring harness
1When Hi ifemalel12) is 1 chassis normal’ Repair or
between Hi (female) (2)
YES grounded to chassis, is ’- Min. 1 MR NO and E2 (female) (14)
replace
- resistancebetweenE2 -
* Turn starting
2 (femalei 114) and Defective contact or
When Hi (female)(1) disconnection in wiring
+ Max. 1 R * Disconnect Hi and E2. Repair or
YES is groundedto chassis, harness between Hi
- is resistance between - * Turn starting NO (female) (2) and E2 replace
E2 (female)13)and switch OFF. (female) (14)
~ 1 chassis normal?
~ * Disconnect Hi and E2.
Is resistance * Max. 1 Cl * Ground Hi (female) (2) to chassis. Defective contact or
between Hi (male) _ * Turn starting disconnection in wiring Repair or
(1) and (2) NO harness between Hi replace
switch OFF.
normal? * Disconnect Hi and E2. (female) (1) and E2
* Ground Hi (female) (I) to (female) (3)
.5-20R
* Turn starting 1 chassis. Defective High solenoid Replace
switch OFF. NO (internal disconnection)
* Disconnect Hi.
I
E2 Hi Hi solenoid
Hi solenoid (+I @
Hi solenoid (-1
TWG00324
20-169
0
ET-13 [b7] (Disconnection in FORWARD solenoid) is displayed
Cause Remedy

Is resistance between controller replace
YES E2 (female) (15). FW
3 - (female) (21and
in wiring harness
When FW(femiii chassis normai? Repair or
between FW (female) (2)
YES isgroundedtochassis. L - replace
* Min. 1 MS2 NO and E2 (female) (15)
- is resistancebetween -
E2(female)115)and * Turn starting
2 Defective contact or
When Hi (female)(1) disconnection in wiring
- Max. 1 R * Disconnect FW and E2. Repair or
YES Is grqundedto chassis, harness between FW
- ISreelstancebetween - * Turn starting NO (female) (2) and E2 replace
E2(female)(4) and switch OFF. (female) (15)
~ 1
~chassisnormal? * Disconnect FW and E2.
Is resistance * Max. 1 f2 Defective contact or
* Ground FW (female) (2) to chassis.
between FW * Turn starting disconnection in wiring Repair or
(male) (1) and (2) - switch OFF. NO harness between FW reolace
normal? * Disconnect FW and E2. (female) (1) and E2
-5-200 * Ground FW (female) (I) (female) (4)
*Turn starting to chassis. Defective FORWARD Replace
switch OFF. NO solenoid (internal
- Disconnect FW. disconnection)
FORWARD
YE2 FW solenoid
FORWARD solenoid(-)
I I TWG00325
20- 170
0
ET-14 [b8] (Disconnection in REVERSE solenoid) is displayed
-)r Always connect any disconnected connectors before going on to the next step.
Cause Remedy

.1
Is resistance between
controller replace
YES E2 (female) (16), RE
3 - (female1 12) and
chassis normal?
between RE (female) (2)
YES grounded to chassis, is replace
* Min. 1 MR and E2 (female) (16)
JZ
harness between RE Repair or
(female) (2) and E2 replace
1 (female) (16)
- Ground RE (female) (2) to chassis. Repair or
harness between RE replace
normal? * Disconnect RE and E2. (female) (1) and E2
. Ground RE (female) (1) (female) (5)
*5-20R
* Turn starting 1 to chassis. Defective REVERSE Replace
switch OFF. NO solenoid (internal
* Disconnect RE. disconnection)
REVERSE
E2 solenoid
REVERSE solenoid(t) 5
REVERSE solenold(-) 16
it
I TWG00326
20-171
0
ET-15 [cl] (Disconnection in inching potentiometer) is displayed
+ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
* Check that the inching potentiometer mount is normal.
Cause Remedy
3 YES
GotoA
[When TM11 (female) 12) 1 7
disconnection in wiring Repair or
harness between TM11 replace
YES (female) (2) and E3
1
r (female) (4)

f Ground TM1 1 (female) (2) to chassis. Repair or
is grounded f~ chassis, in wiring harness
is resistance between replace
between TM1 1 (female)
E3 Ifemale) (7) and (3) and E3 (female) (7)
* Disconnect TM1 1
- Max. 1 Q Disconnection in wiring
-Turn starting Repair or
harness between TM1 1
switch OFF. NO replace
(female) (3) and E3
* Disconnect TM1 1 (female) (7)
and E3.
* Ground TM11 6 YES Defective transmission Repair or
(female) (3) to Is voltage controller replace
chassis. YES between TM I I
5 (3) and (2) Defective inching
When E3 is normal? potentiometer (internal Replace
YEIS disconnetied, is * 0.45 - 0.61 v NO
disconnection)
resistance between -
TM11 (female) (1) + Insert T-adapter into TM1 1. Defective contact in
and (21 normal? * Turn starting switch ON. wiring harness between
* Do not depress inching pedal. TM1 1 (female) (2) and E3 Repair or
* Min. 1 Ma
(female) (4) and wiring replace
* Turn starting NO
switch OFF. harness between TM11
* Disconnect TM1 1 (1) and E3 (16)
* Min. 1 MR and E3.
L Short circuit with ground Repair or
* Turn starting in wiring harness replace
switch OFF.
between TM1 1 (female)
* Disconnect TM1 1
(2) and E3 (female) (4)
and E3.
Transmission controller Inching PO en i ome er

I I n
E3
Inching
input
Power SUPP I Y (+5V)
GND
I \ I \ /
1 I
TWG00327
ZO-172
0
ET-31 [C4] (Disconnection in totary switch photo-interrupter) is displayed

(Serial No.: 12099 and up)
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 YES Defective rotary switch

(Abnormality in photo- Replace
interrupter)
YES Is voltage between
T01 (female) (11)
2 and (12) normal?
When T01 (female) Defective transmission Repair or
(11) is grounded to controller replace
YES chassis, is resist- • 24V NO
ance between E1 • Connect T-adapter to
1 (female) (12) and T01. Defective contact or
When T01 (female) chassis normal? • Shift lever (P). disconnection in wiring
(12) is grounded to • Max. 1 Ω • Turn starting switch ON. harness between T01 Repair or
chassis, is resist- • Turn starting (female) (11) and E1 replace
ance between E1 switch OFF. NO
(female) (13) and (female) (12)
• Disconnect T01, E1.
chassis normal?
• T01 (female) (11) is Defective contact or
• Max. 1 Ω chassis ground. disconnection in wiring Repair or
• Turn starting harness between T01
023502
switch OFF. NO replace
(female) (12) and E1
• Disconnect T01, E1. (female) (13)
• T01 (female) (12) is
chassis ground.

20-194
(8)
ET-32 [C5] (Abnormality in totary switch photo-interrupter) is displayed

fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 YES to A
Is resistance
YES between T01
(female) (5), E3
2 (female) (26) and Short circuit with ground
Is resistance chassis normal? in wiring harness between Repair or
YES between T01 • Min. 1 MΩ NO T01 (female) (5) and E3 replace
(female) (4), E3 • Turn starting (female) (26)
1 (female) (33) and switch OFF.
chassis normal? • Disconnect T01, E3. Short circuit with ground
Is resistance
between T01 • Min. 1 MΩ in wiring harness between Repair or
(female) (3), E3 • Turn starting NO T01 (female) (4) and E3 replace
(female) (25) and switch OFF. (female) (33)
chassis normal? • Disconnect T01, E3.
• Min. 1 MΩ Short circuit with ground
• Turn starting in wiring harness between Repair or
023502
switch OFF. NO T01 (female) (3) and E3 replace

6 YES
to B
Is resistance
YES between T01
(female) (8), E3
5 (female) (35) and Short circuit with ground
Is resistance chassis normal? in wiring harness between Repair or
YES between T01 • Min. 1 MΩ NO T01 (female) (8) and E3 replace
(female) (7), E3 • Turn starting (female) (35)
4 (female) (27) and switch OFF.
Is resistance
between T01 • Min. 1 MΩ in wiring harness between Repair or
from A (female) (6), E3 • Turn starting NO T01 (female) (7) and E3 replace
9 YES
to C
When E3 is
YES disconnected, is Defective contact in wiring
resistance between harness between T01
8 T01 (female) (3) and (female) (3) and E3
Is resistance (4) normal? (female) (25) and wiring Repair or
YES between T01 • Min. 1 MΩ NO harness between T01 replace
(female) (10), E3 • Turn starting (female) (4) and E3
7 (female) (36) and switch OFF. (female) (33)
Is resistance Repair or
between T01 • Min. 1 MΩ in wiring harness between
from B (female) (9), E3 • Turn starting NO T01 (female) (10) and E3 replace
20-195
(8)
Cause Remedy
12 YES to D
When E3 is
11 T01 (female) (3) and (female) (3) and E3 (female)
When E3 is (7) normal? (25) and wiring harness Repair or
YES disconnected, is • Min. 1 MΩ NO between T01 (female) (7) replace
resistance between • Turn starting and E3 (female) (27)
10 T01 (female) (3) and switch OFF.
(6) normal? Defective contact in wiring
When E3 is • Disconnect T01, E3. harness between T01
disconnected, is • Min. 1 MΩ (female) (3) and E3 (female) Repair or
from C resistance between • Turn starting NO (25) and wiring harness replace
T01 (female) (3) and switch OFF. between T01 (female) (6)
(5) normal? • Disconnect T01, E3. and E3 (female) (34)
• Min. 1 MΩ Defective contact in wiring
• Turn starting harness between T01 Repair or
switch OFF. (female) (3) and E3 (female) replace
NO
• Disconnect T01, E3. (25) and wiring harness
between T01 (female) (5)
15 YES
to E
When E3 is
YES disconnected, is • Min. 1 MΩ between T01 (female) (10) replace
resistance between • Turn starting
(9) normal? Defective contact in wiring
When E3 is • Disconnect T01, E3. harness between T01
from D resistance between • Turn starting NO (25) and wiring harness replace
023502
switch OFF. NO (female) (3) and E3 (female) replace
18 YES to F
When E3 is
YES disconnected, is between T01 (female) (7) replace
• Min. 1 MΩ NO and E3 (female) (27)
16 T01 (female) (4) and switch OFF. Defective contact in wiring
(6) normal? • Disconnect T01, E3. harness between T01
When E3 is
from E resistance between • Turn starting (33) and wiring harness replace
NO between T01 (female) (6)
T01 (female) (4) and switch OFF.
• Disconnect T01, E3. and E3 (female) (34)
(5) normal?
21 YES
to G
When E3 is
When E3 is
from F resistance between • Turn starting (33) and wiring harness replace
(8) normal?
20-196
(8)
Cause Remedy
24 YES to H
When E3 is
When E3 is
from G resistance between • Turn starting (26) and wiring harness replace
(6) normal?
switch OFF. (female) (5) and E3 (female) replace
NO
27 YES
to I
When E3 is
When E3 is
from H resistance between • Turn starting (26) and wiring harness replace
(9) normal?
023502

30 YES to J
When E3 is
When E3 is
from I resistance between • Turn starting (34) and wiring harness replace
(8) normal?
33 YES
to K
When E3 is
When E3 is
from J resistance between • Turn starting (27) and wiring harness replace
switch OFF. NO between T01 (female) (9)
T01 (female) (7) and
20-197
(8)
Cause Remedy
36 YES Defective rotary switch

(Abnormality Replace
When E3 is in photo-interrupter)
resistance between
35 T01 (female) (9) and harness between T01
When E3 is (10) normal? (female) (9) and E3 (female) Repair or
(28) and wiring harness
YES disconnected, is • Min. 1 MΩ NO between T01 (female) (10) replace
resistance between • Turn starting and E3 (female) (36)
(10) normal? • Disconnect T01, E3. Defective contact in wiring
When E3 is harness between T01
from K resistance between • Turn starting NO (35) and wiring harness replace
• Turn starting Repair or
harness between T01
023502
20-198
(8)
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM
(H MODE)
STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND JUDGEMENT VALUES ................................. .20-202
TABLE OF FAILURE MODES AND CAUSES ............................................................................................................ 20-204
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS.. ............................................ 20-206
H-l Abnormal noise is made (from around pump) ............................................................................................. 20-208
H-2 Relief sound is heard (when not operating) .................................................................................................. 20-208
H-3 Hydraulic oil overheats (when not operating) .............................................................................................. .20-208
H-4 Work equipment does not move when control lever is operated (steering at neutral). .......................... 20-209
H-5 Work equipment is slow, lacks power ........................................................................................................... 20-210
H-6 There is excessive hydraulic drift of work equipment ................................................................................. 20-21 1
H-7 Steering wheel does not turn
(work equipment at neutral) ............................................................................................................................ 20-21 1
H-8 Turning speed is slow, lacks power
(work equipment at neutral) ............................................................................................................................ 20-212
H-9 Feeling when operating steering wheel is strange.. ..................................................................................... 20-212
20-201
0
STANDARDS FOR MEASURING HYDRAULIC
TROUBLESHOOTING PRESSURE, AND JUDGEMENT VALUES
STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND

JUDGEMENT VALUES
Unit: MPa (kg/cm*)
T Judgement values (any value outside

this range indicates a failure)
No. Posture for machine Measurement conditions
Ps (steering PM (main PP (pilot
pressure) oressure) pressure)
*a=
*
l All work equipment
Min. 1.0 (IO), Min. 2.0 (201,
at standard position. and
and Max. 2.0 (20)
l Work equipment + 2.5 + 251
Pp+ 1.0 ( + 101
not operated.
235FO21025
:Hm 235FO2107
l Steering cylinder relief.
16.2 - 18.1
(165 - 185)
Vlax. Ps + 2.5
(25)
l Left blade lift cylinder %I 23.0 - 26.0

relief. PSI & 1.0 (IO) (235 - 265)
235FO2108
n
l Right blade lift cylinder %I 23.0 - 26.0
relief. PSI + 1.0 (IO) (235 - 265)
235FO2109
l Front wheels raised off

ground.
l Steering operated. Max. 5.9 (60) Vlax. 6.4 (65) PQ5 t-205 1
l Operating speed:
1 turn/2 sec.
235FO2110
1. The oil temperature shall be 45 - 55°C.

2. Measure with the engine speed at both low idling and high idling, and check that both measurements are
within the standard.
3. With the CLSS, the hydraulic pressures at different points are mutually related and change together. For this
reason, put the measurement data into a formula for calculating the judgement standard, and check that they
are within the specified range.
El “PSI” is the measured data marked*.
To hydraulic
control valve
PS
\
To steer ir
valve
I
I 235COO2220
20-202
0
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES
Surge
Parts causing failure pressure Priority flow
Pump
absorb- divider valve
Failure mode
Does not move
Slow, lacks power
Turning speed is slow, lacks power 00 0 0

P
‘E
Changes between being heavy and light
8 Feeling when
z
operating steering There is kickback
wheel is strange -
There is a grating feeling
20-204
0
023502
0 0 o
Wrk equipment control link
0 0 Slip clutch
0 0 Shuttle valve for circle rotation gear (%I)
I I I I I I
io do 4 Q z 2 z Troubleshooting code
in A
HYDRAULIC PRESSURE MEASUREMENT AND
TROUBLESHOOTING FILTER MOUNTING POSITIONS
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING

POSITIONS.
Fia 1
0 Measuring port for work equipment main oil pressure
Priority flow
(PM). divler valve PM Ps
l Measuring port for steering oil pressure (Ps). \ \ /
( _______~______t___i_-______
235CD02221
Fia 2
l Pilot pressure measuring port (PP).
Surge Dressure
l LS line filter (3). absorbing valve
1 b@-+@A 235COO2222
Fig 3
. Pump filters (I), (2).
I
Fig 4
0 Filters (41, (5), (6) on top of surge pressure absorbing
valve.
absorbing valve
235CDO2044
20-206
0
HYDRAULIC PRESSURE MEASUREMENT AND
TROUBLESHOOTING FILTER MOUNTING POSITIONS
Fig 5
0 Control valve filters (71, (8).
I Control Valve R.H. COntrOl Valve L.H
235C00204E
Fia 6
l Steering valve LS line filter (9).
Fig 7
Measuring port for brake piston (circle) pressure.
(Serial No.: 11001 - 12050)
20-207
0
TROUBLESHOOTING H-l, H-2, H-3
H-l Abnormal noise is made (from around pump).
Cause Remedy
Zlogged strainer. Clean
YES Is strainer
clogged? YES
_ooseness of piping Tighten
3 :lamp.
- Is problem
corrected when
- piping between -
NO tank and pump is 4YE
Iefective pump. Replace
tightened?
~ Are metal
I;“‘” raulic tank particles found
Y
el normal? NO w,hen hydraulic
011 IS drained?
Natch for a short time to Inspect again
N( ;ee if there is any change [according to
n the condition. change in
condition).
_ack of oil. Add hydraulic

oil.
H-2 Relief sound is heard (when not operating).

1) From priority flow divider valve.
H
Zlogged orifice. Clean
Is LS port orifice
clogged?
Zlogged steering LS line Clean

NO ‘ilter (9) (See Fig. 6).
2) From surge pressure absorbing valve.
Clogged spool orifice of

priority flow divider
valve.
H-3 Hydraulic oil overheats (when not operating).

1 YES
Clogged steering LS line Clean
filter (9) (See Fig. 6).
Is pilot line oil
pressure high?
Defective operation of Repair or

. Priority flow NO servo valve. replace.
divider valve is
being relieved.
* Steering oil
pressure is
high.
[I72 MPa
(175kg/cm?l
20-208
0
TROUBLESHOOTING H-A
H-4 Work equipment does not move when control lever is operated (steering
at neutral).
Cause Remedy
I) No work equipment moves.
YES
Go to Item 2). -
1
Is hydraulic
pump main pre- _ YES
Ssure normal? Pump filter (1) or (2) is Clean
2 clogged. (See Fig. 3)
- 24.5 + 1.5 MPa Is pilot oil pre-

(250+15 NO ssure normal? YES
Clogged filter (3). (See Clean
kg/cm’) 3 Fig. 2)
p Is surge pressure
- Main oil absorbing valve
pressure NO LS line filter 4 YE
$5, MPa clogged? Defective operation of Repair or
Does condition servo valve. replace.
(_$ kg/cm*) - Check filter (3). _ become normal
(See Fig 2) NO when servo valve
is replaced?
Repair or
- Check N(
replace.
operation of
spool.
2) Work equipment for control valve on one
side only does not move.
Clogged filter Xean
Is surge pressure
absorbing valve
filter clogged? 2 YES
Clogged filter. Iean
* Check filter (4) Is control valve

or (6). N filter clogged?
(See Fig 4)
Defective operation of lepair or
* Check filter (7) NO control valve. eplace.
or (8).
(See Fig 5)
3) Work equipment for one line only does not move.
2 YES
Defective operation of Repair or
control valve. replace.
Defective cylinder. Repair or

NO replace.
Is work
equipment
control link Defective motor. Repair or,
normal? replace.
- Check
operation of
linkage? Defective adjustment of 4djust
Circle clutch.
rotation ge
assembly normal?
‘ES Defective operation of qeplace
- Engine low
become normal shuttle valve.
idling
5.gMPat6’
kg/cm?
- Engine high Defective operation of qepair or
idling NC :ontrol valve. replace.
: 8.8MPa (90
kg/cm*)
- Blade raised.
lefective operation of qepair or
inkafge. .eplace.
20-209
0
TROUBLESHOOTING H-5
H-5 Work equipment is slow, lacks power.
Cause Remedy
I) All work equipment.
io to H-4.
2) Work equipment for control valve on one side only.
jefective relief valve. idjust

Does condition
become normal
when relief valve -
of control valve
is adjusted?
;o to H-4.
. Relief pressure NO
:24.5 t 1.5 MPa
(250 2 15 kg/cm’)
3) Work equipment for one line only.
hen slow 2 YES

defective blade float 3epair or
Doescondition 1 I- alve. eplace.
become normal
Blade lift when blade float
valve is
GotoA
1 * Engine: Rated
Is work
equipment
control linkage
normal?
. Check
([i%$Thift ) Whenthereisnopower~ 1
operation of
linkage.
sot0 H-4.
Iefective operation of 3epair or

inkage. .eplace.
Defective cylinder. Repair or

replace.
Is there defect
From IA inside cylinder? 4 YES
Defective pilot check Repair or
valve. replace.
i!ic$q1-
damage, dirt. sd? 11

Defective control valve. Repair or
* Check for oil NO replace.
leakage.
* Defective relief
pressure setting
(only for
machines with
relief valve).
20-210
0
TROUBLESHOOTING H-6, H-7
H-6 There is excessive hydraulic drift of

work equipment.
Cause Remedy
1 YES
Damaged cylinder, Replace
Are cylinder, piston, seal.
piston, seal
damaged?
Defective pilot check Repair or

- Check for oil NO valve. reolace.
leakage, damage.
H-7 Steering wheel does not turn

(work equipment at neutral).
2 YES
Defective steering valve. ?epair or
.eplace.
YE L Does cylinder
move normally?
Defective steering <epair or

- Is there any NO cvlinder. ,eolace.
internal defect?
YES
Clogged pump filters (I), Ilean
‘) I
(2). (See Fig.3)
- 17.2 + 1.0 MPa
(175 + 10 kg/cm’).
I Is pilot pressure
, normal?
- Steering oil
at top and bottom
of surge pressure
YES
Clogged filter Clean
pressure
: ‘_$$ Nm
k.”
r
- Check filters
(3),(5). (See
Fig.2.4)
YES Defective shuttle valve. Repair or
reolace.
1 pees condition 5[ [
From A
Defective servo valve. Repair or
replace.
shuttle valve. replaced?

* Check for dirt. Defective pump. Repair or
- Check replace.
operation of
spool.
* Check for dirt.
20-211
0
TROUBLESHOOTING H-8, H-9
H-8 Turning speed is slow, lacks power

(work equipment at neutral).
Cause Remedy
YES
Go to H-7
4 YE:
Defective steering Repair or
cylinder. replace.
move normally?
Is relief pressure Go to H-7

YI
of double relief
valve normal?
Is relief pressure
- 20.6 MPa , Defective double relief Adjust or
(210 kg/cm? NO valve. replace.
. 17.2 ? 1.0 MPa

1175 + 10 kg/cm2) Defective priority flow Adjust or
10 divider valve. replace.
H-9 Feeling when operating steering wheel

is strange.
I) Changes between being heavy and light.
Defective steering CF line ?epair or

check valve. .eplace.
2) There is kickback.
Defective steering CF, LS qepair or

line check valve. .eplace.
3) There is a grating feeling.
Defective steering valve. 7epair or

.eplace.
20-212
0
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL. . . . . . . . . . . . . . . .30-1-2 BEVEL PINION

COATING MATERIAL LIST . . . . . . . . . . . . . . . . . . .30-1-4 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . 30- 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
STARTING MOTOR FRONT AXLE
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 4 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
ALTERNATOR Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 4 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
NOZZLE HOLDER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 5 STEERING VALVE
FUEL INJECTION PUMP Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
WATER PUMP WHEEL BRAKE
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 7 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
ENGINE OIL COOLER CORE Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 8 AIR TANK
TURBOCHARGER Removal and Installation . . . . . . . . . . . . . . . . . . 30-137
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 9 HYDRAULIC TANK
AIR COMPRESSOR Removal and Installation . . . . . . . . . . . . . . . . . . 30-138
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 10 HYDRAULIC PUMP
CYLINDER HEAD Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 15 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
023502
ENGINE (INCL. TRANSMISSION) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 18 HYDRAULIC CONTROL VALVE
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 23 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
RADIATOR Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 29 MAIN CONTROL VALVE
FUEL TANK Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 33 CIRCLE ROTATION MOTOR
PTO Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 36 DRAWBAR SHIFT CYLINDER, BLADE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 41 LIFT CYLINDER, LIFTER GUIDE
TRANSMISSION Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-45-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-45-5 ARTICULATE CYLINDER
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 46 Removal and Installation . . . . . . . . . . . . . . . . . . 30-199
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 54 REAR MOUNT RIPPER CYLINDER
TRANSFER Removal and Installation . . . . . . . . . . . . . . . . . . 30-200
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 69 HYDRAULIC CYLINDER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 72 Serial No. 11001 – 12502
TRANSMISSION CONTROL VALVE Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 76 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 78 Serial No. 12503 and up
HYDROSHIFT TRANSMISSION PUMP Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 30-205-1
Removal and Installation . . . . . . . . . . . . . . . . . . 30- 80 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205-5
TANDEM AND FINAL DRIVE CIRCLE ROTATION GEAR AND
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 81 HYDRAULIC OIL MOTOR
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 83 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
FINAL DRIVE Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 85 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 94 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
BEVEL GEAR
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
30-1
(6)
BLADE
Removal and Installation . . . . . . . . . . . . . . . . . . 30-215
CIRCLE AND DRAWBAR
Removal and Installation . . . . . . . . . . . . . . . . . . 30-216
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
REAR MOUNT RIPPER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
METHOD FOR LIFTING UP ROPS CAB . . . . . . . . 30-226
INSTALLATION OF ROPS . . . . . . . . . . . . . . . . . . . 30-228
ROPS cab
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223
DISCONNECTION AND CONNECTION
OF ARTICULATE SECTION
Serial No. 11001 – 12502
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
Serial No. 12503 and up
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 30-243
023502
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246
30-1-1
(6)
How to read this manual (Rev. 2009.01)1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r in s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
4:
ber respectively. Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
30-1 - 2
(7)
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
5
79 T- - :
* *** ****
means that they are not available
: Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
30-1 - 3
(7)
Coating materials list 1
(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
023502
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
30-1-4
(6)
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
023502
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
30-1-5
(6)
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
023502
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
30-1-6
(6)
SPECIAL TOOL LIST
Nature of work Symbol Parts No. Part Name Q’ty Remarks
Installation of cylinder
B 790-331-1110 Wrench 1 For tightening cylinder head angle
head
Disassembly, assembly
C 799-301-1500 Leak tester 1 For checking operation of piston
of transmission assembly
D 792-571-1600 Chain puller 1 For securing chain
of final drive assembly
790-502-1003 Repair stand 1
1 790-502-2000 Repair stand 1 Stand for disassembling cylinder
790-101-1102 Pump 1
Removal, installation of round
2 790-330-1100 Wrench 1
head
790-302-1270 Socket (50 mm) 1 Leaning (*1)
790-302-1290 Socket (60 mm) 1 Leaning (*2)

Blade lift Removal,
3 790-102-1320 Socket (70 mm) 1 Drawbar shift installation of
Blade shift nylon nut
Power tilt
790-102-1330 Socket (75 mm) 1
Articulate
790-302-1340 Socket (80 mm) 1 Ripper
A
of hydraulic cylinder 790-201-1702 Push tool Kit 1
023502
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1741 • Push tool 1 Steering
790-201-1751 • Push tool 1 Leaning (*1)

4
790-201-1761 • Push tool 1 Leaning (*2)
Press fitting
coiled bushing
790-201-1781 • Push tool 1 Drawbar shift
Blade lift
Blade shift
790-201-1791 • Push tool 1
Power tilt
Articulate
790-201-1811 • Push tool 1 Ripper
(*1) Serial No.: 11001 – 12050

(*2) Serial No.: 12051 and up
30-2
(6)
Nature of work Symbol Parts No. Part Name Q’ty Remarks
790-201-1500 Push tool KIT 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1550 • Plate 1 Steering
790-201-1560 • Plate 1 Leaning (*1)

5
790-201-1570 • Plate 1 Leaning (*2)
Press fitting
790-201-1590 • Plate 1 Drawbar shift dust seal
Blade lift
Blade shift
790-201-1610 • Plate 1
Power tilt
Articulate
790-201-1620 • Plate 1 Ripper
Disassembly, assembly 6 790-702-1000 Expander 1

A
of hydraulic cylinder
796-720-1630 Ring 1
Steering
07281-00709 Clamp 1
796-720-1650 Ring 1
023502
Leaning
07281-01019 Clamp 1
796-720-1650 Ring 1 Blade lift

Installation of
7 Blade shift
piston ring
07281-01159 Clamp 1 Drawbar shift
796-720-1670 Ring 1
Power tilt
Articulate
07281-01279 Clamp 1
796-720-1680 Ring 1
Ripper
07281-01589 Clamp 1
Disassembly, assembly of
circle rotation gear and
B 791-560-1520 Floating seal installer 1 Installation of floating seat
hydraulic motor assembly
(*1) Serial No.: 11001 – 12050

30-3
(6)
REMOVAL OF STARTING MOTOR
ASSEMBLY
A Disconnect the
minal of the battery.
cable from the negative (-) ter-
1. Disconnect connector (1).
2. Disconnect wiring (2).
3. Remove starting motor assembly (3).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
l Carry out installation in the reverse order to remo-
val.
REMOVAL OF ALTERNATOR
ASSEMBLY
Serial No.: 11001 - 12000
A Disconnect the cable from the negative (-) ter-

Disconnect 3 alternator wires (1).
Remove bolt (2) of adjustment plate, then loosen

mount bolt and nut (3).
Move alternator assembly (4) towards cylinder block,

then loosen belt tension, and remove belt (5) from
alternator assembly.
Remove mount bolt and nut (3), then remove alter-

nator assembly. m
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial No.: 11001 - 12000
val.
l Adjust the fan belt tension.

For details, see TESTING AND ADJUSTING, table of
judgement standard value.
30-4
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
g Disconnect the cable from the negative (-) ter-

1. Open engine side cover.
2. Disconnect alternator wiring (1) and (2).
3. Remove locknut (3), and turn adjustment nut

(4), then remove V-belt (5). m
4. Remove mounting bolts (6) and (7), then re-

move alternator assembly (8).
INSTALLATION OF
ALTERNATOR ASSEMBLY
. Carry out installation in the reverse order to

removal.
m
t After installing the V-belt, adjust the tension
of the belt.
For details, see TESTING AND ADJUSTING,
“Testing and adjusting of belt tension”.
30-4- 1
0
REMOVAL OF NOZZLE HOLDER
ASSEMBLY
1. Remove engine hood, then remove muffler assembly

(I), air cleaner assembly (2), and intake connector ! n
(3).
2. Disconnect delivery tube (4). m
3. Remove cover (5). m
4. Loosen locknut (6). m
5. Remove connector (7). m
6. Remove holder (8). a
7. Use a slide hammer, or screw in bolt (Thread dia. =

10 mm, Pitch = 1.5 mm), then remove nozzle holder
(9) using a bar.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
val.
m Sleeve nut: 23.5 i 1.0 Nm (2.4 + 0.1 kgm)
12
m Mounting bolt: 4.9 + 1.0 Nm (0.5 i 0.1 kgm)
m
m Locknut: 36.8 12.5 Nm (3.75 k 0.25 kgm)
m
w Connector: 36.8 + 2.5 Nm (3.75 + 0.25 kgm)
m Mounting bolt: 66.2 k 7.4 Nm

(6.75 i 0.75 kgm)
30-4-2
0
REMOVAL OF FUEL
INJECTION PUMP ASSEMBLY
1. Open engine right side cover.
2. Remove oil gauge pipe (I), hose flange (2), and ro-
tation guard (3).
* When removing the rotation guard, be careful
not to let the spacer on the inside fall out.
3. Remove coupling lock bolt (4), then remove bolt (5),

and disconnect coupling. m
4. Disconnect fuel control rod (6) and stop motor cable

(7), and remove spring (8).
5. Disconnect fuel hoses (9), (IO), and (II), and fuel re-
turn hoses (12) and (13).
6. Remove lubrication tubes (14) and (15), and discon-

nect 6 fuel injection pipes (16). m
7. Remove 4 mounting bolts (17), then remove fuel in-

jection pump assembly (18). m
g
kc
: INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
val.
w Coupling lock bolt: 78.5 f 4.9 Nm

(8 i 0.5 kgm)
w Lubrication tube (14): 29.4 i 4.9 Nm

(3 _C0.5 kgm)
m Lubrication tube (15): 22.5 i 2.9 Nm
(2.3 + 0.3 kgm)
m Fuel injection pipe sleeve nut: 23.5 k 1.0 Nm
(2.4 + 0.1 kgm)
Adjust fuel injection timing.

For details, see TESTING AND ADJUSTING, Adjust-
ing fuel injection timing.
DISASSEMBLY AND ASSEMBLY
WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain engine cooling water.
2. Disconnect 2 hoses (2) and 2 connectors (3) of

washer tank (I).
3. Disconnect hose (5) and connector (6) of reser-

voir tank (4).
4. Remove washer tank (I) and resevoir tank (4)

together with mounting bracket (7).
5. Remove alternator assembly (8). Serial No.: 11001 - 12000

For details, see REMOVAL OF ALTERNATOR
ASSEMBLY. m
6. Disconnect hoses (9), (IO), and (II).
7. Remove tube (12) and connectors (13).
8. Pull out spring (14), then twist tube (15) with a

bar and push up.
9. Remove bolt (161, then remove pulley (17).
10. Remove mounting bolts (181, then remove wa-

ter pump assembly (19).
30-6
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
INSTALLATION OF WATER
PUMP ASSEMBLY

removal.
Adjust the tension of the alternator belt.

For details, see TESTING AND ADJUSTING, Ad-
justing belt tension.
. Refilling with water

Add water through water filler to the specified
level.
Ir Run the engine to circulate the water through
the system. Then check the water level again.
30-7
0
REMOVAL OF ENGINE OIL
COOLER CORE ASSEMBLY
1. Drain engine cooling water.
2. Disconnect 2 hoses (2) and 2 connectors (3) of

washer tank (1).
3. Disconnect hose (5) and connector (6) of reservoir

tank (4).
4. Remove washer tank (1) and reservoir tank (4)

together with mounting bracket (7).
5. Remove turbocharger lubrication return tube (8) and

exhaust muffler drain tube (9), then remove tube
(IO).
6. Remove engine oil cooler assembly (11).
7. Remove 4 nuts (12), then remove cooler core (13).
INSTALLATION OF ENGINE OIL

COOLER CORE ASSEMBLY
val.

Add water through water filler to the specified level.
* Run the engine to circulate the water through the
system.
Then check the water level again.
% Engine cooling water: Approx. 58 Q
235FO2204
REMOVAL OF TURBOCHARGER
ASSEMBLY
1. Remove hood assembly and air cleaner.

For details, see REMOVAL OF NOZZLE HOLDER AS-
SEMBLY.
2. Disconnect dust indicator hose (3), then remove inlet

connector (4).
3. Remove muffler assembly (5), then remove elbow

(6) and connector (7).
4. Disconnect clamp (8), then remove inlet connector

(8).
5. Disconnect supply hose (IO), and drain tube (‘i 1).
6. Remove mounting bolts and turbocharger assembly

(12). m
INSTALLATION OF
TURBOCHARGER ASSEMBLY
8
4
z l Carry out installation in the reverse order to remo-
val.
m
* Fit the gasket with “UP” mark facing up.
m Mounting bolt: 66.2 & 7.4 Nm

(6.8 k 0.8 kgm)
3%9
REMOVAL OF AIR COMPRESSOR
ASSEMBLY
A Loosen drain valve and drain air tank pressure.
1. Remove engine oil gauge pipe (1) and hose flange

(2), then remove rotation guard (3).
2. Disconnect air hoses (4) and (5), and remove water

tubes (6) and (7).
3. Remove corrosion hose (8).
4. Remove air tubes (9) and (IO), then remove water

tube (11).
5. Remove lubrication tube (12), then remove air com-

pressor (13).
INSTALLATION OF AIR
COMPRESSOR ASSEMBLY
val.
30-&o
REMOVAL OF CYLINDER
HEAD ASSEMBLY
1. Draining cooling water

Loosen drain valve (1) and drain cooling water.
2. Side covers, hood

1) Remove precleaner and exhaust pipe (2).
2) Open R.H. side cover (3), disconnect L.H. side
cover hinge, then remove hood (4) as one unit.
3) Remove L.H. and R.H. covers (5).
3. Air cleaner assembly, inlet connector

1) Disconnect KOMA-CLONE pipe at flange (6) end.
2) Remove inlet connector mounting bolts (7).
3) Remove mounting band, then remove air cleaner
assembly (8).
4) Remove inlet connector (9) together with bracket
as one unit.
5. Inlet connector, air intake heater
1) Remove clip (13).
2) Remove mounting bolts (14) and inlet connector
(15).
3) Disconnect electric wiring (16), (17) and air in-
take heater (18).
6. Corrosion resistor assembly, tube

1) Remove hoses (19) and (20).
2) Remove mounting bolts, and corrosion resistor
assembly (21).
3) Disconnect tubes (22).
7. Fuel, oil filter assembly

1) Disconnect fuel hoses (23) and (24).
2) Disconnect oil tubes (25) and (26).
3) Remove mounting bolts, then remove- bracket
and oil, fuel filter assembly (27) as one unit.
8. Intake manifold
Remove bracket mounting bolts (28), then remove
mounting bolts (29) and intake manifold assembly
(30). m
3022
9. Turbocharger, exhaust manifold assembly m
Disconnect turbocharger oil supply hose (31)
and drain tube (32).
Remove mounting bolts (33) of exhaust man-
ifold, leaning 2 - 3 bolts in position.
Sling turbocharger and remove remaining bolts.
Then remove turbocharger and exhaust manifold
assembly (34) as one unit.
& ks Turbocharger, exhaust manifold

assembly: 40 kg
Remove tube (35).
10. Fuel injection tube, fuel spill tube m

1) Remove 6 fuel injection tube (36).
2) Remove spill tubes (37).
z
4
2
11. Head cover m

Remove mounting bolts (38) then remove head
cover (39).
12. Rocker arm assembly m

Remove mounting bolts (40) then remove rocker
lever assembly (41).
* When installing rocker lever, loosen locknut (42),
then turn adjustment screw (43) back 2 - 3
times to prevent strain on the push rod.
13. Holder /
Remove mounting bolts (44), then remove holder
(45).
14. Connection m
Loosen lock nut (46), then remove connection (47)
and pull out.
15. Nozzle holder ng

Using bolt @ (Thread dia. = 10 mm, Pitch = 1.5
mm), remove nozzle holder (48).
* Check that there is a gasket fitted to the tip of
the nozzle holder.
16. Push rod

Remove push rod (49).
17. Rocker arm housing )

Remove mounting bolts (50) then remove rocker
arm housing (51).
18. Crosshead m
Remove crosshead (52).
19. Cylinder head assembly m

1) Remove mounting bolts (53) then remove cylin-
der head assembly (54).
2) Remove gasket (55).
306’4
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
. Carry out installation in the reverse order to remo-

val. Intake manifold
* Tighten the intake manifold in the order (1 - 24)

shown in the diagram.
Intake manifold mounting bolt
1 21 17 13 9 5 1 4 8 12 16 20 24
235FO2205
* Tighten the exhaust manifold in the order (1 - 3)

shown in the diagram, then tighten the remainder in Exhaust manifold
the order (4 - 24).
w Exhaust manifold mounting bolt
1st 1 29.4 * 4.9 (3.0 + 0.5)
2nd 66.2 + 7.4 (6.8 k 0.8) 7 17 20 2 1 13 16 6 3 21 2412
* Install the gasket with the OUT mark facing the

outside.
I 566FO6352
m Sleeve nut: 4.9 f 1.0 Nm (0.5 + 0.1 kgm)
m Spill tube joint bolt: 8.8 f 1 .O Nm

(0.9 + 0.1 kgm)
m Head cover mounting bolt:

4.9 k 1.0 Nm (0.5 + 0.1 kgm)
m
* Clean the oil hole of the mounting bolt and install.
* Check that the ball of the adjustment screw is fitted se-
curely in the socket of the push rod.
w Rocker arm mounting bolt:
98.1 k 4.9 Nm (10 + 0.5 kgm)
w Adjustment screw locknut:
48.0 k 2.9 Nm (4.9 + 0.3 kgm)
* Adjust the valve clearance.
For details, see TESTING AND ADJUSTING, Adjusting
valve clearance.
* Set one side of holder on head of mounting bolt or

rocker arm housing and tighten.
30-&w
m Connection: 37.2 + 2.9 Nm (3.8 + 0.3 kgm)
m Locknut: 63.7 k 4.9 Nm (6.5 f 0.5 kgm)
* Check that there is no dirt or dust inside the nozzle

holder sleeve.
* Check that there is a copper gasket fitted to the tip of
the nozzle holder.
m Rocker arm housing mounting bolt:

98.1 * 4.9 Nm (10 f 0.5 kgm)
pi?icJ
* Adjust the crosshead as follows.
i) Loosen locknut and turn back adjustment screw.
ii) Hold down top surface of crosshead lightly and
tighten adjustment screw.
iii) When adjustment screw contacts valve stem,
tighten a further 20”.
iv) Tighten locknut to hold in position.
w Locknut: 58.8 i 5.9 Nm (6.0 +_ 0.6 kgm)
302 6
m
* Check that there is no dirt or dust on the cylin-
der head mounting surface or inside the cylin-
der.
* Check that the grommet does not come out
when installing the gasket.
* Coat the bolt threads and seat surfaces com-
pletely with molybdenum disulphide (LM-P).
* Screw in the cylinder head mounting bolts 2 -
3 turns by hand, then tighten as shown in the
diagram.
621 OF301
& Mounting bolt: Anti-friction compound
(LM-P)
w Cylinder head mounting bolt:
. The first time: 147.1 I 9.8 Nm

(15 I 1 kgm)
l The second time: 215.7 + 4.9 Nm
(22 + 0.5 kgm)
l The third time:
1) When using tool B
Use an angle tightening wrench and tighten
go”+30
2) Whe”n not using tool B

566FO6353
Make marks on the bolt and head with a felt
pen, then tighten the bolt 90”‘::
+ Tighten bolt 0 to 66.2 i 7.4 Nm

(6.75 + 0.75 kgm). Put mark on the bolt
and cylinder head
* After tightening, make one punch mark on the
bolt head to indicate the number of times that
the bolt has been used.
. If any bolt has 5 punch marks, do not reuse
it. Replace it with a new bolt.
. Charging air conditioner with gas.

F621201067A 1
Refill with water to the specified level, and run the
engine to circulate the water through the system.
Then check the water level again.
Make mark with punch
F621201061
3027
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
(Incl. TRANSMISSION)
1. Remove drain plug (I) and drain oil from trans-

mission case.
- : Transmission case: Approx. 25 f?
2. Radiator assembly
Remove radiator assembly.
For details, see REMOVAL OF RADIATOR AS-
SEMBLY.
3. Lift up cabin.
For details, see METHOD FOR LIFTING UP ROPS
CAB.
4. Air tank assembly

Remove air tank assembly.
For details, see REMOVAL OF AIR TANK ASSEM-
BLY.
5. Hydraulic tank assembly

Remove hydraulic tank assembly.
For details, see REMOVAL OF HYDRAULIC TANK
ASSEMBLY. P 5 235FO2206
Serial No.: 11001 - 12012, 12016 - 12018
6. Wiring piping, control

Serial No.: 11001 - 12012, 12016 - 12018 Wiring harness end Alignment grove
1) Disconnect speed control wire (2) from trans- I I

mission.
-+ Turn cap A and completely loosen the
thread before disconnecting.
* Ring B does not turn. If you attempt to
turn it by force, you will damage the
wiring harness.
2) Disconnect connectors (31, (3A), (4), (4A), and 0 A
solenoid valve end
(5)
3) Remove clip (6). I TWG00248
4) Remove ground connection (7).

Serial No.: 12013 - 12015, 12019 and UD
Serial No.: 12013 - 12015, 12019 and up
Disconnect connectors (2A), (391, (401, and
(41).
Connector (2A):
FW, RE, HI, LO, Ist, 2nd, 3rd, 4th
Connector (39): TM1 1
Connector (40): TM10
30-18
0
DISASSEMBLY AND ASSEMBLY ENGINE
5) Remove hose (9A) and wiring connectors

(IO) and (11) of radiator sub-tank (8) and
washer tank (9), then remove tank and
mounting bracket (12).
30-18-l
0
6) Remove cables (13) and (’14) from starting
motor.
I,
235FO2207
7) Remove inching control rod (15) frqm trans-

mission.
235FO2208
8) Remove hoses (’16), (17), and (18) from hydraulic

pump.
9) Remove block (19) from frame.
335FO72OC
30&l 9
10) Remove hoses (19A) and (19B).
w 19A 235FO221C
11) Remove air hose (19C).
12) Remove drain hose (20) of engine oil pan from

rear frame.
13) Remove hoses (23), (24), and (25) from com-

pressors (21) and (22).
14) Remove accelerator cable (26) from engine.
15) Remove hoses (27) and (28) from final drive

pump.
I 235FO2212
16) Remove transmission oil filler tube (29).

8. Mounting bolts
Sling engine assembly (32) and remove mounting
bolts.
I?zlkg Engine assembly: 2707 kg
1) Remove transmission from mounting bolts (33).

* Check the number and positions of the
shims (36) which were removed.
32
2) Remove engine front mounting bolts (34).
shims,(37) which were removed.
3) Remove engine rear mounting nuts (35).

shims (38) which were removed.
9. Engine assembly
Remove engine assembly (32) from main frame.
J
235FO2213
3022
INSTALLATION OF ENGINE ASSEMBLY
(Incl. TRANSMISSION)
1. Engine assembly
Sling engine assembly (32) and set to main
frame.
& kg Engine assembly: 2707 kg
t If the engine is raised with the muffler still

installed, the muffler will be damaged, so al-
ways remove it.
Sling engine assembly and install mounting

bolts.
i) Install shim (36) and tighten transmission
front mounting bolts (33).
* Standard shim thickness: 4.1 mm
ii) Install shim (37) and tighten engine front

mounting bolts (34).
iii) Install shim (38) and tighten engine rear

a
* Standard shim thickness: 4.1 mm 235FO2213
30623
3) Adjust shim
J I .._.-.=-,,--/--~+=-
235COO2053
G
shaft coupling ! ! Final drive input

Y shah coupling
P
i) Insert shims at portions BL, BR, and A so iv) Finally, check that the misalignment between
that the center line of the crankshaft is par- the transmission and the propeller shaft is
allel to the final drive and propeller shaft within 3 mm.
when supported by portions BL, BR, and A. m Tightening torque:
When doing this, the standard shim thick- D: 235.4 - 411.9 Nm (24 - 42 kgm)
ness at portions BL and BR shall be 3.8 E: 245.2 - 308.9 Nm (25.0 - 31.5 kgm)
mm. F: 490.3 - 608.0 Nm (50.0 - 62.0 kgm)
ii) Decide the shim thickness so that the clear- G: 245.2 - 284.4 Nm (25 - 29 kgm)
ance at portion C is 0 mm. H: 823.8 - 872.8 Nm (84 - 89 kgm)
iii) Raise the engine and transmission, and add
0.7 mm of shim to portion C. Next, remove
0.7 mm of shim from portions BL and BR,
add 0.5 mm of shim to portion A, then as-
semble.
30624
2. Drive shaft
Using dial gauge, check-again that radial runout and
face runout of coupling face at transmission end
and coupling face at final drive end are within per-
missible value, then install drive shaft (30) with bolts
(31).
* If they are not within the permissible value, ad-
just the engine mount shims again.
m Mounting bolt: 98.1 - 122.6 Nm
(10.0 - 12.5 kgm)
3. Wiring, piping control

1) Install transmission oil filler tube (29).
2) Connect hoses (27) and (28) to final drive pump.
8 235FO2.212
3) Connect accelerator cable (26) to engine.
30625
4) Connect hoses (23), (24), and (25) to compress-
ors (21) and (22).
1
25
23
24
5) Install drain hose (20) of engine oil pan to rear

frame.
6) Install block (19).
7) Connect hoses (19A) and (19B).
235FO2210
8) Connect air hose (19C).
9) Connect hoses (16), (17), and (18) to hydraulic

pump.
10) Connect inching control rod (15) to transmission.
11) Connect cables (13) and (14) to starting motor.
235FO22Oi
12) Install tank and mounting bracket (12) to
rear frame, then connect connectors (IO) and
(II), and hose (9A) to sub-tank (8) and
washer tank (9).
13) Install ground connection (7).
14) Install clip (6).
15) Connect connectors (31, (3A), (4), (4A), and

(5).
Serial No.: 11001 - 12012, 12016 - 12018

16) Connect speed control wire (2) to transmis-
sion.
Set the connector facing 45” down to pre-
vent water from getting inside the con-
nector. Use a tie wrap to secure the wir-
ing harness to prevent the slack in the
wiring from interfering with the frame.
Portion A must not interfere with the
frame.
Secure portion B with a band.
Serial No.: 12013 - 12015, 12019 and up

16) Connect connectors (2A), (39), (40), and (41).
Connector (2A):
I 235FO2206
FW, RE, HI, LO, Ist, 2nd, 3rd, 4th Serial No.: 11001 - 12012, 12016 - 12018
Connector (39): TM1 1

Install hydraulic tank assembly.
For details, see INSTALLATION OF HYDRAULIC
TANK ASSEMBLY.

Install air tank assembly.
For details, see INSTALLATION OF AIR TANK
L
ASSEMBLY.
Serial No.: 12013 - 12015, 12019 and up
6. Cab
Lower cab.
For details, see INSTALLATION OF ROPS CAB.
7. Radiator assembly
Install radiator assembly.
For details, see INSTALLATION OF RADIATOR
ASSEMBLY.
30-28
0
8. Refilling with oil
1) Tighten drain plug.
2) Add engine oil through oil filler (29) to the
specified level.
Q Transmission case: 35 e
* Run the engine to circulate the water and oil

through the system. Then check the water
and oil levels again.
30-28-l
0
REMOVAL OF RADIATOR,
1. Loosen drain valve (1) and drain coolant.

* If the coolant contains antifreeze, dispose of ii
correctly.
:
u Coolant: 58 P
235FO221
2. Remove hood (2).
3. Remove piping and electric wiring

Remove radiator inlet hose (3), outlet hose (4)
and aeration hose (5) from engine.
Disconnect hose (6) from sub tank (6A).
Remove fan guard (7).
Disconnect heater tubes (8) and (9) from radia-
tor (10).
4. Loosen bolts (11) and remove panel (12).
30629
Sling radiator assembly (13). and remove mounting
bolts.
1) Loosen front mounting bolts (14).
& kg Radiator assembly: 183 kg
13
L ”
235COO2056
2) Loosen rear mounting bolts (15). I I
23x002057
6. Raise radiator assembly (13) about 100 mm from

main frame (18), then disconnect transmission cooler
hoses (16) and (17) from radiator and lift off radiator
assembly.
30630
INSTALLATION OF RADIATOR
1. Raise radiator assembly (13) and set on main frame

(18).
&?Ikg Radiator assembly: 183 kg
Connect transmission cooler hoses (16) and (17) to

radiator.
2. Install radiator (13).

1) Tighten front mounting bolts (14)
Y
13 14
i,
Y
235C00205t
2) Tighten rear mounting bolts (15).
I
I
235COO205i
3. Install panel (12) with mounting bolts (11).
235CDO205E
30531
4. Install piping and electric wiring
1) Install fan guard (7).
2) Connect hose (6) to sub tank (6A).
3) Install radiator inlet hose (3), outlet hose (4) and
aeration hose (5) to engine.
4) Connect heater tubes (8) and (9) to radiator (10).
5. Install hood (2).
6. Tighten drain valve and add water through water fil-

ler (19) to the specified level.
* Run the engine to circulate the water through
the system. Then check the water level again.
Q Coolant: 58 Q
235FO2215
30632
REMOVAL OF FUEL TANK
ASSEMBLY
A Disconnect the lead from the negative (-) termi-

nal of the battery.
1. Remove rear mount ripper assembly.

For details, see REMOVAL OF REAR MOUNT RIPPER
ASSEMBLY.
2. Open drain valve (1) and drain fuel from fuel tank
(2).
3. Remove fuel filler pipe (3) from fuel tank.
235FO2216
4. Remove fuel hoses (4) and (5) from injection pump

(6).
235FO2217
-I
5. Remove wiring clips (9) and (9A).
6. Remove cover (7) and disconnect wiring (8).
235F0221E
7. Set jack @ in position under fuel tank to support it.
Fuel tank: 298 kg
8. Remove mount bolt (IO), plate (II), and cushion (12).
9. Loosen nut (13), and remove bolts (14) and (15),

then pull out shaft (16).
10. Lower jack 0 to lower fuel tank.
30633
INSTALLATION OF FUEL
TANK ASSEMBLY
1. Raise fuel tank (2) with jack 0, then pass shaft (16)
through rear frame and fuel tank.
&I Fuel tank: 298 kg
2. Secure shaft (16) with bolt (15).
235FO227C
3. Fit nuts (13) up to head of bolts (14), then install to

frame.
4. Adjust position of fuel tank by adjusting amount that

left and right bolts (14) are screwed in so that
mount bolt (10) is installed straight in rear frame.
5. When position of fuel tank is determined, secure

bolts (14) with nuts (13) in position where bolts are
in contact with fuel tank.
6. Install mount bolt (IO), plate (1 I), and cushion (12).
frame
ill l-1 235FO222'
7. Connect wiring (8) and install cover (7).
8. Install wiring clips (9A) and (9).
235FO2221
30634
9. Connect fuel hoses (4) and (5) to injection pump (6).
235FO2217
10. Install fuel filler pipe (3) to fuel tank (2).
11. Close drain valve (I), then add fuel through fuel fil-
ler.
12. Bleed air from fuel system.

1) Loosen air bleed plug (17).
2) Loosen knob of feed pump (18). and operate it
up and down until no more bubbles come out
with fuel from air bleed plug (17).
3) Tighten air bleed plug (17).
4) Push in knob of feed pump (18) and tighten.
13. Install ripper.

For details, see INSTALLATION OF RIPPER ASSEMBLY.
14. Connect cable to negative (-) terminal of battery.
30-35
0
DISASSEMBLY OF PTO ASSEMBLY
1. Cover, tube
1) Remove tube (2).
2) Disconnect tube (3).
2. PTO assembly
Using plate, sling PTO assembly (4), remove mount-
ing bolts, then lift off PTO assembly.
* The center gravity of the PTO assembly is high,
and .it will fall over to the front, so use a lever
block to. keep it parallel to the mounting face
when lifting.
235COO2060
3. O-ring, gear
1) Remove O-ring (5).
2) Remove gear (6) from transmission case.
3) Remove bearing (7) from gear.
P2350 D 205
4. Tube
Remove tube (8).
5. Gear assembly
I) Screw in forcing screw and remove gear assem-
bly (9).
30636
2i Remove snap ring (IO), then pull out gear from
cage.
3) Remove bearing (1 1) from gear (12).
4) Remove snap ring (13), then pull out bearing
(14) from cage (15).
P23505207 P2350f208
5) Remove bearing (16)
6. Cover, holder
1) Using forcing screw 0 (Thread dia. = 12 mm,
Pitch = 1.75 mm), remove cover (17).
2) Remove holder (18).
7. Gear assembly
1) Screw in forcing screw and remove gear assem-
bly (1 9).
2) Remove snap rings (20) and (21), then pull out

gear from cage.
3) Pull out bearing (22) from cage (23).
4) Remove bearing (24) from gear.
5) Remove mounting bolts then remove shaft (25)
from gear (26).
6) Remove bearing outer race (27) from case.
8. Lubrication tube
I) Turn over PTO case.
2) Remove lubrication tubes (28) and (29).
9. Idler gear assembly

1) Remove snap ring (30).
2) Remove shaft and bearing as one unit.

3) Remove bearing (31) from shaft (32).
4) Remove spacer (33) and gear (34).
5) Remove spacer (35) and bearing inner race (36).
10. Shaft assembly

I) Remove snap ring (37).
2) Turn over case the put case on block.

3) Remove mounting bolts then remove holder (38).
4) Pull out bearing and shaft (39) as one unit.
5) Remove bearing (40) from case.
6) Remove bearing (41) and spacer (42) from shaft

7) Remove gear (43) and bearing.
11. Snap ring, bearing
2) Remove bearing outer races (45) and (46) from
case (47).
3020
ASSEMBLY OF PTO ASSEMBLY
Preparatory work
l Clean the lubrication oil circuit thoroughly.
l Apply engine oil to sliding portion of each part before
installing.
1. Bearing, snap ring

1) Press fit bearing (46).
2) Press fit bearing (451, then fix with snap ring
(44).
t If bearing (45) goes on too far, tap it out
from the opposite side.
2. Shaft assembly
I) Set bearing and gear (43) to case.
2) Press-fit bearing (41) to shaft then install spacer
(42).
z
kc
2
3) Align spline of gear (43) and shaft then install

shaft assembly (39).
4) Fix with snap ring (37).
5) Turn over case (47).
3. Bearing cover
I) Press fit bearing (40).
2) Temporarily install cover (I 7).
4. Holder
Fit dowel pin and install holder (38).
w Mounting bolt: 112.8 f 9.8 Nm

(11.5 + 1.0 kgm)
* Turn over case (47).

5. Idler gear assembly
I) Set bearing inner race (36) and spacer (35).
2) Set gear (34).
3) Press fit bearing (31) to shaft and install spacer

(33).
4) Install shaft (32).
5) Install snap ring (30).
6. Lubrication tube
Fit O-rings and install tubes (29) and (28).
30642
7. Gear assembly
I) Press fit bearing (27) to case.
2) Install shaft (25) to gear (26).
3) Press fit bearing (24) to gear.

4) Press fit bearing (22) to cage, then fix with snap
ring (2 1).
5) Press fit gear (26) to bearing of cage, then fix
with snap ring (20).
6) Fit O-ring (48) and install gear assembly (I 9).

* When installing gear assembly (19). be par-
ticularly careful to mesh the gear and fit the
bearing properly.
8. Cover holder
1) Screw in forcing screw 0 (Thread dia. = 12
mm, Pitch - 1.75 mm) and remove cover (17).
2) Fit dowel pin and install holder (18).
w Mounting bolt: 112.8 + 9.8 Nm
(11.5 + 1.0 kgm)
3) Fit O-ring and install cover (17).
9. Gear assembly
1) Press fit bearing (I 6) to case.
2) Press fit bearing (I 4) to cage, then fix with snap

ring (I 3).
3) Press fit bearing (I 1) to gear (12).
41 Press fit gear (12) to bearing of cage (15). then
fix with snap ring (10).
5) Fit O-ring (49).
6) Install gear assembly (9) to case.

* When installing gear assembly (9) be partic-
ularly careful to mesh the gear and fit the
bearing properly.
10. Tube
Install tube (8)
11. Gear, O-ring

1) Press fit bearing (7) to gear (6).
2) Install gear (6) to transmission case.
3) Fit O-ring (5).
12. PTO assembly
Sling PTO assembly (4) and install it.
* The center of gravity of the PTO assembly is
high, and it will fall over to the front, so use a
lever block to keep it parallel to the mounting
face when lifting.
235COO2061
13. Tube
1) Connect tube (3)
2) Install tube (2).
DISASSEMBLY AND ASSEMBLY TRANSMISSION
REMOVAL OF TRANSMISSION
ASSEMBLY
(AS INDIVIDUAL PART)
1. Remove ROPS cab.
For details, see REMOVAL OF ROPS CAB.
2. Loosen drain plug (I) of hydraulic tank and drain

oil.
- : Hydraulic oil: 108 I?
3. Remove drain plug (2) of transmission case and

drain oil.
- : Transmission case : 25 e

Remove air tank assembly.
For details, see REMOVAL OF AIR TANK AS-
SEMBLY.

Remove hydraulic tank.
For details, see REMOVAL OF HYDRAULIC TANK
ASSEMBLY.
DEG00006
Serial No.: 11001 - 12012, 12016 - 12018

6. Wiring
Serial No.: 11001 - 12012, 12016 - 12018
1) Disconnect speed control wiring (3) from
transmission.
2) Disconnect connector (4).
I k DEG00007
Serial No.: 12013 - 12015, 12019 and up

Serial No.: 12013 - 12015, 12019 and up
1) Disconnect speed control wiring (3) from
transmission.
Connectors to disconnect: FW, RE, HI, LO,
Ist, 2nd, 3rd, 4th
2) Disconnect connector TM1 1 (3A).
. Inching potentiometer wiring
3) Disconnect connector CN30 (4).
l Speed sensor wiring
4) Disconnect connector TM10 (4A).
l Transmission oil temperature sensor wir-
ing
30-45-l
0
7. Remove engine stop motor (5).
-------_.--._-=-~ ($_
DEG00008
8. Remove bolt (7), then remove drive shaft (6)

between final drive and transmission.
9. Piping, control
1) Remove inching control rod (8) from trans-
mission.
OEGOOOIO
2) Remove hoses (9), (IO), and (11) from hy-

draulic pump.
30-45-2
0
3) Remove block (12) from frame.
4) Remove hoses (13) and (14).
5) Remove air hose (15).
6) Remove transmission oil filler tube (16).
30-45-3
0
10. Raise transmission assembly (171, then remove

bolts (181, (19), and (20).
* Check the number and location of shims (22).
I
\ \ \ \,\ DEGOOOl6
DEG00017
11. Remove transmission assembly (17) from main

frame when removing.
elkg Transmission assembly : 1200 kg
DEG00301
30-45-4
0
INSTALLATION OF
TRANSMISSION ASSEMBLY
(AS INDIVIDUAL PART)
1. Raise transmission assembly (17) and set main
frame.
& Transmission assembly : 1200 kg

kkgReplace O-ring (23) with a new part.
DEGO0019
2. Raise transmission assembly (17) and install

mount bolt.
1) Install bolt (18).

m Bolt :
110.5 2 12.5 Nm Ill.25 t 1.25 kgm)
2) Insert shims (22) and install bracket (21).
w Bolts (19), (20) :
549 + 59 Nm I56 2 6 kgm)
I 18 DEG00017
3. Install drive shaft (6) with bolts (7).
DFG00009
30-45-5
0
4. Piping, control
I) Install air hose (15).
2) Install hoses (13) and (14).
DEG00013
3) Install block (12) to frame.
4) Install hoses (91, (IO), and (II).
DDGOOOI 1
30-45-6
0
5) Install inching control rod (8) to transmis-

sion.
DEGOOOIO
6) Install oil filler tube (16) to transmission.
erial No.: 11001 - 12012. 12016 - 12018

Serial No.: 11001 - 12012, 12016 - 12018
7) Connect connector (4).
8) Connect speed control wiring (3) to trans-
mission.
.P OEG00007
Serial No.: 12013 - 12015, 12019 and up

Serial No.: 12013 - 12015, 12019 and up
7) Connect connector CN30 (4).
* Speed sensor wiring
8) Connect speed control wiring (3) to trans-
mission.
Connectors to connect: FW, RE, HI, LO, Ist,
2nd, 3rd, 4th
9) Connect connector TM10 (4A).
. Transmission oil temperature sensor wir-
ing
IO) Connect connector TM1 1 (3A).
. Inching potentiometer wiring
30-45-7
0
5. install engine stop motor (5).

Install hydraulic tank assembly.
For details, see INSTALLATION OF HYDRAULIC
TANK ASSEMBLY.

For details, see INSTALLATION OF AIR TANK
ASSEMBLY.
8. ROPS cab assembly

Install ROPS cab.
For details, see INSTALLATION OF ROPS CAB.
30-45-8
0
DISASSEMBLY OF TRANSMISSION
ASSEMBLY
. Preparatory work
* Sling transmission assembly (I), then set it on block
@ (Height = 470 mm).
1. PTO assembly
Sling PTO assembly (2), remove mounting bolts (3),
then remove PTO assembly from transmission as-
sembly.
235CDO2061
2. Transmission control valve assembly

1) Remove transmission control valve 19 mounting
bolts (4).
* Do not remove seat service bolts (marked
%), or body service bolts (marked A).
* The length of the mounting bolts is different,

so check the length when removing.
2) Using eyebolts @ (Thread dia. = 10 mm, Pitch

= 1.5 mm), sling and remove control valve as-
sembly (5).
3. Cage
Screw in forcing’screw 0 (Thread dia. = 12 mm,
Pitch = 1.75 mm), and remove cage (6).
4. Snap ring, seal ring

Remove snap ring (7) and seal ring.
* Set transmission assembly in place with its trans-
fer assembly down.
5. Sleeve
Remove sleeve (8).
* Using eyebolt (Thread dia. = 16 mm, Pitch =
2.0 mm), remove sleeve.
6. Transmission case
= 1.75 mm), sling transmission case.
2) Remove mounting bolts, then remove transmis-
sion case (9).
7. Tie bolt
+ Using tool C check operating condition of piston
before disassembling.
Remove tie bolts (10).
8. Cage and reverse carrier assembly
Using eyebolts @ (Thread dia. = 16 mm, Pitch =
2.0 mm), sling cage and reverse carrier assembly
(1 11, then remove it.
9. Spring P2350 I 242
Remove spring (12).
10. Spring, disc, plate

Remove spring (13). disc (14). and plate (15) in order.
+ Springs (13) are inserted between each plate.
11. Reverse ring gear

Remove reverse ring gear (16).
12. No. 1 housing, reverse piston

2.0 mm), sling No. 1 housing and reverse piston (1 7)
and remove it.
* Hold piston by hand to prevent it from falling.
13. Snap ring, reverse ring gear

Remove snap ring (18). then remove reverse ring
gear (19).
14. Spring
Remove spring (20).

Remove spring (21), disc (22). plate (23).
* Spring (2 1) are inserted between each plate.
18. Forward ring gear

P23501244
Remove forward ring gear (24).
17. Holder
Remove holder (25).
18, I Forward carrier assembly

Using eyebolts @ (Thread dia. = 16 mm, , Pitch =
2.0 mm), sling forward carrier assembly (26) and
remove it.
1) Remove snap ring (271, raise cage (281, then pull

out carrier assembly (29).
2) Remove spacer (30).
P2350 I249 P23501250
19. Spring
Remove spring (31).

Remove spring (32). disc (33), plate (34). in order.
* Springs (32) are inserted between each plate.
21. Guide pin
Remove guide pin (35).
22. 4th~speed ring gear

Remove 4th~speed ring gear (36).
23. Snap ring

Remove snap ring (37).
24. 3rd. 4th speed carrier assembly

Using bar and remove 3rd. 4th speed carrier assem-
bly (381.
25. No. 2 housing, 3rd. 4th speed piston

Using eyebolts (Thread dia. = 16 mm, Pitch = 2.0
mm), sling No. 2 housing and 3rd. 4th speed piston
(39) and pull them out.
Hold piston by hand to prevent it from falling.
26. Spring
Remove spring (40).

Remove spring (411, disc (421, plate (43) in order.
t Springs (41) are inserted between each piston.
28. 3rd speed ring gear

Remove 3rd speed ring gear (44).
45
29. 3rd. 4th speed sun gear

I) Remove spacer (45) and 4th speed sun gear 46
(46).
2) Remove spacer (47) and 3rd speed sun gear
47
(48).
48
49
30650
30. No. 3 housing, 2nd speed piston
2.0 mm), sling No. 3 housing and 2nd speed piston
(50) and remove them.
31. Spring
Remove spring (5 1).

Remove spring (52), disc (531, plate (54) in order.
* Springs (52) are inserted between each plate.
33. 1 st, 2nd speed carrier assembly

2.0 mm), sling lst, 2nd speed carrier assembly (55)
and remove them.
34. No. 4 housing, 1 st speed piston

2.0 mm), sling No. 4 housing and 1 st speed piston
36. Spring
Remove spring (57).

Remove wave spring (58), disc (591, plate (60) in
order.
t Wave springs (58) are inserted between each
plate.
37. 1 st speed ring gear

Remove 1 st speed ring gear (61).
38. Cage assembly

2.0 mm), sling cage ksembly (62) and remove it.
39. Spring
Remove spring (63).

Remove spring (641, disc (65). plate (66) in order.
t Springs (64) are inserted between each plate.
41. Guide pin

Remove guide pin (67).
* Guide pin (67) is different in length from guide
pin (35).
I’2350 %252 PZ350 B262

42. Ring gear
Remove ring gear (68).
43. No. 5 housing, low speed piston

2.0 mm), sling No. 5 housing and low speed piston
44. Rotary clutch assembly

Sling rotary clutch assembly (70) and remove it.
t There is a bearing assembled at the tip of the
shaft, so tap the transfer case with a plastic
hammer to remove.
45. Transfer assembly

Disassemble transfer assembly.
For details, see DISASSEMBLY OF TRANSFER AS-
SEMBLY.
ASSEMBLY OF TRANSMISSION
ASSEMBLY
* Assemble transfer assembly.

For details, see ASSEMBLY OF TRANSFER ASSEM-
BLY.
* Coat sliding portion of each part with engine ‘oil be-
fore installing.
* Be careful to install the seal facing in the correct di-
rection, and fit the spring securely in the seat.
1. Rotary clutch assembly

* Assemble rotary clutch assembly.
For details, see ASSEMBLY OF ROTARY CLUTCH
ASSEMBLY.
Sling rotary clutch assembly (70) and install it.
s1
4
_-_,\\\\s, ,,,:,,,,i\,,,~&\ zf
2. No. 5 housing, low speed piston
1) Fit seal rings (71) and (721, then install piston to
No. 5 housing.
* Assemble with the seal ring groove facing
the housing side.
* Install seal ring without twisting.

= 2.0 mm), sling No. 5 housing and low speed
piston (69) and install them.
3024
3. Ring gear
Install ring gear (68)
4. Guide pin
Install guide pin (67).
t Guide pin (67) is different in length from guide
pin (35).

Instal,l spring (641, disc (651, plate (66) in order.
* Spring: 5 PCS, disc: 5pcs. plate: 4 PCS.
6. Spring
Install spring (63).
7. Cage assembly
2.0 mm), sling cage assembly (62) and install it.
* Confirm that spring (63) is firmly installed in
groove of cage and piston.
8. 1 st speed ring gear

Install 1 st speed ring gear (61).

Install wave spring (58), disc (591, plate (60) in order.
* Wave spring: 3 PCS.
Disc: 3 PCS.
Plate: 2 pcs.
10. Spring
11. No. 4 housing, 1 st speed piston
I) Fit seal ring and install 1 st piston to No. 4
housing.
Sr When installing seal ring, refer to 2.-l 1.
= 2.0 mm), sling No. 4 housing and 1 st speed
piston (56) and install them.
+ Hold piston by hand to prevent it from falling.
+ Confirm that spring (57) is firmly installed in
groove of piston and housing.
12. 1 st, 2nd speed carrier assembly

* Assemble 1 st, 2nd speed carrier assembly.
For details, see ASSEMBLY OF IST, 2ND SPEED
CARRIER ASSEMBLY.
2.0 mm), sling 1 st, 2nd carrier assembly (55) and in-
stall them.
* Confirm that sun gear and ring gear are firmly in-
stalled to planetary carrier.

Install spring (52), disc (531, plate (54) in order.
Ir Spring: 2 PCS,disc: 2 PCS, plate: 1 pc.
14. Spring
Install spring (5 I).
15. No. 3 housing, 2nd speed piston

1) Fit seal ring and install 2nd speed piston to No. 3
housing.
* When installing seal ring, refer to 2.-l 1.
= 2.0 mm), sling No. 3 housing and 2nd speed
(50) and install them.
+r Hold piston by hand to prevent it from falling.
+r Confirm that spring (5 1) is firmly installed in
16.3rd. 4th speed sun gear
Install spacer (49). 3rd speed sun gear (48). spacer
(471, 4th speed sun gear (46) and spacer (45) in
order.
17. 3rd speed ring gear

Install 3rd speed ring gear (44).
44
Install spring (411, disc (421, plate (43) in order.
+I Spring: 3pcs. disc: 3pcs, plate: 2pcs.
lg. Spring
p*l 20. No. 2 housing, 3rd. 4th speed piston

5: 1) Fit seal ring and install 3rd, 4th piston to No. 2
P2350 I254
5 housing.
* When installing seal ring, refer to 2-I).
2) Using eyebolts (Thread dia. = 16 mm, Pitch = ‘j ,, I
2.0 mm), sling No. 2 housing and 3rd. 4th piston
(39) are install them. ,,
t Hold piston by hand to prevent it from falling. ‘j
* Confirm that spring (40) is firmly installed in
21. Sleeve
Install sleeve (73).
P2350E273
22. 3rd. 4th carrier assembly

* Assemble 3rd, 4th carrier assembly.
For details, see ASSEMBLY OF PLANETARY
GEAR.
Fit seal ring (74). and install 3rd. 4th carrier assembly
(38).
+ Confirm that ring gear is firmly installed on plane-
tary carrier.
23. Bearing, snap ring
Using push tool @ press fit bearing (76) and fix it
24. 4th speed ring gear

Install 4th speed ring gear (36).
25. Guide pin

Install guide pin (35).

Install spring (32), disc (33), plate (34) in order.
* Spring: 3 PCS, disc: 3 PCS, plate: 2pcs.
27. Spring
Install spring (3 1).
28. Forward, reverse carrier assembly

* Assemble forward, reverse carrier assembly.
For details, see ASSEMBLY OF PLANETARY
GEAR.
1) Install spacer (30) to carrier assembly.
2) Install seal ring to cage (28).
3) Press fit carrier assembly (29) to bearing of cage
and fix it with snap ring (27).
3028
42. Seal ring
Install 2 seal rings (78).
43. Spacer, bearing, snapring

1) Install spacer (79).
2) Press fit bearing (80) and fix it with snap ring (7).
44. Cage
1) Install ball to cage and install caller (81).
2) Press fit bearing (82) and fix it with snap ring
(83).
3) Fit O-ring and install cage (6).
45. Control valve assembly

Fit O-ring and using eyebolts @ (Thread dia. = 10
mm, Pitch = 1 .5 mm), sling and install control valve
assembly (5).
m Mounting bolt: 49.0 + 4.9 Nm (5.0 & 0.5 kgm)
& Mounting bolt: Coat the bolt marked @ with

gasket sealant (LG-5).
c3
@
@
235COO206:
L
46. PTO assembly

Fit O-ring, sling PTO assembly (2) install transmission
assembly (1). then tighten mounting bolts (3).
235CDO2061
30$2
DISASSEMBLY OF CAGE AND REVERSE
CARRIER ASSEMBLY
1. Forward sun gear

1) Remove snap ring (1) and remove sun gear (2).
2. Reverse sun gear

Remove sun gear (4).
3. Shaft
Remove shaft (5).
4. Cage
Remove cage (6).
5. Cage assembly
2) Remove cage assembly (8).
ASSEMBLY OF CAGE AND REVERSE CARRIER

ASSEMBLY
* Coat sliding portion of each part with engine oil be-

fore installing.
235FO2224
1. Cage assembly
1) Install spacer (10) to reverse carrier assembly
(9).
2) Press fit bearing (11) to cage assembly (8).
3) Install seal ring (12). install cage assembly (8)
and fix it with snap ring (7).
2. Cage
Install seal ring (13) and install cage (6).
3. Shaft
Install shaft (5).
4. Reverse sun gear

InstaN sun gear (4).
* Confirm that sun gear is firmly engaged in
planetary gear.
5. Forward sun gear

2) Install sun gear (2) and fix it with snap ring (1).
DISASSEMBLY OF 1 ST SPEED AND 2ND
SPEED CARRIER ASSEMBLY
1. Low sun gear

1) Remove snap ring (1) and remove low sun gear
(2).
2. 2nd speed carrier assembly

1) Remove 2nd speed carrier assembly (4).
2) Remove mounting bolt and remove cage (5).
3. 2nd speed ring gear and 1st speed carrier

assembly
1) Remove 2nd speed ring gear and 1 st speed car-
rier assembly (6) from shaft.
2) Remove snap ring (7) and remove ring gear (8).
4. Shaft assembly
1) Remove snap ring (IO) from shaft (9) and
remove 1 st speed sun gear (11).
F23EC019A
P23EC I 56 P23EC I 55
30664
ASSEMBLY OF 1 ST SPEED AND 2ND SPEED
CARRIER ASSEMBLY
* Coat sliding portion of each part with engine oil

before installing.
1. Shaft assembly
I) Install spacer (12) to shaft (9).
2) Install 1st speed sun gear (1 1) and fix it with
snap ring (10).
3) Install seal ring (13) to spacer (12).
2. 2nd speed ring gear and 1st speed carrier

assembly
I) Press fit bearing (15) to 1 st speed caTrier assem- F23ECO IS
bly (14) and fix it with snap ring (I 6).

2) Install 2nd speed ring gear (8) and fix it with
snap ring (7).
3) Install 2nd speed ring gear and 1 st carrier assem-
bly (6) on shaft.
3. 2nd speed carrier assembly

1) Press fit bearing (17) to 2nd speed carrier as-
sembly and fix it with snap ring (18).
2) Install cage (5).
F’Z& Mounting bolt: Thread tightener (LT-2)

s1
I.0
3) Install seal rings (I 9). (20). Using press fit tool
i?
0 (1) install 2nd speed carrier assembly (4).
* Confirm that ring gear is firmly installed on
planetary carrier.
4. Low sun gear

2) Install low sun gear (2) and fix it with snap ring
(1).
P23EC I 56
P23EC f 53
DISASSEMBLY OF HIGH ROTATING CLUTCH
ASSEMBLY
1. Shaft assembly
Remove mounting bolt and remove shaft assembly
(1).
2. Spring, Disc, Plate

Remove wave spring (2), disc (31, plate (4) in order.
* Spring: 4 PCS, Disc: 4 PCS, Plate: 3 PCS.
3. Sun gear
2) Remove sun gear (6).
4. Cage assembly
I) Put punch mark on cage (7) and carrier (8).
2) Remove bearing (9) together with cage.
5. Planetary gear
Remove planetary gear (10).
* For details, see DISASSEMBLY OF PLANETARY
GEAR.
ASSEMBLY OF HIGH ROTATING CLUTCH
ASSEMBLY
* Coat sliding portion of each part with engine oil

before installing.
1. Planetary gear
Install planetary gear (IO).
* For details, see ASSEMBLY OF PLANETARY
GEAR.
2. Cage assembly
1) Press fit bearing (9) to cage (7).
2) Align the punch mark stamped during disassem-
bly and install cage assembly (8).
a>_ Mounting bolt: Thread tightener (LT-2)
3. Sun gear
1) Install sun gear (6).
2) Turn carrier assembly over and fix it with snap
ring (5).
4. Spring, Disc, Plate

Install wave spring (2). disc (3) and plate (4) in order.
* Spring: 4 PCS, Disc: 4 PCS, Plate: 3 PCS.
z
R 5. Shaft assembly
2 Install shat assembly (1).
30667
DISASSEMBLY OF PLANETARY GEAR
1. Pull out shaft (2) from planetary carrier assembly (1)

and remove ball (3). Then remove thrust washer (41,
gear (51, thrust washer (6) in order.
2. Pull out bearing (7) from gear (5).
ASSEMBLY OF PLANETARY GEAR

23P322
* Coat sliding portion of each part with engine of

before installing.
1. Install bearing (7) in gear (5).
2. Inserting shaft (2) into carrier and install thrust

washer (61, gear (5). thrust washer (4) in order. Then
fix shaft with ball (3).
* When shaft comes out, lightly caulk ball groove
of carrier.
3. After assembly, measure side clearance of planetary rl

gear (5) with feeler gauge (1) and confirm measured 4
23P323
internal clearance within standard. z
* Side clearance: 0.35 to 0.80 mm
DISASSEMBLY OF TRANSFER
ASSEMBLY
1. Transmission assembly
Remove transmission assembly from transfer case.
For details, see DISASSEMBLY OF TRANSMISSION
ASSEMBLY.
i. Speedometer output shaft, cover

1) Remove mounting bolts, then remove speedome-
ter output shaft (1).
2) Using forcing screw 8, (Thread dia. = 12 mm,
Pitch = 1.75 mm), remove cover (2).
3. Speedometer drive gear

1) Fjemove mounting bolts (3).
2) Remove speedometer drive gear (4).
4. Input shaft cage, gear

1) Remove mounting bolts, then using forcing
screw @ (Thread dia. = 12 mm, Pitch = 1.75
mm), remove input shaft cage (5) and gear (6).
* Confirm installation direction of gear (6).
2) Remove snap ring (7). then pull out bearing (9)

from cage (8).
3029
5. Cover, brake assembly
I) Remove mounting bolts, then remove cover (I 0).
2) Remove mounting bolts, then remove brake as-
sembly (I I).
6. Coupling assembly
I) Remove mounting bolts (I 2) then remove holder
(I 3).
2) Remove coupling assembly (I 4).

3) Remove mounting bolts (I 5), then remove plate
(I 7) from coupling (I 6).
7. Output shaft assembly

I) Remove mounting bolts, then using eyebolts @
(Thread dia. = 12 mm, Pitch = 1.75 mm), sling
output shaft assembly (I 8) and remove it.
2) Remove mounting bolts (I 9). then remove cage.
30670
3) Remove oil seal (21) from cage (20).
4) Put tool (inside diameter: 90 mm; height: 150
mm) in contaot with bearing (221, push out
shaft, and remove bearing (23). spacer (24). 39 21
gear (251, and spacer (26) from shaft (27). 22
5) Remove cover (28). bearing (22) from cage (29).
29
6) Remove bearing (3 I) from case.
40 26
28
25
24 23
31
8. Cover, idler gear assembly

1) Remove mounting bolts, then using forcing
screw @ (Thread dia. = 12 mm, Pitch = 1.75
mm), remove cage.
2) Remove bearing (331, O-ring (34) from cage
(32).
3) Remove gear assembly (35) from case (30).

4) Remove 2 bearings (36) from gear assembly.
5) Remove bearing outer race from case (30).
P23508300
9. Strainer
Remove connector (38) and strainer.
DISASSEMBLY OF TRANSMISSION CONTROL VALVE
ASSEMBLY
UPPER VALVE
235FO2225
LOWER VALVE
235FO2226
30-&76
UPPER VALVE LOWER VAVE
1. Remove covers (2) and (3) from body (1). 1. Remove cover (50) from body (49).
2. Disassembly of cooler bypass valve 2. Disassembly of valve for L, H, 4,3,2,1 clutch

Remove spring (4), then remove guide (5), shim 1) Remove spring (51) and stopper (52), then
(6), valve (7), and piston (8). remove valve (53).
* Check the number and thickness of the 2) Remove spring (54). and stopper (55), then
shims, and keep in a safe place. remove valve (56).
3. Disassembly of priority valve. 3. Disassembly of valve for F, R clutch

Remove spring (9) and guide (IO), then remove 1) Remove spring (57), then remove collar (58)
shim (II), valve (12), valve (13), spring (14), and valve (59).
and valve (15). 2) Remove spring (60), then remove collar (61)
* Check the number and thickness of the and valve (62).
shims, and keep in a safe place.
4. Disassembly of pilot reducing pressure valve
4. Disassembly of modulation valve. 1) Remove valve (63), then remove shim (64).
1) Remove valve (16), spring (17), shim (18), t Check the number and thickness of the
and spring (19). shims, and keep in a safe place.
2) Remove valve (20), then remove valve (21), 2) Remove spring (65) and shim (66), then
spring (22), valve (23), and shim (24). remove valve (67), valve (68), spring (69),
* Check the number and thickness of the and valve (70).
shims, and keep in a safe place. * Check the number and thickness of the
5. Disassembly of quick return valve
1) Remove stopper (25). 5. Remove spacer (71).
g
z 2) Remove valve (26), then remove plug (27).
z
6. Disassembly of inching valve
1) Remove locknut (28) and yoke (29).
2) Remove cover (30), then remove seal (31).
3) Remove cover (32).
4) Remove spool (33).
5) Remove stopper (34), spring (35), shim (36),
stopper (37), spring (38), and shim (39).
6) Remove valve (40), then remove valve (41),
spring (42), valve (43), sleeve (44), spring
(45), and valve (46).
7. Spacer
Remove plug (47), then remove spacer (48).
30677
ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY
UPPER VALVE
235FO2225
LOWER VALVE
235FO2226
REMOVAL OF HYDROSHIFT
TRANSMISSION PUMP ASSEMBLY
A Lower the work equipment completely to the

ground and stop the engine.
1. Remove air tank assembly.

For details, see REMOVAL OF AIR TANK ASSEMBLY.
2. Remove inlet and outlet tube (1) and hose (2) from
transmission pump.
3. Remove mounting bolts (3) and remove transmission

pump (4).
6?lkg Hydroshift transmission pump assembly: 12 kg
INSTALLATION OF HYDROSHIFT
TRANSMISSION PUMP ASSEMBLY
Install transmission pump assembly (4) to PTO (5)
and tighten mounting bolts (3).
Install inlet and outlet tube (1) and hose (2) to trans-
mission pump.

For details, see INSTALLATION OF AIR TANK AS-
SEMBLY.
Run the engine to circulate the oil through the sys-

tem.
Then check the oil level again.
30680
REMOVAL OF TANDEM AND
FINAL DRIVE ASSEMBLY
1. Cover
Remove cover (IA) and (1 B) from final drive.
2. Draining oil of final drive case

Loosen drain plug (1) and drain final drive case oil.
:
U Final drive case: 57 II
235FO2227
3. Piping of final drive case

Remove tubes (2), (2A) and hoses (3), (3A).
4. Hanger
Loosen bolts (4), disconnect hanger (5) and main
frame.
3
235FO2228
5. Brake hose
Disconnect brake hoses (6) and (7) from joint (8).
6. Drive shaft
Loosen bolts (IO), then remove drive shaft (9) be-
tween transmission and final drive.
30A8 1
7. Cap
Support final drive and main frame mounting cap
(11) with jack 0, and remove.
* Distinguish between L.H. and R.H. caps.
8. Tandem, final drive assembly

Lift up main frame rear end, and turning wheel, pull
out tandem and final drive assembly (12) to rear.
+ After pulling out tandem and final drive assem-
bly, support body with block.
30$2
INSTALLATION OF TANDEM
AND FINAL DRIVE ASSEMBLY
1. Tandem and final drive assembly

1) Lift up main frame rear end, turn the wheel, and
set tandem and final drive assembly (12) under
the chassis.
2) Slowly lower the chassis and connect tandem
and final drive assembly while moving them.
\\\ / 235FO2231
2. Cap
Adjust shims of final drive and main frame mount-
ing cap (II), then support with jack 0, and install.
l Adjusting shims
1) Tighten bolt (B).
a Tighten bolt (A) and measure clearance.
3) Loosen bolt (A) and insert shim (13) (thickness
= clearance above) in (A) end.
4) Loosen bolt (B).
5) Tighten bolt (A).
g ‘3) Tighten bolt (8).

z a Mounting bolt: Thread tightener (LT-2)
235COO2065
z
(280 + 30 kgm)
6 A 13
235FO223;
3. Drive shaft
Using dial gauge, check that radial runout and face
runout of coupling face at transmission end and
coupling face at final drive end are within per-
missible value, then install drive shaft (9) with bolts
(IO).
* For details of the method of measuring and the
permissible values for the radial runout and face
runout, see INSTALLATION OF ENGINE ASSEM-
BLY.
* If they are not within the permissible value, ad-
just the engine mount shims.
(11.25 i 1.25 kgm)
30683
Hanger
Install hanger (5) on main frame by bolts (4).
a Hanger mounting bolt: Thread tightener (LT-2)
w Hanger mounting bolt: 926.7 - 103.0 Nm
(94.5 k 10.5 kgm)
Final drive case piping

Install tubes (2), (2A), hoses (3), (3A) and drain plug
(1).
235FO2227
6. Install cover (IA) and (1 B) to final drive.
3A
235FO2228
7. Brake hose
Connect brake hoses (6) and (7) to joint (8).
Refilling final drive case with oil

Tighten final drive case drain plug, then add engine
oil through oil filler (13) to the specified level.
Q Final drive case: 63 Q
Run engine to let oil circulate in hydraulic system.

Then check the oil level again.
30684
DISASSEMBLY OF FINAL DRIVE
ASSEMBLY
Special tool
I Part number I Part name I O’e

D I 792-571-l 600 1 Chain puller-

1) For details, see DISMOUNTING TANDEM DRIVE
AND FINAL DRIVE ASS’Y.
2) Sling tandem and final drive assembly (1) and
remove wheel (2).
& kg Tandem and final drive assembly (with-

out wheel): 4290 kg
3) Set tandem and final drive assembly on block

0, remove drain plug (3) and drain tandem
case oil.
.(. Tandem case (each): Approx. 120 9.
4) Remove drain plug (4) and drain final drive case

oil.
:
u Final drive case: Approx. 63 Q
* Set block with three places under the L.H. and

R.H. tandem case and final drive.
2. Cover
Remove covers (5)
Chain
I) Turn the pinion and align connection part of
chain to access position.
2) Using tool 0 squeeze the chain, remove lock

pin (6) and pull out connection pin (7).
3) Remove chain (8).
Tandem case assembly

1) Sling tandem case assembly (9).
2) Remove mounting bolts (IO), then remove
tandem case assembly.
Tandem case assembly (each): 1242 kg

& kg
5. Drive shaft
Remove bolts (111, then remove drive shaft (I 2)
from coupling.
3026
6. Coupling
Pull out coupling (13) from pinion shaft.
7. Tube
Remove tube (I 4) together with O-ring.
235FO2233
8. Strainer
Remove spring (15) and strainer (I 6) from pipe.
9. Cover, pipe
1) Remove pipe (17) together with O-ring.
10. Tube
Remove tubes (19) and (20) then remove flanges
(21) and (22).
11. Side case assembly

Remove side case mounting bolts (23) and 24 wash-
ers (24), then sling and remove side case assembly
(25) from center case.
kg Side case assembly (each): 655 kg

ET?!
P2350 I325 ti
0
I’2350 1326
12. Plate
Remove bolt (26) then remove plate (27).
P2350 I327
13. Carrier assembly
Sling and remove carrier assembly (28).
63kg
Carrier assembly: 1 10 kg
14. Gear, carrier, pin

Remove bolts (29), lock plate (301, plate (31) and Pin
(32). then remove gear (33).
15. Holder, shim

Remove holder (34) and shim (35).
16. Sprocket
Remove sprocket (36) from shaft.
17. Bearing
Remove bearing (37) from shaft.
18. Rear axle shaft assembly

Pull out rear axle shaft assembly (38) to lower side.
lg. Plate
Remove bolts (39). washer (40) and plate (41).
20. Washer, O-ring, shim

Remove washer (42). O-ring (43) and shim (44).
21. Flange
Sling and remove flange (45).
Flange: 74 kg
Remove O-ring (46)

22. Side case
1) Pull out 2 bushings (47).
2) Remove washer (49) from side case (48).
23. Shaft, bearing

Pull out bearing (5 1) from shaft (50).
24. Ring gear

Remove ring gear (52) from center case.
25. Sun gear

Remove snap ring (53) from axle shaft, then remove
collar (54) and sun gear (55).
26. Shaft
Remove axle shaft (56) from center case.
27. Bevel pinion assembly

2) Remove bevel pinion assembly (58) together

with shim (59).
Bevel pinion assembly: 74 kg

& kg
* Check the number and positions of the shims

which were removed.
28. Bevel gear assembly

1) Sling bevel gear assembly (60).
30692
2) Remove bolts (65), then remove cages (62) and
(63).
3) Remove shim (64).

t Check the number and thickness of the
shims on the left and right, and keep in a
safe place.
4) Raise bevel gear assembly, and remove from

center case (61).
& kg Bevel gear assembly: 188 kg
5) Remove bolt (67), then remove gear (66).
30693
ASSEMBLY OF FINAL DRIVE
ASSEMBLY
Special tool
Part number Part name O’ty
D 792-571-l 600 Chain puller 1
1. Center case assembly

1) Position gear (66) to center case (61) with dowel
pin, then install with bolts (67).
2) Set left and right shims (64) on center case (61),
then temporarily assemble cages (62) and (63)
(with bearing outer races already press fitted).
* Insert shims (64) on the left and right of the
same thickness as those which were
removed during disassembly.
* Types of shims
t - 0.1 mm t = 0.2 mm t = 0.5 mm
2. Bevel gear assembly

Sling bevel gear assembly (60) and install case, then
install bearing outer race of cage.
A kg Bevel gear assembly: 188 kg
3. Bevel pinion assembly

1) Fix O-ring insert shim (59), insta’ll bevel pinion
assembly (58) and it is engaged in bevel gear.
* Backlash adjusting shims
i) Insert adjusting shims (59) of the same
thickness as those which were removed
during disassembly.
ii) Standard shim thickness: 2.0 mm
iii) Type of shims
t = 0.1 mm, t y 0.2 mm, t = 0.5 mm
2) Measuring with fuse wire
Put a fuse wire @ (approx. 41.5 mm) between
the teeth of the bevel gear and bevel pinion.
Rotate the bevel gear and then measure the
thickness of the wire with a micrometer 0.
* Put the fuse wire in the center (approx. 20
mm from small end) and measure at least
three points around the gears.
* Standard value for backlash: 0.2’5 to 0.33
mm
3) Measuring preload
Install @ and bolt @ (16 mm x 2 mm -
locknut
120 mm) to bevel pinion assembly, then measure
starting torque with torque wrench 0.
* Adjust so that the starting torque at the bevel
pinion is 0.68 - 1.0 Nm (0.07 - 0.10 kgm)
greater than the torque for the bevel pinion
alone 9.8 - 12.8 Nm (1 .O - 1.3 kgm).
When doing this, measure the starting torque
at the outside circumference of the bevel gear
alone.
Starting force (bevel gear alone):
9.8 - 12.8 N (1.0 - 1.3 kg)
4. Testing and adjusting
Adjust preload to taper roller bearing, backlash and
tooth contact of bevel gear and bevel pinion.
Adjust bevel pinion assembly for starting force
of 9.8 to 12.8 Nm (1.0 to 1.3 kgm) as a single
assembly.
Install bevel pinion assembly on case with the
same shims as those before removal.
Perform adjustment of preload, backlash and
tooth contact in parallel.
Measure starting torque of bevel gear assembly
while bevel gear is in mesh with bevel pinion.
When adjusting the preload of the bearing,
change the amount of shims inserted in the
cages at the left and right sides of the center
case. a=20to33mm
b = 13to26mm
end side
Small
23F032
1) Adjust tooth contact

Coat the tooth face of the bevel pinion lightly
with red lead (minimum). Rotate the bevel gear
forward and backward and inspect the pattern
left on the teeth.
* The center of the tooth contact pattern
should be located 13 - 26 mm from the
small end of the bevel gear. It should be in
the center of the tooth height. If the gears
are adjusted to this pattern, the tooth con-
tact will be correct when load is applied.
t If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) If bevel pinion is too far from center line of
bevel gear.
Contact is at the small end of the convex
tooth face of the bevel gear and at the big
end of the concave tooth face.
* Procedure for adjustment
Reduce the thickness of the shims at the
bevel pinion mount to move the pinion in
direction A, nearer to the bevel gear. Adjust
the shim thickness at both cages of the
bevel gear to move the bevel gear in direc-
tion B by the same amount that the bevel
pinion has moved nearer. Check the tooth
contact pattern and backlash again.
ii) If bevel pinion is too close to center line of

bevel gear.
Contact is at the small end of the concave
tooth face of the bevel gear and the big end
of the convex tooth face.
* Procedure for adjustment
Increase the thickness of the shims at the
bevel pinion mount to move the pinion in
direction A, away from the bevel gear. Ad-
just the shim thickness at both cages of the
bevel gear to move the bevel gear in direc-
tion B by the same amount equal that the
bevel pinion has moved away. Check the
tooth contact pattern and backlash again.
v 23FO50
30697
6. Shaft
Install axle shaft (56) to center case.
6. Sungear
Install sun gear (55) and collar (54) to axle shaft, and
fix them with snap ring (53).
7. Ring-gear
Install ring-gear (52) to center case.
8. Shaft, bearing
Press fit bearing (51) to shaft (50).
* When doing this, position it so that the distance
from the end face of the shaft to the tip of the
bearing is distance A (1 15 mm).
30698
9. Side case
i) Assemble washer (49) to side case (48) (with
bearing and oil seal) so that end of washer is as
shown in diagram on right.
#TIJ= Washer (contact surface) :
Anti-friction compound (LM-P)
ii) Assemble bushing (47) so that slit is at bottom

compared to UP mark on side case.
Assemble the second bushing so that the slit is
at the top compared to the UP mark on the side
case.
& Bushing: Anti-friction compound (LM-P)
10. Flange
Fit O-ring to side case, then sling and install flange
(45).
ks Flange: 74 kg
C?J
a O-ring: Grease (G2-LI)
11. Washer, O-ring, shim

i) Assemble washer (42) so that end of washer is
as shown in diagram on right.
ii) Assemble O-ring (43).
ECC& Washer (contact surface):
Anti-friction compound (LM-P)
iii) Assemble shim (44) so that it is the same height
as washer (42).
* Standard shim thickness: 1 .O mm
(t = 0.1 mm, 0.2 mm, 0.5 mm) .
12. Plate
Install plate (41) and tighen bolts (39) with washer
(40).
m Bolt: 549.2 * 58.8 Nm (56 YC6 kgm)
13. Axle shaft assembly

Install axle shaft assembly (38).
14. Bearing
Install bearing (37) to shaft.
15. Sprocket
Install sprocket (36) to shaft.
* Assemble the sprockets so that the long ribs are
alinged.
16. Adjusting preload of axle shaft bearing

i) Install shim (35) and temporarily install holder
(34).
30-A00
ii) Install 3 gears (33) to carrier with pin (32), plate
(31) lock plate (30), and bolts (29).
iii) Sling and install carrier assembly (28).
rE?kg Carrier assembly: 110 kg
P2350 B328
iv) Install plate (27) and tighten bolts (26).

w Bolt: 926.7 + 103.0 Nm (94.5 k 10.5 kgm)
* Tighten bolt (26) and bring the end faces of

plate (27) and shaft (38) in contact. Add
shim (35) (temporarily installed in Step 16)
and adjust the starting torque of the bearing
to 9.8 - 12.8 Nm (1.0 - 1.3 kgm).
Type of shims: (t = 0.1 mm, t = 0.2 mm, t
= 0.5 mm)
P2350 I327
4 Rotate the shaft at least three times to the left

and right to settle the bearing, then check the
starting torque again. Install holder (34) and lock
washer (67) with bolt (68).
m Bolt: 277.0 + 31.9 Nm (28.25 + 3.25 kgm)

17 . Side case assembly
Sling and install side case assembly (25) to center
case and tighten 24 bolts (23) with washer (24).
& Side case assembly (each): 655 kg
KI& Bolt (26) and axle shaft contact surface:

Antifriction compound (LM-P)
m Side case mounting bolt: 549.2 f 58.8 Nm

(56 k 6 kgm)
18. Tube
Install flanges (22) and (2 I) then connect tubes (20)
and (1 9).
19. Cover, pipe

i) Install cover (I 8).
ii) Fit O-ring and install pipe (17) suction port at
lower side.
20. Strainer
Install strainer (16) and spring (15) to pipe.
21. Tube
Fit O-ring and install tube (14).
235FO2233
22. Coupling
Install coupling (13) to pinion shaft.
23. Drive shaft

Install drive shaft (12) to coupling and tighten bolts
(1 1).
26. Cover
Attach gasket on covers (5) (Front and rear: 6 PCS).
& Mounting bolt (tandem case side) :

Liquid gasket (LG-1)
dII& Gasket side: Liquid gasket (LG-1)

I) Lift tandem and final drive assembly (1) and in-
stall wheel (2).
2) Tighten tandem case drain plug and refill engine
oil through filler port to the specified level.
Q Tandem case (each): Approx. 120 Q
3) Tighten final drive case drain plug and refill gear

oil through filler port to the specified level.
lb Final drive case: Approx. 63 Q

DISASSEMBLY OF BEVEL GEAR
ASSEMBLY
1. Remove bolts (I), lock plates (2) then remove bevel

gear (3) from differential case A (4).
2. Remove bolts, lock plates them remove cage (5).
3. Remove bearing (6) and seal ring (7) from cage (5).
4. Remove piston (8) from cage (5) then remove seal

ring (9) from piston (8).
5. Remove seal ring (10) and washer (1 1) from cage (5).

6. Remove mating plates (121, discs (13) in order.
* Mating plate: 7 PCS, disc: 6 PCS.
7. Remove plate (I 4).
8. Remove gear (I 5) from differential case.
9. Remove differential case B (16) from differential

case A (4).
10. Remove cross joint assembly (17).
11. Remove pinion assembly (18, 18A, 19, 19A, 19B, 19C,
and 19D) from cross joint (17).
12. Remove nut (18A) from sleeve (18), then remove pi-
nion (19) and bearing assembly (19A, 19B. 19C, and
19D).
13. Remove gear (20) and thrust washer (21) from dif-
ferential case A (4).
30208
ASSEMBLY OF BEVEL GEAR
ASSEMBLY
1. Install thrust washer (21) and gear (20) to differential

case A (with bearing) (4).
2. Press fit bearings (19A), (19B) and spacers (19C), (19D)

to pinion (19).
2A. Insert sleeve (18) and tighten nut (18A).
w Nut: 490.3 - 608.0 Nm (50 - 62 kgm)

* This bearing is a set, so the combination of large
and small bearings and 2 spacers must not be
changed.
* The bearings and spacers all have the same sym-
bols on the end face.
8 * After tightening the nut to the specified torque, ro-
4 tate the bearing at least 5 times, and check that it
s1
rotates smoothly.
3. Install cross joint assembly (17).
4. Install differential case B (16) to differential case A (4).
5. Install gear (15) bite on pinion of cross joint assembly

(17).
6. Install plate (14). mating plate (121, disc (13) in order.
* Assemble the discs so that lubricating holes @
are 15” - 22” apart. To do this, insert the 2nd
disc so that it is rotated three teeth from the 1 st
disc.
* Plate: 7 PCS, disc: 6 PCS.
7. Install seal ring (I 0) and washer (1 1) to cage (5).
8. Install seal ring (9) to piston (8) and install to cage (5).
30210
9. Install bearing (6), seal ring (7) to cage (5) and install
them by bolts and lock plate.
10. Stop bevel gear (3) with dowel pin of differential case
A (4),. then install with lock plate (2) and bolt (1).
30211
DISASSEMBLY OF BEVEL PINION
ASSEMBLY
1. Set bevel pinion assembly (I) in vice and remove

nuts (21, (3) and lock plate (4).
2. Use press fit tool @ (I.D. 4200 mm) and set cage (5)
in press. Press pinion (6). pull it out from cage to
separate pinion and cage.
* It is possible to remove bearing (7) and pull out
pinion at the same time.
3. Remove bearing outer races (8) (upper and lower: 2

PCS.) and O-ring (9) from cage (5).
4. Use a bearing separator, pull out bearing (IO).
30212
ASSEMBLY OF BEVEL PINION
ASSEMBLY
1. Use press fit tool to press fit bearing (10).
P2350t366
2. Using press fit tool, press fit outer races (8) (upper
and lower: 2 PCS.) in cage (5).
3. Fit O-ring (9) to cage (5) and install pinion (6).
4. Pass bearing (7) through pinion (6) and press fit to

cage (5).
6 Bearing roller section: Fill with grease G2-LI.
5. Set the pinion in a vice and install nuts (3), (2) and
lock plate (4).
6. Starting torque adjustment

1) Tighten nuts (2) and measure starting torque.
* Starting torque: 49.0 to 58.8 Nm (5 to 6 kgm)
2) Turn the shaft at least 3 times left and right,
then loosen nut (2) so that it can start to rotate
at 4.9 to 7.9 Nm (0.5 to 0.8 kgm)
* Do not fully loosen the nut.
3) Tighten second nut (3).
* Tightening torque of second nut:
392.3 & 98.1 Nm (40 k IO kgm)
* Starting torque:
9.8 to 12.8 Nm (1.0 to 1.3 kgm)
A Measure the rotating force again after rotating

pinion shaft 3 times and after the bearing roller Pirs50 I 367
fits well. Then bend lock plate (4) securely.
P2350t363
REMOVAL OF FRONT AXLE
ASSEMBLY
1. Front wheel assembly

1) Loosen wheel nut (1) a little.
2) Raise front wheel using the blade as a jack and
support the lower part of frame center firmly with
a block.
3) Temporarily sling wheel and remove wheel nuts
(1) and remove wheel assembly (2).
kg
r6?l Front wheel assembly: 530 kg
2. Front axle assembly

1) Sling front axle assembly (3) and put on the
block 0.
2) Remove leaning cylinder and steering cylinder
hoses (41, (5). (6) and (7).
3) Remove bolt (91, pin (IO), and remove leaning

rod (8) from bracket (11) then remove leaning
stopper bolt (12).
3. Center pin
1) Remove stopper bolt (13).
2) Remove center pin (141, then remove front axle

assembly (3) from main frame.
& Front axle assembly: 1080 kg

INSTALLATION OF FRONT AXLE
ASSEMBLY
1. Sling front axle assembly (3). matching center hole

@ and main frame hole 0.
Always align the holes with left mount @ of the lean-
ing rod and leaning stopper @ removed.
-- kg Front axle assembly: 1080 kg

&?I
2. Fit center pin (14).
Tighten stopper bolt (13).
3. Fix stopper bolt (12) to leaning rod (8).

Install leaning rod L.H. side to bracket (1 I) by pin (10)
and bolt (9).
& Bolt (9): Thread tightener (LT-2)
w Bolt (9): 147.1 - 308.9 Nm (15 - 31.5 kgm)
4. Connect hoses (6), (7), (4) and (5) to leaning cylin-
der and steering cylinder.
36
5. Front wheel assembly

1) Temporarily sling front wheel assembly (2), then
install to hub shaft assembly and temporarily
tighten wheel nut (1).
2) Raise front wheels using blade as a jack,
remove the block, and lower body to the
ground.
3) Tighten wheel nut (1).
el kg Front wheel assembly: 530 kg
& Wheel nut: Anti-friction compound (LM-P)

w Wheel nut:
P2350 E369
2206.5 k 245.2 Nm (225 f 25 kgm)
‘DISASSEMBLY OF FRONT AXLE
ASSEMBLY
* Drain the oil from inside the housing.
:
I Front axle housing: 1.8 11
1) Loosen bolt (I) and pull out pin (2), remove
steering cylinder (3) bottom end from front axle
(4).
2) Loosen locknut (5) and remove steering cylinder
head end from hub shaft assembly (6).
& ks Steering cylinder: 15 kg
2. Tie rod assembly

1) Loosen locknut (7) and remove tie rod assembly
(8) from hub shaft assembly.
Tie rod assembly: 54 kg
3. Leaning rod, leaning cylinder

1) Loosen bolts (9), (10) and pull out washer (II),
pin (12).
Remove leaning rod (13) and leaning cylinder
(14) head end from yoke (15).
Leaning rod: 50 kg
30218
2) Loosen bolt (16) and pull out pin (17). then
remove leaning cylinder bottom end from front
axle.
Leaning cylinder: 26 kg
& kg
4. Kingpin
Loosen bolt (18) and pull out king pin (191, then
remove hub shaft assembly.
& Hub shaft assembly: 154 kg
5. Bracket
Loosen nut (201, pull out shaft (211, then remove
bracket (22) from front axle.
& Bracket: 29 kg
6. Hub shaft assembly

I) Loosen bolt (23) and remove cover (24).
2) Loosen bolt (25) and remove washer (26).
3) Sling housing (27) and remove it from hub shaft

(28).
ASSEMBLY OF FRONT AXLE
ASSEMBLY
1. Hub shaft assembly

1) Install housing (27) to hub shaft (28).
2) Adjust rotating torque

. Insert (30) and tighten bolts (25) with
shims
washers (26) so that it starts to rotate at 294 to
343 N (30 to 35 kg), as measured by a spring
balance 0 hooked to hub bolt (29).
Turn the shaft at least 3 times left and right.
l Loosen bolt (25) and pull out shims (30) so
that it can start to rotate at 147 to 196 N (15 to
20 kg).
l Measure the rotating force again after rotat-
ing hub shaft 3 times and after the bearing
roller fits well. Then bend lock plate (31)
securely.
l Adjust the preload after the bearing tem-
perature becomes normal.
3) install cover (24) with bolts (23).

2. Bracket
Serial No.: 11001 – 12502

1) Assemble bracket (22) to front axle (4), and
insert shaft (21).
2 Shaft and shaft insertion portion:
Grease (G2-LI)
2) Insert lock (21A) into groove [A] of shaft
(21), then assemble collar, bolt, and nut
(21B), (21C), (21D), (21E), and (21F) tem-
porarily. (Do not assemble shim (21G).)
3) Measure clearance [B].
Standard clearance: 1.5 mm
4) Insert shim of thickness [B] + 0.2 mm, then
assemble.
3 Bolt (21D):
343 – 427 Nm {35 – 43.5 kgm} Serial No.: 11001 –
a Standard shim thickness: 1.7 mm
a Types of shims:
t = 0.1 mm, t = 0.5 mm, t = 1.0 mm
5) Insert nut (20) to shaft (21).
3 Nut: 490 – 608 Nm {50 – 62 kgm}
023502
1) Assemble bracket (22) to front axle (4), and
insert shaft (21).
2 Shaft and shaft insertion portion:
Grease (G2-LI)
2) Install nut (20) to shaft (21).
3 Nut: 490 – 608 Nm {50 – 62 kgm}
30-122
(6)
3. King pin
1) Assemble hub shaft assembly (6) and bear-
ing (33) to bracket (22), then insert king pin
(19).
2) Measure clearance (C).
a Standard clearance: 6 mm
3) Select one thrust washer of a thickness
closest to (C) – 0.2 mm.
a Types of thrust washer:
t = 4.5 mm, t = 5.5 mm, t = 6.5 mm
4) Pull out king pin (19), and assemble
selected thrust washer (32) to bracket (22).
5) Insert king pin into hub shaft assembly and
bracket, insert bolt into hole [1] and secure.
3 Stopper bolt:
59 – 74 Nm {6.0 – 7.5 kgm} Serial No.: 11001 – 12502
023502
30-123
(6)
023502
30-124
(6)
023502
30-124-1
(6)
DISASSEMBLY OF STEERING
VALVE
t Cleanliness is extremely important when repairing a

steering control unit. Work in a clean area. Before
disconnecting the lines, clean port area of unit thor-
oughly. Use a wire brush to remove foreign material
and debris from around exterior joints of the unit.
Although not all drawings show the unit in a vise,

we recommended that you keep the unit in the
vise during disassembly. Follow the clamping
procedures explained throughout the manual.
Rotor (Gerotor) End
1. Clamp unit in vise 0, rotor end up. Clamp lightly on

edges of mounting area. Use protective material on
vise jaws. Do not overtighten jaws.
23EFO I lOi
2. Remove cap screw (1).
3. Remove end cap (2).
4. Remove seal (3) from end cap.
5. Remove rotor (4). Be careful not to drop star.
6. Remove seal (5) from rotor.
7. Remove drive spacer(s) (6) (not used on 49 and 73

cm3/rev. displacement units).
I 23EFOI 109
302 25
8. Remove drive (7).
9. Remove spacer plate (8).
10. Remove seal (9) from housing (10).
Control End
11. Remove housing from vise. Place housing on a

clean soft cloth to protect surface finish. Use a thin
bladed screwdriver to pry retaining ring (11) from
housing (10).
I 23EFOI I I I
12. Rotate spool and sleeve until pin is horizontal. I

Push spool and sleeve assembly forward with your
thumbs just far enough to free gland bushing (12)
from housing. Remove bushing.
I 23EFOI I I2
13. Remove quad ring seal (13) from seal gland bush-
ing.
14. Use a thin bladed screwdriver to pry dust seal (14)

from seal gland bushing. Do not damage bushing.
I 23EFOI I13
15. Remove 2 bearing races (15) and the needle thrust
bearing (16) from spool and sleeve assembly.
23EFOI II4
16. Remove spool and sleeve assembly from 14 hole

end of housing.
* Do not bind spool and sleeve in housing. Rotate

spool and sleeve assembly slowly when removing
from housing.
17. Push pin (18) from spool and sleeve assembly (17).
18. Push spool partially from control end of sleeve (19),

then remove 6 centering springs (21) from spool
(20) carefully by hand.
19. Push spool back through and out of sleeve. Rotate

spool slowly when removing from sleeve.
20. Remove seal (22) from housing.
21. Remove set screw (23) from housing.
22. Screw a #IO - 24 machine screw into end of check

ball seat (24). Then by pulling on screw, with a
pliers, lift seat out of housing.
23. Remove 2 seals (25) from check valve seat.
24. Tip housing to remove check ball (27) and check

ball retainer (28).
23EFOI II7
ASSEMBLY OF STEERING
VALVE
* Check all mating surfaces. Replace any parts that

have scratches or burrs that could cause leakage.
Clean all metal parts in clean solvent. Blow dry with
air. Do not wipe dry with cloth or paper towel be-
cause lint or other matter can get into the hydraulic
system and cause damage. Do not use a coarse grit
or try to file or grind these parts.
* Lubricate all seals (with exception of new guad ring

seal) with clean petroleum jelly such as Vaseline. Do
not use excessive lubricant on seals for meter
section.
A good service policy is to replace all old seals with
new seals.
Control end
1. Use a pincette to lower-check ball retainer (28) into

check valve hole of housing. Make sure retainer is
straight (not tilted on edge) in housing.
2. Install check ball (27) in housing.
3. Lubricate 12.9 diameter seal (25) and 11.1 diameter

seal (26). Install seals on check ball seat (24).
4. Lubricate check ball seat and seals thoroughly be-

fore installing seat in housing. When installing seat
do not twist or damage seals. Install check ball seat
in housing, insert open end of seat first. Push check
ball seat to bottom of hole.
5. Install set screw. Use a l/4” allen wrench to torque a

set screw to 11.8 Nm (1.2 kgm). To prevent inter-
ference, make sure top of set screw is slightly be-
fore housing mounting surface.
6. Assemble spool (20) and sleeve (19) carefully so

that
spool
the spring
while sliding
slots line up at the same
parts together. Some
end.
spool
Rotate
and
I 23EFOI I IS
sleeve sets have identification marks, align these

marks. Test for free rotation. Spool should rotate
smoothly in sleeve with finger tip force applied at
splined end.
* a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring slot
* b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification marks.
30228
7. Bring spring slots of both parts in line and stand
parts on end of bench. Insert spring (21) installation
tool through spring slots of both parts. Tool is avail-
able as part No. 600057. Position 3 pairs of center-
ing springs (or 2 sets of 3 each) on bench so that
extended edge is down and arched center section is
together. In this position, insert one end of entire
spring set into spring installation tool.
8. Compress extended end of centering spring set and 19

push into spool sleeve assembly (17) withdrawing
\
installation tool at the same time.
ZBEFO I I20
9. Center the spring set in the parts so that they push

down evenly and flush with the upper surface of
spool (20) and sleeve (19).
10. Install pin (18) through spool and sleeve assembly

(17) until pin becomes flush at both sides of sleeve.
8
4
si 23EFOI 121
11. Position the spool and sleeve assembly (17) so that

the splined end on the spool enters the 14 hole end
of housing (10) first.
* Be extremely careful that the parts do not tilt out of

position while inserting. Push parts gently into place
with slight rotating action, keep pin nearly horizon-
tal. Bring the spool assembly entirely within the
housing bore until the parts are flush at the meter
end or 14 hole end of housing. Do not pull the
spool assembly beyond this point to prevent the lO---
cross pin from dropping into the discharge groove
23EFO I I22
of the housing. With the spool assembly in this
flush position, check for free rotation within the
housing by turning with light finger tip force at the
splined end.
12. Place housing on clean, lint free cloth. Install 54.0

diameter seal (22) in housing (IO).
13. Install 2 bearing races (15) and the needle thrust

bearing (16) in the order.
23EF0 I I23
14. Install dust seal (14) in seal gland bushing (12), flat
or smooth side of dust seal must face down to-
wards bushing.
f==b 11
15. Install dry quad ring seal (13) in seal gland bushing
(12).
Smooth seal in place with your finger. Do not use
any seal that falls freely into pocket of buhisng.
16. Install seal gland bushing over the spool end with a
twisting motion. Tap the bushing in place with a
rubber hammer. Make sure that bushing is flush
23EFO I I.24
against the bearing race.
17. Install retaining ring (11) in housing. After installing

ring, tap on ring end or pry with screwdriver A
around entire circumference of ring to properly seat
ring in grove.
23EF ‘01 125
18. Clamp housing in vise. Clamp lightly on edges of

mounting area. Do not over tighten jaws.
* Check to insure that the spool and sleeve are flush

or slightly below the 14 hole surface of the housing.
Clean the upper surface of the housing by wiping
with the palm of clean hand. Clean each of the flat
surfaces of the meter section parts in a similar way
when ready for reassembly. Do not use cloth or
paper to clean surfaces.
23EF0 I I26
19. Install 76.2 diameter seal (9) in housing.
20. Install spacer plate (8). Align bolts holes in spacer

plate with tapped holes in housing.
23EF0 I I27
21. Rotate spool and sleeve assembly until pin (18) is
parrallel with port face “a”. Install drive (7), make
sure you engage drive with pin. To assure proper
alignment, mark drive. Note relationship between
slotted end of drive to splined end of drive when
marking.
22. Install 76.2 diameter seal (5) in meter (4).
I 23EFOI 129
23. With seal side of meter toward spacer plate, align

star valleys (X) (ref. A) on drive (Y) (ref. B).
Note the parallel relationship of reference lines A, B,
C and D.
Align bolt holes without disengaging meter from
drive.
I 23EF0 I I30
24. Install drive spacer(s) (6) when used, in meter. I
25. Install 76.2 diameter seal (3) in end cap (2).
26. Install end tap on gerotor, align holes.
27. Install 7 cap screws (1) in end cap. Pretighten

screws to 14.7 Nm (1.5 kgm), then torque screws to
27.5 Nm (2.8 kgm) in the sequence shown in Fig.
23EFOI I31
F23EH01212
30-G31
ASSEMBLY
1. Remove bolt (1) holder (2) an collar @ in order.
2. Remove spacer (3). sprocket (4) and collar (5) in

order.
A There are two types of wheel brake. In the other

type, collar (5) must be removed before the
sprocket.
(The photograph shows the rear left and front
right.)
3. Remove 4 bolts (6) then remove support (7).
4. Remove plates (81, discs (9) in order.

+ Plate: 9 PCS,disc: 8 pcs
5. Remove gear (I 0).

6. Remove spacer (1 1).
7. Remove guide bolts @ (Thread dia. = 10 mm, pitch

= 1.5 mm, length = 95 mm), th*en sling cage assem-
bly (12) and remove it.
& kg Cage assembly: 80 kg
8. Remove 6 bolts (13). 6 springs (14) then remove

piston (15).
* If air is blown in to raise the piston, it is easier to
remove. Be careful not to damage the O-ring or
the sliding surface of the piston.
9. Remove O-rings (16) and (17) from piston (15).
10. Pull out bearing (18) and spacer (19) from shaft
assembly.
P2350 1,406
30-l 33
0
ASSEMBLY OF WHEEL BRAKE
ASSEMBLY
1. Fit O-ring to shaft and install spacer (I 9).
AD+ O-ring groove part: Grease (G2-LI)
2. Press-fit bearing (18).
3. Fit O-rings (I 6) and (I 7) to piston.
a O-ring groove part: Grease (G2-LI)
4. Press-fit bearing outer race (20) and oil seal (21) to

cage.
a Oil seal: Grease (G2-LI)
5. Insert piston (15) slowly to cage (22)
a*,2 Inner surface of cage (non-machined

portion) : Rust prevention coating (PU-4)
AMITY= Sliding surface of piston: Grease (G2-LI)
AC& Machined part (except for sliding surface

inside cage in contact with piston:
Rust preventive (KP-I)
* Be careful not to damage the O-ring and sliding

surface when pushing in.
* Push the piston in to the end of its stroke, then
pull back 5 mm.
30234
6. Install 4 springs (14) and 4 bolts (I 3).
ATL Mounting bolt: Thread tightener (LT-2)
m Mounting bolt: 49.0 Nm (5.0 kgm)
7. Blow in compressed air through cage brake piping air

port @ and move piston up and down two or three
times to check that piston is returned to stroke end
by the force of the four springs.
8. After checking operation of pistion, tighten remaining

two springs (I 4) and two bolts (13) according to
procedure in step 6.
9. Sling cage assembly (I 2) and install to shaft.
Cage assembly: 80 kg
& kg
10 To prevent misalignment of cage and shaft, install

four guide bolts @ (I 0 mm x 1.5 mm - 95 mm).
11. Install spacer (1 1).

12. Install gear (I 0).
13. Install plates (81, discs (9) in order.

* Plate: 9 PCS,disc: 8 PCS.
14. Fit 2 O-rings to support (7) then install them to cage

with 4 bolts (6).
15. Install collar (51, sprocket (4). spacer (3) in order.
A There are two types of wheel brake. In the other

type, collar (5) must be installed after the sprocket.
(The photograph shows the rear left and front right.)
16. Install collar @ (c$ 95 mm) then temporarily install

holder (2) with bolts (1).
302 36
DISASSEMBLY AND ASSEMBLY AIR TANK
REMOVAL OF AIR TANK
a Lower the work equipment completely to the

ground and stop the engine.
1. Disconnect the cable from the negative H ter-

2. Depress brake pedal several times to completely

release compressed air in air tank.
3. Remove outer panels (IA) and (IB).
4. Disconnect 5 air hoses (I) at bottom right of air

tank.
5. Remove clips (2) and (3).
6. Disconnect wiring connectors (4), (5), (6), and

(7).
7. Remove wiring harness from welding clip (8).

zz
z 8. Remove wiring connector (9) from clip. (Serial 235CDO2068
8 No.: 11013 and up)
9. Sling air tank assembly (IO), then loosen bolt

(11) and remove.
INSTALLATION OF AIR TANK

ASSEMBLY

removal.
To transmission DWG00233
REMOVAL OF HYDRAULIC
TANK
1. Disconnect cable from negative (-) terminal of battery.
2. Remove drain plug (1) and drain oil. i
:
w Hydraulic oil: 108 Q
3. Remove outer panels (IA) and (IB).
4. Remove clip (2).
5. Disconnect wiring connectors (3) and (4).
1235FO2244 / /I
6. Disconnect hydraulic hoses (5), (6), (7), (8), and (9).
7. Disconnect hydraulic hoses (IO), (1 I), and (12).
8. Sling hydraulic tank (13), then loosen bolts (14) and

remove.
INSTALLATION OF HYDRAULIC
TANK
l Carry out installation in the reverse order to removal.
m Tighten the drain plug and add engine oil

through the oil filler to the specified level.
Q Hydraulic tank: 108 R
235COO2
PUMP ASSEMBLY
A Lower work equipment completely to the ground.
1. Disconnect cable from negative (-) terminal of bat-

tery.
2. Loosen drain plug (1) and drain hydraulic oil from

hydraulic tank.
:
I Hydraulic tank: 108 Q
3. Remove air tank.

For details, see REMOVAL OF AIR TANK ASSEMBLY.
4. Disconnect hoses (3), (4), (5), (6), and (7) from hy-
draulic pump (2).
5. Remove bolt (8), then remove clip (9) from pump.
6. Remove bolts (IO), and disconnect flange (11).
7. Remove bolts (12), and disconnect tube (14) from

transmission pump (13).
Remove bolts (15), then remove transmission pump

(13).
* The pump is removed with hose (16) installed,
so be careful not to damage the hose.
9. Sling hydraulic pump, and remove mounting bolts

(19).
* There are few spacers for the mounting bolts at
the bottom of the pump, and they are difficult
to loosen, so modify the ‘t’ portion of spanner A
(make it 7.0 mm) to loosen.
10. Remove hydraulic pump (2). 4
Hydraulic pump assembly: 106 kg
Rear trame 235C002074
235CD0207t
PUMP ASSEMBLY
1. Set hydraulic pump (2) in mounting position, and

tighten bolts (19).
* There are few spacers for the mounting bolts at
the bottom of the pump, and they are difficult
to tighten, so modify the ‘t’ portion of spanner
A (make it 7.0 mm) to tighten.
2. Set transmission pump (13) in mounting position,

and tighten bolts (15).
3. Install tube (14), and tighten bolts (12).
4. Connect hoses (3), (4), (5), (6), and (7) to hydraulic

w-w (2).
5. Install clip (9) to pump.
6. Install flange (11) to pump.
7. Bleed air from hydraulic pump.

For details, see BLEEDING AIR FROM HYDRAULIC
PUMP.
8. Install air tank.

For details, see INSTALLATION OF AIR TANK AS-
SEMBLY.
! F23501322
9. Add hydraulic oil to hydraulic tank.
Qz Hydraulic tank: 108 Q
Reartram 235CDO2074
30- 140
0
BLEEDING AIR FROM HYDRAULIC PUMP
A When
replaced
the
or
hydraulic
removed,
pump
always
or piping
bleed
have
the air
been
as
follows.
1. Bleeding air from hydraulic pump case

1) Remove plugs (2) and (3).
2) Disconnect hose (1); and fill hose with engine oil
(EO SAEI OW).
Q Oil: 3.5 - 4 Q
3) When oil comes out from air bleed port, tighten

plugs (2) and (3), then install hose (1).
2. Bleeding air from hydraulic pump piping

1) Start engine, and raise and lower left and right
blade lift cylinders at low idling 2 - 3 times.
2) Run engine at high idling, and raise and lower
left and right blade lift cylinders 2 - 3 times.
3) Run engine at low idling, loosen plug (4)
slightly, check that clean oil with no foam
comes out, then tighten plug.
4) Run engine at low idling, raise left and right
blade lift cylinders to end of stroke, and bleed
air from circuit at hydraulic relief.
: 5) Add engine oil (EO SAEIOW) to hydraulic tank
E to specified level.
1. Hose (for draining oil from pump Case)

2. Plug (for bleeding air from front pump)
3. Plug (for bleeding air from rear pump)
4. Plug (for bleeding air)
DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY
Special tools
1. Draining oil, cleaning

Raise pump, put oil container under drain plug,
then remove drain plug (I), and drain oil.
:
W Hydraulic pump: Approx. 3 S?
* The drained oil cannot be used again.
Fit removed plug (I), and blind plugs (2) again,

and fit blind covers (4) to suction port and de-
livery port.
* The plugs and blind covers are to prevent
dirt from entering the pump during cleaning,
so they can be fitted simply.
Clean pump with flushing oil.
After cleaning, remove plugs and blind covers
fitted at Item 2).
235CDO2076
2. Seal assembly
1) Remove snap ring (5), then remove seal assem-
bly (6) from front cover.
* The stationary seal and O-ring cannot be
used again.
2) Remove rotating seal (7) at front shaft end.

* The rotating seal cannot be used again.
3. LS valve (common for F and R pumps)
Loosen 5 bolts (1 I), then remove LS valve (IO).
* Loosen bolts in the order shown in the diagram
on the right.
235FO2246
4. Servo valve assembly (common for F and R pumps)

1) Loosen plug (12), and remove 6 bolts (13), then
raise servo valve assembly (14) straight up and
remove.
* The gasket cannot be used again.
5. Front pump
1) Loosen 8 bolts (16), then remove bolts leaving 2
bolts marked % remaining in position.
2) Loosen 2 bolts marked % in turn, and separate
pump and center section.
* The mounting surface of the servo valve is
easily scratched, so put a rubber mat under
the pump when carrying out the operation.
P2350 I 529 _ F2350133i
3) Pull out front pump (17) from center section

(18).
* If the pump does not come out by the force
of the spring and cannot be pulled out, tap
it with a plastic hammer to remove it.
5) Remove 2 pins (19A).

1lA
6) Remove valve plate (20) with screwdriver 0 as

shown in the diagram on the right.
* The mating surface of the valve plate and
center section is lapped precisely, so be
careful not to scratch it.
7) Remove pin (20A).
8) Pull out coupling (21).
Ll
F23501333
9) Remove bearing cup (22) and shim (23).

* Make match marks to indicate the assembly
position of the bearing cup and shim.
6. Rear pump
Remove rear pump in the same way as Item 5.
Front pump.
7. Disassembly of front pump

1) Set front pump (24) on stand 0.
* Set the front pump in position and be care-
ful not to let bearing plate (27) fall.
2) Remove O-ring together with backup ring (26).
30244
3) Remove bearing plate (27) with screwdriver 0.
* The mating surface of the cylinder block and
bearing plate is lapped precisely, so be care-
ful not to scratch it.
4) Remove pilot (28).

* The mating surface of the cylinder block and
pilot is lapped precisely, so be careful not to
scratch it.
5) Pull out pin (29) with pliers.
6) install tool A to bearing, and pull out using pul-

ler 0.
7) Remove bearing (30) and spacer (31).
* Make match marks to indicate the assembly
position of the bearing.
8) Remove guide (32).

9) Remove pump from stand and set so that shaft
is horizontal.
10) Rotate cylinder block kit (33) and pull out.
* Pull out the cylinder block kit together with
9 piston assemblies.
11) Loosen 8 bolts (34), and remove front cover

(35).
8
k=G
P23501541
8

13) Pull out front shaft (37) from housing.

14) Set front shaft in press, push down shaft in di-
rection of arrow, then remove bearing (38).
* The bearing is press fitted to the shaft, so
do not disassemble it unless necessary.
30- 146
a
15) Loosen 3 bolts (39), then tap bottom of trunnion
with hammer X, and remove trunnion assembly
(40).
* Make match marks to indicate the mounting
position of the trunnion.
16) Remove shim (41) and O-ring (42) from trunnion

assembly.
* Check the number and thickness of the
* The O-ring cannot be used again.
P23508547
17) Pull out swash plate assembly (43) from hous-

ing.
* Make match marks to indicate the mounting
position of the swash plate.
18) Insert handle of hammer ‘; into center hole of

swash plate (43), then push edge of thrust plate
(44) lightly, and remove.
* When removing the thrust plate, be careful
not to drop or scratch it.
19) Remove snap ring (45) from swash plate (43),
then remove pin (46).
8. Disassembly of rear pump

Disassemble rear pump in the same way as shown
in Item 7. Disassembly of front pump.
* There are some differences in the shape of the
parts for the front pump and rear pump.
9. Disassembly of cylinder block kit

1) Remove retainer (47) together with 9 pistons
from cylinder block kit.
2) Pull out 9 piston assemblies (48) from retainer

(47).
* The piston and slipper are caulked together,
so do not disassemble them.
3) Remove guide (49).

4) Remove 6 springs (50).
30-&48
5) Set bolt 0 in vice, insert cylinder block (51) and
spacer @ , then tighten nut 0 slightly, and
remove snap ring (52).
6) Remove retainer (53), spring (54), and seat (55)

in turn.
10. Disassembly of servo valve assembly

1) Remove O-ring (79) and back-up ring (80).
235COO2078
2) Remove plug (69).

3) Remove 4 control cover mounting bolts (81).
t Remove only the 4 bolts marked * in the 81
diagram.
3’
8
:
O\dL
-\
’
235CW2CBZ 235FO2247
4) Loosen remaining 2 control cover mounting

bolts (81) in turn gradually, and remove control
cover (61).
A Remove
from
the
flying
cover
off under
carefully
the
to prevent
pressure of the
it
spring.
6) Remove O-ring (72) and back-up ring (73)
30250
7) Remove spring (63).
8) Remove piston (65).
235CDO2084
9) Remove spring (84).
235CDO2086
10) Set housing (60) at an angle, and remove spool

60 83
(83).
* Be careful not to damage the spool.
11) Hold link (76) in position, and loosen bolt (71).

* Bolt (71) cannot be reused more than 5
times.
* Use a jig for holding the link.
235CD02087
66 71 u
235FO2248
12) Remove link (76)
13) Remove servo piston (66).
14) Remove 2 pins (67).
15) Remove taper plug (77), then remove spring

(76).
16) Remove pin (74).

* Use long-nosed pliers to remove.
Long-nosed pliers
235F0224E
17) Remove sleeve (64) from cover (61). -
I
18) Remove O-ring (82) from sleeve (64).
6432
19) Remove plug (68) from cover (61). 61

68
\ I
\l\ 235COO2096
20) Remove plug (68A).

::!2
0
J
--
77
--
-A -
235CD02097
11. Disassembly of LS valve assembly

1) Remove 3 O-rings (94).
235CD02098

* If it is necessary to use a vice, clamp with
the vice at the position shown by the arrow.
Mating surface
T-4 235FO2251
3) Remove spring (92), spool (87), spring seat (89)

and (93).
235FO2252
302 54
t If it is necessary to use a vice, clamp with
Mating surface
235FO2251
235CD0210(
5) Remove O-ring (91) from plug (90).
6) Remove O-ring (86) from plug (85).
7) Remove 3 plugs (68).
235FO225L
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY
Special tools
I Part No. I Part name Q’ty
* I 790-445-6520 Push tool I 1

790-445-6530 Bar 1
B
790-445-6540 Coupling 1
c I 790-445-6550 1 Guide I 1
A When assembling, coat the sliding surfaces of

all parts with engine oil (CLASS CD, SAEIOW).
A. The gasket,
used again.
O-ring, and backup ring cannot be
A When using vice, do not grip the lapped surface

of parts.
A When
form
tightening
the parts;
the vice,
use the minimum
be careful
force
not
needed.
to de-
A When replacing the bearing, replace the cone

and outer race as a pair.
A The rotating
used again.
seal and stationary seal cannot be
1. Assembly of front cover

Using push tool 8, press fit bearing outer race in
front cover (59) with press.
2. Assembly of rear cover

Using push tool @, press fit bearing outer race in
rear cover (6.0) with press. 6
P
3. Assembly of front and rear shafts
1) Press fit bearing (61) to front shaft (64) with
press.
2) Press fit bearing (61) to rear shaft (65) with
press.
* When replacing the bearing, replace it with
the outer race as a pair.
4. Assembly of trunnion
Press fit bearing (62) in trunnion (40) with press.
5. Assembly of swash plate

Press fit bearing outer race (63) in swash plate (43)
with press.
6. Assembly of seal assembly
1) Install O-ring (67) to rotating seal (66).
& O-ring: Grease (G2-LI)

* The seal is precision finished, so handle it
carefully.
* The seal cannot be used again.
‘66
_,?2350 i 665
2) Install 1 pin (69) and 6 springs (70) to retainer

(68).
P2350 I566
3) Install O-ring (71) to retainer (68).
6 O-ring: Grease (G2-LI)

P.2350 I567
-, . ..“.“.. _._..-..-. , _“._.. \, -, ._ .“_ _..._. \--,.
* Rotating seal (66) is installed to the pump; it

is not assembled to the seal assembly.
t The seal is precision finished, so handle it
carefully.
* The seal cannot be used again.
7. Assembly of cylinder block kit *,*
1) Set bolt @ in vice, and insert cylinder block (51)

to bolt 0.
2) Assemble seat (55).

* Install the seat with the tapered side facing
down.
3) Install spring (54) and retainer (53).

* Install the retainer with the stepped side fac-
ing up.
5) Install 6 springs (50).
6) Install guide (49).
* When installing guide (49), align spline “a”

of cylinder block (51) and spline “b” of
guide (49) in a straight line.
a: Undersize 1 place
b: No tooth 1 place
7) Install 9 piston assemblies (48) to retainer (47).
8) Install retainer (47) together with 9 piston as-

semblies to cylinder block.
& Cylinder block bore: EO SAEIOW
a Piston assembly: EO SAEIOW
30-A60
8. Assembly of pump (common for F and R pumps)
1) Install pin (46) to swash plate (43), and secure
2) Set swash plate assembly (43) in housing.

* Install the swash plate in the same position
as when disassembling.
3) Install O-ring (42) and shim (41) to trunnion as-

sembly.
* Install the same thickness of shim as was
2 disassembled.
% The shim thicknesses are distinguished by
8 color.
Colors and shim thicknesses Unit: mm
Color Thickness
Amber 0.025
Green 0.075
Blue 0.127
Brown 0.254
Yellow 0.508

ADJUSTING PRELOAD OF TRUNNION
BEARING
A If any swash plate (43), housing (56), trunnion

d 43 56
(40), and bearing (57) have been replaced, ad-
just the preload of the bearing.
0 Install trunnion without shims, and measure
clearance “d”.
0 Standard shim shickness = Clearance “d” +
0.075 + 0.025 mm.
0 Remove trunnion, divide shims between left and
right, and install.
* The difference between left and right shim
thickness should be within 0.13 mm.
5i 40 =33501337
5) Tighten 3 trunnion mounting bolts (39).

* Tighten together with bracket (58) in the po-
sition shown in the diagram on the right.
m Bolt: 49.0 Nm (5.0 kgm)
F23501338
6) Install thrust plate (44) to swash plate.

* Install the thrust plate with the chamfered
portion of the outside circumference facing
the swash plate.
* Coat with grease (G2-LI) when installing to
prevent the thrust plate from falling out.
7) Coat slipper portion of piston assembly (48) with

engine oil (EO SAEI OW).
8) Install cylinder block kit (33) to housing (56).
9. Assembly of front pump

1) Install front shaft assembly (37)
* Align missing tooth portion “e” of the spline

of the cylinder block kit with missing tooth
portion “f” of the spline of the shaft when
assembling.
2) Set gasket (36) to housing.

3) install front cover assembly (35) and tighten 8
bolts (34).
m Bolt: 98.1 + 9.8 Nm (IO f 1 kgm)
* Tighten the front cover mounting bolts in

the order shown in the diagram on the
right.
F23501338
4) Set front pump on stand, and install guide (32).

6) Using push tool A, press fit bearing (30) with
press.
* When press fitting, be careful not to damage
the part.
* After press fitting, clean off all dirt and iron
particles.
3op
7) Install pilot (28).
8) Install pin (29).
9) Install bearing plate (27).
* Align pin (29) and the mounting hole when
installing the bearing plate.
10. Assembly of rear pump

1) Install rear shaft assembly (73).
* Align missing tooth portion “e” of the spline

of the cylinder block kit with missing tooth
portion “f” of the spline of the shaft when
assembling.
2) Stand rear pump upright.

”‘,\:: i,,, ,:
,,
* Lay rubber mat 0 under the shaft to pre-
vent damage.
P2350 L 585
30265
3) Install guide (32).

5) Using push tool A, press fit. bearing (30) with
press.
* When press fitting, be careful not tc3 damage
the parts.
* After press fitting, clean off all dirt and iron
particles.
6) Set gasket (36) to housing.

+ Make sure that the gasket is dry when in-
stalling it.
P23501588
7) Install rear cover assembly (74), and tighten 8

w Bolt: 98.1 + 9.8 Nm (10 k 1 kgm)

* Tighten the rear cover mounting bolts in the
order shown in the diagram on the right.
F23501340
8) Install pilot (28).

9) Install pin (29).
IO) Install bearing plate (27).
* Align pin (29) and the mounting hole when
installing the bearing plate.
prevent the bearing plate from falling out.
11. Rear pump

1) Install taper plug (76) to center section.
w Plug: 14.7 Nm (1.5 kgm)
2) Install shim (23) to rear pump side.

disassembled.
3) Install bearing cup (22) to rear pump side.
* Install the bearing cup in the same position
prevent the bearing cup from falling out.
4) Align valve plate (20) with pin hole “g”, and in-
stall to rear pump side.
* The shape of the rear valve plate is as
* Coat the rear surface of the valve plate with
grease (G2-LI) when installing to prevent it
from falling out.
F23501342
5) Install O-rings and backup rings (26) to rear

pump at 2 places.
* The O-ring and backup ring cannot be used
again.
6) Install gasket (19).
+ The gasket cannot be used again.
7) Coat bearing plate (27) of rear pump with en-

gine oil (EO SAEl OW).
8) Stand rear pump (77) upright, and install center

section (18) to rear pump from top.
t When installing, be careful not to let the
center section valve plate fall out.
302 68
Method of tightening bolts
@ Tighten in turn 2 bolts marked % in diagram on
right until center section (18) is in close contact.
@ If bolt becomes difficult to tighten but center section
is still not in close contact, loosen bolts and tighten
again.
@ Install remaining 6 bolts and screw them in.
F2350134:
@ Set pump on its side, and tighten 8 bolts (16) in

order shown in diagram on right.
m Bolt: 62.8 f 5.9 Nm (6.4 + 0.6 kgm)

* Lay rubber mat 0 under the pump to prevent
damage to the ports when tightening.
F23501344 F23601345
9) Measure shaft end play of rear pump

i) Set tool B to rear shaft, and measure end
play with dial gauge.
Standard end play: 0.15 - 0.41 mm
ii) If measurement is outside
standard range,
adjust shim (23) again in Item 11.2).
End play too large: Add shims
End play too small: Remove shims
12. Front pump
1) Install shim (23) to center section.
disassembled.
2) Install bearing cup (22) to center section.
* Install the bearing cup in the same position
prevent the bearing cup from falling out.
3) Align valve plate (20) with pin hole “g”, and in-
stall to center section.
* The shape of the front valve plate is as
prevent the valve plate from falling out.
F23501346
4) Install coupling (21) to center section.
5) Install O-rings and backup rings (26) to front

pump at 2 places.
* The O-ring and backup ring cannot be used
again.
3oi!70
7) Coat bearing plate (27) with engine oil (EO
SAEI OW).
8) Install front pump (17) to center section (18).

* Be careful not to let the bearing plate and
valve plate fall out.
Method of tightening bolts

@ Tighten in turn 2 bolts marked % in diagram on
right until center section (18) is in close contact. ,
0 If bolt becomes difficult to tighten but center section
is still not in close contact, loosen bolts and tighten
again.
0 Install remaining 6 bolts and screw them in.
F23501343
@ Tighten 8 bolts (16) in order shown in diagram on

right.
m Bolt: 62.8 k 5.9 Nm (6.4 + 0.6 kgm)

* Lay a rubber mat under the pump to prevent
damage to the ports when tightening.
F23501345
9) Measure shaft end play of front pump
i) Set tool C to front shaft, and measure end
play with dial gauge.
Standard end play: 0.15 - 0.41 mm
ii) If measurement is outside standard range,
adjust shim (23) again in Item 12.1).
End play too large: Add shims
End play too small: Remove shims
13. Assembly of servo valve assembly

1) Install plug (68) to cover (61).
235CD02096
2) Install O-ring (82) to sleeve (64).

* To prevent damage to the O-ring, wrap the
thread with seal tape before inserting.
3) Install sleeve (64) to cover (61).

61 64
m Sleeve: 86.3 Nm (8.8 kgm)
302 72
4) Install plug (68A) to housing.
m Plug: 14.7 Nm (1.5 kgm)
5) Install pin (74) and spring (78) to housing with plug

(77).
m 24.5 Nm (2.5 kgm)
6) Install plug (77) to housing.
m 24.5 Nm (2.5 kgm)
7) Set pin (67) to servo piston (66), then insert in

housing.
Q Servo piston: Engine oil (SAE IOW)

* Insert so that the chamfered portions (2
places) of the large diameter of the servo
piston are at the top (spring chamber).
8) Install link (76) to servo piston (66).
m Bolt( 71): 111.8 Nm (11.4 kgm)

* Use a jig for holding the link.
66 71 LJ
235FO2248
9) Insert spool (83) in housing (60).
Q Spool: Engine oil (SAEIOW)
235COO2087
10) Assemble spring (84) in housing.

8?
235CDO2OBe
11) Assemble spring (63) in housing.
I 235CDO2084
30274
12) Install O-ring (72) and back-up ring (73).
2?5COO2083
13) Insert piston (65) in sleeve (64).
Q Piston: Engine oil (SAEI OW)
235COO210;
14) Install gasket (62) to housing.
235COO2103
15) Install cover (61) to housing, and tighten with

bolt (81).
* Be careful not to let the piston drop out.
f When tightening the bolts, first tighten two
bolts on diametrically opposite sides, then
tighten all the other bolts.
m Bolt: 32.4 + 2.9 Nm (3.3 + 0.3 kgm)
235CDO21OL
16) Fit O-ring to plug (69) and install to housing.
17) Install O-ring (79) and back-up ring (80).

* Coat with a small amount of grease.
235COO2078
14. Servo valve assembly (common for F and R pump)

2) Move swash plate (43) fully in direction of arrow
(front cover or rear cover side).
3) Align link “h” of servo valve (14) and pin “i” of
swash plate, then install.
* Check that there are the O-rings and the
backup rings fitted to the servo valve.
* The O-ring and back-up ring cannot be used
again.
* Tighten the mounting bolts in the order
shown in the diagram below.
w Bolt: 62.8 + 5.9 Nm (6.4 + 0.6 kgm)
-- F23501348
F23501349
15. LS valve (common for F and R pump)
1) Install 3 plugs (68).
2) Insert spool (87) in housing.

* Be careful to insert the spool facing in the
correct direction.
3) Fit O-ring to plug (85) and tighten to housing.
m Plug: 23.5 i 7.9 Nm (2.4 + 0.8 kgm)

* If it is necessary to use a vice, clamp with
4) Insert spring holder (93), spring (92), and spring

holder (89).
5) Fit O-ring to plug (90) and tighten to housing. 235FO2252
w Plug: 122.6 i 9.8 Nm (12.5 f 1.0 kgm)
235FO2251
6) Install 3 O-rings (94).

16. Installation of LS valve
Install LS valve (10) to servo valve with bolt (11).
* When installing, check that 3 O-rings are fitted
to the mating surface.
* See the diagram for details of the order for
tightening the bolts.
m Bolt: 29.4 - 35.3 Nm (3.0 - 3.6 kgm)
5 3
‘w
235FO2256
17. Plugs
Install 3 plugs (8).
w plug: 117.7 + 9.8 Nm (12 &- 1 kgm)
18. Seal assembly (front side only)

1) Install rotating seal (7).
* Do not use dirty hands or wear gloves for
this operation.
2) Install seal assembly (6).

3) Install snap ring (5).
* Install the snap ring with the side with the
curve facing the outside.
CONTROL VALVE ASSEMBLY
A Lower work equipment completely to the

ground.
1. Disconnect cable from negative (-) terminal of bat-

tery.
2. Loosen drain plug and drain hydraulic oil.
:
w Hydraulic tank: 108 Q
j235FO2244 / /I
3. Remove control levers (2) from hydraulic control

valve.
4. Remove covers (3), (4), and (5) from platform.
5. Remove 11 hoses and tubes (6) from control valve

(7), then remove bolts (IO), and control valve (7).
* There are 13 hoses and tubes when the ripper
is installed.
6. Remove 11 hoses and tubes (8) from control valve

(9), then remove bolts (IO), and control valve (9).
CONTROL VALVE ASSEMBLY
1. Install control valve (9) with bolts (lo), and connect

hoses and tubes (8) to control valve.(g).
2. Install control valve (7) with bolts (IO), and connect

hoses and tubes (6) to control valve (7).
3. Install covers (3), (4), and (5) to platform.
4. Install control levers (2) to hydraulic control valve.
5. Close drain plug (1) and add hydraulic oil through

oil filler (11) to specified level.
Q Hydraulic tank: 108 II

system. Then check the oil level again.
35FO2257
DISASSEMBLY OF MAIN CONTROL VALVE
* Be careful to check that there is no dirt or 8. Loosen 2 bolts (18), and remove plate (19).
scratches on any part.
* Be careful not to damage the sliding surface 9. Pull out spool (16) from spring cap.
and the mating surface.
* When disassembling the spools, shuttle valves, 10. Remove oil seal (20) with a screwdriver.
or any other parts, mark with tags to distin-
guish the location. 11. Removal of pressure compensation valve
When assembling, be sure to assemble in the (without adjustment screw)
same valve case. 1) Remove cap (21), then remove spring (22).
* Be careful not to let the spring fly. off.
1. Hold nuts (1) and (2) with a box wrench, and 2) Remove plug (23), then pull out spool (24).
loosen nuts (3) and (4).
* Leave nuts (1) and (2) fitted to the stud 12. Removal of pressure compensation valve (with
bolts. adjustment screw)
Remove cap (25).
2. Pull out each valve body assembly from stud Remove locknut (26) and adjustment screw
bolts (5) and (6). (27) from cap (25).
* Make match marks on the mating surface Remove collar (28), o-ring (29), backup ring
of each valve body. (30), and spring (31).
Remove plug (32), then pull out spool (33).
3. Remove O-rings (7) and (8) from valve body.
13. Disassembly of pilot relief valve
4. Pull out shuttle valve assembly (9). 1) Remove pilot relief valve assembly (34).
2) Loosen cap nut (35) and nut (36), then re-
5. Loosen 2 bolts (IO), and remove cap (11). move adjustment screw (37) and 2 seal
washers (38).
6. Loosen bolt (12), and remove 2 collars (13), * Be careful not to let the spring fly off.
spring (14), and plate (15). 3) Remove spring (40), valve (41), o-ring (42),
* When removing bolt (12), be careful not to and backup ring (43) from valve body (39).
let the spring fly off.
7. Push spool (16) towards lever, and remove oil

seal (17) with a screwdriver.
1
235F501
30; 83
ASSEMBLY OF MAIN CONTROL VALVE
Be careful to check that there is no dirt or 3. Assembly of pressure compensation valve

scratches on any part. (without adjustment screw)
Be careful not to damage the sliding surface 1) Insert spool (24) in valve body, then fit
and the mating surface. O-ring (47) to plug (23) and install to valve
When assembling the spools, shuttle valves, or case.
any other parts, match with tags used to distin- w Plug: 78.5 k 9.8 Nm (8 + 1 kgm)
guish the location and be sure to assemble in 2) Insert spring (22) in cap (21).
the same valve case. * There are two springs in the circle rota-
Replace the O-rings, backup rings, and oil seals tion only.
with new parts.
3) Fit O-ring (48) to cap (21) and install to
Coat the sliding surface with engine oil before valve case.
assembling.
m Cap: 78.5 + 9.8 Nm (8 F 1 kgm)
Assembly of pilot relief valve

4. Install oil seal (20) to valve body.
1) Insert valve (41) and spring (40) in valve
body (39), and screw in adjustment screw & Lip of oil seal: Grease (G2-LI)
(37) lightly.
2) Tighten 2 washers (38), nut (36), and cap 5. Insert spool (16) in valve body.
nut (35) to adjustment screw (37) tempo- * Be careful not to damage the oil seal.
rarily.
3) Install backup ring (43) and O-ring (42) to 6. Fit plate (19) and tighten 2 bolts (18).
valve body (39).
@El Bolt: 7.9 k 1.0 Nm (0.8 & 0.1 kgm)
4) Fit O-ring (44) to pilot relief valve assembly
(34), and install to valve case.
7. Install oil seal (17) to valve body.
m Pilot relief valve: 68.6 f 9.8 Nm
& Lip of oil seal: Grease (G2-LI)
(7 * 1 kgm)
* After adjusting the set pressure of the
8. Assemble plate (15), 2 collars (13), and spring
pilot relief valve, tighten nut (36) and
(14) to valve body, then tighten bolt (12).
cap nut (35) fully.
&?YZ Bolt: Thread tightener (LT-2)
m Nut: 44.1 + 4.9 Nm (4.5 i 0.5 kgm)
m Bolt: 11.28 + 1.47 Nm (1.15 k 0.15 kgm)
m Cap nut: 44.1 14.9 Nm (4.5 + 0.5 kgm)
9. Insert cap (1 I), and tighten 2 bolts (10).

2. Assembly of pressure compensation valve
(with adjustment screw) m Bolt: 7.8 + 1.0 Nm (0.8 i 0.1 kgm)
1) Insert spool (33) in valve body, then fit

O-ring (45) to plug (32) and install to valve 10. Insert shuttle valve (9) to each valve body.
case.
11. Install O-rings (7) and (8) to each valve body.
m Plug: 78.5 & 9.8 Nm (8 k 1 kgm)
2) Install backup ring (30) and O-ring (29) to
12. Insert valve body in stud bolts (5) and (6) in
collar (28).
the same order as for disassembly.
3) Tighten adjustment screw (27) and locknut
* Be careful not to bend the shuttle valve or
to cap (25) temporarily, and insert collar
let the O-ring protrude.
(28) and spring (31) in cap.
4) Fit O-ring (46) to cap (25) and install to
13. Tighten nuts (2) and (3).
valve case.
m Nut (2): 58.8 Nm (6 kgm)
m Cap: 78.5 f 9.8 Nm (8 k 1 kgm)
* Tighten the locknut fully after adjusting w Nut (3): 98.1 Nm (10 kgm)
the set pressure.
3Oi.84
LO
27/
34
235F501
302 85
DISASSEMBLY OF CIRCLE ROTATION MOTOR
Serial No.: 11001 - 12050
Special tools
No. 1 Part No. I Part NekF\c
A 1 790-445-6200 1 Stand assembly [MY
A, 1 790-445-6210 1 * Stand I 1
A, 1 790-445-6220 / . Stud bolt I 1
A, 1 790-445-6230 / * Stud bolt I 1
A., / 790-445-6240 I * Handle I 2
A, / 790-445-6250 ) . Nut I 2
A, 1 01010-31045 1 - Bolt I 4
A, 1 01643-31032 1 * Washer I 4
F23501351
A, 1 04025-00332 I . Spring pin I 2
B I 790-445-6260 I Plate I 1
B, / 790-445-6270 I . Plate I 1
B, 1 01010-31030 1 - Bolt I 5
4 01643-31032 * Washer 5
* Be careful to check that there is no dirt or scratches

on any part.
* Be careful not to damage the sliding surface and
the mating surface.
1. Remove drain plug (1) and drain oil from motor,
2. Remove plug (2) from retainer plate (3). F23501352
3. Set shaft facing up, put motor on stand (A,), then

secure with bolt (AJ and washer (A,).
* Install bolt (As) in the hole for the piping flange 6, ‘P-l 5
mounting bolt.
4. Insert stud bolt (A,) in hole of plug (2) removed

from retainer plate (3), screw into cylinder block (4),
secure with nut (A& and install handle (AJ and
spring pin (A&.
5. Loosen bolt (5), and remove cover (6), O-ring (7),

and shim (8).
* Make match marks to cover (6) and case (9).
F23501353
30-186
0
* Be careful not to damge oil seal (IO) with the
shaft when removing the cover.
6. Loosen bolts (ll), (12), and (13), and pull out case
(9) from top.
7. Fit plate (B,) to swash plate (14), and secure with

bolt (B,) and washer (BJ
8. Using gear puller, remove swash plate (14) while

pulling out inner race of bearing (15).
* Be careful not to let pistons (16) fall.
9. Remove plate (B,) from swash plate (14).

I I
10. Remove piston (16) and springs (17) at shaft end. F23501354
11. Remove stud bolt (A,) screwed into cylinder block

(4), then remove cylinder block (4).
* Be careful not to remaining pistons (16) fall.
* Be careful not to let timing plate (18) fall out.
12. Remove pistons (16) inside cylinder block (4).
13. Remove timing plate (18), spring (19), and pin (20).
14. Using gear puller, remove inner race of bearing (21)

from retainer plate (3).
15. Loosen bolts (22) from retainer plate (3) and swash
plate (14), then remove retaining rings (23), retaining
plates (24), and slippers (25).
L F23501355
16. Remove O-ring (26) from retainer plate (3).
F23501356
17. Remove O-ring (28) and backup ring (29) from
sleeve (27) fitted to retainer plate (3).
* Do not remove sleeve (27) except when replac-
ing it.
18. Remove outer race of bearing (21) from cylinder

block (4).
19. Remove oil seal (10) from cover (6).

* Insert pins in two holes of the cover, and pull
out the oil seal.
F23501356
F23501357
ASSEMBLY OF CIRCLE ROTATION MOTOR
Serial No.: 11001 - 12050
Special tools
No. Part No. Part Name Q’ty

D 790-445-6400 Inserting tool ass’y 1
D, 790-445-6410 . Push tool 1
D* 790-445-6420 . Inserting tool 1
E 790-445-6430 Top hat ass’y 1
B, 790-445-6440 . Top hat 1
E2 01010-31035 . Bolt 1
B, 01643-31232 . Washer 1
F 790-445-6450 Adjusting tool ass’y 1
* Shim adjusting ,
F, 790-445-6460
tool
F, 1 01010-31055 1 . Bolt I 4
F, 1 01643-31032 1 * Washer I 4
F, 1 01050-31030 1 . Bolt I 3
CL3 01643-01232 * Washer 1
C, 04205-00835 . Pin 1
C 10 04205-01038 * Pin 1
C,, 04052-00833 . Snap pin 1
C 12 04052-01038 . Snap pin 1
Be careful to check that there is no dirt or scratches

on any part.
Be careful not to damage the sliding surface and
the mating surface.
Coat the sliding surface with engine oil (EOlO-CD)
before assembling.
Replace the O-rings and oil seals with new parts.
30-189
0
1. Fit O-ring (26) to retainer plate (3).
6 O-ring: Grease (G2-LI)
2. Knock sleeve (27) into retainer plate (3).
3. Install backup ring (29) and O-ring (28) to sleeve

(27) in order.
-
& Backup ring, O-ring: Grease (G2-LI) 16.n A---‘
4. Install stoppers (25), retaining plate (24), and re-

taining ring (23) to retainer plate (3) with bolts (22). 25.
B Bolt: 5.9 Nm (0.6 kgm)
5. Shrink fit inner race of bearing (21) to retainer plate

(3) to install.
* Shrink-fitting temperature: Max. 13o’C
6. Insert spring (19) in sleeve (27).
7. Install pin (20) to timing plate (18).
& Pin: Grease (G2-LI)

8. Put retainer plate (3) on stand (A,), and secure with
F23501356
bolt (4) and washer (A,).
9. Put timing plate (18) on sleeve (27), and secure tim-

ing plate (18) with stud bolt (AJ, nut (A,), handle
(AJ, and spring pin (A,).
F23501358
* When assembling timing plate (18), set it sym-
metrically to the left and right of the line joining
the high side and low side of the angled surface
of retainer plate (3).
10. Knock outer race of bearing (21) into cylinder block

(4).
11. Set cylinder block (4) to retainer plate (3) secured to

stand.
12. Remove stud bolt (As) holding timing plate (18).
13. Fit stud bolt (A*), and secure cylinder block (4) and
retainer plate (3).
* Align slipper (25) with the position of the bore
of the cylinder block.
14. Fit piston rings (30) to pistons (16).
15. Insert pistons (16) at retainer plate (3) end in cylin-

der block (4).
16. Insert springs (17) in cylinder block (4). F23501356

t Set the piston at the retainer plate end in posi-
s!
z tion securely.
8
17. Install retention tools (C, - C,,) to cylinder block (4).
* Align stopper (C,) with the position of the piston
hole.
18. Using inserting tools (D,) and (D,), insert piston (16)
at swash plate (14) end, then stop piston with stop-
per (C,).
F23501359
F23501360
19. Install slippers (25), retaining plate (24), and retain-
ing ring (23) to swash plate (14) with bolts (22).
w Bolt: 5.9 Nm (0.6 kgm)
20. Set swash plate (14) in position on cylinder block

(4).
* Align the thick sides of swash plate (14) and re-
tainer plate (3) so that they are on the same
side.
21. Set top hat (E,) over shaft, then screw bolt (E2) and
washer (EJ into bolt hole in end face of shaft to
tighten top hat (E,). F23501361
22. Remove retention tools (C, - C,,).
23. Install positioning pin to swash plate (14).
24. Set case (9) over cylinder block (4), then secure
case (9) and retainer plate (3) with bolt (13).
& Bolt: Thread tightener (l-T-2)
w Bolt: 78.5 Nm (8 kgm)
25. Fit seal washers (31) to bolts (11) and (12), then
tighten case (9) and swash plate (14).
& Bolt: Thread tightener (LT-2)
Q&z Bolt: 46.1 Nm (4.7 kgm)
26. Remove top hats (E, - EJ and stud bolt (A,).
27. Shrink fit inner race of bearing (15) to shaft, then in-
stall.
F23501362
* Shrink-fitting temperature: Max. 130°C
F23501363
28. Knock outer race of bearing (15) into case (9).
29. Adjusting shim

1) Put shim adjusting tool (F,) on case (9), and
tighten to swash plate (14) with bolt (F2) and
washer (F3).
2) Tighten 3 bolts (F,), and press fit bearing outer
race (15).
* Make sure that it goes down uniformly.
w Bolt: 9.8 Nm (1 kgm)
* Rotate the shaft at the same time.
3) Using each hole of shim adjusting tool (F,),

measure clearance between end face of outer
race and end face of shim adjusting tool, and
take the average of each dimension as dimen-
sion X.
F23501364
X=A-B
* The difference between the dimensions at
each place of measurement shall be within
0.05 mm. F2 F3 F4 FI
4) Measure dimension Y, of shim adjusting tool (F,)

and dimension Y, of cover (6) when installed.
. When Y, > Y,
Subtract Y, - Y, = 2 from dimension X.
. WhenY,<Y,
Add Y, - Y, = Z to dimension X.
5) Calculate (X + Z) and add a preload of 0.05 - I

15
0.1 mm to decide the shim thickness, then in-
stall the shim. F23501365
6) Remove shim adjusting tool.
F23501366
30. Knock oil seal (10) into cover (6).
& Lip of oil seal: Grease (G2-LI)
31. Fit O-ring (7) to cover (6).
32. Install cover (6) to case (9) with bolt (5).
w Bolt: 62.8 Nm (6.4 kgm)
33. Rotate shaft, and measure rotating torque.

* Rotating torque: 6 kgm
34. Install plug (2) to retainer plate (3).
F23501367
F23501368
F23501352
30294
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
DISASSEMBLY OF CIRCLE ROTATION MOTOR ASSEMBLY

\I
J DWG00277
1. Bolt (5 or 7) 8. Rotor set 13. Bearing (inside)

IA. Bolt (7) 8A. Rotor 14. Thrust washer
IB. Bolt (7) 8B. Stator half 15. Thrust bearing
IC. Bolt (7) 8C. Vane 16. Seal
2. End cover 8D. Stator half 17. Backup washer
3. Seal ring 8E. Vane 18. Housing
4. Seal ring 9. Wear plate 19. Bearing (outside)
5. Commutator IO. Drive link 20. Seal
6. Commutator ring 11. Thrust bearing 21. Backup washer
7. Manifold 12. Coupling shaft
12A. Key
12B. Nut
12C. Washer
12D. Bolt
12E. Lock washer
12F. Retaining ring
30-194-l
0
1. Remove shaft key (12A), bolt (12D), washers

(12E) and (12C), and retaining ring (12F).
Ir Polish the area around the key groove on
the shaft and remove all burrs and flashes.
DWG00278
2. Fix motor in vice and make mark to prevent it

from moving out of position.
* Grip the flange portion of the motor in the Mark /
vice.
3. Remove 7 bolts (I) from end cover (2).
4. Remove end cover (2) and seal ring (4).
30-194-2
0
5. Remove commutator ring (6).
6. Remove commutator (5) and seal ring (3).
7. Remove manifold (7).
DWGO
8. Remove rotor set (8) together with wear plate

(9), then remove drive link (IO) and thrust bear-
ing (II).
* Lift rotor set (8) up together with the wear
plate to prevent the rotor set from coming
apart.
* Make a mark to indicate the top surface of
the rotor set.
30-194-3
0
9. Pull out coupling shaft (12) from housing (18).
10. Pull out inside bearing (13) from housing (18).

Ir Measure the mounting depth (position) of
bearing (13) and note the measurement.
=, DWG00287
11. Remove thrust bearing (15) and thrust washer

(14).
12. Remove seal (16) and backup washers (21) and

(17).
30-194-4
0
13. Remove seal (20) and pull out outside bearing

(19) from housing (18).
30-194-5
0
ASSEMBLY OF CIRCLE ROTATION MOTOR ASSEMBLY

DWG00277
1. Bolt (5 or 7) 8. Rotor set 13. Bearing (inside)

IA. Bolt (7) 8A. Rotor 14. Thrust washer
IB. Bolt (7) 8B. Stator half 15. Thrust bearing
IC. Bolt (7) 8C. Vane 16. Seal
2. End cover 8D. Stator half 17. Backup washer
3. Seal ring 8E. Vane 18. Housing
4. Seal ring 9. Wear plate 19. Bearing (outside)
5. Commutator 10. Drive link 20. Seal
6. Commutator ring 11. Thrust bearing 21. Backup washer
7. Manifold 12. Coupling shaft
12A. Key
128. Nut
12C. Washer
12D. Bolt
12E. Lock washer
12F. Retaining ring
30- 194-6
0
* Replace all seals and bearings with new parts.

* Wash all parts with a petroleum-based solvent,
then blow with air to dry.
1. Press fit outside bearing (19) to housing (18).

* Press-fitting depth (from flange surface):
7.37 - 7.87 mm
& Bearing : Grease (G2-LI)
2. Press fit seal (20) to housing (18).

* Press-fitting depth (from end face of flange):
0.5 mm
3. Install backup washers (17) and (211, and seal

(16).
* Install seal (16) with the lip at the top (the
inside of the motor).
Inset-t thrust washers (14) and thrust bearing

(15).
* Install so that washers hold the bearing on
both sides.
5. Press fit inside bearing (13) to housing (18).

+ Press-fitting depth (from flange surface) :
2.67 - 3.18 mm
=, DWG00287
6. Install coupling shaft (12).

* To prevent damage to the seal, wind mask-
ing tape around the key groove before in-
stalling.
. Grip housing (18) in a vice.
. If the assembly is made correctly, the cou-
pling shaft will be approx. 2.5 mm lower
than the mounting surface of the housing
wear plate.
7. Insert thrust bearing (II), and install seal ring

(4) to housing (18).
6 Seal ring : Grease (G2-LI)
8. Install drive link (IO), then put wear plate (9) on

it.
9. Install seal ring (4) to rotor set (8), then put wear
plate (9) on it.
* Install with the seal ring side at the bottom.
* Replace seal ring (4) between stators (8B)
and (8D) of the rotor set with a new part.
30-194-8
0
10. Install seal ring (4) in seal groove of manifold

(7).
& Seal ring : Grease (G2-LI)
11. Put manifold (7) on rotor set (8).

Ir Be careful to install the manifold the right
way up. (Set it so that the oil passage hole
with the large diameter pitch is at the bot-
tom (rotor set side).)
/ I II ---lJ--- I\ DWG00296
12. After installing seal ring (4) in seal groove of

manifold (71, install commutator ring (6).
_=;i=;_ 1 DWG00297
13. Install seal ring (3) to commutator (5), then in-

stall so that head of drive link enters hole in
center of commutator.
3 DWG00298
30-194-9
0
14. Install seal ring (4) in seal groove of end cover

4 / \ I
(2).
15. Put end cover (2) on commutator ring (6), and

install bolts (I).
m Bolt : 67.7 + 6.9 Nm IS.90 + 0.70 kgm1
Bolt tightening order
DWG00300
16. Install shaft key (12A), bolt (12D), washers (12E) B port
and (12C), and retaining ring (12F). /
* Check the direction of rotation of the motor.

Direction of rotation of motor (seen from
output shaft side)
When pressure oil is applied to port A:
Counterclockwise
When pressure oil is applied to port B:
Clockwise
(Thread size of ports A and B: 518 - 14UNF)
I DWG00278
30-194-10
0
REMOVAL OF DRAWBAR SHIFT CYLINDER,
BLADE LIFT CYLINDER, LIFTER GUIDE
A Lower work equipment completely to the ground.
A Stop
times
the engine.
the remaining
Operate
pressure
control
from
lever several
the hydraulic
piping.

Disconnect hoses (2) and (3) from drawbar shift
cylinder (1) and remove it.
kg Drawbar shift cylinder: 72 kg

C?YI

I) Temporarily sling blade lift cylinder (41, then dis-
connect hoses (5) and (6) from blade lift cylinder
and remove cylinder head end from drawbar
joint (7).
2) Loosen bolt (81, and remove holder (9).

3) Remove blade lift cylinder assemblv (1 1) from B
lifter guide (10).
kg Blade lift cylinder assembly: 158 kg

tT?z
3. Upper lifter guide

1) Sling upper lifter guide (101, then remove nut
(12) and bolt (13).
Upper lifter guide: 96 kg
P2350 F424
2) Sling and remove upper lifter guide (10).
P2350 i 425
4. Lower lifter guide

1) Sling lower lifter guide (14). Loosen bolt (15)
and pull out bank control pin assembly (16).
A
m Lower lifter guide: 550 kg
2) Sling lower lifter guide (14) and lower.
P2350 I427
INSTALLATION OF DRAWBAR SHIFT CYLINDER,
BLADE LIFT CYLINDER, LIFTER GUIDE
1. Lower lifter guide

1) Sling lower lifter guide (14) and lift up align
guide hole 1s and main frame hole 8.
Lower lifter guide: 550 kg

& kg
2) install bank control pin assembly (16).
2. Upper lifter guide

Sling upper lifter guide (lo), insert shim (17) and
tighten bolt (13) and nut (12).
kg Upper lift guide: 96 kg

C!z!
w Mounting bolts: 539.4 & 49.0 Nm (55 k 5 kgm)
P2350 I425
P2350 I430
1) Temporarily sling blade lift cylinder (4) and insert
in upper lifter guide hole.
kg Blade lift cylinder: 158 kg

&?I
2) Fix with holder (9) and bolt (8).
3) Install blade lift cylinder head side to drawbar ball

joint (7) and connect hoses (5) and (6).

Install drawbar shift cylinder (1) head side to lifter
guide ball joint (18).
Install bottom side to drawbar ball joint (191, and con-
nect hoses (2) and (3).
Drawbar shift cylinder: 72 kg

& kg
REMOVAL OF ARTICULATE CYLINDER
ASSEMBLY
1. Disconnect head greasing tube (1) from pin (2), then

remove bolt (3) and pin (2).
A If it is difficult to remove the pin because of re-

sidual pressure in the cylinder, loosen the sleeve
nut of hoses (4) and (5) to discharge the resid-
ual pressure.
2. Disconnect hoses (4) and (5) from cylinder.
3. Sling articulate cylinder assembly (6).
4. Remove bolt (9) and pin (8).
5. Sling and remove articulate cylinder assembly (6).
Articulate cylinder assembly: 72 kg
INSTALLATION OF ARTICULATE
CYLINDER ASSEMBLY
1. Sling articulate cylinder assembly (6) and set bottom

to mounting bracket (IO), then insert pin (8) and fix
it with lock plate (11) and bolt (9).
2. Connect hoses (4) and (5) to cylinder.

* Install hoses without twisting and interference.
3. Start engine and extend cylinder rod, align piston

rod connecting pin holes with holes in bracket (12),
insert pin (2) and fix it with lock plate (13) and bolt
(3).
4. Connect grease tube (1) to pin (2).

* Operate the control lever to circulate oil in the
cylinder then add engine oil into the hydraulic
tank to the specified level.
30?A99
REMOVAL OF REAR MOUNT
RIPPER CYLINDER ASSEMBLY
‘A Lower work equipment completely to the ground.
1. Sling cylinder assembly (I 1.
2. Remove lock plate (2) at head end and remove pin (3).
A If it is difficult
residual pressure
to remove
in the
the
cylinder,
pin because
loosen
of
the
sleeve nut of the hose to discharge the residual
pressure.
3. Disconnect cylinder bottom hose (4) and cylinder

head hose (5) from cylinder.
4. Remove support (6).
5. Sling and remove cylinder assembly (1).
& Rear mount ripper cylinder assembly: 130

kg
INSTALLATION OF REAR
MOUNT RIPPER CYLINDER
ASSEMBLY
1. Sling cylinder assembly (11, and set bottom hole to

mounting bracket.
2. Install support (6).
3. Connect cylinder head hose (5) and cylinder bottom

hose (4).
* Install hoses without twisting.
4. Start engine and fully extend cylinder. Align piston

rod hole and bracket hole.
5. Install head pin (13) and fix with lock plate (2).
6. Operate the control lever to circulate engine oil

through in cylinder. Then add engine oil into hydraulic
tank to be specified level.
30200
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
Serial No.: 11001 – 12502
023502
30-201
(6)
3. Piston and head assembly
1) Set piston rod assembly (6) to tool A1.
2) Using tool A3, remove nut (7).
Cylinder Width across flats

of nut
Steering 46 mm
50 mm (*1)
Leaning
60 mm (*2)
Blade shift 70 mm
Blade lift 70 mm
Drawbar shift 70 mm
Articulate 75 mm
Power tilt 75 mm
Ripper 80 mm
(*1) Serial No.: 11001 – 12050
3) Remove piston (8) and slider (9).

a Slider (9) is installed to the steering cyl-
inder only.
4) Remove cylinder head assembly (10).
4. Disassembly of piston assembly
023502
Remove piston ring (11) and water ring (12)
from piston (8).
5. Disassembly of head assembly

1) Remove O-ring and backup ring (13).
2) Remove snap ring (14), then remove dust
seal (15).
3) Remove rod packing (16).
4) Remove bushing (17).
30-202
(6)
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
Serial No.: 11001 – 12502
023502
30-203
(6)
023502
3. Piston, head assembly
1) Set piston rod to tool A1.
2) Assemble cylinder head (10) to piston rod.
3) Fit slider (9) and install piston assembly (8),
then using tool A3, tighten nut (7).
inder only.
a Wash and remove all grease and oil
from the thread of the piston rod where
the nylon nut is fitted.
2 Rod thread:
Thread tightener (Loctite #262)
3 Piston nut
Cylinder Width across Nm

flats of nut {kgm}
Steering 46 mm 785 ± 78.5
{80 ± 8}
50 mm (*1) 1,080 ± 110
{110 ± 11}
Leaning
60 mm (*2) 1,770 ± 177
{180 ± 18}
2,600 ± 260
Blade shift
{265 ± 26.5}
3,330 ± 333
Blade lift 70 mm {340 ± 34}
2,600 ± 260
Drawbar shift
{265 ± 26.5}
3,140 ± 314
Articulate {320 ± 32}
75 mm
2,840 ± 284
Power tilt
{290 ± 29}
3970 ± 397
Ripper 80 mm {405 ± 40.5}
(*1) Serial No.: 11001 – 12050
30-204
(6)
023502
30-205
(6)
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
a The symbols used in the special tools and illus- 1. Set cylinder assemble (1) to tool A1.
trations indicate the following cylinders.
Cylinder Cylinder symbol
Steering ST
Leaning LE
Blade shift BS
Blade lift BL
Drawbar shift DS
Articulate AR
Power tilt PT
Ripper RP
Special tools
Sym-
Parts No. Part Name Q’ty Remarks
bol
790-502-1003 Repair stand 1
1 790-502-2000 Repair stand 1
790-101-1102 Pump 1
2 790-330-1100 Wrench 1
790-302-1290 Socket (60 mm) 1 LE
790-102-1320 Socket (70 mm) 1 BL, BS, DS
3
790-102-1330 Socket (75 mm) 1 PT, AR
790-302-1340 Socket (80 mm) 1 RP
023502
790-201-1702 Push tool KIT 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1741 • Push tool 1 ST
4
790-201-1761 • Push tool 1 LE
790-201-1781 • Push tool 1 DS
790-201-1791 • Push tool 1 BL, BS, PT, AR
790-201-1811 • Push tool 1 RP
790-201-1500 Push tool KIT 1
A 790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1550 • Plate 1 ST
5
790-201-1570 • Plate 1 LE
790-201-1590 • Plate 1 DS
790-201-1610 • Plate 1 BL, BS, PT, AR
790-201-1620 • Plate 1 RP
6 790-702-1000 Expander 1
796-720-1630 Ring 1
ST
07281-00709 Clamp 1
796-720-1650 Ring 1
LE
07281-01019 Clamp 1
796-720-1650 Ring 1
7 BL, BS, DS
07281-01159 Clamp 1
796-720-1670 Ring 1
PT, AR
07281-01279 Clamp 1
796-720-1680 Ring 1
RP
07281-01589 Clamp 1
30-205-1
(6)
2. Cylinder head assembly • Blade shift cylinder
• Power tilt, Blade lift, Drawbar shift, Articulate, Using tool A2, loosen cylinder head assembly
Ripper cylinder (4) and disconnect from the cylinder.
1) Remove cylinder head bolt. a Do not loosen bolt (18) but disconnect plate
2) Disconnect cylinder head assembly (2) from (19), collar (20) and cylinder head (4) as an
the cylinder. assembly.
Width across flats of
Cylinder
mounting bolt
Blade lift, Drawbar shift 22 mm
Power tilt, Articulate 24 mm
Ripper 27 mm
023502
• Steering, leaning cylinder

1) Raise rotation stopper.
2) Using tool A2, disconnect cylinder head
assembly (4) from the cylinder.
30-205-2
(6)
3. Piston rod assembly 4. Piston and head assembly
Pull out piston rod assembly (5). 1) Set piston rod assembly (5) to tool A1.
a Put a container under the cylinder to catch 2) Using tool A3, remove nut (7).
the oil.
Width across flats of
Cylinder
mounting bolt
Steering 46 mm
Leaning 60 mm
Blade shift 70 mm
Blade lift 70 mm
Drawbar shift 70 mm
Articulate 75 mm
Power tilt 75 mm
Ripper 80 mm
3) Remove piston (8) and slider (9).

023502
inder only.
4) Remove cylinder head assembly (10).
30-205-3
(6)
5. Disassembly of piston assembly • Blade shift cylinder
Remove piston ring (11) and wear ring (12) from 1) Remove bolts (18) (width across flats: 13
piston (8). mm) to remove plate (19) and collar (20).
2) Remove ring (21) and dust seal (22) from
collar (20).
3) Remove O-ring, backup ring (13) and O-ring
(23).
4) Remove dust seal (15) and rod packing
(16).
6. Disassembly of head assembly

• Steering, Leaning, Blade lift, Drawbar shift,
Articulate, Power tilt, Ripper cylinder
1) Remove O-ring and backup ring (13).
2) Remove snap ring (14), then remove dust
seat (15).
3) Remove rod packing (16).
023502
30-205-4
(6)
ASSEMBLY OF HYDRAULIC 2) Using tool A5, assemble dust seal (15).
CYLINDER ASSEMBLY
a The symbols used in the illustrations indicate
the following cylinders.
Cylinder Cylinder symbol
Steering ST
Leaning LE
Blade shift BS
Blade lift BL
Drawbar shift DS
Articulate AR
Power tilt PT
Ripper RP
a Be careful not to damage the packings, dust

seals, and O-rings when assembling.
1. Assembly of head assembly

• Cylinders other than blade shift cylinder
1) Using tool A4, press fit bushing (17) to head
(10).
3) Install snap ring (14) to dust seal (15).
023502
4) Install rod packing (16), then install O-ring
and backup ring (13).
a Do not try to force the backup ring into
position. Warm it in warm water (50 –
60°C) before fitting it.
30-205-5
(6)
• Blade shift cylinder 2. Assembly of piston assembly
1) Using tool A4, press fit bushing (17) to head 1) Using tool A6, expand piston ring (11).
(10). a Set the piston ring on the expander and
2) Using tool A5, assemble dust seal (15). turn the handle 8 – 10 times to expand
a Take care of the installed direction of the the ring.
dust seal. 2) Remove piston ring (11) from tool A6, and
install to piston (8).
3) Using tool A7, retract piston ring (11).
3) Install rod packing (16), O-ring (23), O-ring

and backup ring (13).
a Take care of the installed direction of the 4) Install wear ring (12).
rod packing.
a Do not try to force the backup ring into
position. Warm it in warm water (50 –
60°C) before fitting it.
023502
4) Set dust seal (22) and ring (21) to collar (20)

and install them to head (10).
a Take care of the installed direction of the
dust seal.
5) Install plate (19) and tighten bolts (18).
30-205-6
(6)
3. Piston, head assembly
1) Set piston rod (5) to tool A1.
2) Assemble cylinder head (10) to piston rod.
3) Fit slider (9) and install piston assembly (8),
then using tool A3, tighten nut (7).
inder only.
a Wash and remove all grease and oil
from the thread of the piston rod where
the nylon nut is fitted.
2 Rod thread:
Thread tightener (Loctite #262)
3 Piston nut
Width across Nm
Cylinder 4. Piston rod assembly
flats of nut {kgm)
Steering 46 mm
785 ± 78.5 • Steering, blade shift, leaning cylinder.
{80 ± 8} 1) Set cylinder to tool A1.
1,770 ± 177 2) Assemble piston rod assembly (5) to cylin-
Leaning 60 mm
{180 ± 18}
2,600 ± 260 der.
Blade shift
{265 ± 26.5}
3,330 ± 333
Blade lift 70 mm
{340 ± 34}
2,600 ± 260
Drawbar shift {265 ± 26.5}
3,140 ± 314
Articulate
{320 ± 32}
75 mm
2,840 ± 284
Power tilt
{290 ± 29}
3,970 ± 397
Ripper 80 mm {405 ± 40.5}
023502
3) Using tool A2, install cylinder head (4).
3 Cylinder head
Cylinder Nm {kgm}
Steering 441 ± 44.1 {45 ± 4.5}
Blade shift 785 ± 78.5 {80 ± 8}
Leaning 677 ± 67.6 {69 ± 6.9}
4) Caulk rotation stopper to cylinder.

a Steering and leaning cylinder only.
30-205-7
(6)
• Power tilt, ripper, blade lift, drawbar shift, ar-
ticulate cylinder.
1) Set cylinder to tool A1.
2) Assemble piston rod assembly (5) to cylin-
der.
5. Remove cylinder assembly (1) from tool A.

023502
3) Assemble cylinder head (2) to cylinder, then

tighten with a torque wrench.
3 Cylinder head mounting bolt
Width across Nm
Cylinder flats {kgm}
Blade lift
177 ± 19.6
22 mm
{18 ± 2}
Drawbar shift
Power tilt
278 ± 32.3
24 mm {28.3 ± 3.3}
Articulate
385 ± 42.1
Ripper 27 mm {39.3 ± 4.3}
30-205-8
(6)
REMOVAL OF CIRCLE ROTATION GEAR AND
HYDRAULIC OIL MOTOR ASSEMBLY
Serial No.: 11001 - 12050
A Lower the work equipment to the grond.
Disconnect cable from negative (-) terminal of bat-

tery.
Loosen drain plug (1) and drain hydraulic oil.
:
I Hydraulic tank: 108 P
235FO2244
Remove hoses (2), (3), (41, (5), (6), and (7).
4. Remove mount bolt (8), and tap dowel pin (9) from
bottom to remove.
+ Dowel pin: 2 places
5. Using eyebolts (Thread dia. = 12 mm, Pitch = 1.75

mm), sling circle rotation gear and hydraulic motor
assembly (IO), and remove gear assembly (11).
* For details of disassembling the clutch portion of
gear assembly (II), see DISASSEMBLY OF
CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
ASSEMBLY.
Circle rotation gear, hydraulic motor assembly:

m 17 235CDO2107
6 kg
262 kg
1
6. Remove circle rotation gear and hydraulic motor as-

semf$y (IO).
235FO227t
30-206
0
INSTALLATION OF CIRCLE ROTATION GEAR AND
Serial No.: 11001 - 12050
1. Using eyebolts, raise circle rotation gear and hy-

draulic motor assembly (IO), then set on drawbar,
and install gear assembly (11).
f For details of assembly and adjustment of gear
assembly (II), see ASSEMBLY OF CIRCLE RO-
TATION GEAR, HYDRAULIC MOTOR ASSEMBLY.
2. Align dowel pin (9) with pin hole, and tighten mount / 7
bolt (8).
3. Connect hoses (2), (3), (4), (5), (6), and (7).
235COO2106
4. Tighten drain plug (1) and add hydraulic oil through

oil filler (12) to specified level.
Q Hydraulic tank: 108 li

system. Then check the oil level again.
235CDO2107
235FO2244
30-207
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
REMOVAL OF CIRCLE
ROTATION GEAR, HYDRAULIC
MOTOR ASSEMBLY
a Lower the work equipment completely to the

ground.
1. Remove cable from negative 4-J terminal of bat-

tery.
2. Loosen drain plug (I) and drain hydraulic oil.

A
& Hydraulic tank : 108 e
3. Remove hoses (2) and (3).
4. Remove mount bolts (4).
II k DWG00248
5. Using eyebolts (Thread = 20 mm, Pitch = 2.5 mm),

lift off circle rotation gear and hydraulic motor
assembly (5).
& kg Circle rotation gear, hydraulic motor as-

sembly : 345 kg
DWG00249
30-207-l
0
INSTALLATION OF CIRCLE
MOTOR ASSEMBLY
1. Using eyebolts, raise circle rotation gear and

hydraulic motor assembly (5) and install to draw-
bar.
DWG00249
w Mount bolts (4) :

549 + 59 Nm I56 t 6 kgm}
4
4
DWG00248
2. Connect hoses (2) and (3).
L
DWG00247
Tighten drain plug (I) and add oil through oil

filler (6) to specified level.
Hydraulic tank : 108 e
Connect negative (-1 terminal of battery.

* Run the engine to circulate the oil through
the system. Then check the oil level again.
30-207-2
0
DISASSEMBLY OF CIRCLE ROTATION GEAR AND
Serial No.: 11001 - 12050
1. Draining oil
1) Remove plug (I) and drain oil
_ : Circle rotation gear: Approx. 16 II
2) Remove plug (2) and drain oil
_ : Clutch: Approx. 180 mQ
2. Circle rotation gear - hydraulic oil motor assembly

Remove bolt (3) and dismount hydraulic oil motor as-
sembly (5) from circle rotation gear assembly (4).
I 9A 2 1 235FO2277
3. Key
Remove key (6) from hydraulic oil motor assembly
z
P2350 1483
z
4. Clutch
1) Remove cover (9A).
2) Loosen locknut (7) and remove bolt (8).
4) Remove washer (1 O), spring (1 I), piston (12) in

order.
30-208
0
4) Remove discs (13) and plates (14) in order.
* Disc: 6 PCS, plate: 5 PCS.
5. Reverse gear (with dry clutch)

1) Loosen bolt (18A). then remove cover (18C),
shim (18E), springs (18F), end plate (18G), plates
(18H), and discs (18J).
2) Loosen lock plate (18L) and bolt (18K), then
remove holder (18M), shims (18N), coupling
(18P), gear (18R), and collar (18T).
Ej
+ziiib
18H - 18J
F235014OI
6. Cover
Remove collar (2 1)
7. Housing
Remove housing (22) and shim (23).
$2350 I466
8. Worm wheel shaft assembly

1) Remove lock plate, then remove gear (25) from
shaft (24).
2) Remove shaft (24) and washer (26) from case.
9. Worm gear . Bearing assembly

1) Remove worm gear - bearing assembly from
case.
2) Remove bearing (28) from shaft (27).
P23503468
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
ASSEMBLY OF CIRCLE
ROTATION GEAR AND
HYDRAULIC OIL MOTOR
ASSEMBLY
Serial No.: 11001 - 12050
1. Worm gear . bearing assembly

1) Using press-fit tool ($1751, press fit bearing
(28) on shaft (27).
P2350 I468
2) Inset-t worm gear . bearing assembly (29)

into case.
P2350 9 469

1) Using push tool kit (o98), press fit bearing
(31) to case (30).
2) Using push tool kit (o115), press fit oil seal
(32).
& Oil seal lip: Grease (G2-LI)
& Outside circumference of oil seal:
Gasket sealant (LG-I)
3) Install gear (18) to shaft (17) and fix it with a
lock plate.
Sr Bend lock plate securely.
Ir Insert washer (26) at the upper and lower
DEG00023
ends of the shaft securely.
3. Housing
1) Attach shim (23) to housing (22) and install
it in case.
Sr Fix O-ring in housing.
* Adjust rotating torque with shim.
Ir Rotating torque:
4.9 to 15.7 Nm {0.5 to 1.6 kgm)
& O-ring groove: Grease (G2-LI)
P23501470
30-211
0
4. Reverse gear (with drv clutch)

1) Fit O-ring (18% to dollar (18T) and gear (18R),
then install to shaft (24).
& Rotating portion: Lubricant (LC-G)
6 O-ring groove: Grease (G2-LI)
2) Fit O-ring (180) to coupling (18P), then in-
stall to shaft (24).
6 Spline portion of shaft and coupling
(18P): Lubricant (LM-PI
3) Insert plates (18H) and discs (18L) between
gear (18R) and coupling (18P).
& Spline portion of gear (18R): DEG00024
Lubricant (LM-P)
4) Install shims (18N), holder (18M), and lock
plate (18L) to shaft with bolt (18K).
* Adjust so that clearance A of the shim is
1 mm.
5) Assemble end plate (18G) and springs (18F),
then install shims (18E) and collar (18C) with
bolt (18A).
.lUJ
F23501409
F235014
30-212
0
5. Cover i
$
Using push tool kit (o95), press fit bushing (33) i:
to cover (21), then install to case. Q
$
Ir Install an O-ring to the cover. 8
6 O-ring groove: Grease (G2-LI) $
i
6. Clutch
1) Press fit oil seal (34).
2) Insert plate (17) and snap ring (16) to hous-

ing (15).
t Install an O-ring to the housing.
3) Install discs (13) and plates (14) in turn.

+ Discs: 6 PCS.
* Plates: 5 pcs.
4) Install piston (12).

Ir Install an O-ring to the piston.
5) Install spring (II) and washer (IO).
6) Install cover (9).

7) Install bolt (8) and locknut (7), loosen l-1/4
turns after tightening, then lock with locknut.
* Adjust the load on the clutch as follows.
a) Loosen bolt (8) completely (with
spring (11) not compressed).
b) Tighten bolt (8) to compress spring
(II).
w Bolt:
56.9 2 4.9 Nm t5.8 + 0.5 kgml
c) Turn bolt (8) back l/6 turns, then z
tighten locknut (7).
F23501326
%
g
8) Remove every second mounting bolt (re-

move 3 bolts, one from each pair) of cover
(9), then install cover (9A), and tighten with
bolts that were removed.
7. Key
Install key (6) to hydraulic oil motor assembly
(5).
P2350 1483
30-214
0
8. Circle rotation gear, hydraulic oil motor assem-

bly
Align circle rotation gear assembly (4) and hy-
draulic oil motor assembly, then tighten with
bolts (3).

1) Tighten drain plug (1), then add gear oil to
the specified level.
5 Circle rotation gear case:

Approx. 16 ¬ (GO90)
2) Tighten drain plug (2), then add engine oil

to the specified level.
5 Clutch: Approx. 180 m¬ (EO30)

023502
30-214-1
(6)
DISASSEMBLY OF CIRCLE
MOTOR ASSEMBLY
1. Draining oil
I) Remove drain plug (I) and drain oil.
- : Upper case: Approx. 9.8 Q
2) Remove drain plug (2) and drain oil.
- : Lower case: Approx. 0.2 k? 2’ DWG00250
2. Hydraulic motor assembly

Remove 4 bolts (31, then remove motor 14).
Ir Be careful not to drop key (41) fitted to the
shaft of the motor.
3. Clutch
1) Remove 8 bolts (61, then remove cover (7).
2) Remove 3 bolts (8), then remove holder (9)
and shims (IO).
3) Remove collar (II), spring (12), and plate
(13).
4) Remove clutch discs (14) and plates (15) in
order, then remove washer (16).
Clutch disc (14) : 11
Clutch plate (15) : 10
30-214-2
0
4. Housing
Remove nut (171, then remove housing (18).
Ir Check the number and thickness of shims
(191, and keep in a safe place.
5. Worm wheel
Install eyebolts (Thread = 6 mm, Pitch = 1 mm) to
worm wheel (20), then remove worm wheel.
Ir The % mark in the diagram shows the eyebolt
hole.
-
-
OWC
Worm gear, bearing assembly

I) Remove worm gear and bearing assembly
from case (5).
2) Remove bearing (22) from worm shaft (21).
7. Pinion gear
1) Remove 8 bolts (231, then remove cover (24).
23
24
1 DWG00256
30-214-3
2) Extend lock plate (251, remove bolt (26), then

remove holder (27).
shims under the lock plate, and keep in
a safe place.
3) Remove 4 bolts (291, then remove housing
(30).
DWG00257
4) Pull out bushing (31) from housing (30).
I DWG00258
5) Remove collar (321, then remove pinion gear

(33) and washer (34).
Ir Be careful not to damage floating seal
(35).
8. Worm wheel shaft

1) Remove worm wheel shaft (36), then remove
washer (37).
2) Pull out bushing (38) from case (5).
33
32 DWGO
30-214-4
0
ASSEMBLY OF CIRCLE
MOTOR ASSEMBLY
1. Worm gear, bearing assembly

I) Press fit bearing (22) to worm gear (211, and
insert worm gear (21) to case (5).
2) Install housing (18) to case (5).

. Install an O-ring to the housing.
& O-ring : Grease (G2-LI)
. Insert the same thickness of shim (19)
that was removed during disassembly.
3) To apply preload to bearing, add suitable
thickness of shim (19) so that rotating torque
of worm gear (21) is 4.9 - 9.8 Nm iO.5 - 1.0
kgm1

I) Press fit bushing (38) in case (5).
2) Pass washer (37) over shaft (36), and insert
in case (5).
. Install so that the chamfered P portion
of washer (37) is at the top.
3. Pinion gear
I) Press fit bushing (31) to housing (30).
30-214-5
0
2) Adjust shim at pinion gear portion.

* With floating seal (35) removed, assem-
ble pinion gear portion completely, and
adjust clearance between washer (34)
and pinion gear (33).
i) Install washer (34) and pinion gear (33).
Sr Insert three 0.2 mm clearance gauges
between washer (34) and pinion gear
(33) from 3 directions, and install in
this condition. (In order to maintain
0.2 mm clearance)
ii) Install collar (321, insert shims (28), then is ‘25 DWG00261
install holder (26).

. Standard shim thickness: 2.5 mm
l Types (thickness) of shim (28):
235-70-15860: 1 .O mm
235-70-I 5870: 0.5 mm
235-70-15880: 0.2 mm
iii) Install housing (30).
iv) Adjust clearance between washer (34)
and pinion gear (33) with shim.
Clearance: 0.2 mm
VI After adjusting, remove all parts installed
in Steps i) - iii).
3) Using tool B, install floating seal (35) to case

(5), pinion gear (331, and housing (30).
* Remove all oil and grease from the O-
ring and the O-ring contact surface.
Ir There must be no dirt stuck to the mat-
ing surface (sliding surface) of the float-
ing seal.
DWG00262
30-214-6
0
4) Install washer (34) and pinion gear (33) to

shaft (36).
5) Install collar (321, insert shim (281, then in-
stall holder (26).
Ir Insert the thickness of shim adjusted in
Step 2) iv).
+ After tightening bolt (261, secure the bolt
with lock plate (25).
6) Install housing (30).
7) Install cover (24) to housing (30).
* Fit the O-ring in the O-ring groove of the
housing. I DWG00256
& O-ring : Grease (G2-LI)
33
32
28
30
29
is ‘25 DWG00261
4. Worm wheel
Fit eyebolt to worm wheel (201, and install to
shaft (36).
* Remove the housing of the worm gear. Mesh
it with the worm gear, then install the worm
gear housing again.
DWG00254
5. Clutch
1) Insert washer (16) in worm wheel, then in-
sert discs (14) and plates (15) in order.
Discs (14): 11
Plates (15): 10
2) Install plate (II), spring (12), and collar (13).
3) Insert shim (IO) on top end of shaft (36),
then install holder (9) with bolt (8).
6. Cover
Install cover (7) to case (5).
* Install the O-ring to the cover.
a O-ring : Grease (G2-LI)
30-214-7
0
7. Hydraulic motor assembly

install hydraulic motor (4).
Ir Install the key to the shaft of the hydraulic
motor.

I) Install drain plug (I).
2) Remove oil filler plug (39), add a small
amount of gear oil, and check that oil comes
out from drain plug (2).
3) Install drain plug (2).
4) Remove level plug (40), then add gear oil
until oil comes out from plug.
Case : Approx. 10 e
2’ DWG00250 1
30-214-8
0
REMOVAL OF BLADE ASSEMBLY
Serial No.: 11001 - 12050
A Start engine,
work equipment
operate the control
(approx. 200 mm).
lever to raise the
Set a block (approx. 780 mm) under the circle to sup-

port it securely.
1. Operate the control lever and extend blade side shift

cylinder piston rod (1) to pull out blade (2).
2. Loosen bolts (3) and (4), pull out pin (5) and remove
bracket (6).
3. Fully retract piston rod (1) and sling blade (2).

Raise blade (2) with a crane, slide the sling position
of the wire to the center of the blade, and dismount it.
kg
C!?J Blade assembly: approx. 1540 kg
INSTALLATION OF BLADE
ASSEMBLY
Serial No.: 11001 - 12050
z
% 1. Sling center of blade (2) and set to adjuster.
P2350 B43,
2
2. While sliding the wire, operate the control lever to
extend the cylinder piston rod (1) and push it in until
it reaches a position where it can be connected.
a=d Blade guide rail (upper, lower): Grease

(G2-LI)
3. Raise blade side shift cylinder with a crane, start

engine and operate the control lever to extend piston
rod (1).
4. Set cylinder rod to bracket (6) fix with pin (5) and
tighten bolts (3) and (4).
P2350 I437
5. Raise blade and pull out block from under the circle.
30-2 15
0
REMOVAL OF BLADE
ASSEMBLY
Serial No: 12051 and up
A Start the engine, operate the blade lift lever to

raise the blade approx. 200 mm from the ground,
then put a stand under the circle to support it
securely.
1. Operate blade side shift lever to extend blade

side shift cylinder piston rod (I) fully and push
out blade (2).
2. Remove 2 bolts (3), remove plate (4), then pull

out pin (5).
3. After retracting blade side shift cylinder rod (I)

fully, raise blade (21, and move position of wire
towards center while pushing blade out to re-
move.
+j kg Blade assembly : 1600 kg
INSTALLATION OF BLADE
ASSEMBLY
1. Raise center of blade (2), and set in position on

adjuster.
2. Move position of wire while extending blade
side shift cylinder rod (I) and push in to posi-
tion where it is possible to connect.
& Blade guide rail (top, bottom):
Grease (G2-LI)
3. Lift blade side shift cylinder rod (I), then start

engine and extend fully.
4. Position cylinder rod to bracket (61, secure with

pin (5), then tighten plate (4) and bolt (3).
5. Raise blade and remove support from under cir-

cle.
30-215-l
0
REMOVAL OF CIRCLE AND
DRAWBAR ASSEMBLY
1. Lower work equipment completely to the ground.
2. Remove drawbar shift cylinder (I) bottom cap (2)

and remove from drawbar (3).
3. Remove blade shift cylinder (4) head cap (5) and

remove from drawbar (3).
4. Sling circle and drawbar assembly (6). loosen nut (7)

and pull out cover (8) from bolt (9).
Remove circle and drawbar assembly from main
frame.
+ Check the number and thickness of shims (II),
and keep in a safe place.
Circle and drawbar assembly:

3,050 kg (Serial No.: 11001 - 12050)
3,600 kg (Serial No.: 12051 and up)
INSTALLATION OF CIRCLE
AND DRAWBAR ASSEMBLY
1. Sling circle and drawbar assembly, install drawbar

top ball joint (I 0) to main frame, fix with shim (1 I) -
235FO2279
and cover (81, and tighten nut (7).
* Install the same number of shims (11) as was
disassembled.
. Standard shim thickness: 2 mm (0.2t x IO)
It After assembling, if there is excessive play in the
drawbar, remove one shim (11) each to adjust.
Note: If too many shims are removed, the ball joint
will not move properly, and this will cause the
nut to come loose.
&‘& Ball joint: Anti-friction compound (LM-P)
2. Install blade lift cylinder (4) head cap (5) to drawbar

(3) with shim (I 2).
3. Install drawbar shift cylinder (1) bottom cap (2) to

drawbar (3) with shim (I 3).
30-216
0
DISASSEMBLY OF CIRCLE AND
DRAWBAR ASSEMBLY
Serial No.: 11001 - 12050
1. Ball joint
Loosen nut (1) and remove ball joint (2) and cover
(3) from drawbar top end.
P2350 I445
/,
Circle rotation gear and hydraulic oil motor

assembly
Remove circle rotation gear and hydraulic oil motor
assembly.
For details, see REMOVAL OF CIRCLE ROTATION
GEAR AND HYDRAULIC OIL MOTOR ASSEMBLY.
Circle guide
1) Loosen nut (6) and remove circle guides (5),
then separate drawbar and circle assembly.
5 5 5
235FO2281

Remove snap ring (7), washer (8) and pin (9), then
remove blade side shift cylinder (11) from R.H. ad-
juster (IO).
Blade side shift cylinder: 106 kg
P2350 t 448
30-217
0
I) Remove power tilt cylinder (12) head bolt (131,
lock plate (I 4) and pin (151, then remove it from
center bracket (16).
2) Remove power tilt cylinder (12) bottom bolt (I 7)
and cap (181, then remove it.
r+ Power tilt cylinder: 83 kg
6. L.H. adjuster
Loosen nuts (20), (21) and (221, and remove L.H.
adjuster.
& L.H. adjuster: 60 kg
7. Shaft
Loosen nut (23) and pull out shaft (24).
Shaft: 20 kg
& kg
8. Power tilt center bracket

Loosen bolt (25) and remove power tilt center brack-
et (26).
kg
CII?T?? Power tilt center bracket: 82 kg
9. R.H. adjuster
Loosen nuts (27) and (28), and remove R.H. adjuster
(29).
& kg R.H. adjuster: 69 kg

ASSEMBLY OF CIRCLE AND
DRAWBAR ASSEMBLY
Serial No.: 11001 - 12050
1. R.H. adjuster
Install R.H. adjuster (29) to circle (30) and tighten
nuts (27) and (28).
2. Power tilt center bracket

I) Install power tilt center bracket (26) to circle.
2) Insert shim (32) to cap (31) and tighten bolt (25).

$ ,, .b ‘I:
‘,{
3. Shaft
Insert shaft (24) to R.H. adjuster and center bracket
and fix with nut (23).
30-219
0
4. L.H. adjuster
Install adjuster (19) to circle and shaft and fix with
nuts (201, (21) and (22).

Install power tilt cylinder (12) bottom end with cap
(18) and tighten bolt (17).
Install power tilt cylinder head end to center bracket
(161, fix with pin (151, then tighten bolt (13) with
lock plate (14).
,, ,,‘, _,,
I ,, I’
Install blade side shift cylinder (1 1) to R.H. adjuster
and fix with pin (91, washer (8) and snap ring (7).
P2350 t 448
7. Circle rotation gear and hydraulic oil motor

assembly
Install circle rotation gear and hydraulic oil motor
assembly.
For details, see INSTALLATION OF CIRCLE ROTATION
GEAR AND HYDRAULIC OIL MOTOR ASSEMBLY.
8. Circle guide
I) Insert shim in circle guides (5), then tempo-
rarily assemble drawbar assembly and cir-
cle assembly with bolts (34A), (34B) and
(340.
* Length of bolts:
. 34A: 195 mm (x 4)
. 34B: 170 mm (x 12)
. 34C: 150 mm (x 2)
'35FO2282
2) Inspection clearance of circle guide.

Ir If there is no clearance between the cir- Front Center Rear
cle and root and tip of the teeth of the
pinion gear of the circle rotation gear
assembly, replace the guide to adjust.
a When raising the blade off the ground,

do not raise it higher than necessary.
i) Set with the blade raised off the ground.
ii) Measure clearance of portion P with
feeler gauge.
. Standard clearance of portion P:
235FO2283
1.5 f 0.5 mm
iii) Measure clearances of portion P, C and

R with feeler gauge.
. Standard clearance
F: 0 mm
C: 0.7 mm
R: 1.5 mm
orF=C=R=l mm
F is the clearance of the guide at the front.
C is the clearance of the guide at the center.
R is the clearance of the guide at the rear. A-A 0-B
* If the clearance at portion P and portion
F, C and R is not the standard clearance, DDG00026
carry out adjustment. J
DDG00027
30-221
0
3) Adjusting clearance of circle guide.
i) Raise blade so that drawbar and ground
are parallel, and so that dimension E at
tip of blade edge and ground surface is
approx. 90 mm.
E 235FO2287
ii) Loosen bolt (I), put circle guides (21, (31,

and (4) and portion F, C and R of circle
(5) in contact, and adjust shim (6) so
that clearance P between top surface of
circle and bottom surface of drawbar is
1.5 r 0.5 mm.
ii) Loosen locknut (7), tighten pusher bolt
(8) of rear circle guide (41, and move
whole of circle to rear.
* When not using circle guide pusher ‘4
bolt (8) to move the circle, use a le-
ver block to move it. DEG00028
iv) Move circle to rear, and set clearance L
between tip of teeth of pinion gear (9)
and root of teeth of circle (IO) to 0 mm.
When doing this, measure clearance H
between pinion gear (9) and circle (IO)
(take the measurement as a). Adjust so
that clearance H = a + 3.9 mm.
v) Loosen locknut (121, tighten pusher bolt
(13) of front circle guide (2), maintain
clearance H between pinion gear (9) and
circle (IO), and set clearance F between
circle guide (2) and circle (5) to 0 mm,
then tighten locknut (12).
L 9
3
If-
ii- 10
I ‘2 I 4 !-
A-A DOG000 30 H
235FO229
30-222
0
vi) Check that clearance L between tip of
teeth of pinion gear (9) and root of teeth
of circle (IO) is 3.86 mm.
vii) Check clearance H between pinion gear
(9) and circle (IO) again, loosen locknut
(14), then tighten pusher bolt (15) of
center circle guide (3), and set clearance
C between center circle guide (3) and
circle (5) to 0.7 mm, then tighten locknut
(14).
viii)Adiust with pusher bolt (8) so that clear- I 3
ante R between rear circle guide (4) and B-B DDG00031
circle (5) is 1.5 mm, then tighten locknuts

(7).
ix) Tighten bolt (I) and locknuts (71, (12) and
(14).
& Lubricated portion of circle guide:
Anti-friction compound (LM-PI
x) Check that rotation is possible at 90”
high-bank position to both left and right.
* If thickness Tl of wear plate (15) has
reached 2 mm, replace it with a new
part.
* If either thickness T2 or T3 of wear
plate (16) has reached 2 mm, replace
with a new part. DDG00032
9. Ball joint
I) Install ball joint (2) and cover (3) to drawbar
top end.
2) Tighten nut (I).
P2350t445
30-223
DISASSEMBLY AND ASSEMBLY CIRCLE, DRAWBAR
DISASSEMBLY OF CIRCLE,
DRAWBAR ASSEMBLY
1. Ball joint
Loosen bolt (I), and remove ball joint (2) and
cover (3).
2. Circle rotation gear, hydraulic motor assembly

Remove circle rotation gear and hydraulic mo-
tor assembly.
For details, see REMOVAL OF CIRCLE ROTA-
TION GEAR, HYDRAULIC MOTOR ASSEMBLY. DWG00265
3. Circle guide
Remove 16 bolts (8) and 2 bolts (8A), then re-
move circle guides (51, (61, (7) and (7A), and
disconnect drawbar and circle assembly.
5’ s ‘7 DWGOO266

Remove bolt (9), lock plate (IO), and pin (II),
then remove blade side shift cylinder (13) from
adjuster (12).
&I kg Blade side shift cylinder : 105 kg
DWG00267

1) Remove bolt (151, lock plate (16), and pin
(17) at head end of power tilt cylinder (14),
and disconnect from adjuster (12).
2) Remove bolt (18) at bottom end of cylinder,
remove cap (19), then remove cylinder.
el kg Power tilt cylinder : 83 kg
I DWC00266
30-223-l
I?\
6. Adjuster
I) Remove cotter pin (20) and nuts (21) and
26 15 23
(22).
DWG00169
2) Pull out shaft (241, then remove adjuster (12). //
Adjuster : 300 kg
30-223-2
0
ASSEMBLY OF CIRCLE,
DRAWBAR ASSEMBLY
1. Adjuster
1) Insert adjuster (12) in circle.
&I kg Adjuster : 300 kg
I DWGOO270
2) Insert washer (25) and shims (26) in clear-

ance between circle and adjuster, and adjust
clearance.
Clearance.(left, right): 0.5 - 1.0 mm each
* Insert washer (25) and shims (26) uni-
formly on left and right.
* Coat the contact surface of the shim and
the circle with LM-P.
Thickness of Washer: 3 mm
Thickness of Shim (2 types):
0.5 mm, 1.0 mm
3) Pass shaft (24) through, then install washer DWG00269
(231, nuts (21) and (221, and cotter pin (20).

1) Secure bottom end of power tilt cylinder (14)
with cap (19) and bolt (18).
& Power tilt cylinder : 83 kg

2) lni:all head end to adjuster with pin (17),
and secure with lock plate (16) and bolt (15).
I DWG00266
Blade side shift cylinder

Install bottom end of blade side shift cylinder
(13) to right side of adjuster (12) with pin (II),
then secure with lock plate (IO) and bolt (9).
& kg Blade side shift cylinder : 105 kg
Circle rotation gear, hydraulic motor assembly

Install circle rotation gear and hydraulic motor
assembly to drawbar.
For details, see INSTALLATION OF CIRCLE RO-
TATION GEAR, HYDRAULIC MOTOR ASSEMBLY. OWG00267
30-223-3
0
5. Circle guide
1) Set wear plate (28), put circle assembly on
drawbar, lay out shims (29), then temporar-
ily tighten guides (5), (6), (7) and (7A) with
bolts.
fl Lay out 2 wear plates (28) each.
fl Install wear plate (27) to each circle
guide.
• Standard shim thickness : 5.5 mm
• Bolt length
• (8) : 175 mm (16 bolts)
• (8A) for circle guide (7A): 155 mm (2
bolts)
6. Adjusting clearance of circle guide

1) Adjusting top and bottom clearances be-
tween circle and wear plate
i) Loosen all mounting bolts, expand each
023502
circle guide towards outside, then make

sideways clearance between wear plate
and circle 0 mm.
ii) Adjust thickness of shims (29) to adjust
clearance P in vertical direction of wear
plate (27) and circle.
fl Adjust for all circle guides.
fl Measure the clearance with the wear
plate pushed tightly against the cir-
cle guide.
• Clearance P: 1.5 ± 0.5 mm
2) Adjusting clearance from circle rotation gear
case
i) Loosen locknut (30) and pull in pushing
bolt (31). (For front, center, and rear cir-
cle guides)
ii) Loosen all mounting bolts, and move cir-
cle towards rear.
iii) Push front circle guide (5) to front with
pushing bolt (31) so that clearance H be-
tween circle (33) and circle rotation gear
case (32) is specified value.
• Clearance H: 20 – 21 mm
iv) Tighten bolt to hold front circle guide (5)
in position.
• Clearance F: 0 mm
30-223-4
(6)
3) Adjust clearance between circle and circle

guide (center, rear)
i) Set clearance F to 0 mm, then adjust
clearance C between circle and center
circle guide (6), and tighten bolt (8) to
hold in position.
Clearance C: 0.7 mm
3d 3i 29 28 27
B-B DWG00275
ii) Set clearance F to 0 mm, then adjust

clearance R between circle and rear cir-
8 (8A) 7(7A) 31 30
cle guides (7) and (7A), and tighten bolts
(8) and (8A) to hold in position.
Clearance R: 1.5 mm
2i
c-c DWG002:‘6 I
7. Ball joint
Install ball joint (2) and cover (3) to drawbar,
and tighten bolt (I).
w Bolt : 534.5 + 73.5 Nm I54.50 2 7.50 kgml
I bWG00265 1
30-223-5
0
REMOVAL OF REAR MOUNT RIPPER
ASSEMBLY
A Lower the work equipment completely to the ground.
1. Set stand @ (height: approx. 800 mm) under body

(I).
2. Raise shank (2) with a crane, pull out pin (3). then
remove shank (2).
3. Disconnect hoses (5) and (6) from cylinder (4).
4. Raise body (lj, pull out pin (71, then disconnect rod
(8).
5. Hold rod (9) with jack, pull out pin (IO), then discon-
nect link (1 I).
6. Lift off body.

Sr Rod (81, link (I I), and cylinder (4) are attached
to the body.
kg
CE?l Body: 1390 kg
7. Lift off bracket (12) with a crane.
& kg Bracket: 241 kg
8. Pull out pin (131, and remove rod (9).
30-224
0
INSTALLATION OF REAR MOUNT
RIPPER ASSEMBLY
1. Hold rod (9) with jack, and knock in pin (I 3).
2. Raise bracket (I 2) and install.
3. Raise body (1). align pin hole of bracket, link (1 1) and

rod (9). then knock in pin (I 0).
4. Align pin holes of rod (8) and bracket, then knock in

pin (7).
5. Set stand @ under body (11, raise shank (2) with a

crane, align pin holes, then knock in pin (3).
* If the center shank is installed upside down, it
will hit the work equipment cylinder and may
break, so be sure never to install it upside down.
6. Connect hoses (5) and (6) to cylinder (4).

system. Then check the oil level in the hydraulic
tank again.
P2350 I475
30225
METHOD FOR LIFTING UP ROPS
g When lifting the cab, the lock pin which sup-

ports the cab must be securely locked. In addi-
tion, be extremely careful not to let the cab tilt
at an angle during the lifting operation.
1. Remove mounting bolts (I) of ceiling of ROPS.
I 235CD02108
2. Remove floor mat, and loosen mounting bolts

(21, then remove plate (3).
’ 235COO210<
3. Loosen bolt (4), then remove left and right door

locks (5).
4. Loosen bolt (61, and remove cover (7). (Both left

and right)
Cover (7) on the left side of machines
equipped with an air conditioner is fresh air
filter (37), but remove this also.
DWG00224
5. Remove cab mounting bolts (8), (9), and (IO).
235CD02111 235COO2112
30-226
0
* When lifting up the cab, the operator’s seat and I
air conditioner stand are lifted at the same time,
so remove only the 15 mounting bolts of the
cab mount shown in the diagram.
1235FO2293
6. Disconnect connecting wiring CN79 (11) between

cab and floor.
* Push the wiring harness on the right side into
the box.
1235FO2294
7. Tilt steering post back one stage.
235FO2295
8. Install chain block (14) to ROPS and cab.

f When using a chain block, always use the tools
supplied with the machine.
30-227
0
9. Remove lock pin (13) installed to cab.
10. Wind up chain block and raise cab until ROPS and
hole of cab lock pin are aligned.
A Never go under the ROPS cab during the

lifting operation.
* Before lifting the cab, always check that all the
wiring and piping have been disconnected.
* Check that no parts hit or interfere with other
parts.
11. Secure ROPS and cab with lock pin (13).
INSTALLATION OF ROPS Floor surface for removing cab
l Carry out installation in the reverse order to removal.
A When lifting the cab, the lock pin which sup-

ports the cab must be securely locked. In addi-
tion, be extremely careful not to let the cab tilt
at an angle during the lifting operation.
A During the operation,

until the cab has been lowered
do not go under
fully to the floor.
the cab
30-228
0
DISASSEMBLY AND ASSEMBLY ROPS CAB
REMOVAL OF ROPS CAB

This shows the procedure for lifting up the op-
erator’s seat and air conditioner mount at the
same time in the same way as when lifting up
the cab.
When lifting up the cab only, see the section for
“Lifting up cab only”.
Cab vibration stopper

1) Loosen bolts (4), and disconnect brackets
(I), (2), and (3) from stopper (5). (Both left
and right)
2. Remove bolts (6), then remove ROPS roof (7).

u
* Eyebolts @ (Ml2 x 1.75) : 04530-l 1222
ROPS roof : 160 kg
30-229
0
DISASSEMBLY AND ASSEMBLY
ROPS CAB
3. Remove bolts (81, then remove bracket (9). (Both

left and right) m
4. Remove bolts (IO), then remove door lock (II).

(Both left and right)
5. Remove bolts (12), then remove cover (13). (Both

left and right)
Cover (13) on the left side of machines
equipped with an air conditioner is fresh air
filter (371, but remove this also.
DWG00225
I DWG00224
6. Remove floor mat, then remove bolts (14), and

remove plate (15).
7. Remove bolts (161, then remove plate (17).
DECO0037
8. Disconnect coupler (18) of air conditioner warm

water piping.
9. Remove cab mounting bolts (19), (201, (211, and

(221, and bolts (23). a
30-230
0
s-i-4 -
-XT+---
DEG00039
* Remove the bolts with the white paint on

the head.
Serial No.: 11001 - 11013: 16 bolts
11014 and up: 18 bolts
(part marked % added)
FWD+
DWG00234
10. Disconnect connecting wiring CN79 (24) between

cab and floor.
* Push the wiring harness on the right side
into the box.
DEG00042
11. Move steering post 1 stage back.
DEG00043
30-231
12. Disconnect connector (25) from hose, then re-

move hose from clamp (26).
DWG00235
13. Disconnect couplers (27) and (28) of freon pip-

ing of air conditioner.
14. Lift off cab.

+ Lifting positions: 4 places marked by arrows
Cab assembly : 600 kg
DECO0046
OEG00047
30-232
0
15. After lifting ROPS column, remove bolts (30),

then remove ROPS column (29). 1151
& kg ROPS column : 450 kg
DEG00046
INSTALLATION OF ROPS CAB

removal.
m
Adjusting cab vibration stopper
1) Front-to-rear direction
Mounting dimensions of stopper
Unit: mm
Free After setting Amount to push in
Ll 45 40 5
ROPS/FOPS roof Plate
i) Set mounting dimension Ll of stopper
(5) to 45 mm.
ii) Put brackets (1) and (3) in light contact
with stopper (51, then tighten bolts (4)
temporarily.
iii) Tighten adjustment bolt @ six turns, then
tighten bolts (4).
Adjustment bolt 0: 235-950-5440
iv) Remove adjustment bolt 0.
2) Left-to-right direction 3 ‘5 DWG00236

Mounting dimensions of stopper
Unit: mm
Free After setting Amount to push in ROFQ'FOPS roof plate
L2 47 42 5
i) Set mounting dimension L2 of stopper

(5) to 47 mm. Outside
ii) Put bracket (2) in light contact with stop- +

per (5), then tighten bolts (4) temporar-
ily.
iii) Tighten adjustment bolt @ three turns,
then tighten bolts (4).
Adjustment bolt 0: 01010-51075 DWG00237
iv) Remove adjustment bolt 0.
I
30-233
0
m
Installation of ROPS roof
m ROPS roof mounting bolt (6) :
277 f 32 Nm (28.25 f 3.25 kgm}
v, Rail guide
‘Adjust rail guide to front or rear so that rail
at rear of cab is at center of rail guide.
2) Roller
Adjust roller bracket to front or rear so that
clearance between roller and ROPS column DWG00238
is 4 + 1 mm.
Cab mounting bolt :

110.5 = 12.5 Nm (11.25 2 1.25 kgm}
Unit: mm
Length of
Bolt No. Bolt length
tube to use
19 30 -
20 60 -
Roller bra
21 I 465 I 400
22 365 300
23 25 -
m ROPS column mounting bolt (30) :

1715 + 195 Nm (175 + 20 kgm}
0
Tube
EL
i
o cabin
DWG00240
30-234
0
When lifting up cab only

Serial No.: 11001 - 11008
When not lifting up the operator’s seat and air con-
ditioner mount, the procedure for the following items
is different.
1. Removal
1) It is unnecessary to remove plates (15) and
(17) and mounting bolts (14) and (16) in Items
6 and 7.
2) It is unnecessary to disconnect coupler (18)
in Item 8. DWG00226
3) Remove front defroster duct.

a) Remove bolts (33) and (341, then remove
duct (35) and gasket (36).
b) Remove cap (37) and bolt (19) (white),
then remove duct (38).
* Duct (38) is tightened together with
the cab mounting bolts.
4) Remove cover (32) at rear of operator’s seat
mount.
5) There is a partial change in the bolts to be
removed in Item 9. m
See diagram on right. (Remove bolts with
8 red paint also.)
k? No. of bolts to remove: 18 I DEG00055
g 6) Push backrest of operator’s seat down to

front, then raise cab.
2. Installation
. 21 (White)
Carry out installation in the reverse order to
removal.
22IWhite)
116
w Cab mounting bolt : I
(Wh
110.5 2 12.5 Nm (11.25 = 1.25 kgm}
31 (Red)
Unit : mm
Length of
Bolt No. Bolt length 22 (White)
tube to use
19 30 - Ig(White) j[(White) DWG00241
20 60 -
21 465 400
22 365 300
31 270 200
Tube
b
1
To cabin
DWG00303
30-235
0
When lifting up cab only

Damper assembly
When not lifting up the operator’s seat and air con-
ditioner mount, the procedure for the following items
is different.
1. Removal
1) It is unnecessary to remove plates (15) and
(17) and mounting bolts (14) and (16) in Items
6 and 7.
2) It is unnecessary to disconnect coupler,(l8)
in Item 8.
3) Remove bolt (33) from left console box, then

remove cover (34).
4) Disconnect connector A6 (35).
5) Remove bolt (36), then remove fresh air fil-

ter (37).
6) Remove bolt (38), then remove damper as-
sembly (40) together with bracket (39).
7) Remove front defroster duct.

a) Remove cap (41) and bolts (42) and (43),
then remove duct (44) and gasket (45).
b) Remove cap (46) and bolt (19) (white),
then remove duct (47).
Ir Duct (47) is tightened together with
the cab mounting bolts.
c) Remove bolt (48), then remove duct (49).
8) Remove cover (32) at rear of operator’s seat

mount.
(Serial No. 11001 - 11013, only machines
equipped with air conditioner)
DEG00055
30-236
0
9) There is a partial change in the bolts to be

removed in Item 9. m
21 (White)
See diagram on right. (Remove bolts with
red paint also.)
. 22IWhitel
No. of bolts to remove: 18
IO) Push backrest of operator’s seat down to
front, then raise cab.
22fWhite)
jQ(Whlte) 20CWhite) DWG00241
2. Installation
removal.
a
w Cab mounting bolt :
110.5 + 12.5 Nm Ill.25 f 1.25 kgml
Unit: mm
Length of
Bolt No. Bolt length
tube to use I
19 I
I
30 I
To cabin
DWC00303
20 60 -
21 465 400
22 365 300
31 I 270 I 200
30-237
0
Serial No.: 11001 – 12502
k Lower the work equipment to the ground. 4. Remove right and left articulate cylinder assem-
k Stop the engine and move the each work blies (4). For details, see “Removal and installa-
equipment control lever to release the resid- tion of articulate cylinder assembly”.
ual pressure in the piping.
k Disconnect the cable from the negative (–)
terminal of the battery.
Disconnection
1. Remove the ROPS cab. For details, see “Re-
moval and installation of ROPS cab”.
2. Lift off floor assembly (1).
5. Disconnect 9 left-hand hoses (5).
023502
3. Remove engine mount brackets (2) and (3).
6. Disconnect grease hose (7) from lower center

pin (6).
30-238
(6)
7. Disconnect grease hose (9) from upper center
pin (8).
11. Remove bolts (14) and remove lock washers

(15) from the upper and lower center pin
nuts.
8. Disconnect 9 right-hand hoses (10). fl Secure plates (16) with bolts (14) tempo-
9. Disconnect wiring harness (11). rarily.
(Serial No. 12051 and up)
023502
10. Remove O-rings (12) and (13) from the upper

and lower center pins. 12. Remove upper center pin nut (17). 1
30-239
(5)
13. Remove upper center pin (8). 2 16. Remove upper and lower plates (16) from
fl Loosen the lower center pin nut. the rear frame.
fl Serial No. 12051 and up
14. Remove nut (18) of lower center pin (6) and

remove lower center pin (6). 3 17. When replacing bushings (21) and (22)
 When removing the nut, take care that the fitted to the rear frame, cut them with
center pin will not fall. gas. 4
023502
15. Sling front frame (19) and slowly pull out and 18. When replacing bushing (23) fitted to the
disconnect it from rear frame (20). front frame, cut it with gas. 5
fl Check that all the connections are discon-
nected.
 When disconnecting, take care of the bal-
ance of the front frame.
30-240
(5)
Connection 3. Install lock washers (15) to the upper and lower
• Carry out connection in the reverse order to dis- center pins and tighten the nuts.
connection. a Install plates (16) before tightening the nuts.
(Serial No. 12051 and up)
• Install the upper and lower center pins according
to the following procedure.
1. Insert upper and lower center pins (8) and (6) in
front frame (19) and rear frame (20) and then
tighten lower center pin nut (18) so that upper
and lower clearances "A" will be even.
2. After adjusting the clearance, tighten nut (17) of
upper center pin (8) to torque of 255 ± 9.8 Nm
{26 ± 1 kgm} and then loosen it and tighten
again to torque of 215 ± 9.8 Nm {22 ± 1 kgm}.
• Install bushings (21) and (22) by expansion fit.

023502
• Install bushing (23) by expansion fit.
30-241
(6)
• Bleeding air
Bleed air from the hydraulic cylinders. For
details, see “Precautions when carrying out
operation, 2. Precautions when carrying out
installation work”.
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
023502
30-242
(6)
k Lower the work equipment to the ground. 5. Disconnect left-hand hoses (5).
k Stop the engine and move the each work
equipment control lever to release the resid-
ual pressure in the piping.
k Disconnect the cable from the negative (–)
terminal of the battery.
Disconnection
1. Remove the ROPS cab. For details, see
“Removal and installation of ROPS cab”.
2. Lift off floor assembly (1).
6. Disconnect grease hose (7) from lower center

pin (6).
023502
3. Remove engine mount brackets (2) and (3).
7. Disconnect grease hose (9) from upper center

pin (8).
4. Remove right and left articulate cylinder assem-

blies (4). For details, see “Removal and installa-
tion of articulate cylinder assembly”.
30-243
(6)
8. Disconnect right-hand hoses (10).
11. Remove bolts and washer (14) and remove lock

9. Disconnect wiring harness (11). washers (15) from the upper and lower center
pin nuts.
a When removing, take care not to lose wash-
ers (16) between lock washers (15) and
frame.
023502
10. Remove O-rings (12) and (13) from the upper
and lower center pins.
30-244
(6)
12. Remove upper center pin nut (17). 15. Sling front frame (19) and slowly pull out and
disconnect it from rear frame (20).
a Check that all the connections are discon-
nected.
k When disconnecting, take care of the bal-
ance of the front frame.
13. Remove upper center pin (8).

a Loosen the lower center pin nut.
16. When replacing bushings (21) fitted to the rear

frame, cut them with gas.
023502
14. Remove nut (18) of lower center pin (6) and

remove lower center pin (6).
k When removing the nut, take care that the
center pin will not fall.
17. When replacing bushing (22) fitted to the front

frame, cut it with gas.
30-245
(6)
Connection 3. Install lock washers (15) to the nuts of the upper
• Carry out connection in the reverse order to dis- and lower center pins and tighten bolts and
connection. washers (14).
a Be sure to install washers (16) between lock
washers (15) and frame.
• Install the upper and lower center pins ac-
cording to the following procedure.
1. Insert upper and lower center pins (8) and (6) in
front frame (19) and rear frame (20) and then
tighten lower center pin nut (18) so that upper
and lower clearances "A" will be even.
a Install O-rings (23) to upper and lower center
pins (8) and (6).
2. After adjusting the clearance, tighten nut (17) of
upper center pin (8) to torque of 255 ± 9.8 Nm
{26 ± 1 kgm} and then loosen it and tighten
again to torque of 215 ± 9.8 Nm {22 ± 1 kgm}.
023502
• Install bushings (21) by expansion fit.
30-246
(6)
• Install bushing (22) by expansion fit.
• Bleeding air
Bleed air from the hydraulic cylinders. For
details, see “Precautions when carrying out
operation, 2. Precautions when carrying out
installation work”.
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
023502
system. Then, check the oil level again.
30-247
(6)
40 MAINTENANCE STANDARD
HYDROSHIFT transmission and transfer.. .... .40- 2

Transmission pump ........................................ 40- 4
Transmission control valve ............................ 40- 6
Transmission solenoid valve ......................... 40-10
Final drive ........................................................ 40-I 1
Differential lock-up pump ............................... 40-12
Tandem drive .................................................. 40-13
Front axle ......................................................... 40-14
Steering cylinder ............................................. 40-16
Disc brake ........................................................ 40-17
Parking brake ................................................... 40-18
Spring cylinder ................................................ 40-19
Hydraulic control valve.. ................................. 40-20
Hydraulic cylinder ........................................... 40-22
Hydraulic pump.. ............................................. 40-24
Drawbar and lifter ........................................... 40-26
Blade.. ............................................................... 40-28
Circle rotation gear ....................................... 40-29-I
Ripper ............................................................... 40-30
Frame ............................................................... 40-31
40- 1
0
023502
40-3-2
(6)
MAINTENANCE STANDARD TRANSMISSION PUMP

SAR (3)-080
023502
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

Clearance between gear
1 case and side plate gear 0.10 – 0.15 0.19
Clearance between plain Replace

2 bearing I.D. and gear shaft O.D. 0.06 – 0.149 0.20
0
3 Pin insertion depth 14 –0.5
Spline shaft rotating 6.9 – 11.8 Nm (0.7 – 1.2 kgm)
4 torque
Pump Delivery Standard Repair limit
Deliver speed pressure delivery of delivery
— Engine oil CLASS-CD (rpm) (MPa {kg/cm2}) (¬/min) (¬/min) —
45 – 55°C 20.6
2,500 {210} 184 169
40-5
2
(6)
LOWER VALVE
Serial No.: 11001 - 12012.12016-12018
40-8
0
Unit: mm
No. Checkitem Criteria Remedy
Tolerance
1 Clearance between F-R spooland body

I I I I I I
+0.013 0.035 -
22 -0.035 0.08
-0.045 0 0.058
-0.035 +0.013 0.035 -

2 Clearance betweenlstspooland body 22 0.08
-0.045 0 0.058
-0.035 +0.013 0.035 -

3 Clearance between 2ndspooland body 22 0.08
-0.045 0 0.058
Replace
-0.035 +0.013 0.035 -
4 Clearance between 3rd spooland body 22 0.08
-0.045 0 0.058
-0.035 +0.013 0.035 -

5 Clearancebetween4th spooland body 22 0.08
-0.045 0 0.058
-0.035 +0.013 0.035 -

6 Clearance between Lspooland body 22 0.08
-0.045 0 0.058
-0.035 +0.013 0.035 -

7 Clearance between H spool and body 22 0.08
-0.045 0 0.058
Standard size
Ist,2nd,3rd,4th speed
40-9
Serial No.: 12013 - 12015, 12019 and up
/ 5
/
9
4 9
9 2
IO
IO
11
13
12
8
SWG00398
40-9-l
0
Unit: mm
Stasn$rd ~ ,ha~‘er~Hole 1 ;‘,“,:b; Cle,;ar&xe
Clearance between F-R spool and body
I 22 -0.035
-0.045 +0.013
0 0.035
0.058
- 0.08 I
-
2
Clearance between 1st spool and body 22 -0.045
-0.035 0
+0.013 0.058
0.035 0.08 I
-
3 Clearance between 2nd spool and body 22 -0.035 f0.013 0.035 0.08
-0.045 0 0.058
Replace
-
4 Clearance between 3rd spool and body 22 -0.035 +0.013 0.035 0.08
-0.045 0 0.058
-
5
Clearance between 4th spool and body 22 -0.045
-0.035 0
+0.013 0.058
0.035 0.08 I
-
6
Clearance between L spool and body 22 -0.045
-0.035 0
f0.013 0.058
0.035 0.08 I
-
-
Clearance between H spool and body 22 -0.045
-0.035 0
+0.013 0.058
0.035 0.08 I
-
Clearance between pilot reducing -0.035 +0.013 0.035 -
a valve spool and body 25 -0.045 0 0.058 0.08
-
Standard size Repair limit
Spring for L., H., Free Installation Installation Free Installation

9
1st. 2nd. 3rd. 4th speed length length load length load
78 47 103 N 75.7 98.1 N

(10.5 kg) (1 o kg)
Replace
Spring for F-R spool 60.6 39 104 N 99 N
10
(10.6 kg) (10.1 kg)
-
Pilot reducing valve spring (outer) I 62 43.7 163.6 N 60.1 155.9 N
11
(I 6.7 kg) (15.9 kg)
5.7 N 5.4 N
12 Pilot reducing valve spring (inner) 26 19 25.2
I / (0.58 kg) (0.55 kg)
13 Thickness of pilot reducing valve 3 mm [Pressure per each shim: 0.03 MPa (0.26 kg/cm?)] Adjust
I
40-9-2
0
MAINTENANCE STANDARD TRANSMISSION SOLENOID VALVE

Serial No.: 11001 - 12012, 12016 - 12018
i-l l-h rl n l-l l-l/’

I
4th
1st
LOW
Hioh
3rd
F
R
40-10
0
MAINTENANCE STANDARD TRANSMISSION SOLENOID VALVE
Serial No.: 12013 - 12015, 12019 and up
4th
1st
LOW
A-A
SwG00400
40-10-l
0
FINAL DRIVE
235CDO2033
Unit: mm
1 Preload of bevel pinion bearing Starting torque: 9.8 - 12.7 Nm (I .O - 1.3 kgm)
2 Preload of shaft bearing Starting torque: 9.8 - 12.7 Nm (1.0 - 1.3 kgm)
Starting torque: (Starting torque of bevel pinion bearing) + 0.69 - 0.98 Nm

3 Preload of bevel gear bearing
(0.07 - 0.10 kam)(Measured of pinion shaft)
Tolerance Repair limit

4 Backlash between ring gear and gear Adjust
0.20 - 0.63 1.6
Backlash between bevel pinion and
5
bevel gear
0.25 - 0.33 1.3
6 Backlash between gear and gear 0.25 - 0.33 1.3
7 Backlash between gear and gear 0.17 - 0.44 1.4
40-l 1
MAINTENANCE STANDARD DIFFERENTIAL LOCK-UP PUMP
DIFFERENTIAL LOCK-UP PUMP

LAL12
- Unit: mm
I I
-
No Check item
I
Criteria
I Remedy

Clearance between gear
case and side plate, gear 0.05 - 0.10 0.15
Clearance between plain

0.06 - 0.119 0.20
bearing I.D. and qear shaft O.D. I I
Pin insertion depth -

I I
Spline shaft rotating
2.0 - 4.9 Nm (0.2 - 0.5 kgm}
torque
Pump Delivery Standard Repair limit
Delivery speed pressure delivery of delivery
(Engine oil CLASS-CD (rpm) (MPa {kg/cm% (Urnin) (Urnin) -
45 - 55°C) 17.2
3500 I1751 26 23
40-12
0
TANDEM DRIVE
023502
40-13
(6)
023502
40-15-1
(6)
023502
40-15-2
(6)
STEERING CYLINDER
F23501044
I I I I I
Clearance between piston rod and

bushing
40 -0.060 +0.132 0.036 - 0.6 Replace

-0.142 +0.006 0.274 bushing
Clearance between piston rod - 0.060 +0.010 0.050 -

2 support shaft and bushing 60 0.6
- 0.090 -0.010 0.100
-
-
3
Clearance between cylinder bottom
support shaft and bushing I 35
- 0.025
- 0.064
+0.039
0
0.025 -
a 103 0.6 -1
40-16
DISC BRAKE
F23501062
Unit: mm

Thickness of disc
3.8 i 0.1 3.3 2 0.1
2 Thickness of plate 2.3 i 0.1 -

I I I
3 Total thickness of discs and plates 51.1 f 1.7 47.1 i 1.7 Replace
Free Installation Installation Free Installation

4 Return spring
length length load length load
247.1 N
71 52 67 -
(25.2 kg)
40-17
PARKING BRAKE
Section A -A
F23501063A

Wear of brake pad Replace pad
16 8
2 Tightening torque of mounting bolt 441.3 - 539.4 Nm (45 - 55 kgm) Retighten
40-18
MAINTENANCE STANDARD SPRING CYLINDER
SPRING CYLINDER
277*31_9Nm
{28.25*3.25bml
SWG00413
Unit: mm
Standard size
Free length Installation load

1 Piston spring Replace
260 5001.4 N {510 kg}
Play of rod in axial

2 2.1
direction Adjust
3 Installed dimension of rod 132
40-19
0
MAINTENANCE STANDARD HYDRAULIC CONTROL VALVE

Serial No.: 11001 - 12022
L.H. VALVE
1.5Nm
0.15!+3
A-A
40-20
0
R.H. VALVE
(Right blade lift, Leaning, Articulate, Drawbar side shift and Service)
SWG00403
40-21
L.H. VALVE
F-F
00.3*9.8Nm 68.3*9.8Nm
'S*llaml S*lkPml
A-A. B-0 E-E
/
c-c. D-D
I SWG00404
40-21-l
0
R.H. VALVE
(Right blade lift, Leaning, Articulate, Drawbar side shift and Service)
88.3i9.8Nm
(9*lkpml
SWG00405
40-2 1-2
0
HYDRAULIC CYLINDER
Serial No.: 11001 - 12050
F23501109
Unit: mm
T
No Check item
l- Criteria Remedy
Clearance
limit
Blade lift 0.6
Blade side -0.100 +0.262 0.167 -

65 0.6
shift -0.174 +0.067 0.436
3learance between Drawbar -0.100 +0.163 0.106 -

60 0.6 Replace
liston rod and bushing shift +0.174 + 0.006 0.337
45 -0.080 +0.152 0.067 -

Leaning 0.6
-0.142 + 0.007 0.294
c
65 -0.100 + 0.262 0.167 -
Articulate 0.6
-0.174 +0.067 0.436
L
Power tilt 0.6
Ripper 0.6
- i
40-22
0
Unit: mm
Check item Criteria Remedy
Standard Tolerance Standard Clearance

size , ,ole clearance limit
-
Blade lift 100 -0.05 +O.l 0.05 1.0
-0.15 0 0.25
Blade side -0.030 +0.174 0.130 -
shift 55 -0.076 +O.lOO 0.250 1.0
Clearance
between
Drawbar -0.05 +O.l 0.05 -
piston rod shift 100 -0.15 0 0.25 1.0
support shaft
(ball joint) -
Learning 55 -0.030 +0.174 0.130 1.0
and bushing -0.076 +O.lOO 0.250
(rod end)
Replace
-
Blade lift 75 -0.100 +0.074 0.100 1.0
-0.174 0 0.248
Clearance Blade side -0.030 +0.174 0.130 -

shift 55 -0.076 +O.lOO 0.250 1.0
between
cylinder
bottom yoke
(Support,
-
support Learning 55 -0.030 +0.046 0.030 1.0
-0.076 0 0.122
shaft, sup-
port ball -
Articulate 65 -0.030 +0.174 0.130 1.0
joint) and -0.076 +O.lOO 0.250
bushing (rod -
end) Power tilt 85 -0.120 +0.087 0.120 1.0
-0.207 0 0.294
I Rippar
(if equipped) go
-0.120
-0.207
+0.207
+0.120
0.240 -
0.414
1.0
Blade lift 3.3 5 0.3 kNm 1340 e 34 kgm1 (Width across flats: 70 mm)
Blade side
shift 2.3 2 0.2 kNm 1230 2 23 kgm} (Width across flats: 70 mm)
Drawbar
shift 2.6 + 0.3 kNm (265 + 26.5 kgm1 (Width across flats: 70 mm)
Tightening
torque of Learning 912 2 91.2 Nm {93.0 + 9.3 kgm1 (Width across flats: 50 mm) Retighten
piston nut
Articulate 3.1 2 0.3 kNm {320 2 32 kgm} (Width across flats: 75 mm)
Power tilt 2.8 2 0.3 kNm (290 2 29 kgm1 (Width across flats: 75 mm)
Ripper
(if equipped) 4.0 + 0.4 kNm 1405.0 2 40.5 kgm) (Width across flats: 80 mm)
I
40-23
0
HYDRAULIC CYLINDER
F23501109
Unit: mm
NC Check item
T Criteria Remedy
Blade lift 65 -0.100 +0.262 0.167 - 0.6

-0.174 +0.067 0.436
Blade side
65 -0.100 +0.262 0.167 - 0.6
shift -0.174 +0.06? 0.436
Clearance between Drawbar -0.100 +0.163 0.106 -

1 60 0.6 Replace
3iston rod and bushing shift +0.174 +0.006 0.337
-
Leaning 50 -0.025 +0.152 0.032 0.6
-0.087 -l-o.007 0.239
Articulate 65 -0.100 +0.262 0.167 - 0.6

-0.174 l +0.067 0.436
Power tilt 65 -0.100 +0.262 0.167 - 0.6

-0.174 +0.067 0.436
-
Ripper 70 -0.100 +0.271 0.175 0.6
-0.174 +0.075 0.445
40-23- 1
0
Unit: mm
-
Nc3.
- T Check item
1 Standard
Criteria
Tolerance Standard Clearance

Remedy
size Shaft Hole clearance limit
Blade lift -
110 -0.05 +O.l 0.05 1.0
-0.15 0 0.25
Blade side -0.030 +0.174 0.130 -
Clearance shift 1.0
55 -0.076 +O.lOO 0.250
between
Drawbar -0.05 +O.l 0.05 -
piston rod 1.0
shift 110 -0.15 0 0.25
i support shaft
(ball joint) Learning -
55 -0.030 +0.174 0.130 1.0
and bushing -0.076 +O.lOO 0.250
(rod end)
Articulate 65 -0.030 -
+0.174 0.130 1.0
-0.076 +O.lOO 0.250
hl
0
Fi
0 - ~~ Replace
Clearance Blade side -0.030 +0.174 0.130 -

shift 55 -0.076 +O.lOO 0.250 1.0
between
cylinder Drawbar -0.05 +O.l 0.05 -
shift 110 -0.15 0 0.25 1.0
bottom yoke
(Support,
3 support
shaft, sup-
port ball
joint) and
bushing (rod
end)
Ripper -0.120 +0.207 0.240 -

(if equipped) go -0.207 +0.120 0.414 1.0
Blade lift 3.3 + 0.3 kNm (340 + 34 kgm1 (Width across flats: 70 mm)
4
Tightening
torque of
piston nut
)l 2.3 2 0.2 kNm
2.6 + 0.3 kNm
1.8 2 0.2 kNm

(230 2 23 kgm}
(265 2 26.5 kgm)
I180 2 18 kgm}
(Width
(Width
(Width
across
across
across
flats:
flats:
flats:
70 mm)
70 mm)
60 mm)
Ret,ghten
Articulate 3.1 k 0.3 kNm {320 2 32 kgm} (Width across flats: 75 mm)
Power tilt 2.8 2 0.3 kNm (290 2 29 kgm} (Width across flats: 75 mm)
Ripper
(if equipped) 4.0 2 0.4 kNm 1405.0 + 40.5 kgm} (Width across flats: 80 mm)
40-23-2
0
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
FOR WORK EQUIPMENT
VXD70-1 F
-
98* 9.8Nm I
(lO*lbml amI
I
SWG00406
40-24
0
MAINTENANCE STANDARD DRAWBAR AND LIFTER
DRAWBAR AND LIFTER

Serial No.: 11001 - 12050
\
m 981+49Nm
~100~5koml
SDG00029
Unit: mm
Standard Tolerance Standard Clearance If it is impos-

size Shaft Hole clearance limit sible to adjust
, Wear of ball joint at
with shims,
drawbar tip
180 -0.05 +O.l 0.5 - 0.9 - reolace ioint
-0.15 0 or’ball joint
Clearance -
2 between yoke 110 4.035 +0.207 0.120 0.6
and bushing +0.120 0.242 Replace
Clearance between and - bushing
3 bushing 75 -0.100 +0.074 0.100 0.5
yoke at blade lift cylinder bottom -0.146 0 0.220
40-26
0
A-A 0-B
\ \ \
m 981*49Nm
(100*5bml
m 981*49Nm
~100*5kPml
F-F G-G SOG00030
Unit: mm
Standard clearance Clearance limit f it is impos-

jible to adjust
4 Clearance between circle with shims,
and drawbar 1.5 1.0 - 2.0 replace circle
guide
5 Clearance of yoke in axial Replace

0.3 - 0.8 1.7
direction bushing

6 Thickness of wear plate
6 2 Replace wear
plate
7 Thickness of wear plate 8 2
If it is impos-
sible to adjust
8 Wear of lifter bracket Standard shim thickness: 2 with shims,
replace lifter
bracket
9 End play of ball joint 0.7 -c 0.2 Replace
40-27
0
Standard Tolerance Standard Cl~;~i;ce If it is impos-

, Wear of ball joint at size Shaft Hole clearance sible to adjust
drawbar tip with shims,
180 -0.05 +O.l replace joint
-0.15 0.5-0.9 -
0 or ball joint
2 Clearance between yoke +0.207 0.120 -
and bushing 110 0.6
4.035 +0.120 0.242 Replace
Clearancebetween bushingand -0.100 +0.074 bushing
75 0.100 -
3 yoke at bladelift
cylinder
bottom -0.146 0.5
0 0.220
40-27-l
0
7
981*49Nm
G-G ~100~5koml
F-F f SWG00408
Unit: mm
-
Nt3. Check item Criteria Remedy

-
Standard clearance Clearance limit If it is impos-
sible to adjust
Clearance between circle with shims,
4
and drawbar 1.5 1.0 - 2.0 replace circle
guide
Clearance of yoke in axial Replace

5 0.3 - 0.8 1.7
direction bushing
-
6 Thickness of wear plate
7 2 Replace wear
I I plate
7 Thickness of wear plate 8 2

I
-
If it is impos-
sible to adjust
8 Wear of lifter bracket Standard shim thickness: 2 with shims,
replace lifter
bracket
9 End play of ball joint 0.7 + 0.2 Replace

I
40-27-2
0
MAINTENANCE STANDARD BLADE
BLADE
Serial No.: 11001 - 12050
SDG00031
Unit: mm
Wear of cutting edge I Less than 10 mm from blade holder
Side face 25
Wear of side edge Repair limit: Replace
Within 10 mm from blade holder
Height 85
Wear of blade rail Repair limit:
Thickness 35

I Replace as
Wear of blade rail guide 9 6 soon as one
value
reaches limit
9 5
40-28
0
MAINTENANCE STANDARD BLADE
Xl
------;~5------.
!it SWG00409
Unit: mm
Check item Criteria Remedy
1 Wear of cutting edge I Less than 10 mm from blade holder I
Repair limit: Side face 25

2 Wear of side edge Within IO mm from blade holder Replace
Height 85
3 Wear of blade rail Repair limit:
Thickness 35
4 Wear of blade rail guide 11 !gii :it
40-29
0
CIRCLE ROTATION GEAR
Serial No.: 11001 - 12050
‘.
\
“-
\7
L.3 F235014’12
Unit: mm
Clearance between worm wheel

1
shaft and bushing
90 -0.036 +0.144 0.088 - 0.215 0.4

-0.071 +0.052
Replace
Clearance between worm wheel -0.036 +0.223
2 shaft and bushing 90 -0.071 +0.065 0.101 - 0.294 0.4

Backlash between worm
3
and worm wheel
0.3 - 0.5 2.0
Clearance between worm wheel _

4 1.o Adjust
shaft and wear plate

5 Wear of pinion gear
6 Thickness of disc 2.8 ‘O0.1 2.4 I

I I
7 Thickness of plate 2.0 f 0.07 _ Replace

I I
8 Thickness of disc 3.6 k 0.1 2.6 I
I I
9 Thickness of plate 1.7 f 0.05 1.5

I I
10 Total thickness of disc and plate 97.1 95.4
I I
Starting torque: 4.9 - 9.8 Nm (0.5 - 1.0 kgm)
11 Preload of worm shaft bearing Adjust
(when worm wheel is not meshed)
40-29- 1
0
MAINTENANCE STANDARD CIRCLE ROTATION GEAR
swcoo4 I I
Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
1 Clearance between worm
wheel shaft and bushing
-0.036 +0.207 0.156 -
90 0.4
-0.090 +0.120 0.297
Clearance between pinion gear -0.036 +0.207 0.156 - Replace
2 bottom collar and bushing 100 -0.090 +0.120 0.297 0.4

Backlash between worm
and worm wheel 0.3 - 0.5 2.0
Clearance between blade

0.2 - Adjust
and worm wheel shaft
5 Wear of pinion gear

34 28
Replace
6 Thickness of disc 3.2 + 0.08 1.8
7 Thickness of plate I 2.0 2 0.05 I - I

-
Preload of worm shaft bear- Starting torque: 4.9 - 9.8 Nm {0.5 - 1.0 kgm}
8 Adjust
ing (when worm wheel is not meshed)
40-29-2
0
RIPPER
Section A-A
Section E-E
sectionc-c Section D-D

Section F-F
F23501124
Unit: mm
Tolerance
Standard Standard Clearance
Clearance between pin and size clearance limit
1 Shaft Hole Replace
bushing
- 0.025 +0.174
60 0.125 - 0.229 0.5
-0.055 +0.100

2 Wear of point Replace
320 170
40-30
0
FRAME
023502
Unit: mm

1 Outside diameter of center pin Replace
–0.036
118 –0.090 116.910
1. Adjust nut at bottom pin end when tightening so that clearance A

and B are uniform.
2 Tightening torque of nut
2. After tightening nut at top pin end to 255 ± 10 Nm {26 ± 1 kgm},
Tighten
loosen once, then tighten again to 235 ± 30 Nm {22 ± 1 kgm}.
40-31
(6)
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

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SEBM002308

GD825A-2 11001 and up

• GD825A-2 mount the S6D140-1 and S6D140E-2 engine.

The affected pages are indicated by the use of the

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time of Time of Time of Time of Time of

‡ 00- 1 (8) 00-24 (7) 10- 1 (2) 10-26 10-34 (2)

Time of Time of Time of Time of Time of

10-60 10-85 10-115 (2) 10-146-9 (6) 20- 4 (3)

Time of Time of Time of Time of Time of

20-56 (2) 20-60-74 (7) 20-67 20-105-1 (4) 20-175 (4)

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

30-169 (1) 30-199 (1) 30-220 (1) 40- 5 (6)

30-186 (2) 30-207-1 (2) 30-232 (2) 40-17

1. General precautions 7) If welding repairs are needed, always

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

4. Repair limit and allowable value or allow-

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

5. Points to remember when troubleshooting

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the

4. Do not let any dirt or dust get in during

Disconnect connector (1) according to the fol-

Disconnect connector (3) according to the fol-

q 107, 114 engines

3) While pressing lock (D), pull out connector

a If the lock is on the underside, use

2) Connect the connector according to the

Indicates size of wire by nominal No.

Indicates type of wire by symbol.

1. Type, symbol, and material

Nominal No. 8 15 20 30 40 50 60 85 100

“f” of nominal No. denotes flexible”.

4. Types of circuits and color codes

1. Precautions when carrying out removal work

2) Split flange type hoses and tubes

3. Precautions when completing the operation

1. Table of tightening torques for bolts and nuts