d275 PDF

SEBM000207
Shop
Manual
BULLDOZER
SERIAL NUMBERS
D275A-2 - 10001 andup
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
November 2000 Copyright 2000 Komatsu

DataKom Publishing Corporation
CONTENTS
No. of page
01 GENERAL ,............,,.....,.........,,,.................................~........... 01-l
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-I
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-l
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . ..*........................... 40-l
00-2
0
The affected pages are indicated by the use of the
following marks. Itis requested that necessary actions
Mark Indication Action required
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Pages having no marks are not revised atthistime.
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D275A-2 00-2-3
0
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-) terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and
maintenance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling
each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@...J is recorded on the bottom of the
Chassis volume: issued for every machine model pages.
Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
volume to cover all REVISIONS
Attachments volume:
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach- SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
2. Following examples
page number.
show how to read the
Example 1 (Chassis volume):

a Safety necessary
the work.
when performing
Special technical precautions

10 -3 or other precautions for pre-
Caution serving standards are neces-
*
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Example 2 (Engine volume):

el kg Weight lecting hoisting wire, or when
working posture is important,
etc.
Places that require special at-

‘ighteninc
Unit number (I. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Xl, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the Places where oil or water
page number. File as in the example. Drain must be drained, and quan-
Example: tity to be drained.
IO-4 12-203
10-4-I -
k Added pages -c~f~~~~~~
1O-4-2
IO-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
A Heavy parts (25 kg or more) must be
lifted with a hoist, etc. In the DISAS-
cause the rope to slip off the hook during
hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

(Standard “Z” or “S” twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN (2000 kg) of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 (1000 kg) when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two
ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg) if they sling
30 98.1 10.0
a 19.6 kN (2000 kg) load at a lifting angle
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
* The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
2) Sling wire ropes from the middle portion

30 60 90 120 150
of the hook. Lifting anele tdeoree) SAD00460
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

* There are 2 types of push-pull type coupler. The method of disassembling and connecting is differ-
ent, so see the table below when disassembling and connecting the coupler.
Twe 1 Type 2
1) Hold the mouthpiece of the tightening por- 1) Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (I) contacts contact sur- ing prevention ring (I) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end. end.
2) Hold in the condition in Step I), and push 2) Hold in the condition in Step I), and turn
until cover (3) contacts contact surface a of lever (4) to the right (clockwise).
the hexagonal portion at the male end.
-r
2
$ 4
%
.E
0
CWPO6393 CWPO6394
3) Hold in the condition in Steps 1) and 21, and 3) Hold in the condition in Steps I) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
CWPO6395 CWPO6396
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Tvw 1 Type 2
l Hold the mouthpiece of the tightening por- l Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (I) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end to connect it. end to connect it.
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
t The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
* For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’w Container Main applications, features
. Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
. Used in places requiring an immediately

effective, strong adhesive. Used for plas-
Polyethylene e
LT-1 B 790-129-9050 20 g tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
. Features: Resistance to heat and chemi-

Polyethylene 2 cals
LT-2 09940-00030 50 g .
container Used for anti-loosening and sealant pur-
pose for bolts and plugs.
.
790-129-9060 rd hesive: Used as adhesive or sealant for metal, glass
(Set of adhe- 1 kg and plastic.
LT-3 sive and ardeninc Can
hardening agent:
agent) 500 g
Adhesives
Polyethylen e- Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
. Used as heat-resisting sealant for repair-
Holtz
790-126-9120 75 g Tube
MH 705 ing engine.
. Quick hardening type adhesive

Three bond Polyethylene e l
Cure time: within 5 sec. to 3 min.
790-I 29-9140 50 g . Used mainly for adhesion of metals, rub-
1735 container
bers, plastics and woods.
. Quick hardening type adhesive

Quick cure type (max. strength after 30 min-
Aron-alpha Polyethylen e l
790-129-9130 29 utes)
201 container
. Used mainly for adhesion of rubbers, plas-
tics and metals.
. Features: Resistance to heat, chemicals

Loctite Polyethylerr e .
79A-129-91 IO 50 cc Used at joint portions subject to high tem-
648-50 container
peratures.
. Used as adhesive or sealant for gaskets

LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
. Used as sealant for various threads, pipe

Polyethylens e joints, flanges.
LG-5 790-129-9080 1 kg . Used as sealant for tapered
container plugs, elbows,
Gasket nipples of hydraulic piping.
sealant
Features: Silicon based, resistance to heat,
cold
LG-6 790-129-9020 250 g Tube Used as sealant for flange surface, tread.
Used as sealant for oil pan, final drive case,
etc.
00-l0
FOREWORD COATING MATERIALS
Category 1 Komatsu code 1 Part No. Q’ty Container Main applications, features
1 I I
I I I
l Features: Silicon based, quick hardening
type
LG-7 790-I 29-9070 150 g Tube l Used as sealant for flywheel housing, in-
Gasket take manifold, oil an, thermostat housing,
sealant etc.
Three bond l Used as heat-resisting sealant for repairing

790-129-9090 100 g Tube engine.
1211
I I I
l Used as lubricant for sliding portion (to pre-

LM-G 09940-00051 50 g Can
Molybde- vent from squeaking).
I
num
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
SYG2-4OOLI l General purpose type

SYG2-35OLI
G2-LI SYG2-4OOLI-A Various Various
SYG2-16OLI
SYGA-IGOCNLI
l Used for normal temperature, light load

SYG2-400CA bearing at places in contact with water or
Grease SYG2-350CA steam.
GP-CA SYGP-4OOCA-A Various Various
SYG2-16OCA
SYGA-15OCNCA
l Used for places with heavy load

Belows type
00-l1
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

* In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width

of bolt across flats
mm mm Nm bm
f? 10 13.2+ 1.4 1.35~0.15
8 13 3153 3.2+ 0.3
10 17 66r7 6.7kO.7
12 19 113*10 11.5il
14 22 177219 1822
16 24 279230 28.5* 3
18 27 382+39 3924
20 30 549+59 5626
22 32 745+83 76~8.5
24 36 927*103 94.5* 10.5
27 41 1320~140 135215
30 46 1720~190 175220
33 50 2210~240 225k25
36 55 275Ok290 280230
39 60 32901t340 335235
,
Thread diameter Width
of bolt across flats
mm mm Nm km
6 10 7.852 1.95 0.8kO.2
8 13 18.62 4.9 1.9kO.5
IO 14 40.225.9 4.1 20.6
12 27 82.3527.85 8.42 0.8
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Sr In the case of flared nuts for which there is no special
instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter Width across flat T Tightenin! j torque
mm mm Nm U-n
14 19 24.5 2 4.9 2.5 2 0.5
18 24 49* 19.6 522
22 27 78.5~ 19.6 822
24 32 137.3 * 29.4 1423
30 36 176.5 + 29.4 1823
33 41 196.12 49 2055
36 46 245.2 z 49 2525
42 55 294.2 2 49 3025
00-l 2
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

+ In the case of split flange bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 65.7r 6.8 6.72 0.7
12 17 11229.8 11.551
16 22 279229 28.5+3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

* Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kom
02 14 34.3* 4.9 3.5+ 0.5
03,04 20 Varies depending on 93.1k9.8 9.5*1
05,06 24 type of connector. 142.12 19.6 14.522
10, 12 33 421.4258.8 4326
14 42 877.1k132.3 89.52 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

* Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat

-r Tighteni I torque
Nominal No.
mm mm Nm kgm
08 8 14 7.352 1.47 0.75kO.15
10 10 17 II.272 1.47 1.15~0.15
12 12 19 17.64k1.96 1.8r0.2
14 14 22 22.54k1.96 2.32 0.2
16 16 24 29.4k4.9 3r0.5
18 18 27 39.2* 4.9 420.5
20 20 30 492 4.9 5%0.5
24 24 32 68.62 9.8 721
30 30 32 107.8k14.7 llT1.5
33 33 - 127.42 19.6 1322
36 36 36 151.9524.5 15.52 2.5
42 42 - 210.7229.4 21.5*3
52 52 - 323.4~ 44.1 33k 4.5
:
00-l 3
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque

mm Nm kgm
6 IO +2 1.02 _'0.20
8 24 k 4 2.45 ST0.41
10 43 + 6 4.38 2 0.61
12 77 f 12 7.85 f 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

mm Nm kgm
6 822 0.81 + 0.20
8 10 22 1.02 + 0.20
IO 12 k2 1.22 + 0.20
12 24 2 4 2.45 + 0.41
14 36 2 5 3.67 -'0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.

inch Nm kgm
I/ 16 321 0.31 r 0.10
118 822 0.81 f 0.20
II4 12 i2 1.22 + 0.20
318 15 k2 1.53 + 0.41
l/2 24 2 4 2.45 r 0.41
314 36 k 5 3.67 2 0.51
1 60 2 9 6.12 +-0.92
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Curre&rating
N;tyaf;sof Dia. $$tr$nds Crosm$tion Applicable circuit
Ca17kZjD.
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Ground Starting Lighting 1 Instrument / Signal ( Other
Rri_ Code W B B R Y G L
1
mary Color White Black Black Red Yellow Green Blue
Code WR - BW RW YR GW LW
2
Color White & Red - Black &White Red & White Yellow & Red Green & White Blue & White
Code WB - BY RB YB GR LR
3
Color White & Black - Black & Yellow Red & Black Yellow & Black Green & Red Blue & Red
Ami- Code WL - BR RY YG GY LY
4
liary _
Color White & Blue - Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
RG YL GB LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL YW GL -
Red & Blue Yellow &White Green & Blue -
00-l5
FOREWORD CONVERSION TABLE
CONVERSION TABLE
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.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @I, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by IO (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches 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 i 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 . . . .. . .. . . . 12.1651
. . . . . . .. . . .. . .2.126 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-l6
FOREWORD CONVERSIONTABLE
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 b.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
00-17
Liter to U.S.Gallon
le = 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
Liter to U.K. Gallon

le = 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 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
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 l439.b
00-19
kg/cm* to lb/in*
Ikg/cm2 = 14.2233lb/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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 !646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 ,916 2930 2944 2958 2973
210 ,987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ;a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the centeror boldface column of figures.
These figuresrefertothetemperature in eitherFahrenheitor Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.w
“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 81 117.8

-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 46 118.4 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 -6 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 66 154.4 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 IO 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with lnternatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { 1.
Example:
N {kg}
Nm {kgm}
MPa (kg/cm21
kPa ImmHzOI
kPa {mmHg)
kw/rpm IHP/rpmI
glkwh @/I-W-i1
00-22
01 GENERAL
General assembly drawing ............... Ol- 2

Specifications .......................... 01- 3
Weight table ........................... Ol- 8
List of lubricant and water ............... 01-10
D275A-2 01-l
GENERAL ASSEMBLY DRAWING
SEMI U-DOZER WITH VARIABLE MULTIPLE RIPPER
17MF02001
01-2 D275A-2
SPECIFICATIONS
Machine model D275A-2
Serial numbers 10001 - 10167 10168 and up
Operating weight
l Bare tractor 37200
l With semi U-dozer 44180
l Semi U-dozer with variable multiple ripper kg 48830
l Semi U-dozer with variable multiple ripper 50000
+ with ROPS cab assembly
Minimum turning radius m 3.9

Grade ability degree 30
Stabilitiy (Front, rear, left, right) degree 35
7 1st 0- 3.8
$ 2nd km/h 0- 6.7
2 3rd O-11.8
$ 1st 0- 4.9
& km/h
2 2nd 0- 8.7
cT 3rd 0 - 14.9
Bare tractor 8.63 IO.881

With Semi U-dozer 10.29 (1.05)
Semi U-dozer with variable multiple ripper kPa
11.37 11.16)
Semi U-dozer with variable multiple ripper (kg/cm*} 11.67 {1.19}
+ with ROPS cab assembly
Bare tractor 5445

With Semi U-dozer mm 7085
Semi U-dozer with variable multiple ripper 9055
Bare tractor 2935

mm
Wtih Semi U-dozer 4300
To top of exhaust pipe 3875

mm
Except exhaust pipe, operatior’s seat 2880
Track gauge 2260

Length of track on ground mm 3450
Show width 610
Minimum ground clearance mm 507
01-3
@
Engine model S6D170-1 S6D170-2
4-cycle, water-cooled, $-cycle, water-cooled,

Type in-line vertical, direct
in-line vertical, direct
injection type with injection type with
turbocharger
turbocharger
mm 6-170x170 6-170x170
No. of cylinders-bore x stroke
Piston displacement cc 23150 23150
kW/rpm 302/I ,800 (41 O/l ,800)

Flywheel horsepower 302/l ,800 141 O/l ,800)
:HP/rpmI
Nm/rpm 2,079/l ,300 (2 12/l ,300)
Max. torque 2,079/l ,300 (2 12/l ,300)
cgmlrpm
High idling speed rpm 2,000 2,000
Low idling speed rpm 630 630
g/kWh
Min. fuel consumption ration 214 {I581 224 {I651
{glpshl
Starting motor 24V, 7.5kw x 2

Alternator 24V, 50A
Battery 12V, 170Ah x 2
ZG
Radiator core D type
2
Torque converter 3-element, l-stage, single phase (with lock-up clutch) ;;
Planetan/ gear, multiple disc clutch, hydraulically

Transmission actuated, force-feed lubrication pump, forward
B-speed, reverse 3-speed
Bevel gear Spiral bevel gear, splash type lubrication

Wet type, multiple clutch disc, spring boosted,
Steering clutch hydraulically actuated (manual type), interconnected
with brake
Wet type, multiple clutch disc, spring boosted,
Steering brake hydraulically actuated (pedal operated, manual type),
interconnected with clutch
Spur gear l-stage, planetary gear l-stage reduction,
Final drive
splash type lubrication
Suspension Semi-rigid balancing beam type

Carrier roller 2 (each)
Track roller 8 (each)
Track shoe type Assembly type, single grouser
l No. of shoes 39 (each)
l Pitch mm 260.35
l Width mm 610
01-4
@
Serial numbers f 10001 - 10167 10168 and up

I
Relief valve setting RPafkglcm: 20.6 (210)
Hydraulic pump type Gear type, 2 tandem x 2EARlOO + 050)
Delivery (at engine speed 1,800 rpm) L?/min 288
. Blade lift control valve Single spool type with demand spool
. Blade tilt control and ripper low valve 3-tandem spool type
l Ripper high valve 2-tandem pilot spool type
Hydraulic cylinder type Reciprocal, piston type
Cylinder bore 130

Outside diameter of Piston rod 80
Piston stroke mm 1,420
Max. distance between Pins 2,365
Min. distance between Pins 945
Cylinder bore 200

Piston stroke mm 190
Min. distance between Pins 1,365
Cylinder bore 200

Piston stroke mm 465
Min. distance between Pins 1,100
01-5
@
o
Wrk.equipment Hydraulic cylinder
Dozer equipment Jin puller cylinder Dual tilt cylinder Gpper tilt cylinder
‘efformance limension
R
21
D
L¶
017M02

I
Type Variable angle type, parallelogram type
Weight kg 4,490
Beam length mm 2,495
No. of shanks 3
Ripping angle (standard) degree 51.7 (Possible to adjust steplessly 36.9 - 61.2)
Ripping depth P-stage selection possible
Max. digging depth mm 900
Max. lifting height mm 955
Type Variable angle type, parallelogram type

Weight kg 3,640
Beam length mm 1,252
No. of shanks 1
Ripping angle (standard) degree 52.7 (Possible to adjust steplessly 39.7 - 62.2)
Ripping depth 3-stage selection possible
Max. digging depth mm 1.300
Max. lifting height mm 870
01-7
@
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
Unit: kg
Serial numbers 10001 and up
Engine and damper assembly 2810
l Engine assembly 2580
l Damper assembly 160
l Engine mounting parts 70
Radiator assembly 350
Oil cooler assembly 100
Fuel tank assembly (Full) 390 (1150)
Power train unit
Power train assembly 3360
Torque converter and PTO assembly 740
Transmission assembly 890
Transmission control valve assembly 35
Steering clutch and brake assembly 1600
Steering control valve assembly 60
Final drive assembly (each side) 1940
Main frame assembly 4200
Track group assembly (each side) 4100
Track frame 1200
Idler assembly 340
Track roller assembly (single) (each) 110
Track roller assembly (double) (each) 120
Carrier roller assembly (each) 70
Track shoe assembly (width 610 mm) 6800
Pivot shaft (each side) 145
Equalizer bar 255
Bolster 195
Hydraulic tank assembly 350
l Blade lift control valve assembly 56
l Blade tilt and ripper low valve assmebly 47
01-8 D275A-2
Unit: kg

I
Semi-U dozer assembly 6330
l Blade 2980
l L.H. straight frame 780
l R.H. straight frame 780
l Tilt cylinder assembly 220
Variable multiple shank ripper assembly
l Shank assembly (each) 350
l Lift cylinder assembly 205
Variable giant ripper assembly 3600
l Shank assembly 500
l Lift cylinder assembly 205
Radiator guard assembly (with cylinder yoke) 1700
l Radiator guard 750
l Blade lift cylinder assembly (each side) 210
Front guard (with grille) 330
Engine under guard 260
Power train under guard 330
Engine hood 90
L.H. fender 300
R.H. fender 320
ROPS mount assembly 500
ROPS assembly 580
Floor frame assembly 320
Cab assembly 490
Operator’s seat assembly 70
D275A-2 01-9
TABLE OF FUEL, COOLANT AND LUBRICANTS
KIND OF AMBIENT TEMPERATURE

RESERVOIR FLUID -22 -4
Engine oil pan
Power train oil pan

(Incl. torque converter,
transmission and bevel
gear case)
Engine oil
Hydraulic tank I
*I Gear oil
Fuel tank Diesel fuel
-
Cooling system I Coolant Add antifreeze 136
* ASTM D975 No. 1
NOTE:
(1) 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 use
tenance hours described in this manual. engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table if SAEl5W-40 even though an atmospheric tem-
fuel sulphur content is above 0.5 %. perature goes up to 10°C more or less in the
day time.
(3) Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
(4) There is no problem if single grade oil is mixed
with multigrade oil (SAEIOW-30, 15W-40), but
be sure to add single grade oil that matches
Above 1 .O % l/4 of regular interval the temperature in the table on the left.
(5) We recommend Komatsu genuine oil which
has been specifically formulated and approved
ASTM: American Society of Testing and for use in engine and hydraulic work equip-
Material ment applications.
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.
01-10
@
.*-
10 STRUCTURE AND FUNCTION
General ...................................................... IO- 2 Blade lift control valve ............................. IO- 78

Power train ............................................... IO- 3 Blade tilt control and ripper low valve ... IO- 82
Power train unit.. ...................................... IO- 4 Ripper high valve ................................... IO- 84
Power train unit mount ........................... IO- 5 Ripper tilt suction valve.. ....................... IO- 86
Power train piping ................................... IO- 7 Piston valve ............................................ IO-104
Power train hydraulic circuit diagram ... IO- 8 Quick drop valve .................................... IO-105
Damper and universal joint .................... IO-IO Cylinder stay.. ......................................... IO-106
Torque converter . PTO ........................... IO-12 Semi U-dozer .......................................... IO-108
Torque converter valve ........................... IO-16 Ripper ...................................................... 10-110
Transmission ............................................ IO-24 l Variable multiple shank ripper.. ...... IO-I 10
Transmission control ............................... IO-29 l Variable giant ripper.. ....................... IO-I 12
Transmission control valve ..................... IO-30 Pin-puller solenoid valve.. ..................... IO-I 12-2
Transmission lubrication relief valve.. ... IO-37 Electrical circuit diagram ....................... IO-I 14
Scavenging pump .................................... IO-38 l Chassis electrical circuit diagram.. .. IO-I 14
Oil strainer ................................................ IO-39 l Cab electrical circuit diagram.. ........ 10-118-4
Power train oil filter l Air conditioner
and lubrication oil filter.. ....................... IO-40 electrical circuit diagram ............... IO-I 18-6
Steering unit ............................................. IO-42 EVMS
Transfer, bevel pinion.. ............................ IO-44 (Electrical vehicle monitoring system) ... IO- 119
Bevel gear, steering clutch APS control system ............................... IO-132
and steering brake ................................. IO-46 Torque converter lock-up
Steering control ........................................ IO-51 control system ...................................... IO-133
Steering control valve ............................. IO-52 For SSC system
Final drive ................................................. IO-60 Machine monitor system
Main frame ............................................... IO-63 (with SSC system) ............................... IO-137
Track group.. ............................................. IO-64 Model selection system.. ....................... IO-I 42
Recoil spring ............................................. IO-65 Engine control system ........................... IO-157
Suspension ............................................... IO-66 ELPC controller.. ..................................... IO-152
Hydraulic piping ....................................... IO-69 ELPC actuator ......................................... IO-I 54
l Blade .................................................... IO-69 Torque converter lock-up
l Variable multiple shank ripper.. ........ IO-70 control system ...................................... IO-161
l Variable giant ripper.. ......................... 10-70-I
Hydraulic control ...................................... IO-71
l Blade control ....................................... IO-71
l Blade control (for dual tilt dozer). ..... IO-72
l Ripper control ..................................... IO-73
Hydraulic circuit system .......................... IO-74
Hydraulic circuit diagram ........................ IO-75
Hydraulic tank.. ......................................... IO-77
D275A-2 10-l
0
GENERAL
F19702001
1. Engine 6. Transfer
(S6D170) 7. Steering clutch
2. Damper 8. Steering brake
3. Universal joint 9. Final drive
4. Torque converter 10. Sprocket
5. TORQFLOW transmission 11. Track
The power produced by diesel engine (1) goes from The steering clutch connects and disconnects the
the engine flywheel to torque converter (4) through power from the bevel gear shaft to final drive (9). SO
damper (2) and universal joint (3). The torque con- that the traveling direction of the machine is con-
verter (4) transmits the power to transmission (5) by trolled (steering). For example, when the R.H. steer-
converting the mechanical energy - fluid energy - ing lever is pulled, the steering control valve linked
mechanical energy. The transmission (5), with a to the lever is operated, the power is disconnected,
planetary gear mechanism and a hydraulic control and the machine turns to the right. Steering brake
unit combined, allows an easy selection of three (8) is installed between steering clutch (7) and final
forward speeds and three reverse speeds. drive (9). It is the same type as the steering clutch.
Through the drive shaft, the power is transmitted Steering brake (8) not only stops the machine, but
from transmission (5) to transfer drive gear (6) on also controls the turning radius of the machine.
the rear of the machine body. The transfer gears re- Final drive reduces the revolution speed by spur
duce the speed and, then, the power is transmitted gear single reduction and planetary gear system,
to bevel pinion. Bevel pinion and bevel gear direct and the revolution speed is transmitted to sprocket
the power to the right and left, and the power is (10). Sprocket (10) drives track (11).
transmitted to the left and right steering clutches (7)
and final drives (9).
1 o-2 D275A-2
POWER TRAIN
17 M F02002A
1. Engine (S6D170) 6. Transfer 11. Track shoe

2. Damper 7. Steering clutch 12. PTO
3. Universal joint 8. Steering brake 13. Power train pump (BALI 00 + 140)
4. Torque converter 9. Final drive 14. Scavenging pump (BAR63 + 200)
5. Transmission 10. Sprocket 15. Hydraulic pump (SAR(3)lOO + (2)50)
10-3
0
POWER TRAIN UNIT
I4
D275A-2 10061 and up
SI
A
6
1. PTO
2. Torque converter
3. Torque converter valve
4. Transmission control valve
5. Transmission
6. Steering clutch and brake
7. Steering control valve
8. Power train pump
9. Power train oil filter
10. Power train oil strainer
11. Scavenging pump
12. Power train oil tank
OUTLINE
0 The power train unit can be broadly divided
into the torque converter and transmission unit
and the steering unit.
Therefore, after removing the power train as a
unit, it can be disassembled into the torque
converter and transmission unit and the steer-
ing unit.
The steering unit consists of the transfer, bevel
gear shaft, steering clutch, and steering brake.
17MF02003B
POWER TRAIN UNIT MOUNT
6 7 8 9 10 11
A-A
17MF02004
1. Main frame 7. Clamp

2. PTO 8. Seal
3. Torque converter 9. Cover
4. Transmission 10. Coupling
5. Steering clutch and brake 11. Cap
6. Cage
D275A-2 1o-5
Oil cooler
Power train lubrication oil filter
Power train oil filter
Torque converter valve
Transmission control valve
Steering control valve
Oil tank
Power train oil strainer
Power train pump
Scavenging pump
D275A-2
1 o-7
?
setpressure
2.7 kg/cm2
!r
1.
2.
Oil tank
Power train oil strainer
3. Power train pump (BALI401
4. Power train lubrication pump (BALIOO)
5. Power train oil filter
6. Main relief valve
7. Modulating valve
8. Quick return valve
9. Reducing valve
10. Transmission F-R valve
11. Transmission speed valve
12. Reverse clutch
13. Forward clutch
14. 3rd speed clutch
15. 2nd speed clutch 8
16. 1st speed clutch E
Se!t pressure i--J
Power train lubrication oil filter
1!7I f 1 kg/cm2
17. 6
18. PTO lubrication
:racking 19. Transmission lubrication valve
Cracking pressw ,VZS”E
20. Transmission lubrication
ir
1.4 kg/cm2 i 1: .4 kg/cm*
21. Transmission case
22. Torque converter relief valve
23. Torque converter case
24. Torque converter
25. Torque converter lock-up modulating valve
26. Torque converter lock-up clutch
27. Stator clutch modulating valve
28. Stator clutch
; 29.
30.
Torque converter lock-up selector valve
Torque converter lock-up solenoid valve
46
F17M02001A 31. Stator and clutch lubrication
32. R.H. steering clutch valve
33. R.H. brake valve
34. L.H. brake valve
35. L.H. steering clutch valve
Plug for transmission main relief pressure
36. Pin puller solenoid valve
Plug for torque converter relief pressure
37. Pin puller cylinder
Plug for torque converter regulator Steering clutch and brake lubrication
38.
pressure
39. R.H. Steering clutch
Plug for torque converter stator clutch
40. R.H. Brake
modulating pressure
41. L.H. Brake
Plug for torque converter lock-up pressure
42. L.H. Steering clutch
Plug for transmission reducing pressure
43. Steering case
Plug for R.H. steering clutch pressure
44. Scavenging pump (BAR63 + 200)
Plug for R.H. brake pressure
45. Oil cooler
Plug for L.H. brake pressure
46. Oil filler
Plug for L.H. steering clutch pressure
1 O-8
0
DAMPER AND UNIVERSAL JOINT
r-7
17MF02007
10-10 D275A-2
OUTLINE
The damper acts as a cushion to prevent the
vibration of the engine from being transmitted
directly to the torque converter and trans-
mission.
The power from the engine is transmitted to
damper outer body (1) through flywheel (9).
The power is absorbed the engine vibration by
rubber coupling (7), and is transmitted to shaft
(8) and universal joint (4), and then is trans-
mitted to the torque converter.
As the damper uses rubber, it absorbs the vi-
bration by the vibration-reducing effect of rub-
ber, and the twist by the friction-reducing ef-
fect of the deformation of the rubber. The
number of part is fewer than the friction plate
type damper.
I. Outer body
2. Oil level gauge
3. Coupling
4. Universal joint
5. Flange
6. Cover
7. Rubber coupling
8. Output shaft
9. Engine flywheel
D275A-2 10-11
TORQUE CONVERTER l PTO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
‘C.
17MF02008
A. Mount of hydraulic pump

B. Mount of power train pump
C. Mount of scavenging pump
1. Coupling 13. Stator shaft 26. Lock-up clutch plate

2. Seal cage 14. Bearing cage 27. Lock-up clutch piston
3. Input shaft 15. Retainer 28. Scavenging pump gear (63 teeth)
[PTO drive gear (61 teeth)] 16. Shaft 29. Scavenging pump boss
4. Front housing 17. Transmission input shaft 30. Seal seat
5. Idler gear (77 teeth) 18. Stator shaft boss 31. Spacer
6. Idler gear shaft 19. Stator clutch housing 32. Cover
7. Clutch housing 20. Return spring 33. Hydraulic pump gear (57 teeth) 37'
8. Drive case 21. Stator clutch plate 34. Power train pump gear (57 teeth)
9. Turbine 22. Stator clutch disc 35. Drive shaft
IO. Rear housing 23. Stator clutch piston 36. Cover
11. Stator 24. Turbine boss 37. Cover
12. Pump 25. Lock-up clutch disc
z-z 17MF02009
10-12 D275A-2
OUTLINE STRUCTURE
0 The torque converter is a 3-element, single- 0 Pump (12) forms one unit with coupling (I),
stage, l-phase torque converter, and it forms a shaft (3), clutch housing (7), and drive case (8);
single structure with the transmission. To im- and is rotated by the motive force from the en-
prove the fuel consumption and ease of oper- gine.
ation and to reduce consumption of the engine l Turbine (9) forms one unit with turbine boss (24)
horsepower, a wet-type, multiple-disc clutch and transmission input shaft (turbine shaft) (17),
type torque converter lock-up device and a wet- and is rotated by oil from the pump.
type, double-disc stator clutch device are as- 0 Stator (11) forms one unit with stator shaft (13)
sembled inside it. and stator shaft boss (18), and is locked to rear
0 When the machine is carrying out continuous housing (10) by the stator clutch.
low-load dozing or grading operations, it is 0 The lock-up clutch consists of three parts:
more efficient if the motive power of the engine clutch plate (26) (meshed with drive case (8)),
is transmitted directly to the transmission input clutch disc (25) (meshed turbine boss (24)), and
shaft. clutch piston (27) (that slides inside housing (7)
To achieve this, a lock-up clutch actuated by hy- that forms one unit with the drive case).
draulic pressure is assembled inside the torque l The stator clutch consists of three parts:
converter. clutch disc (22) (meshed with boss (18) that is
When the torque converter is locked up (the connected by a spline to stator shaft (13)), clutch
pump and turbine form one unit), the oil sup- plate (21) (supported by a pin to clutch housing
plied from the torque converter relief valve does (19) and rear housing (IO)), and clutch piston (23)
not stop, so the oil leaving the turbine from the (that slides inside the rear housing).
pump is given unneeded direction by the stator, 0 The PTO consists of a drive gear forming one
and this resists the rotation of the pump and tur- unit with input shaft (3), idler gear (5), scaveng-
bine (the oil is churned). ing pump drive gear (28), hydraulic pump drive
To prevent this, a stator clutch similar to the gear (33), and power train pump drive gear (34).
lock-up clutch is built in. This allows the stator to
rotate freely when the torque converter is
locked up. The oil then moves together with ro-
tation of the pump and turbine; it is discharged
from the pump and turbine with little resistance,
and is returned to the pump.
* The condition for the torque converter to enter
the lock-up range and torque converter range
are as follows.
0 Lock-up range
When both of the following conditions are ful-
filled:
Torque converter output shaft speed:
Above 1170 rpm
Transmission set pressure:
‘_
Above 19.5 kg/cm2
0 Torque converter range
When either of the following conditions are ful-
filled.
Below 1110 rpm
Transmission set pressure:
Below 15 kg/cm2
D275A-2 10-13
PATH OF TRANSMISSION OF MOTIVE FORCE
1. Lock-up clutch OFF, stator clutch ON 7 8 9 10 11 12 13 17

When the lock-up clutch is OFF, the connec-
tion between drive case (8) and turbine (9)
is cut; and when the stator clutch is ON,
rear housing (IO) and stator shaft (13) are
connected, so stator (11) is locked and the
torque converter provides the normal func-
tions of a torque converter.
The motive force generated by the engine
passes through the damper and universal
joint, and is transmitted to coupling (1).
Input shaft (3), clutch housing (7), drive
case (8), and pump (12) rotate as one unit.
The motive force from the pump uses oil to
rotate turbine (9), and is transmitted to
transmission input shaft (17), that forms
one unit with the turbine.
I
Lock-up clutch Stator Clutch
17MF02010
2. Lock-up clutch ON, stator clutch OFF

1 3!3 9 110
,,,I 11 12 13
When the lock-up clutch is ON, drive case
(8) and turbine (9) are connected to form
one unit; and when the stator clutch is OFF,
the connection between rear housing (10)
and stator shaft (13) is cut, so stator (11)
follows the rotation of pump (12) and tur-
bine (9).
The motive force generated by the engine
passes through the damper and universal
joint, and is transmitted to coupling (1).
Input shaft (3), clutch housing (7), drive
case (8), and pump (12) rotate as one unit.
In addition, the drive case and turbine (9) _
are connected by the clutch, so the oil is 4
not used. The motive force is transmitted
directly to the turbine and transmission
input shaft (17).
Lock-up clutch Stator clutch

17MF02011
10-14 D275A-2
FLOW OF OIL
0 Oil set to within Max. 10 kg/cm2 by the tor-
que converter relief valve flows from port
A, passes through the oil hole inside rear
housing (IO), and enters pump (12).
The pump is always being rotated by the
motive force from the engine, so the oil en-
tering the pump is given centrifugal force,
and enters turbine (9). The turbine is ro-
tated by the centrifugal force of the oil.
The turbine forms one unit with trans-
mission input shaft (17), so the motive force
received by the turbine is transmitted to the
transmission.
The oil leaving the turbine is sent to stator
(11) and enters the pump again, but some
of the oil passes from the stator through
port B and is sent to the oil cooler.
D275A-2 10-15
TORQUE CONVERTER VALVE
A-A
Pl
\
17MF02013
1. Valve body 18. Stopper P: Stator clutch pressure

2. Torque converter relief valve 19. Load piston pickup port
3. Valve spring 20. Cover P,: Torque converter relief
4. Valve spring 21. Cover pressure pickup port
5. Main relief valve 22. Valve spring P.3‘ Lock-up clutch pressure
6. Cover 23. Valve body pickup port
7. Piston 24. Lock-up selector valve P,: Main relief pressure
8. Piston spring 25. Piston pickup port
9. Piston 26. Cover P10'. Lock-up clutch initial
IO. Stator clutch modulating valve Lock-up solenoid valve assembly pressure pickup port
11. Lock-up clutch modulating 27. Push pin P11'* Stator clutch initial
valve 28. Valve seat pressure pickup port
12. Cover 29. Return spring
13. Piston 30. Valve body
14. Piston spring (Small) 31. NO valve
15. Piston 32. Return spring
16. Valve spring (Outer) 33. Cap
17. Valve spring (Inner)
lo-16 D275A-2
E-E
8
E
6
17MF02014
OUTLINE
0 The torque converter valve is installed at the 4. Torque converter lock-up solenoid valve
top of the rear housing of the torque converter Solenoid valve receives an electrical signal
and consists of the following six types of from the lock-up controller and switches the
valves. pilot pressure to lock-up selector valve (24). It
1. Main relief valve operates lock-up selector valve (24) and swit-
Main relief valve (5) sets the hydraulic pressure ches the two clutches ON * OFF.
to 25.4 - 28.0 kg/cm2 in the transmission, 5. Stator clutch modulating valve
steering clutch, brake and torque converter Modulating valve (10) sets the clutch pressure
lock-up clutch, and stator clutch circuits. to 26 - 28 kg/cm* to protect the stator clutch
2. Torque converter relief valve from abnormally high pressure and acts to
Torque converter relief valve (2) sets the inlet raise the pressure of oil from lock-up selector
pressure of the torque converter to within 8.7 valve (24) gradually until it reaches the set
kg/cm2 to protect the torque converter from pressure.
abnormally high pressure. 6. Lock-up clutch modulating valve
3. Torque converter lock-up valve Modulating valve (11) acts in the same way as
Lock-up selector valve (24) acts to switch the stator clutch modulating valve (IO) and sets
lock-up clutch and stator clutch ON * OFF. the clutch pressure to 13 - 14 kg/cm* to pro-
tect the stator clutch from abnormally high
pressure.
10-17
0
To torque converter To oil tank
OPERATION OF MAIN RELIEF VALVE
The oil from the power train pump passes
through the oil filter, and enters port A of the
main relief valve. It then passes through ori-
fice a and enters port B.
When the oil from the pump fills the circuit, the
pressure starts to rise.
When the pressure in the circuit rises, the oil
entering port B pushes piston (9). The reaction
force compresses spring (4), moves main relief
valve (5) to the left in the direction of the
arrow, and opens ports A and C.
When this happens, the oil from the pump is
relieved from port A to port C, and flows port
C to the torque converter.
The pressure in the circuit at this point is 25.4
- 28.0 kg/cm*. Q
From pump
F19702004
OPERATION OF TORQUE CONVERTER RELIEF

VALVE
The oil relieved from the main relief valve
flows into the torque converter from port C,
and at the same time passes through orifice b
and enters port D.
When the oil fills the torque converter, the
pressure starts to rise.
If the pressure in the torque converter rises ab-
normally high, the oil entering port D pushes
piston (9). The reaction force compresses
spring (3), moves relief valve (2) to the right in
the direction of the arrow, and opens ports C
and E.
When this happens, the oil at port C is relieved
to port E, and is drained to the oil tank.
The pressure in the circuit at this point is From pump
below 8.7 kg/cm*. F19702005
From pump
F19702006
lo-18 D275A-2
OPERATION OF TORQUE CONVERTER LOCK-UP
VALVE, SOLENOID VALVE
The torque converter lock-up valve supplies oil
to switch the lock-up and stator clutch built.into
the torque converter ON - OFF.
The lock-up valve is actuated by the pilot press-
ure from the solenoid valve that is actuated
when it receive an electrical signal from the
lock-up controller.
When the lock-up switch on the switch panel at

the side of the operator’s seat is pressed ON
(the indicator lamp inside the switch lights up),
the auto-lock-up system is actuated, and when
the torque converter reaches the lock-up range,
the lock-up controller, that has received signals
from the two sensors, connects the solenoid to
the ground and current flows. The hydraulic cir-
cuit is switched and pilot pressure is sent to the
lock-up valve to lock up the torque conveter.
0 The diagram on the right shows the electrical

circuit for the torque converter lock-up system.
(For details, see the electrical circuit diagram)
The electricity from the battery flows from the
relay box to the panel switch.
2 When the lock-up switch is pressed ON, the
switch is connected to the ground, and this ac-
E tuates the relay inside the relay box. The elec-
6
tricity from the battery passes through the pilot
lamp and acts as the power source for the lock-
up controller.
In this condition, if both the torque converter
output shaft speed detected by the speed sen-
sor is above 1170 rpm, and the transmission
modulating pressure detected by the hydraulic
sensor is above 19.5 kg/cm* (AND circuit), the
controller connects the pilot lamp and solenoid
to the ground, and they light up or are excited
respectively.
LOC~.“P
power
If either the torque converter output shaft speed Transm,ss,o
is below 1110 ram or the modulating pressure is pressure
sens
LocL-“pgro”“d
below 15 kg/cm* (OR circuit), the controller cuts
the circuit connecting the pilot lamp and sole-
noid to the ground, and they go out or are deac-
tivated respectively.
In other words, when the torque converter %%
comes close to the stall range or tries to shift
gear, the machine changes to torque converter J
drive, and when there is continuous light oper-

197FO26
ation, the machine changes to direct drive.
10-19
0
OPERATION OF TORQUE CONVERTER LOCK-
UP VALVE, SOLENOID VALVE
(with SSC system)
. The torque converter lock-up valve supplies The diagram shows the electrical circuit for
oil to switch ON ++ OFF the lock-up clutch the torque converter lock-up mechanism.
and stator clutch built into the torque con- (For details, see the electrical circuit dia-
verter. gram.)
The lock-up valve is actuated by the pilot When the starting switch is turned ON, the
pressure from the solenoid valve. The sole- lock-up relay inside the relay box is actu-
noid valve itself is actuated when it receives ated. The electricity from the battery passes
an electrical signal from the lock-up control- through the pilot lamp and flows to the lock-
ler. up controller to act as the power source.
l When the lock-up switch on the mode se- In this condition, if both the torque con-
lection panel at the side of the operator’s verter output shaft speed detected by the
compartment is pressed ON (the indicator speed sensor is above 1,170 rpm and the
lamp inside the switch lights up), the auto- transmission modulating pressure detected
lock-up mechanism is actuated. When the by the hydraulic sensor is above 1.9 MPa
torque converter reaches the lock-up range, i19.5 kg/cm21 (AND circuit), the lock-up con-
the lock-up controller, which has received troller connects the pilot lamp and solenoid
signals from the two sensors, connects the to the ground, and they light up and are
solenoid to the ground and current flows. energized respectively.
The hydraulic circuit is switched and pilot If either the torque converter output shaft
pressure is sent to the lock-up valve to lock speed is below 1,100 rpm or the modulat-
up the torque converter. ing pressure is below 1.5 MPa (15 kg/cm*}
(OR circuit), the lock-up controller cuts the
circuit connecting the pilot lamp and sole-
noid to the ground, and they go out or are
deenergized respectively.
In other words, when the torque converter
comes close to the stall range or tries to
shift gear, the machine changes to torque
converter drive, and when there is continu-
ous light operation, the machine changes to
direct drive.
The torque converter speed sensor is con-
nected to the SSC controller and transmits
the rotation speed of the torque converter
to the SSC controller.
The SSC controller receives the ON signal
from the mode selection panel (lock-up
mode switch) and transmits the input torque
converter speed to the lock-up controller.
10-19-l 0275A-2
0
LOCK-UP SYSTEM (SSC SPECIFICATION MACHINE)
Battery relax
Battery n h -b E
I
Relax box
Lock-up controller
Pilot lamp
Torque converter speed t+)
I
q
Transmission oil Pressure sensor

Transmission oil
Pressure sensor
J
Torque converter speed t-1
Lock-up Power source

Lock-up
solenoid
Lock-up GND
- Lock-up valve
- Lock-up valve power source
SSC controller
Lock-up switch
+.-I- @I
Mode selection Panel

t I
Torque converter
speed sensor
SWD03772
D275A-2 10-19-2
a
1. Travel in torque converter drive
:lutch
197FO2023
When the machine is in the torque converter range, When this happens, oil from the pump flows ports
the solenoid valve is deactivated, so valves (28) and P and N into port L of the lock-up valve. When the
(31) are pushed to the right in the direction of the pressure inside the circuit rises, piston (25) is
arrow by the tension of spring (29). Ports N and M pushed to the left in the direction of the arrow, and
close and ports N and P open. the piston pushes out lock-up selector valve (24) to
the left.
197FO2024
When lock-up selector valve (24) moves to the left in the circuit rises, the stator clutch is engaged.
in the direction of the arrow, ports F and G and At the same time, the oil that is the back pressure
ports H and K close, and ports F and H and ports G of the lock-up clutch piston is drained from port G
and J open. to port J, and the lock-up clutch is disengaged.
When this happens, the oil from the pump flows
from port F to port H, and becomes the back press-
ure of the stator clutch piston. When the pressure
1O-20 D275A-2
2. Travel in direct drive
197FO2025
When the machine is in the direct drive range, the Ports F and H and ports G and J close, and ports F
solenoid valve is excited, so push pin (27) is pushed and G and ports H and K open.
to the left in the direction of the arrow and valves When this happens, the oil from the pump flows
(28) and (31) are moved. Ports N and P close and from port F to port G, and becomes the back press-
ports N and M open. ure of the lock-up clutch piston. When the pressure
When this happens, oil from the pump stops at P. in the circuit rises, the lock-up clutch is engaged.
The high-pressure oil at port L is drained from port At the same time, the oil that is the back pressure
N to port M. of the stator clutch piston is drained from port H to
When the pilot pressure at port L is lost, piston (25) port K, and the stator clutch is disengaged.
and lock-up selector valve (24) are returned to the
right in the direction of the arrow by the tension of
spring (22).
D275A-2 10-21
Operation of stator clutch, lock-up clutch modu-
lating valve
0 The modulating valves are in the circuit be-
tween the lock-up selector valve and the inlet
ports of the two sets of clutches. When the
clutch is switched ON, the modulating valve
acts to raise the pressure on the piston grad-
ually until it reaches the set pressure so that the
clutch is engaged smoothly, thereby reducing
any shock to the torque converter or trans-
mission.
j, The following explanation of operation takes the
stator clutch as the example, but the operation
of the lock-up clutch is the same.
However, the oil flow to the clutch during direct
drive or torque converter drive is the reverse.
1. Travel in direct drive

When the machine enters the direct drive range, TO solenoid
Frompump valve
the oil at port L of lock-up selector valve (24) re-
turns to the solenoid valve and is drained.
When this happens, lock-up selector valve (24) is
pushed to the right in the direction of the arrow
by the tension of spring (22). Ports F and H
close, and ports H and K open, and the oil at
port H is drained from port K.
When the hydraulic pressure at port H is lost,
modulating valve (10) is returned to the right in
the direction of the arrow by the tension of
spring (16), and ports H and 0 open fully. At this
point, the actuating pressure of the stator clutch
is drained from port H to port K, and the clutch
is disengaged.
197FO2026
1o-22 D275A-2
2. Travel in torque converter drive To solenoid
From pump valve
When the machine is in the torque converter
drive range, the oil from the solenoid valve en-
ters port L of lock-up selector valve (24) and
moves the lock-up selector valve to the left in
the direction of the arrow. Ports F and G, and
ports H and K close, and ports F and H open. A
circuit is then formed from port F through
modulating valve (10) to the stator clutch. The
oil from the pump flows from port F to the sta-
tor clutch, and the pressure in the circuit starts
to rise.
As the hydraulic pressure in the circuit rises,
the oil passing through orifice d in modulating
valve (IO) pushes piston (13), and the reaction
force moves the modulating valve to the left in
the direction of the arrow to throttle ports Q
and H.
Port Q is connected with port S that applies
back pressure to load piston (19), and moves
the load piston to the right in the direction of
the arrow to compress spring (16). The tension
of the spring opens ports Q and H.
This operation is repeated intermittently to in-
crease the load of spring (16). While this is
happening, the hydraulic pressure gradually in-
creases, and finally stops at the position where
ports Q and H are closed to complete the rise
197FO2027
in hydraulic pressure. _ II
The hydraulic pressure at this point is 26 - 28
kg/cm2. To solenoid
The hydraulic pressure of the lock-up clutch is From pump valve
13 - 14 kg/cm2.
//I I 197FO2028
D275A-2 1 O-23
TRANSMISSION
17MF02015
OUTLINE
The D275A-2 bulldozer is equipped with a plane- No. 1 clutch is fixed in reverse, No. 2 clutch in for-
tary type, “3-forward and 3-reverse speed” trans- ward, No. 3 clutch in third speed, No. 4 clutch in
mission which is a combined structure of a plane- second speed, and No. 5 clutch in first speed.
tary gear mechanism and disc clutches. Any speed can be selected from three forward
The rotational direction and the revolution of the speeds and three reverse speeds by fixing either
transmission output shaft is selected by fixing two No. 1 or No. 2 clutch and one clutch among No. 3,
disc clutches out of five disc cluthes by means of No. 4 and No. 5 clutches and by combining two of
control valve operation. the above.
1 O-24 D275A-2
1. Input shaft Speeds and operating clutches
2. Transmission valve
3. Front case
4. Rear case Speed Operating clutch
5. Front cover
1 5 f : 8 9 1,s ‘17 l,B ;2 /23 f4 ;5 36 Neutral No. 5 clutch
\ \ \ \ 6. Reverse sun gear (34 teeth)
First speed No. 2 and No. 5 clutches
7. Reverse ring gear (91 teeth)
Forward Second speed No. 2 and No. 4 clutches
8. Pinion shaft
Third speed No. 2 and No. 3 clutches
9. Reverse planetary pinion (25 teeth)
10. Reverse ring gear (84 teeth) Neutral No. 5 clutch
11. Forward sun gear (41 teeth) First speed No. 1 and No. 5 clutches
12. Forward planetary pinion (25 teeth) Reverse Second speed No. 1 and No. 4 clutches
13. Forward ring gear (91 teeth) Third speed No. 1 and No. 3 clutches
14. Pinion shaft
15. 3rd speed ring gear (91 teeth)
16. 3rd speed planetary pinion (25 teeth) Number of discs and plates on each clutch
17. 3rd speed sun gear (41 teeth)
18. 2nd speed ring gear (93 teeth)
19. 2nd speed planetary pinion (23 teeth) Clutch No. Number of plates Number of discs
20. Pinion shaft
21. 2nd speed sun gear (47 teeth) No. 1 clutch 5 5
22. No. 5 gear (1 st speed gear)
23. No. 5 clutch piston No. 2 clutch 4 5
24. No. 5 clutch piston housing No. 3 clutch 2 3

25. Output shaft
26. Spacer No. 4 clutch 3 3
27. Block No. 5 clutch 4 5

28. No. 5 clutch spring
29. Seal seat
30. No. 4 carrier
31. Plate
32. No. 2, 3 carrier
33. No. 2, 3 piston housing
34. No. 1 carrier
35. No. 1 piston housing
36. Clutch piston
37. Clutch spring
38. Clutch plate
39. Clutch disc
40. Tie bolt
41. Reverse carrier gear (91 teeth)
40/////I 39 38 37 I / I I I I I I \
36 35 34 33 32 31 30 29 28 27 4
17MF02016
D275A-2 1 o-25
FUNCTION OF PISTON
3.7 4.2 3.! 38 36 35
To lock ring gear (7), the discs (39) and plates (38)
are brought into close contact. The clutch consists
of a clutch piston (36), clutch plates (38), clutch
discs (39), pins (42) and piston return springs (37).
The disc’s internal teeth engage with the ring
gear’s external teeth.
The plates, whose notch on the outside diameter
engage with pins (42) on housing (35), are locked
against the rotating direction. Piston (36) also is
locked against the rotating direction.
Clutch engaged (oil pressure is acting)

Oil from the control valve flows under pressure
through the port in housing (35) to the piston 39 3p 36C ?5
(36). The piston presses clutch plates (38) and
clutch discs (39) together, and the frictional
force developed stops clutch discs (39) revol-
ution, thus ring gear (7) meshing with the
disc’s internal teeth is locked.
Clutch disengaged (oil pressure is not ac-

ting)
When the supply of pressure oil from the con-
trol valve is shut off, piston (36) returns to the
initial position by the force of piston return
spring (37), thus relieving the frictional force
between plates (38) and discs (39), making the
ring gear (7) free.
F19702010
1 O-26 D275A-2
POWER TRAIN OF TRANSMISSION
FIRST FORWARD SPEED
I
30
17MF02017
For FORWARD Ist, No. 2 clutch and No. 5 l Ring gear (13) is locked in position by No. 2
clutch are engaged. The motive force trans- clutch, so planet gear (12) rotates carrier (32),
mitted from the torque converter to input shaft which is on the inside of ring gear (13).
(1) is transmitted to output shaft (25). No. 5 clutch is also engaged, so the No. 5 gear
No. 2 clutch is actuated by the hydraulic press- (22), sun gears (17) and (21), planet gears, ring
ure applied by the clutch piston and locks ring gears (15) and (18), and No. 4 carrier (30) form
gear (13) in position. No. 5 clutch is actuated one unit, and carrier (32) rotates as one unit
by hydraulic pressure applied by the clutch with the gears of No. 3, 4 and 5 clutches to ro-
piston and engages No. 5 gear (22) and No. 4 tate output shaft (25).
ring gear (18) in position. Output shaft (25) rotates at the same speed as
The motive force from the torque converter is carrier (32).
transmitted to the input shaft. The rotation of
the input shaft is transmitted through sun gear
(11) to planet gear (12).
D275A-2 1 O-27
6 9 10 11 12 13 15 17 18 21 22 25
17MF02018
For REVERSE Ist, No. 1 clutch and No. 5 clutch l Carrier (34) is locked in position by No. 1
are engaged. The motive force transmitted clutch, so the rotation of planet gear (9) rotates
from the torque converter to input shaft (1) is ring gear (IO).
transmitted to output shaft (25). Ring gear (IO) rotates in the opposite direction
No. 1 clutch is actuated by the hydraulic press- from the input shaft, and it rotates carrier (32).
ure applied by the clutch piston and locks car- No. 5 clutch is engaged, so the No. 5 gear, sun
rier (34) in position. No. 5 clutch is actuated by gears, planet gears, ring gears, and No. 4 car-
hydraulic pressure applied by the clutch piston rier form one unit, and carrier (32) rotates as
and engages No. 5 gear (22) and No. 4 ring one unit with the gears of No. 3, 4 and 5 clut-
gear (18) in position. ches to rotate output shaft (25).
The motive force from the torque converter is
transmitted to the input shaft (1). The rotation
of the input shaft is transmitted through sun
gear (6) to planet gear (9).
1 O-28 D275A-2
TRANSMISSION CONTROL
1. Gear shift lever 17MF02019

2. Safety lever
3. F-R spool linkage
4. Speed spool linkage
5. Transmission control valve
D275A-2 1 O-29
TRANSMISSION CONTROL VALVE
E-E
17MF02020
A From power train pump

B To speed valve G
C To speed valve J
D To forward clutch port (No. 2)
E To reverse clutch port (No.1)
F To 1st speed clutch port (No. 5)
Modulating pressure 26-28 G From reducing valve B
H To 2nd speed clutch port (No. 4)
Reducing pressure 20.5 - 22.5 J From reducing valve C
K To 3rd speed clutch port (No. 3)
1O-30 D275A-2
A-A
18
K J H 19
17MF :02021
B-B
1. Piston 11. Reducing valve

2. Modulating valve 12. Stopper
3. Modulating valve load piston 13. Reducing valve spring
4. Modulating valve spring (Inner) 14. Stopper
5. Modulating valve spring (Outer) 15. Modulating sleeve spring (Small)
6. Quick return valve 16. Stopper
7. Cover 17. Piston
8. Piston spring 18. F-R valve
9. Piston 19. Speed valve
10. Piston
D275A-2 10-31
MODULATIING VALVE
OUTLINE
l The modulating valve consists of a modulating
relief valve and a quick return valve, and acts
to modulates the pressure.
l When the gear shift lever is operated to shift
gear, the clutch is pushed into close contact by
the piston. However, if high pressure is sud-
denly applied, the piston will suddenly engage
the clutch. This will make the machine sud-
denly start, and it will receive an excessive
shock.
To prevent this, the modulating valve is in-
stalled. When the gear shift lever is operated
to shift gear, the pressure on the piston grad-
ually rises to the set pressure and the clutch is
engaged smoothly. This allows the machine to
start without any shock, thereby improving the
durability of the power train and at the same
time providing a comfortable ride for the oper-
Modulating time
ator.
l The figure shows the relationship between the
time and the increase in the hydraulic pressure (kg/cm?
of the modulating valve. 30 -
For example, when the gear is shifted from Fl
27 -
and F2, the oil from the pump passes through
(Set pressure)
the speed valve spool, flows to the second
clutch and fills the circuit up to the clutch pis-
2 20-
ton port.
.?
The time taken for the circuit to be filled up to 2
the clutch piston port is called the “filling 5i
time”, and the oil pressure during this time is 0 - 3 is
kg/cm2. 10 -
When the circuit up_to the clutch piston port is
filled with oil, the oil pressure starts to rise.
The time taken for the pressure to rise to the (Sec.)
set pressure is called the “built-up time”. The 0 I , 1 I I , , , ,
filling time and build-up time together are 0 0.5 1.0

called the “modulating time”. Time
1JMF02022
1 O-32
0
Operation From pump
1. Immediately after shifting

When the transmission shift lever is operated
and the clutch is engaged, the passage from
the pump to the clutch piston port is opened
and the oil flows to the clutch piston port.
When this happens, the passage between port
B and port D is restricted by orifice b, so a dif-
ference in pressure is generated, and quick re-
turn valve (6) is moved to the left in the idrec-
tion of the arrow by the pressure at port B.
This connects port E and drain port F, and
removes the back pressure of load piston (3).
2. Pressure starting to rise, during rise

When the oil sent under pressue from the TO clutch cylinder Drain
pump fills the circuit from port A to the clutch
piston port, the hydraulic pressure starts to 6 17MF02023
rise.
When this happens, the difference in pressure
on the two sides of orifice b of quick return A From pump
valve (6) is lost, and the quick return valve is

moved to the right in the direction of the arrow
to close the passage between port E and drain
port F.
The oil flows form orifice a of modulating valve
(2) to port C, and pushes piston (1). Because
of the reaction force, the modulating valve
compresses springs (4) and (5), and moves to
the right in the direction of the arrow to drain ,E
the oil from port A to port G.

At the same time, the oil flowing from orifice e
in quick return valve (6) through the central
port passes through orifice d and enters port
E. It becomes the back pressure of load piston
\ “F
(3), moves the load piston to the left in the di-
rection of the arrow and compresses springs
6
(4) and (5). 17MF02024
To clutch cylinder Drain

\
6
17MF02025
D275A-2 1o-33
During rise in oil pressure, completion of
rise
As the pressure rises, the back pressure of A From G
load piston (3) increases. When the movement \ pump \
of the load piston to the left increases, modu-
lating valve (2) closes the passage between
port A and port G because of the tension of
springs (4) and (5).
As the pressure at port C pushing piston (1)
increases, modulating valve (2) moves to the
right in the direction of the arrow due to the
reaction force, compresses springs (4) and (5),
and opens the passage between port A and
port G.
By repeating this operation intermittently, the
load of springs (4) and (5) increases and the
pressure rises slowly. Finally, load piston (3)
contacts the valve body and does not move
any further.
When this happens, modulating valve (2) stops
at the position where the passage from port A 17MF02026
to port G is closed, and the rise in hydraulic
pressure is completed.
The hydraulic pressure at this point is 26 “0
kg/cm2.
The oil frbm the pump is relieved through the
main relief valve assembled to the torque con-
\From
PumA
/
verter assembly.
To clutchcylinder
17MF02027
1o-34 D275A-2
REDUCING VALVE
OUTLINE
l The reducing valve is in the circuit between From modulating
the modulating valve and the 1st speed valve valve
spool. It reduces the pressure applied to the
1st clutch to 20.5 - 22.5 kg/cm*.
The hydraulic pressure in the circuit as a whole
is set to 26 - 28 kg/cm* by the modulating
valve.
OPERATION
C’
1. Valve OPEN
The oil from the modulating valve flows from
port A. Some passes through port B and flows To F-R spool To 1st spool
to the 1st valve spool and clutch, and at the To 2nd & 3rd spool
same time, passes through orifice a and enters 17MF02028
port D.
The oil also flows from port A through port C,
and flows to the 2nd and 3rd spools and the
directional spool. 13
From modulating 1
When the circuit up to the clutch that has been valve
shifted becomes filled with oil and the press-
ure rises according to the operation of the
modulating valve, the oil entering through ori-
fice a of reducing valve (11) pushes piston (12).
The reaction force compresses spring (13) and
moves reducing valve (11) slowly to the left in
the direction of the arrow in accordance with
the rise in the hydraulic pressure, and starts to
throttle port B.
To F-R s;ool To 1;t spool

To 2nd & 3rd spool
17MF02029
2. Valve CLOSED From modulating

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

To 2nd & 3rd spool
17MF02030
D275A-2 10-35
If the pressure in the 1st clutch circuit drops
because of leakage from the transmission Iu-
brication or seal ring, the reaction force of the
spring of reducing valve (11) opens the circuit.
This raises the pressure to the set pressure of
reducing valve (11) and maintains the set
pressure.
Except for the 1st clutch circuit, the pressure in From reducing valve
all the circuits continues to rise to the set
pressure of the modulating valve.
* The 1st clutch is farthest from the control
valve, and the piping to the cylinder is longer,
so it takes a longer time for the oil to fill the
piping.
For this reason, even when the gearshift lever
is in neutral, oil still flows to the 1st clutch.
Therefore, when moving the gearshift lever
from neutral to Fl, it is only necessary for the
oil from the pump to fill the FORWARD clutch.
When the gearshift lever is moved from Fl to
F2, the FORWARD clutch is already filled with
oil, so the oil from the pump only needs to fill
the 2nd clutch. By using the oil in this way, the
time lag when shifting gear is reduced. 1st clutch piston
17MF02031
1 O-36 D275A-2
TRANSMISSION LUBRICATION RELIEF VALVE
A-A
561 FO3032
1. Valve body FUNCTION

2. Lubrication relief spool l This valve is installed to the right side of the
a. Lubrication pressure measurement plug transmission and prevents abnormal pressure in
the transmission lubrication circuit.
Cracking pressure: 2.7 kg/cm2
D275A-2 1o-37
SCAVENGING PUMP
(BAR63 + BARZOO)
197 F058A
A. Discharge port OUTLINE

B. Small pump suction port l This pump is installed on the lower of the PTO
C. Large pump suction port case, and consists of a small pump and a large
pump.
1. Small pump l The small pump sucks the torque converter
2. Large pump case oil and the large pump sucks the steering
case oil, and this oil is returned to the oil tank.
Discharge pressure
(kg/cm2)
At rated speed (rpm)
1 O-38
0
OIL STRAINER
17MF02032
1. Cover OUTLINE
2. Spring l The strainer is installed on the front and left of
3. Magnet the power train unit.
4. Screen l Open the fender located at the front of oper-
5. Case ator’s seat, and maintain the strainer.
l The oil from the oil tank is filtered by screen
A. From oil tank (4), and is sucked by the power train pump and
B. TO power train pump and lubrication pump the lubrication pump.
Passage flow 600 a/min
Screen mesh 80
D275A-2 1o-39
POWER TRAIN OIL FILTER AND LUBRICATION OIL FILTER
z
17MF02033
1. Cover OUTLINE
2. Element The two filters are the same part, and are in-
3. Body stalled on the front of power train unit. Open
4. Valve (Setting pressure: I.4 kg/cm*) the fender located at the right and front of
5. Spring operator’s seat, and maintain the filter.
The oil from the oil tank is sucked by the
A. Inlet power train pump and the lubrication pump
B. Outlet through the strainer, and is sent to each filter.
If element (2) is clogged or the oil temperature
is low, the oil pressure increase, so valve (4) is
installed to prevent the filter from breaking.
Cracking pressure 1.4 kg/cm*
Passage flow 273 Illmin.
Filter ability 30 microns
1O-40 D275A-2
STEERING UNIT
II%
0
=
--
-
-
--
--
--
--
--
17MF02034
OUTLINE
The steering unit consists of the transfer, bevel
gear shaft, steering clutch, and steering brake.
1 O-42 D275A-2
A-A
F-F
E-E
D-D 17MF02035
1. Transmission
2. Breather
3. Steering unit
4. Torque converter output shaft speed sensor
A. Mount of steering control valve

B. Center of bevel gear shaft
C. Center of crank shaft
D. Center of bevel pinion
D275A-2 1o-43
TRANSFER, BEVEL PINION
17MF02036
1. Input shaft OUTLINE

2. Drive shaft l The transfer and bevel pinion are installed at
3. Drive gear (33 teeth) the rear inside the steering case and receive
4. Rear cover the motive force from the transmission output
5. support shaft with input shaft (1).
6. Torque converter output shaft speed sensor The transfer consists of drive gear (3) and
7. Bearing cage driven gear (11). It reduces the speed of the
8. Drum motive force from input shaft (1) and transmits
9. Cover it to bevel pinion (12).
10. Bearing cage Drive shaft (2) rotates drum (8), which sends a
11. Driven gear (34 teeth) pulse signal to torque converter speed sensor
12. Bevel pinion (6).
13. Bevel gear
1o-44 D275A-2
OUTLINE
Bevel gear shaft Steering brake

The motive force from the engine - torque l The steering brakes are connected with the left
converter -+ transmission -, transfer enters the and right steering clutches, and act to brake
bevel gear system. The bevel pinion and bevel the machine or change the direction of travel
gear are meshed and act both to reduce the by braking or connecting the motive force
speed of rotation and to send to the power at from the steering clutches to the final drive.
right angles to the left and right. l The steering brakes are wet, multiple-disc clut-
The bevel gear system uses spiral bevel gears ches with a spring booster. They are intercon-
for the bevel pinion and bevel gear, and a nected with the brakes and are hydraulically
splash-type lubrication system is employed actuated by a steering valve that is actuated
that uses the oil from the power train oil when the brake pedal and steering lever are
cooler. operated.
The bevel gear system consists of the follow- A forced lubrication system is employed in
ing: bevel gear (17) that meshes with the bevel which the oil from the power train oil cooler
pinion, bevel gear shaft (16). two steering passes through the passage inside the steering
shafts (15) that are connected to the bevel case, enters the housing and cage, and is then
gear shaft by a spline, the bearing that sup- sent to the discs and plates.
ports the bevel gear shaft, and bearing cages The steering brakes are designed so that when
(14) and (18). the engine has stopped, the back pressure of
the brake piston drops and the brake are ap-
Steering clutch plied without the brake pedal being depressed.
l The steering clutches are connected by a However, when the engine is started again, the
spline to the left and right steering shafts, and brake is released as the hydraulic pressure in-
act to engage or disengage the motive force to side the circuit rises, so the brake pedal must
the final drive, thereby changing the direction always be locked.
of travel of the machine. l The steering brakes consist of the following:
l The steering clutches are wet, multiple-disc clutch housing (27), hub (12) that is connected
clutches with a spring booster. They are inter- with cage (28) and output shaft (I), disc (10)
connected with the brakes and are hydrauli- that is meshed with the hub, plate (8) and
cally actuated by a steering valve that is actu- housing (5) that are mated at the outside cir-
ated when the steering lever is operated. cumference by torque pin (7), piston (6) that
A forced lubrication system is employed in presses the discs and plates together, spring
which the oil from the power train oil cooler (4) and stopper (II), and cage (3) that supports
passes through the passage inside the steering these parts.
case, enters the housing and cage, and is then Housing (5) and cage (3) are secured to the
sent to the discs and plates. steering case.
l The steering clutch consists of the following:
hub (19) that is connected with the steering
shaft by a spline, disc (23) that meshes with
the hub, plate (22) and housing (27) that are
mated at the outside circumference with tor-
que pin (24), piston (25) that presses the discs
and plates together, spring (26) and stopper
(20), and cage (28) that supports these parts.
Housing (27) and cage (28) are connected with
brake hub (12), and send the motive force from
the bevel gear through the brake hub to output
shaft (1).
D275A-2 1o-47
OPERATION OF STEERING CLUTCH
1. When steering clutch is engaged

When the steering lever is at the neutral posi- 1 12 27 26 25 24 23 22 20 19 15
tion, the steering valve is also at the neutral
position, so no back pressure is applied to pis-
ton (25).
In this condition, the piston is pushed to the
right by the tension of spring (26), and disc
(23) and plate (22) are brought into close con-
tact with stopper (20).
The stopper is connected with housing (27) by
torque pin (24).
Therefore, the motive force from steering shaft
(15) is transmitted from hub (19) to housing
(27) through the discs and plates that are held
together. The motive force is then transmitted
from brake hub (12), which forms one unit with
the housing, through the output shaft (1) to the
final drive.
F19702025
2. When steering clutch is disengaged

When the steering lever is pulled, the steering
valve is switched and oil enters the area be-
hind piston (25). When the hydraulic pressure
rises, it pushes the piston to the left, and com-
presses spring (26) to release the pressure
holding disc (23) and plate (22) together.
When this happens, the motive force from
steering shaft (15) rotates only hub (19) and
the disc, so the motive force is not transmitted
beyond housing (27) and does not go to the
final drive. When the steering lever is released,
the steering valve opens the drain circuit, and
the tension of spring (26) pushes piston (25)
back to its original position to return the clutch
to the engaged condition explained is Section
1.
When the left steering clutch is disengaged,
the motive force is transmitted only to the right
steering clutch, so the machine turns to the left
(travels to the left).
F19702026
1 O-48 D275A-2
OPERATION OF STEERING BRAKE
1. When steering brake is released

When the steering lever and brake pedal are at 1 4 5 6 7 -27 1.5
the neutral position, the steering valve is also
at neutral, so the steering clutch is engaged,
and oil enters the back pressure port of steer-
ing brake piston (6). When the hydraulic press-
ure rises, it pushes the piston to the left, com-
presses spring (4), and releases the pressure
holding disc (10) and plate (9) together.
When this happens, the motive force trans-
mitted from steering shaft (15) through the
steering clutch to housing (27) is transmitted
from hub (12) to output shaft (I), and goes to
the final drive.
lb ;1
F19702027
2. When steering brake is applied

(steering lever pulled)
When the steering lever is pulled fully, the
steering valve is switched and the steering
clutch is disengaged. At the same time, the oil
applying back pressure to piston (6) is con-
nected to the drain circuit.
In this condition, the piston is pushed to the
right by the tension of spring (4), and disc (10)
and plates (9) are brought into close contact
with stopper (11).
The stopper is connected to case (5) by torque
pin (7), so it is locked in position.
Therefore, even if the steering clutch is disen-
gaged, the rotation of output shaft (I), that is
the rotation of hub (12) caused by inertia, is
stopped when the disc and plate are pushed
into contact.
The hydraulic force applied to spring (4) is con-
trolled by the amount that the steering lever is
pulled, so it is possible to adjust the braking
force, thereby controlling the turning speed
and turning radius.
Y 10 1’1 li F1970202%
D275A-2 1o-49
3. When steering brake is applied
(brake pedal depressed)
When the brake pedal is depressed, the steer- 1 4 5 6 7 27 15
ing valve is switched, and the oil applying back
pressure to piston (6) is connected to the drain
circuit. The steering clutch remains engaged,
and only the brake is actuated to stop the rota-
tion of output shaft (1).
I I#I II I
10 1’1 1’2
F19702029
1 O-50 D275A-2
STEERING CONTROL
17MF02038
1. L.H. steering lever

2. R.H. steering lever
3. Brake lock lever
4. Brake pedal
5. Brake pedal return spring
6. Steering control valve
D275A-2 10-51
STEERING CONTROL VALVE
z 197FO2045
‘CL
1. Plug 12. Shaft ass’y A. To R.H. steering clutch
2. Return spring 13. Guide piston port
3. Piston 14. L.H. brake valve B. To R.H. steering brake
4. Valve body 15. L.H. steering valve piston port
5. R.H. steering valve 16. Plug C. To steering case
6. Modulating spring 17. Return spring D. From power train pump
7. Shaft ass’y 18. Piston E: To L.H. steering brake
8. Cover 19. Seat piston port
9. Return spring 20. Check valve F: To L.H. steering clutch
10. R.H. brake valve 21. Spring piston port
11. Modulating valve CL: Plug for L.H. steering
clutch pressure
CR: Plug for R.H. steering
clutch pressure
BL: Plug for L.H. steering
brake pressure
BR: Plug for R.H. steering
brake pressure
1 o-52 D275A-2
197FO2046
OUTLINE
The steering control valve consists of two
steering valves and brake valves, and is in the These operations are made possible by switching
circuit between the steering clutch and brake the steering control valve which is interconnected
pistons and the power train pump passing with the lever and pedal.
through the main relief valve. The steering control valve sends oil from the
When the steering lever is pulled, the steering power train pump to the steering clutch and
clutch is disengaged. If it is pulled further, the brake, and operates the disc clutch of each.
brake is engaged and the machine stops.
When the lever on one side is pulled, it is
possible to adjust the angle of turning to give
gradual turns or sharp turns.
If the brake pedal is depressed, the brake is
engaged and the machine stops.
D275A-2 1o-53
VALVE CONTROL LEVER
D-D
I97FO72
22. R.H. steering lever shaft OUTLINE

23. L.H. and R.H. brake lever shaft l The steering control valve is operated by lever
24. Lever box shafts (22) and (29) and levers (26) and (28) in-
25. Roller terconnected with the steering lever in the
26. R.H. steering lever operator’s compartment, and lever shaft (23)
27. Brake lever and lever (27) interconnected with the brake
28. L.H. steering lever pedal.
29. L.H. steering lever shaft l The steering valve and brake valve inside the
steering control valve are interconnected by
cam (25) of levers (26) and (28) to enable the
steering lever system to be operated.
1o-54 D275A-2
OPERATION
1. When steering lever, brake pedal are at neutral

(clutch engaged, brake released)
To toI que converter val ve,

To tri lnsmission control valve flnnnnn
From
F19702030
l When the steering lever and brake pedal are at The rest of the oil pushes open check valve (20),
neutral (not operated), levers (26), (27), and enters port E of left and right brake valves (10)
(28) are also at neutral, and the oil ports of and (14), and then flows from port F to the back
each valve are opened or closed by the ten- pressure port of the brake piston. When the hy-
sion of the spring. draulic pressure in the circuit rises, the piston
The oil from the power train pump passes moves to the left, compresses the brake spring,
through the main relief valve and enters port A and the brake is released.
of check valve (20).
Some of the oil entering port A enters port B
of left and right steering valves (5) and (15),
and stops. When this happens, the oil from the
back pressure port of the clutch piston returns
from port C to drain port H, and the clutch is
engaged by the tension of the clutch spring.
D275A-2 1o-55
2. When steering lever is pulled
(clutch disengaged, brake released)
From power train pump
F19702031 A
When the left steering lever is pulled, roller The hydraulic pressure beyond port C is deter-
(25) of lever (28) pushes shaft (7) to the left mined by the tension of modulating spring (6),
and compresses modulating spring (6). The re- which changes the load in accordance with the
action to this moves steering valve (15) to the amount the steering lever is operated.
left. Therefore, if the steering lever is moved a short
When this happens, the circuit between port C distance, the hydraulic pressure beyond port C is
and drain port H is closed, and the circuit be- set low and the clutch remains partially engaged,
tween ports B and C is opened. and if it is moved a large distance, the hydraulic
The oil from the power train pump flows from pressure is set high and the clutch is fully disen-
port B and enters port C. Some of the oil flows gaged.
to the clutch piston port and becomes the back
pressure, and the rest of the oil passes
through orifice b and enters port D.
The oil entering port D pushes piston (3). and
the reaction compresses spring (6) and moves
valve (15) to the right. This closes the circuit
between ports B and C, so the oil cannot flow
beyond port C. As a result, the hydraulic press-
ure does not rise and is maintained at the
same level.
If the steering lever is pulled further, the above
operation is repeated, and when roller (25) of
lever (28) reaches the position where it con-
tacts shaft (12) of the brake valve, the hy-
draulic pressure beyond port C rises to the set
pressure of the main relief valve (26 kg/cm*),
and the clutch is fully disengaged.
1 O-56 D275A-2
3. When steering lever is pulled
(clutch disengaged, brake applied)
18 20 14 11 12
From 3 pump
F19702032A
When the left steering lever is pulled further If the steering lever is pulled further, the above
from the condition in Item 2, roller (25) of lever operation is repeated, and when it reaches the
(28) pushes shaft (12) to the left and com- end of its travel, the brake is fully applied.
presses modulating spring (11). The reaction to The hydraulic pressure beyond port F is deter-
this moves brake valve (14) to the left. mined by the tension of return spring (17) which
When this happens, the circuit between ports changes the load in accordance with the amount
E and F is closed, and the circuit between port the steering lever is operated.
F and drain port H is opened. Therefore, if the steering lever is moved a short
The oil from the power train pump flows from distance, the hydraulic pressure beyond port F is
port A, pushes open check valve (20), and en- set high and the brake is partially applied, and if it
ters port E, where is stops. is moved a large amount, the hydraulic pressure
Some of the oil that flows to the brake piston is set low and the brake is fully applied.
port and becomes the back pressure flows Port J is connected to port F, and this reduces the
from port F and is drained to port H, and the operating force of lever (28) that pushes out shaft
rest of the oil passes from port F through ori- (12) to the left.
fice c and enters port G. However, when the However, the hydraulic pressure at port J, that is,
oil beyond port F is drained to port H and the the booster pressure, follows the hydraulic press-
hydraulic pressure drops, the oil enters port G ure of port F that changes in accordance with the
and pushes piston (18). The reaction force change in the amount that the steering lever is
pushing valve (14) to the left also becomes moved, so the operating force of the steering
smaller, so valve (14) is returned to the right lever also changes.
by the tension of return spring (17). This closes
the circuit between ports F and H, so the hy-
draulic pressure beyond port F does not drop,
but is maintained at the same level.
D275A-2 1o-57
4. When brake pedal is depressed
(clutch engaged, brake applied)
To torque converter valve,

To transmission
cs
From power train pump ~--fCG%
F19702033
When the brake pedal is depressed, the two

rollers (25) of lever (27) push left and right
shafts (12) to the left, and left and right brake
valves (IO) and (14) are actuated in the same
way as in Item 3.
Therefore, the hydraulic pressure is set in ac-
cordance with the amount the brake pedal is
depressed, and it is possible to adjust the brak-
ing effect.
The left and right steering levers are not being
operated, so the clutch is engaged.
1 O-58 D275A-2
FINAL DRIVE
17MF02039
GENERAL
The reduction system consists of one stage l Between inner body (15) and outer body (13)
using spur gears and another using planetary of the sprocket and sprocket boss (12), there
gears. The lubrication system uses the gears to are rubber bushings (20) installed equally
splash up the oil in the final case to lubricate spaced around the circumference at ten places
all the parts. on each side. These rubber bushings are cy-
The rotating and sliding parts of the sprocket lindrical with a two layer construction of rub-
have floating seals (19) to prevent dirt from ber and metal. The rubber bushings are de-
getting in from the outside, and to prevent the formed when there is external force such as
oil from leaking out. impact force of drawbar pull during operations.
This reduces the load on the final drive compo-
nents. In addition, seal (14) is assembled to
separate rubber bushings (20) completely from
the outside in order to prevent the entry of dirt
or water from outside.
1 O-60 D275A-2
17MF02040
1. Bearing cage 9. Cover 17. Hub

2. Final drive case 10. Sun gear (17 teeth) 18. Carrier
3. No. 1 pinion (20 teeth) 11. Sprocket teeth 19. Floating seal
4. No. 1 gear hub 12. Sprocket bos 20. Rubber bushing
5. No. 1 gear (77 teeth) 13. Outer body 21. Wear guard
6. Cover 14. Seal 22. Shaft
7. Ring gear (67 teeth) 15. Inner body 23. Pivot shaft
8. Planet gear (25 teeth) 16. Cover
D275A-2 lo-61
TRANSMISSION OF MOTIVE FORCE
The motive force from the bevel gear shaft and

steering clutch is transmitted to No. 1 pinion
(3).
It is then transmitted through No. 1 gear (5)
and No. 1 gear hub (4) to rotate sun gear (10).
The rotation of sun gear (10) is transmitted to
planet gear (8). However, ring gear (7), which
is meshed with the planet gears, is fixed to
cover (9). Therefore, planet gear (8) rotates on
its own axis and moves along the ring gear in
orbit around sun gear (10). The rotation of sun
gear (10) is transmitted to carrier (18), and
then passes through hub (17) to rotate inner
body (15). The inner body rotates in the same
direction as sun gear (10).
Rubber bushing (20) is installed between inner
body (15) and outer body (13) and sprocket
boss (12), so the rotation of inner body (15) is
transmitted through rubber bushing (20) to
outer body (13), sprocket boss (12), and
sprocket teeth (11).
17MF02041
1 O-62 D275A-2
MAIN FRAME
I I A-A B-B
1. Main frame
D-D
17MF02042
D275A-2 1 O-63
A-A 17MF02043
1. Idler 7. Track roller (Double flange)

2. Idler yoke 8. Track roller guard
3. Carrier roller 9. Cap
4. Track frame 10. Bushing
5. Sprocket 11. Pivot shaft
6. Track roller (Single flange) 12. Bushing
1 O-64 D275A-2
RECOIL SPRING
B-B
17MF02044
1. Idler yoke OUTLINE

2. Front pilot l Recoil spring (3) is assembled inside track
3. Recoil spring frame inner cvlinder (5). One end is connected
4. Piston shaft to idler yoke (I) through front pilot (2), and the
5. Track frame inner cylinder other end is connected to inner cylinder (5)
6. Track frame outer cylinder through rear pilot (7).
7. Rear pilot Adjustment cylinder (8) is fixed to track frame
8. Adjustment cylinder outer cylinder (6), and moves inner cylinder (5)
9. Adjustment valve backwards or forwards by pumping in or re-
10. Outer cylinder bushing leasing grease from valve (9) to adjust the
track tension.
D275A-2 1O-65
SUSPENSION (l/Z)
Serial No. : 10001 - 10127
----,
___.-~’ \..
../--
___.--.--------
__
rT-cM_I-
17MF02045
1. Pivot shaft assembly 9. Side pin

2. Equalizer bar 10. Lock plate
3. Seal cage 11. Bushing
4. Pivot shaft 12. Center pin
5. Thrust plate 13. Bolster
6. Cover 14. Small cushion
7. Thrust plate 15. Large cushion
8. Joint
1O-66 D275A-2
@
[Left side of pivot shaft] [Right side of pivot shaft]
* For machines with the dual tilt specification, the

right side is also the same.
c
Rear
I) Front
B-B \
11
Y
17MF02046
D275A-2 1 O-67
Serial No. : 10128 and up
17MF02045
1. Pivot shaft assembly 9. Side pin

2. Equalizer bar 10. Lock plate
3. Seal cage 11. Bushing
4. Pivot shaft 12. Center pin
5. Thrust plate 13. Bolster
6. Cover 14. Small cushion
7. Thrust plate 15. Large cushion
8. Joint
1 O-67- 1
@
A-A
Left side of pivot shaft Right side of pivot shaft
Ei c
z
z
Rear Front
B-B
SBDOl511
10-67-2
@
SUSPENSION (2/2)
/
13
- /
16
REAR 17
-'-
E-E '16 F-F
D-D
17MF02047
16. Rod
17. Rod pin
18. Bushing
1 O-68 D275A-2
HYDRAULIC PIPING
BLADE
17MF02048
1. Blade tilt cylinder

2. Blade lift cylinder
3. Hydraulic pump
4. Blade lift valve
5. Ripper low valve
6. Hydraulic tank
7. Hydraulic filter
8. Ripper high valve
D275A-2 1O-69
VARIABLE MULTIPLE SHANK RIPPER
17MF02049
9. Ripper tilt cylinder

10. Ripper lift cylinder
1O-70 D275A-2
VARIABLE GIANT RIPPER
198FlO89
9. Ripper tilt cvlinder

10. Ribber lift cilinder
11. Pin puller cylinder
12. Pin puller solenoid valve
10-70-l
0
HYDRAULIC CONTROL
BLADE CONTROL
/
197FO2069
1. Blade control lever

2. Lock lever
A. RAISE
B. LOWER
C. FLOAT
D. L.H. TILT
E. R.H. TILT
D275A-2 1o-71
BLADE CONTROL (For dual tilt dozer)
17MF02050
1. Blade control lever Dual tilt operation

IA. Dual tilt switch l Dual left tilt : Switch IA +position D
1 B. Pitch switch l Dual right tilt : Switch IA fposition E
2. Lock lever l Pitch back : Switch 1B fposition D
l Pitch dump : Switch 1B -l-position E
A. RAISE
B. LOWER
C. FLOAT
D. L.H. TILT
E. R.H. TILT
1 O-72 D275A-2
RIPPER CONTROL
3. Ripper control lever

4. Lock lever
A. RAISE
B. LOWER
C. TILT ON
D. TILT BACK
D275A-2 1o-73
HYDRAULIC CIRCUIT SYSTEM
ENGINE RUNNING, HYDRAULIC CONTROL LEVER IN “HOLD”
I-% /
33
I#
M 1
t I .
17MF02051
1o-74 D275A-2
HYDRAULIC CIRCUIT DIAGRAM
ENGINE RUNNING, HYDRAULIC C6NTROL LEVER IN “HOLD”
Ripper high val\ie Blade-tilt ripper low valve

.-
r
34
34
1. Hydraulic tank
2. Hydraulic pump
4. Check valve
5. Check valve
6. Demand spool
7. Blade lift valve spool
35 8. Shuttle valve
9. Shuttle valve
IO. Blade lift suction valve
11. Quick drop valve
12. Blade lift cylinder
14. Check valve
15. Blade tilt valve spool
16. Check valve
-_
Pi3Y I 17. Ripper tilt valve spool
i 18. Check valve
19. Ripper lift valve spool
I I
-------
-- 20. Shuttle valve
2’ I r-----
! 1 !
lift valve
5
21.
22.
Blade tilt cylinder
Fixed differential pressure
1:I-
j [ Blade _ _ - ‘2 ‘I
-I I
valve (for ripper tilt)
i___________________--______
I
I ----------------_____ ----------7
D-&__ _-_ 23. Shuttle valve
&I -t------
7 l-l
I
.---------$----- - 24. Fixed differential pressure
12 valve (for ripper tilt)
f--,
25. Shuttle valve
1 ! ! 26. Ripper tilt valve spool
27. Fixed differential pressure
- valve (for ripper lift)
28. Shuttle valve
0 ,I 29. Fixed differential pressure
I( A valve (for ripper lift)
/
\
-
-1
Lower X - 30. Shuttle valve
Fr
f-----
B
e 31. Ripper lift valve spool
11 -
)( Float
32. Check valve
-II- , / 33. Ripper lift suction valve
0 100 I -’ \ . \
-1 r+ Z (Engine at 1915 rpm)
L ----
36. Ripper tilt suction valve
37. Hydraulic filter
17MF02052
D275A-2 1o-75
FOR DUAL TILT DOZER
ENGINE RUNNING, HYDRAULIC CONTROL LEVER IN “HOLD”
38
A -
Y -
1 Wooer hiah valve Blade-tilt ripper low valve
.-
36
I r-l-i-----+
~ 11 Low
__~&._*
1+- +
r-- -
-5-z --- ---3
I 1.
I Tilt bi Hydraulic tank
36 vi L--J 2. Hydraulic pump
k#
on
+{____T= 3. Main relief valve
4. Check valve
++-_----____+l,9~
_.IA 5. Check valve
6. Demand spool
Bz, 7. Blade lift valve spool
0 8. Shuttle valve
4, I. A2 9. Shuttle valve
i-i
I4 1
-4 IQ. Blade lift suction valve
37 IZ 11. Quick drop valve
I
1 I
t :
-_c_--_--
I
_---_---I
I 11% 12. Blade lift cylinder
*f-R- 14.
15.
16.
Check valve
Blade tilt valve spool
Check valve
17. Ripper tilt valve spool
-4 .--
1 18. Check valve
19. Ripper lift valve spool
---__----_-- --__ ---__---- ____ --1
4l L P T 20. Shuttle valve

-----_------~-----_----------~~~ _ _ 21. Dual tilt solenoid valve
-_-_ -7 , f 22. Blade pitch solenoid valve
----- , 1 Blade liftvalve _ _ - P‘2 5 23. Blade tilt cylinder
r-----
I---_-__ ______ __ _____ -_ ______
---I!
_----------1 24. Fixed differential pressure
f 7
-t------
-------~~--------____ _ __---__--+---__ “-+--_ -- valve (for ripper tilt)
2 &I t 25. Shuttle valve
12
I--, 26. Fixed differential pressure
I * I
I valve (for ripper tilt)
\
--
27. Shuttle valve
-i, 28. Ripper tilt valve spool
valve (for ripper lift)
30. Shuttle valve
0 -0
I
I( valve (for ripper lift)
E
32. Shuttle valve
g.E+(
11
E 33.
34.
Ripper lift valve spool
Check valve
0
I I
35. Ripper lift suction valve
I----,,
I 37.
38.
Ripper lift cylinder
Ripper tilt suction valve
12.
I
I
1 -_
5
L ______ -_ ________----_____ -----___A \I
.
I
I
I
/
Ll
17MF02053
39. Hydraulic filter
1O-76 D275A-2
HYDRAULIC TANK
-I----“\ 1 i
I
=:_._.-. LL.il_.‘,
17MF02054
7. Oil lever gauge P : From small pump

2. Oil filler P, : From large pump
3. Valve A : To blade lift cylinder head
4. Hydraulic oil filter B: To blade lift cylinder bottom
5. Baffle A, : To blade tilt cylinder bottom
6. Tube B, : To blade tilt cylinder head
7. Blade tilt, ripper low valve A,: To ripper tilt cylinder head
8. Blade lift valve B, : To ripper tilt cylinder bottom
A,: To ripper lift cylinder head
B, : To ripper lift cylinder bottom
T: From ripper high valve
D275A-2 1o-77
BLADE LIFT CONTROL VALVE
I97FOSS
OUTLINE P, : From large pump

l Demand valve (14) is assembled in the blade P, : From small pump
lift valve, and the oil from the two hydraulic A : To blade lift cylinder head
pumps is merged by check valve (4). B : To blade lift cylinder bottom
The demand valve uses the oil from the two T : To hydraulic tank
hydraulic pumps effectively: the oil from the
large pump becomes the pilot pressure; the oil
from the ripper circuit and the blade lift circuit
through shuttle valve (18B) becomes the pilot
pressure.
1 O-78 D275A-2
B-B
li 1'1 io
A-A
18
18
E-E
F-F I97FO99
1. Valve body 8. Shuttle valve ball 15. Suction valve spring

2. Check valve spring 9. Return spring 16. Suction valve (for LOWER side)
3. Check valve 10. Detent spring 17. Suction valve (for RAISE side)
4. Check valve (for small pump) 11. Detent ball 18. Main relief and shuttle valve assembly
5. Check valve spring 12. Detent shaft 18A. Main relief valve
6. Blade lift valve spool 13. Demand valve spring 18B. Shuttle valve
7. Shuttle valve seat (plug) 14. Demand valve spool
D275A-2 1 o-79
MAIN RELIEF VALVE, SHUTTLE VALVE
A-A z 197FlOO
1. Adjustment screw for main relief pressure 8. Piston

2. Sleeve 9. Shuttle valve
3. Main relief valve spring 10. Shuttle valve spring
4. Main relief valve poppet PL. From shuttle valve in ripper valve
5. Valve seat PB. From shuttle valve in blade lift valve
6. Plug P To demand valve pilot port
7. Valve body TY’ To hydraulic tank
1 O-80 D275A-2
OUTLINE
l The main relief valve is in the circuit between
the hydraulic tank and the ripper circuit and
blade lift circuit (which passes through shuttle
valve (9)). The main relief valve sets the hy-
draulic pressure in the large pump circuit that
is, the blade lift cylinder to 210 kg/cm*.
l The shuttle valve is in the circuit between the
demand valve (which passes through the main
relief valve) and the blade lift and ripper cir-
cuit. It selects the two circuits to apply pilot
pressure to the demand valve.
In other words, it selects either the blade lift
circuit or the ripper circuit.
When the work equipment is not being used
(control lever at HOLD), the tension of spring
(IO) in the shuttle valve connects the pilot port
of the demand valve and the blade lift circuit.
Operation of main relief valve

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

valve spring force (set pressure), the pilot
valve moves, allowing the oil in chamber B to 204FO82
flow into chamber C through chamber D. In ad-
dition, the oil flows from chamber A to B
through orifices.
l If the oil flows through the orifice of valve, a
differential pressure occurs between the cham-
bers A and B, moving valve to the right. This
allows the oil in chamber A to flow into cham-
ber C.
204FO83
D275A-2 lo-81
BLADE TILT CONTROL AND RIPPER LOW VALVE
197FIOI
OUTLINE
l The ripper low valve consists of a 3-spool P : From small pump
valve. It acts to reduce the hydraulic loss in the A, : To blade tilt cylinder bottom
independent blade tilt circuit when the blade is B, : To blade tilt cylinder head
being tilted. In the ripper lift and tilt circuits, A, : To ripper tilt cylinder head
the pilot pressure switches the demand valve B, : To ripper tilt cylinder bottom
when the control lever is operated. At the A, : To ripper tilt cylinder head
same time, the oil which passes through the B, : To ripper tilt cylinder bottom
low valve operates the ripper high valve (fixed C, : To demand valve
differential pressure type valve) at the rear, P,: To shuttle valve in blade lift valve
and improves the response of the ripper.
1 O-82 D275A-2
B-B
D-D
197FlO2
1. Blade tilt valve spool 8. Adjustment screw for 15. Main relief valve
2. Ripper tilt valve spool main relief pressure 16. Valve seat
3. Ripper lift valve spool 9. Sleeve 17. Check valve
4. Valve body 10. Main relief valve body 18. Check valve spring
5. Valve joint 11. Poppet spring 19. Valve seat
6. Return spring 12. Main relief valve poppet 20. Shuttle valve seat (plug)
7. Bolt 13. Valve seat 21. Shuttle valve ball
14. Main relief valve spring 22. Shuttle valve seat
D275A-2 1 O-83
RIPPER HIGH VALVE
61-l BZ-1
\ /
AI-2 AZ-2
P : From large pump

PAI : From low valve tilt on
PB, : From low valve tilt back
PA2 : From low valve ripper raise
P : From low valve ripper lower
197FlO3 A::, : To left tilt cylinder bottom
B,., : To left tilt cylinder head
A,, : To right tilt cylinder bottom
B,., : To right tilt cylinder head
A,., : To left tilt cylinder bottom
B,., : To left tilt cylinder head
A,., : To right tilt cylinder bottom
B,., : To right tilt cylinder head
1 O-84 D275A-2
10
A-A ,a B-B
D-D
197FlO4
1. Valve body 11. Plug

2. Shuttle valve seat 12. Check valve spring
3. Shuttle valve ball 13. Check valve
4. Valve body 14. Valve return spring
5. Plug 15. Plug
6. Fixed differential pressure valve spring 16. Ripper lift valve spool
7. Fixed differential pressure valve 17. Suction valve spring
8. Fixed differential pressure valve 18. Suction valve
9. Fixed differential pressure valve 19. Ripper tilt valve spool
10. Fixed differential pressure valve
D275A-2 1 O-85
RIPPER TILT SUCTION VALVE
I
C
A-A
17MF02055
1. Valve body A. To hydraulic tank

2. Valve B. From ripper high valve
3. Spring C. To ripper tilt cylinder bottom
4. Stopper
5. Plug
1 O-86 D275A-2
OPERATION
1. Blade lever at HOLD, ripper lever at HOLD
I. II’ t.
r.
,.Gz ‘a R.
17MF02056
1O-88 D275A-2
l When the blade lever is at the HOLD position,
blade lift spool (5) closes the circuit from port
B to ports C and D, and opens the circuits of
ports H and E and ports J and F. Blade tilt
spool (16) closes the circuit from port B, to
ports C, and D,.
Therefore, the circuits for blade lift cylinder (9)
and blade tilt cylinder (17) become closed cir-
cuits, and the cylinders are held in the same
position.
If the ripper lever is placed at the HOLD posi-
tion, ripper tilt spool (19) closes the circuit
from port B, to ports C, and D4, and ripper lift
spool (21) closes the circuit from port B, to
ports C, and D,.
Therefore, the circuits for ripper tilt cylinder
(45) and ripper lift cylinder (33) become closed
circuits through the two ripper valves, and the
cylinders are kept in the same position.
If the engine is started in this condition, the oil
from the large pump enters port A of the blade
lift valve. Some of the oil pushes open check
valve (3) and enters port B where it stops. The
rest of the oil passes through orifice a of de-
mand valve (I), and enters ports L and M. (The
demand valve is pushed to the right by the
tension of spring (2).)
The oil from the large pump flows to the blade
lift valve, but it also enters port A, of the ripper
Hi valve, pushes open the two check valves
(23) and (35), then enters ports B, and B,, and
stops.
The oil from the small pump flows from port
A, of the ripper Lo valve and blade tilt valve to
ports A,, A,, and A,. Some of the oil pushes
open check valves (15), (18), and (20), then en-
ters ports B,, B,, and B,, and stops. The rest of
the oil flows from port A,, enters port R of the
blade lift valve, pushes open check valve (4),
and flows to port A, where it merges with the
oil from the large pump.
D275A-2 1 O-89
Blade lever at HOLD, ripper lever at HOLD
(oil being drained)
In the condition in Item 1, if the hydraulic
pressure in the circuit rises, the surface press-
ure (force pushing the demand valve to the
left) on port L of demand valve (1) becomes
greater than the combined force (force push-
ing the demand valve to the right) of the sur-
face pressure bearing on port M and tension of
spring (2), it moves the demand valve to the
left, opens the circuits between ports A and E,
and ports R and F. The oil from the large and
small pumps is then relieved to ports E and F,
and is drained from port G to the hydraulic
tank.
Therefore, both the large and small pumps are
put in an unload condition.
From shuttle
I/ ripper Lo valve
17MF02057
1O-90 D275A-2
3. Blade lever at RAISE
(blade operating at high speed)
When the blade lever is moved fully to the
RAISE position, spool (5) moves to the left, and
fully opens the circuits between ports B and C,
ports C and H, and ports D and F.
When this happens, the oil from the two
pumps passes from ports A and B and enters
port C. Some of the oil flows to the head end
of cylinder (9), and the rest flows from port H,
pushes shuttle valve (8) to the right and opens
it, flows to port K, and enters ports N, 0, and P
of shuttle valve (10). It then enters port Q of
demand valve (1) and becomes the pilot press-
ure.
At the same time, the oil from the pump
passes through orifice a of demand valve (I),
enters ports L and M, and becomes the pilot
pressure.
The oil at the bottom end of cylinder (9) flows
from port D to port F, and returns from port G
to the hydraulic tank. When the hydraulic
pressure in the circuit rises in this way, spool
(5) opens the circuit between ports B and C
fully, so the resistance of the oil flowing from
port B to port C is small, and there is little
pressure difference generated between port B
and port C.
Therefore, no pressure difference is generated
between port L and ports M and Q of the de-
mand valve. The surface pressure acting on
the left and right of the demand valve is equal,
so the demand valve is moved to the right by
the tension of spring (2).
When this happens, the circuits between ports
A and E, and ports R and F are closed, and all
the oil from both the large and small pumps
flows to the head end of the cylinder to in-
crease the speed of movement of the cylinder. From shuttle
- valve inside
ripper Lo valve
17MF02058
D275A-2 10-91
(blade operating at low speed)
When the blade lever is moved finely to the
RAISE position, spool (5) moves slightly to the
left, and partially opens the circuit between
ports B and C, ports C and H, and ports D and
F.
When this happens, the oil from the two
pumps passes from ports A and B, is throttled
by spool (5), and enters port C. Some of the oil
flows to the head end of cylinder (9), and the
rest flows from port H, pushes shuttle valve (8)
to the right and opens it, flows to port K, and
enters ports N, 0, and P of shuttle valve (IO). It
then enters port Q of demand valve (1) and
becomes the pilot pressure.
At the same time, the oil from the pump
passes through orifice a of demand valve (I),
enters ports L and M, and becomes the pilot
pressure.
The oil at the bottom end of cylinder (9) flows
from port D to port F, and returns from port G
to the hydraulic tank. When the hydraulic
pressure in the circuit rises in this way the situ-
ation is different from in Item 3: spool (5) is
throttling the circuit between ports B and C, so
the flow of oil from port B to port C is re-
stricted, and a pressure difference is generated
between port B and port C. The hydraulic
pressure in the circuit up to port B becomes
higher.
Therefore, when the surface pressure acting
on port L of the demand valve (1) becomes
greater than the combined force of the surface
pressure acting on port M, the surface press-
ure acting on port Q and the tension of spring
(2), the demand valve is moved to the left.
When this happens, the circuits between ports
A and E and ports R and F are opened, and the
oil from both the large and small pumps is re-
lieved to the hydraulic tank. This suppresses ripper to Lo valve
the rise in the hydraulic pressure at ports A
and B, and the cylinder moves slowly.
N 10 17MF02059
As explained in Items 3 and 4 above, the speed
of movement of the cylinder is determined by
the amount of opening of ports B and C corre-
sponding to the movement of the lever. If it is
wide open, the flow of oil beyond port C in-
creases, the hydraulic pressure rises, and the
speed of movement becomes faster. If it is op-
ened only slightly, the flow of oil beyond port
C is throttled, so the oil flow is reduced, the
hydraulic pressure becomes low, and the
speed of movement is slow.
In other words, the hydraulic pressure and oil
flow beyond port C is proportional, so this pro-
vides not only operation of the blade that fol-
lows the fine movements of the blade lever,
but reduces the pulling force (flow force) ac-
ting on spool (5), so the operating force of the
spool does not increase.
1 O-92 D275A-2
(cylinder at stroke end)
If cylinder (9) moves to the end of its stroke
from the condition in Items 3 and 4, the hy-
draulic pressure in the whole circuit rises.
Therefore, the hydraulic pressure beyond port
C rises, and the oil entering the main relief
valve (45) through shuttle valves (8) and (IO),
that is, the oil at port P, pushes open poppet
(13) and is relieved to port T.
At this point, the circuit from port 0 to port P
is throttled by orifice c, so the supply of oil to
port P is delayed. As a result, the hydraulic
pressure of pilot port Q of demand valve (1)
drops, and the demand valve moves to the
left.
When this happens, the circuit between ports
A and E and ports R and F are opened, and the
oil from the two pumps is relieved to prevent
the hydraulic pressure from rising any further.
The hydraulic pressure at this point is 210 kg/
cm2.
4% t
:...:.:.:.:.:.:.:.:.:.:.:.:.:!/
1 il.,.,.,.,...
_ From small pump

through ripper valve
* From large pump
From shuttle
c valve inside
ripper Lo valve
1'0 i
17MF02060
D275A-2 1o-93
6. Blade lever at LEFT TILT
a 4 To ripper Hi valve
IS
A’
17MF02061
l When the ripper lever is moved to the LEFT The oil from the large pump enters port A of the
TILT position, spool (16) moves down, opens blade lift valve, and actuates demand valve (1) in
the circuits of ports B, and C, and ports D, and the same way as in Item 2. It is relieved from port
F,, and closes the circuit of ports A, and A,. A to E, and is drained to the hydraulic tank.
When this happens, the oil from the small When the blade tilt is operated, the circuit be-
pump flows from port A,, pushes open check tween ports A, and A, is closed, so the oil does
valve (15), flows from port B,, and enters port not enter the ripper circuit, and it is impossible to
C,. It flows to the bottom end of cylinder (17), operate the ripper.
and when the hydraulic pressure in the circuit In other words, the blade tilt circuit is given
rises, it extends the cylinder. priority over the ripper circuit.
At this point, the oil at the head end of the cy-
linder returns from port D, to port F,, and is
drained from port E, to the hydraulic tank.
1o-94 D275A-2
Blade lever at LEFT TILT
(cylinder at stroke end)
B - To ripper Hi valve
17MF02062
From the condition in Item 6, if cylinder (17) is

moved to the end of its stroke, the hydraulic
pressure in the whole circuit rises.
When this happens, the oil from the small
pump flows from port A,, and pushes open
main relief valve poppet (14). It is then relieved
to port E,, so the hydraulic pressure does not
rise any further.
cm*.
D275A-2 1 o-95
8. Ripper lever at TILT ON
(ripper Lo valve, shuttle valve actuated)
/Hs
---22
17MF02063
. When the ripper lever is moved to the TILT ON The oil entering port S passes through orifice b,
position, spool (19) moves up, opens the cir- and pushes piston (11). The reaction moves
cuits between ports B, and D,, ports C, and E,, shuttle valve (IO) to the left, closes the circuit be-
and ports A, and G,, and closes the circuit between ports N and 0, and opens the circuit be-
tween ports A, and A,. tween ports S and 0.
When this happens, the oil from the small The oil entering port 0 from port S then passes
pump enters port A, and A,. Some of the oil through orifice c, and enters ports P and 0. It
pushes open check valve (18), flows from port becomes the pilot pressure of demand valve (I),
B, into port D,, and the flows to port G, of the and moves the demand valve to the right.
ripper Hi valve. The rest of the oil passes When this happens, the circuit between ports A
through the groove in spool (19), enters port and E is closed, so the oil from the large pump is
G,, pushes shuttle valve (22) down fully, then not drained to the hydraulic tank. The whole
flows from port H, to port S of shuttle valve amount of the oil flows to port A, of the ripper Hi
(IO). valve.
1 O-96 D275A-2
9. Ripper lever at TILT ON
(ripper Hi valve actuated)
As explained in Item 8, the oil from the
large pump enters A, of the ripper Hi valve,
pushes open check valves (23) and (35),
flows to ports B, and B,, and stops.
The oil from the small pump flows from
port D4 of the ripper Lo valve and enters
port G,.
Some of the oil entering port G, passes
through the passage inside valve (39), flows
to port L,, and pushes shuttle valve (41) up
fully. It then enters port N,, pushes spool
(36) to the right, and becomes the pilot
pressure.
The rest of the oil is throttled by orifice f
and enters port C,.
Some of the oil entering port C, passes
to port J,, and pushes shuttle valve (44)
down fully. It then enters port 0,, pushes
spool (36) to the left, and becomes the pilot
pressure.
The rest of the oil flows from port C, to the
bottom end of ripper tilt cylinder (45).
When all the above hydraulic circuits are
filled with oil, the hydraulic pressure starts
to rise.
17MF02064
D275A-2 1o-97
. From the condition previously explained, if
the hydraulic pressure continues to rise,the
oil at port G, is throttled by orifice f and en-
ters port C,. Because of the resistance, the
hydraulic pressure at port G, becomes
higher than the pressure beyond port C,.
Therefore, the hydraulic pressure at pilot
port N, of spool (36) becomes higher than
the hydraulic pressure at port 0,, so when
this pressure difference becomes greater
than the tension of spring (38), it pushes
spool (36) out to the right.
When this happens, the circuits between
ports B, and C,, and ports D, and F, open,
the oil from the large pump flows from port
B, to port C,, enters the bottom end of rip-
per tilt cylinder (45), and merges with the
oil from the small pump to extend the cylin-
der.
Some of the oil at the head end of the cylin-
der returns from port D, to port F,, and is
drained to the hydraulic tank. The rest of
the oil flows from port D,, is throttled by
orifice g of valve (42), and returns to port
H,. It then flows from port C, of the ripper
Lo valve, returns to port E,, and is drained
to the hydraulic tank.
17MF02065
1 O-98 D275A-2
10. Ripper level at LOWER
(ripper Lo valve, shuttle valve actuated)
- To ripper Hi valve (A, port)
I / /
A2 A3 A4
17MF02066
0 When the ripper lever is moved to the The oil entering port S passes through orifice b,
LOWER position, spool (21) moves down, and pushes piston (11). The reaction moves
opens the circuits of ports B, and C,, ports D, shuttle valve (IO) to the left, closes the circuit be-
and F,, and ports A, and G, and closes the tween ports N and 0, and opens the circuit be-
circuit of ports A, and A,. tween ports S and 0.
When this happens, the oil from the small The oil entering port 0 from port S then passes
pump enters ports A,, A,, and A4. Some of through orifice c, and enters ports P and 0. It
the oil pushes open check valve (20), flows becomes the pilot pressure of demand valve (I),
from port B, into port C,, and then flows to and moves the demand valve to the right.
port H, of the ripper Hi valve. The rest of the When this happens, the circuit between ports A
oil passes through the groove in the spool, and E is closed, so the oil from the large pump is
enters port G,, pushes shuttle valve (22) up not drained to the hydraulic tank. The whole
fully, then flows from port H, to port S of amount of the oil flows to port A, of the ripper Hi
shuttle valve (IO). valve.
D275A-2
1o-99
11. Ripper lever at LOWER
(ripper Hi valve actuated)
As explained in Item 10, the oil from the large
pump enters port A, of the ripper Hi valve,
pushes open check valves (23) and (35), flows
to ports B, and B,, and stops.
The oil from the small pump flows from port
C, of the ripper Lo valve and enters port H,.
Some of the oil entering port H, passes
to port M,, and pushes shuttle valve (32)
down fully. It then enters port 0,, pushes
spool (24) to the left, and becomes the pilot
pressure.
The rest of the oil is throttled by orifice e and
enters port D,.
Some of the oil entering port D, passes
to port K,, and pushes shuttle valve (29) up
fully. It then enters port N,, pushes spool (24)
to the right, and becomes the pilot pressure.
The rest of the oil flows from port D, to the
bottom end of ripper lift cylinder (33).
When all the above hydraulic circuits are
filled with oil, the hydraulic pressure starts to
rise.
From CS
17MF02067
10-100 D275A-2
. From the condition previously explained, if
the hydraulic pressure continues to rise, the
oil at port H, is throttled by orifice e and en-
ters port D,. Because of the resistance, the
hydraulic pressure at port H, becomes higher
than the pressure beyond port D,.
Therefore, the hydraulic pressure at pilot port
0, of spool (24) becomes higher than the hy-
draulic pressure at port N,, so when this
pressure difference becomes greater than the
tension of spring (25), it pushes spool (24) out
to the left.
When this happens, the circuits between
ports B, and D, and ports C, and E, open, the
oil from the large pump flows from port 6, to
port D,, enters the bottom end of ripper lift
cylinder (33), and merges with the oil from
the small pump to extend the cylinder.
Some of the oil at the head end of the cylin-
der returns from port C, to port E,, and is
drained to the hydraulic tank. The rest of the
oil flows from port C,, is throttled by orifice d
of valve (27), and returns to port G,. It then
flows from port D, of the ripper Lo valve, re-
turns to port E,, and is drained to the hy-
draulic tank.
17MF02068
D275A-2 10-101
12. Ripper lever at LOWER (cylinder at stroke end)
-1 I I I I
17MF02069
D275A-2
a From the condition in Items 10 and 11, if cy-
linder (33) is moved to the end of its stroke,
the hydraulic pressure in the whole circuit
rises.
When this happens, in the same way as in
Item 7, the oil from the small pump flows
from port A, and pushes open main relief
valve poppet (14). It is then relieved to port
E,, so the hydraulic pressure does not rise
any further.
2
;Te’ oil passing through shuttle valves (22)

and (IO), and flowing from ports S and 0 to
port P also pushes open main relief valve
poppet (13), and is relieved to port T. The cir-
cuit from port 0 to port P is throttled by ori-
fice c, so the supply of oil to port P is de-
layed. As a result, the hydraulic pressure at
pilot port 0 of demand valve (1) also drops,
and the demand valve moves to the left.
When this happens, the circuit between ports
A and E opens, and the oil from the large
pump is relieved, so the hydraulic pressure in
the circuit of the large pump does not rise
any further.
cm2.
When the hydraulic pressure in the whole cir-
cuit is set at 210 kg/cm2, the pressure dif-
ference on both sides of orifice e of valve
(30), that is, the difference in pressure be-
tween ports H, and D,, disappears. The pilot
pressure at port 0, that is pushing spool (24)
to the left becomes the same pressure as the
pressure at port N,. When this happens,
spool (24) is returned to the right by the ten-
sion of spring (25) to a position where it is in
balance with the tension of spring (26).
At this point, the circuits between ports B,
and D, and ports C, and E, are closed. The oil
from the large pump goes as far as port B,,
and stops. The oil at the head end of cylinder
(33) flows from port C,, passes through ori-
fice d of valve (27), and returns only to port
G,.
D275A-2 10-103
PISTON VALVE
(Blade lift and dual tilt cylinder)
STRUCTURE AND FUNCTION

The piston valve is installed on the piston in
the blade lift cylinder. When the piston reaches
its stroke end, the valve releases the oil from
the hydraulic pump to reduce the oil pressure
being exerted on the piston.
When the blade on a dual tilt dozer is tilted, the
blade is subject to a tortional force owing to
the uneven position of the pistons in the two
cylinders; that is the piston one side is still
moving while the piston on the other side has
reached its stroke end.
The piston valves are installed to prevent the
tortional force from occurring. When one of
the pistons reaches its stroke end, its piston
valve opens to relieve the oil pressure.
In addition, the piston valve relieves the shock
which occurs when the piston comes into con- 17MF02070
tact with the cylinder head or the bottom and 1. Piston rod
serves to reduce the subsequent surge press- 2. Cylinder
ure in the cylinder by letting the oil escape 3. Piston valve seat
from the cylinder before the piston reaches its 4. Piston
stroke end. 5. Piston valve
OPERATION
Piston valve CLOSED
Pressurized oil from the hydraulic pump acts
on piston (4) and piston valve (5).
The piston valve is pushed in the direction of
the arrow until piston valve seat (3) comes into \ \ /i
snug contact with the tapered section, thereby,
this causing the pressure in the cvlinder to rise
and moving piston (4) in the direction of the
arrow.
17MF02071
Piston valve OPEN

Just before piston rod (1) reaches its stroke
end, the front end of piston valve (5) comes
into contact with the cylinder bottom (or the
cylinder head) and is prevented from moving
any further while piston (4) alone keeps on
moving ahead.
Then, the oil sealed within the piston valve on
the cylinder head side will escape from piston
valve seat (3) so that the oil pressure in the cy-
linder is prevented from rising.
Strike
17MF02072
10-104 D275A-2
QUICK DROP VALVE
STRUCTURE
The quick drop valve consists of valve body (I),
spring (2), spool (3), check valve (4).
The quick drop valve serves to increase the blade
lowering speed and to reduce the occurrence of
vacuum when the blade is lowering, thereby shor-
tening the time lag before digging is started.
The blade lowering speed,- which is generally
determined by the pump discharge, can be made
faster with the quick drop valve.
1. Valve body 4. Spool

2. Spring
3. Check valve
OPERATION 17MF02073
1. Start of lowering
When the blade lever is operated to LOWER,
the oil from the control valve enters the cylin-
der bottom through port A and pushes the pis-
ton. In the mean time, the oil in the cylinder
head is pushed out into the piston, enters
valve port B, and flows into the tank.
2. While lowering I75F209

Pressurized oil from the cylinder head flows
into port C through port B.
At this time, the oil flow is restricted by an ori-
fice provided along the way, causing a dif-
ferential pressure before and after the orifice.
When the differential pressure becomes
greater than the force of spring (2), it com-
presses the spring and moves spool (3) and
valve (4) to the right.
With the spool and the valve have moved, part
of the oil flowing from the cylinder head to the
tank enters the passage to the cylinder bottom
together with the oil from the control valve.
Thus, the blade lowering speed increases in
accordance with the amount of oil that flows to
the bottom of the cylinder and reduces the for-
mation of vacuum at the bottom of the cylin-
der.
175F210
D275A-2 10-105
CYLINDER STAY
17MF02074
1. Yoke
2. Oil seal
3. Bushing
4. Bushing
5. Air bleeding plug
1 O-l 06 D275A-2
SEMI U-DOZER
A-A 17MF02075
OUTLINE
1. Cutting edge 6. Arm l The dozing attachment can be broadly divided
2. Arm 7. Blade into the blade and the hydraulic control which
3. End bit 8. Brace operates the blade. the diagram shows the
4. Straight frame 9. Blade tilt cylinder semi U-dozer.
5. Trunnion 10. Blade lift cylinder The table shows the dimensions and specifica-
tions of the semi U-dozer.
lo-108 D275A-2
B-B D-D
E-E F-F G-G
J-J
K-K
H-H
L-L M-M
17MF02076
OPERATION
l The blade is moved by hydraulic cylinders. l Table of comparisons
l RAISE: The left and. right lift cylinders re- Unit: mm
tract and raise the frame and
blade together. Semi U-dozer
l LOWER: The left and right lift cylinders ex-
Distance between
tend and lower the blade to the 3636
left and right frame
ground.
. LEFTTILT: The tilt cylinder extends and lo- Length of frame I 3775
wers the left side of the blade to
the ground. Width of blade 4300
I
l RIGHT TILT: The tilt cylinder retracts and lo-
wers the right side of the blade to Height of blade 1910
the ground.
Max. blade raise 1505
Max. blade lower I 660
Max. blade tilt I 1025
D275A-2 10-109
A-A
C-C D-D
17MFOi077
10-l 10
0
OUTLINE
l The ripping attachment can be broadly divided
into the ripper and the hydraulic control which
operates the shank. The diagram shows the
variable multiple shank ripper.
The table shows the dimensions and specifica-
tions of the variable multiple shank ripper.
OPERATION
l The shank is moved bv hvdraulic cvlinders.
. RAISE: The left and’right lift cylinders re-
tract and raise the beam and
shank together.
. LOWER: The left and right lift cylinders ex-
tend and lower the beam and
shank together to the ground.
. TILT ON: The left and right tilt cylinders ex-
tend and move the shank forward.
. TILT BACK: The left and right tilt cylinders re-
tract and move the shank to the
rearward.
l Table of comparisons
Unit: mm
Multiple shank ripper
Length of beam 2495

I
No. of shanks 3
1. Tilt cylinder
2. Lift cylinder Shank pitch (with 3
1130
3. Beam shanks installed)
4. Shank Shank pitch (with 2
2260
5. Protector shanks installed)
6. Point
7.
8.
Arm
Pin
Ripping depth
I 2-stage selection
possible
9.
10.
Bushing
Pin
)
D275A-2 10-l11
8
f
6
-. _
Section A-A Section B-B
P-
Section C-C 9 10
Section D-D
__.-
Detail P
F197UR034A
10-112
0
OUTLINE
l The ripping attachment can be broadly divided
into the ripper and the hydraulic control which
operates the shank. The diagram shows the
variable giant ripper.
The table shows the dimensions and specifica-
tions of the variable giant ripper.
OPERATION
l The shank is moved by hydraulic cylinders.
. RAISE: The left and right lift cylinders re-
tract and raise the beam and
shank together.
. LOWER: The left and right lift cylinders ex-
tend and lower the beam and
shank together to the ground.
l TILT ON: The left and right tilt cylinders ex-
tend and move the shank forward.
. TILT BACK: The left and right tilt cylinders re-
tract and move the shank to the
rearward.
l Table of comparisons
Unit: mm
\ 1 Giant ripper
Length of beam 1252

I
No. of shanks 1
I
1. Tilt cylinder
2.
3.
Lift cylinder
Beam
Ripping depth
I 3-stage selection
oossible
4. Shank
Max. ripping depth 1300
5. Protector I
6. Point
7. Arm Max. raise I 870
8. Pin
9. Bushing
10. Pin
10-112-l
0
123456789
, /
/ I II I J
198F1113
1. Plug OUTLINE
2. Spring
3. Spring retainer l The pin-puller solenoid valve is in the circuit
4. Valve body between the pin-puller cylinder and the power
5. Spool train pump passing through the steering con-
6. Spring retainer trol valve. When the pin-puller switch in the
7. Spring operator’s compartment is operated, it swit-
8. Push pin ches the oil from the power train pump and
9. Solenoid assembly acts on the pin-puller cylinder to operate the
shank mounting pin for the ripper shank.
Solenoid assembly (9) is deactivated when
A: To pin-puller cylinder head pushed in and excited when pulled out.
B: From power train pump
C: To pin-puller cylinder bottom
D. To steering case
1 o-1 12-2
0
OPERATION
1. Pin-puller switch at PUSH IN position From power train pump Switch at PUSH IN position
When the pin puller switch is turned to the
PUSH IN position, no current flows to solenoid
(9) and it is deactivated.
When this happens, spool (5) opens ports A
and B and ports C and D, and the oil from the
power train pump flows from port A to port B
and enters the bottom of pin-puller cylinder
(IO).
The oil entering the bottom end of the cylinder
increases the hydraulic pressure in the circuit
and extends the cylinder.
Shank mounting pin (11) is pushed into shank
(13).
198FO2028
2. Pin-puller switch at PULL OUT position

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

11. Shank mounting pin
198FO2029
12. Beam
13. Shank
1 o-1 12-3
0
CAB ELECTRICAL CIRCUIT DIAGRAM
Serial No. : lOOOl-10127
R.H. door wiper
Front wiper
Rear wiper
Cigarette lighter
Caution lamp
Lock-up
indication
lamp
connection
Front and Rear Car stereo

window washer
oc&o
r P
R.H. and L.H.

window washer
198FO2034-2
10-118-4
@
H
/xd’bor wiper
( ./ !
R. H
door wiDer
P.
ont wiper
ear wiper
II IIll r
CN399
r
Alarm I amp (
1
lamp
L/C indi cat i
L/C indi cat i
rette
ter
iI
1 F 2 Converter
0281330~
02BOQQ1
(12V power source CNMI
for radio) Z
Car stereo
LR
83
LB M
LA Front. rear
LY
wind washe r
0
0
M
10-118-5
8
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM
Serial No. : 10001 - 10127
Control panel
Air-conditioner switch Starting switch Pressure switch

I
-
85
CN 108
CN351
CN12
CN381
7L
Air conditioner
compressor
Floor frame
Thermostat
Blower motor Blower resistor
Air-conditioner relay
17MF02080
Control Panel
Blower motor switch Air-conditioner switch

S tart ina switch Pressure switch
conditioner
ComIpressor
I OOOQQQO~
Floor frame
1,“IP,P,P,!:: 1Ch365 Air conditioner unit
8°K
0 M L-Y
Blower resistor Thermostat
Blower motor
Air conditioner relay

- SAD01517
10-118-7
@
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM)
Monitor panel
I
Sensor signal
Buzzer signal
Buzzer
Caution lamp
Battery
F19702046
OUTLINE
l The vehicle monitoring system monitors vari- l The vehicle monitoring system consists of a
ous conditions of the vehicle by means of sen- monitor panel, sensors, warning lamps, warn-
sors provided throughout the vehicle. It pro- ing buzzers, and the power source.
cesses the information immediately, and in- l The monitor panel, and sensors are connected
forms the operator of the condition by making by wiring harnesses. The power is supplied
a display on the panel. from the battery to the monitor panel.
There are two major kinds of panel display. l As soon as any trouble occurs, the monitor
1. The monitor assembly, which gives a warn- and warning lamps start flashing and the warn-
ing when any fault is monitored on the ve- ing buzzer sounds to protect the vehicle.
hicle.
2. The gauge assembly and service meters,
which constantly indicate the condition of
the vehicle.
(Engine water temperature, torque conver-
ter oil temperature and fuel level.)
D275A-2 10-119
67 8 9
10
F19802003
1. Engine oil level 8. Radiator water level

2. Radiator water level 9. Engine water temperature
3. Fuel level 10. Torque converter oil temperature
4. Torque converter oil temperature 11. Hydraulic oil temperature
5. Engine water temperature 12. Preheat
6. Battery charge 13. Service meter indicator
7. Engine oil pressure 14. Service meter
OUTLINE 2. CHECK items

l The monitor panel consists of the monitor por- 1) After lighting up as explained in Section 1,
tion that gives out warning when any abnor- if there is any abnormality in any CHECK
mality occurs in the machine, and the gauge item, that item flashes.
portion and service meter that always indicate 2) The CHECK items go out when the engine is
the condition of the machine. started.
The monitor and gauge portions each have (The rise in the engine oil pressure is used
microcomputers that process the signals from to judge if the engine is running or not, or if
each sensor and display the results. the voltage from the alternator is more than
A liquid crystal display is used. 1OV.)
For details of the items displayed on the moni-
tor and gauge portion, see the table on the CAUTION
next page. The caution items are checked from the time
the engine is started until the time the engine
OPERATION is stopped.
1. Power switched on (starting switch ON) If there is any abnormality, the item flashes,
1) All items on the gauge and monitor light up and the warning lamp also flashes.
for 3 seconds. If any items in CAUTION 2 flashes, the alarm
2) The warning lamps light up for 2 seconds buzzer also sounds.
and the alarm buzzer sounds for 1 second. The monitor and warning lamps flash in an
ON-OFF cycle of approx. 0.8 sec.
The flashing cycle of the monitor may change
slightly if the ambient temperature is low (ap-
prox. -10°C or below), but this is not an abnor-
mality.
1 o-1 20 D275A-2
Monitor panel indications
Classifi-
cation 0 rmbol Indication items Range of indication Method of indication
displav
Radiator water level Below LOW level Indicates when the starting switch
is turned ON with the engine stopped.
If normal, the lamps do not light up.
4 Engine oil level Below LOW level If abnormal, the lamps flash.
P
When sensor is abnormal or If normal, the lamps do not light up.
Engine oil pressure
wiring harness is disconnected If abnormal, the lamps light up.
Indicates when the starting switch

is turned ON while the engine is
running.
3attet-y charge level Insufficient charge If normal, the lamp does not light.
If abnormal, the lamp flashes and
the warning lamp flashes at the
same time.
Engine oil pressure Below 0.5 kg/cm2
3adiator water level Below LOW level

Indicates when the starting switch
s turned ON while the engine is
When the engine water
running.
!ngine water temperature temperature gauge indicates
If normal, the lamp does not light up.
the red ranqe (108” C or hiaher)
If abnormal, the lamp and the warning
When the torque converter oil ‘amp flash and the warning buzzer
Torque converter oil temperature temperature gauge indicates sounds.
the red range (over 130°C)
iydraulic oil temperature Over 108°C
When the preheat switch of

seat switch is at ON, the lamp lights
ET ‘reheating When preheating .rp (80 sec.) and changes to light going
out to indicate that the preheating
s completed.
Engine water temperature

102°C Lights up in the applicable range
Green 94°C
83°C
70°C
White
Red
Torque converter oil temperature Lights up in the applicable range

Green
FULL
617
Green 517
Fuel level 417 All light up below the applicable level
3/7
Z/7
Red EMPTY
Operates while the alternator is

Indicates between zero and
Service meter charging
9999 hours.
Clock time: 1 :l
When the service meter Flashes while the service meter

Service meter indicator
is working is working
D275A-2 10-121
SUPPLEMENTARY CONTROLLER
l Tne supplementary controller acts as a power

source box to supply electrical power to the
CN 162 (3 pin)
panel assembly, switch panel, lock-up control-
ler, etc.
The variations in voltage of the power supply
for the machine (battery, alternator) is large, so
this supplementary controller transforms the
power to a stable voltage before supplying it
to the panel.
Even if there is over-voltage caused by a
failure in the alternator or regulator, it is cut
here to protect the monitor panel.
CN464 (4 pin)
197FO2076
SENSOR
l The signal from the sensor is input directly to
the machine monitor panel.
One end of contact type sensors is always con-
nected to the chassis ground. When the con-
tacts of all the sensors except the engine oil
pressure sensor close, and the signal wire is
connected to the chassis ground, the panel
judges it to be the normal signal.
When the contact of the engine oil pressure
sensor is open, and the signal wire is separ-
ated from the chassis ground, the panel judges
it to be the normal signal.
Type of sensor Sensor method When normal When abnormal
Engine oil level Contact ON OFF
Radiator water level Contact ON OFF
Hydraulic oil temperature I Contact I ON I OFF I

Engine oil pressure Contact OFF ON
Engine water temperature Resistance - -
Torque converter oil temperature Resistance - -
Fuel level Resistance - -
10-122 D275A-1
Engine oil level sensor
A
Structure of circuit
197FO2077
1. Connector FUNCTION
2. Bracket l The sensor is installed to the L.H. side face of
3. Float the oil pan.
4. Switch When the oil goes below the set level, the float
goes down and turns the switch OFF. The
monitor then flashes to warn of the abnor-
mality.
Radiator water level sensor
m
I
i 2 561FO3177
1. Float FUNCTION
2. Sensor l The sensor is installed to the top of the radia-
3. Connector tor. When the coolant goes below the set level,
the float goes down and turns the switch OFF.
The monitor then flashes to warn of the abnor-
mality.
D275A-2 lo-123
Hydraulic oil temperature sensor
198FO2047
1. Switch FUNCTION
2. Case l The hydraulic oil temperature sensor is installed
3. Wire to the hydraulic pump inlet tube. It detects the
4. Connector temperature at switch (I), and when the tem-
perature goes above the set temperature, the
switch is turned OFF. The display appears on the
monitor panel, the warning lamp flashes, and
the alarm buzzer sounds.
Engine oil pressure sensor
1 2 3 4 5 6
cl 69 @
202FO5175
1. Plug FUNCTION
2. Contact ring This sensor is installed to the engine cylinder
3. Contact block.
4. Diaphragm The diaphragm detects the oil pressure, and
5. Spring when it drops below the standard pressure, the
6. Terminal switch is turned ON, and the lamp lights up to
warn of the abnormality.
1O-l 24 D275A-1
Engine water temperature sensor
Torque converter oil temperature sensor
w
198FO2046
2. Plug l These sensors are installed to the thermostat
3. Thermistor housing and torque converter outlet port tube.
Any change in temperature is taken as a
change in resistance of the thermistor. A signal
is sent to the monitor panel and the tempera-
ture is displayed. When the panel display
reaches a set point, the lamp flashes and the
buzzer sounds to warn of the abnormality.
D275A-2 10-125
Fuel level sensor
A-A
198FO2089
2. Float l The fuel level sensor is installed to the side
3. Arm face of the fuel tank. The float moves up and
4. Body down according to the fuel level. This move-
5. Spring ment of the float is transmitted by the arm and
6. Contact actuates a variable resistance. This sends a
7. Spacer signal to the monitor panel to indicate the re-
maining fuel level. When the display on the
monitor panel reaches a certain level, a warn-
ing lamp flashes.
1 o-1 26 D275A-2
PANEL SWITCH
OUTLINE
l The panel switch incorporates soft touch sheet
switches for the headlights, rear lamps, work-
ing lamps, torque converter lock-up, APS, and
the engine starting switch. When a switch is
depressed, the red lamp will come on; when
depressed once again, the lamp will go off.
When the starting switch is turned off while
any one of the sheet switches is ON, all the
sheet switches will go OFF. They will not come
on again when the starting switch is turned on
(to prevent the bulbs from breaking).
197F127
RELAY BOX
OUTLINE
l The relay box houses various relays which en-
ergize the lamps, torque converter lock-up and
APS. The lamp come on or go off through the
operation of the corresponding relay when the
panel switch is operated. The relay box also
houses the APS controller, fuses for protecting
various electrical equipment, and the safety
relay that protects the panel switch and relays
from over-voltage from the power source (bat-
tery and alternator).
198FO2055
D275A-2 lo-127
RELAY BOX CIRCUIT
Serial No.: 10001-10127
CN 362 CN361
197FO2085-1
lo-128
@
017M02
0.75 _
1.25 _
0. 5
P 0. 76
‘1. ” ::
0. 6
:
I. 26
I,
E
e
L
I I
!
i
Ii
0. 75
‘-++? 1.25
I
I
I- -0 00
2. 0
‘t
017M02
l An over-voltage protection circuit is built into
the controller for the monitor power source.
The output of this controller turns the safety
relay inside the relay box ON, and supplies
electrical power to the relay coil and panel
switches.
In other words, if any over voltage (approx.
34V) should occur in the power source circuit
due to an abnormality in the battery or alterna-
tor, the output of the controller is cut and the
safety relay is turned OFF to protect the relay
coil and panel switches. At the same time,
power source to the monitor panel is cut.
(When this happens, the monitor panel goes
out and the panel switches cannot be oper-
ated.)
When the engine is started, the battery voltage
drops, so the circuit does not pass through the
controller. A circuit is formed directly from
starting switch C to turn the safety relay ON.
Safety function circuit drawing
r
Monitor panel
--
Relay box
--
--1
- power source
I
I-T +
Pane'switch
Relay power source
I
tw Lock-up
I
I
______
I
I
Safety relay
Supplementary ~ I+ ;;E& y& ~

controller I
24” output (monitor power
source)
I l e:lp
1GND I
lA
km Alternator
197fO2086
D275A-2 1O-l 29
OPERATION OF LAMP SYSTEM
. The lamps are lighted up by operating the panel

switch. A signal is then sent to the relay box,
and the relay inside the relay box is actuated to
supply electricity to the lamp.
Panel switch
Example of head lamp system
l When the head lamp switch on the panel is
pressed, the contacts of the head lamp switch
close, and are connected to the ground. Elec-
tricity flows from the battery through the safety
relay and fuse to the head lamp relay coil to Monitor panel \..._,,*’
(night lighting)
close the head lamp relay contacts.
When this happens, the electricity from the bat-
tery passes through the fuse, enters the head
lamp relay, and flows to the head lamp to light
up the head lamp.
At the same time, electricity also passes through
diode D,, and flows to the monitor night lighting
and air conditioner night lighting to light up
these lamps also. The electricity flows in the F19702047
same way when the rear lamp switch and work-
ing lamp switch on the panel are pressed. The
electricity then lights up the respective lamps,
monitors, and air conditioner night lighting.
Head lamp system circuit diagram
Relay box
r--- --1
Safety relay
Panel switch I
Head lamp relay

(L.H. and R.H.) Head lamp
The power for the monitor
I
night lighting is supplied
from R.H. head lamp relay
D4
+.a- _ I
Monitor illumination
m -
(3
Rear lamp -1 ncr
I
I Working lamp -1
Air conditioner illumination ,
L
Diode
I
__ __I 747
197FO2088
10-130 D275A-2
APS CONTROL SYSTEM
Serial No. : 10001 - 10167
Engine
From fuel injection pump

Air intake manifold Water temperature
sensor
Monitor panel ’
I
I
I
1 Water manifold
y Glow plug I I
Relay
F19702048
APS SYSTEM DIAGRAM
Fuel motor
1
Glow plug
2
- -__
Nozzle
nl7
Alternator
CzGT J
197FO2090
1O-l 32
@
FUNCTION
APS start APS stop

Flowoftime --------- I - _____-----------
Starting motor Engine start
Glow plug preheating
running Heat up the glow plug
START
Starting switch ON (hand) ON
(hand)
Preheat switch
(panel switch) I
OFF
I
ON (hand)
I OFF (hand)
APS water temp.

Max. 20°C Min. 20°C
sensor
Monitor panel
OFF Light up OFF
display
Preheat relay ON OFF
Heater relay OFF ON OFF

I I I
Preheat back-up
relav I
OFF
I ON
I OFF
Glow plug OFF ON OFF
Nozzle OFF ON OFF
197F134
l The APS functions to heat the air intake by

sj
burning the fuel in the intake manifold.
Z
Z
The APS will operate in the following order After the APS pilot lamp goes off, the APS con-
When the engine cooling water temperature troller is activated by turning the starting switch
goes below 2o”C, the APS water temperature to START. The fuel injection nozzle in the intake
sensor contacts will close, thereby causing the manifold starts injecting fuel intermittently (IO
signal line to connect to the machine body and times/set) through ON operation.
causing the preheating relay to energize.
After the engine is started, the fuel injection
Under the above condition, when the engine nozzle is operated by the alternator signal (so
heat switch on the panel switch is depressed or that the nozzle works only when the engine is
when the starting switch is turned to HEAT, the running).
large capacity heater relay to come ON, causing
the current to flow to the glow plug to heat up When the engine water temperature rises above
the glow plug. The impressed voltage is lowered 2o”C, the APS water temperature sensor con-
by a resistor to 18V to meat the rated voltage of tacts open and the heater relay goes off, caus-
the glow plug. The bimetal timer will operate ing the glow plug to stop heating and the fuel
while the glow plug is heating and the preheat injection nozzle to stop injection fuel.
(APS) pilot lamp will also light up.
The preheat backup relay make use of the
When the glow plug preheating time is up, the START signal to short both terminals of the re-
bimetal timer will come OFF and the pilot lamp sistor to supplement the voltage drop of the
will go OFF. This indicates that the glow plug is battery when the engine is started.
heated enough to operate the APS.
10-132-l
6%
Panel switch
Engine
From fuel 1I
inject i,on Pump
Air intake manifold I
APS water temperature
sensor n
I
Nozzle
aI
I
:<* ,’
0
_-
Water manifold
i / I Glow Plus ;
_____i_______ i______ _j
II II
-1
II II
II
I fI
I
1 I
_____________-_/ ;
___________---------------_’ I
~-__________________----____________---______~’
SAD01521
APS SYSTEM DIAGRAM
Controller CN142
Power
Glow 1
Glow 2
Nozzle
CN143
GND
Water illmination lam0
Water temp.
sensor
Starting mater
Preheat lamp
Monitor illmination lamp Preheating lamo
Spare
SAD01 544
lo- 132-2
@
APS ACTUATION CHART
APS start APS stops completely

Flow of time ___________________ I ________________________________________________
-l-+1- I-
Glow plug preheating Starting motor Engine starts,
turns intake air heated
Starting switch ON 1 START 1 ON

I I
OFF
Preheating switch OFF ON
(manual)
zntLrtemperature Specified water Specified water temperature

temperature (20°C) or below
or above
I
Glow plug 1 OFF 1 ON I OFF
APS fuel injection

OFF ON OFF
nozzle
Lamp display Flashes

OFF ON (12 set OFF OFF
(2 times/ 3 set)
When abnormal 1 OFF 1 ON
l The APS burns fuel inside the intake mani-

fold to heat the intake air.
The APS acts in the following order.

1. When the temperature of the engine cooling 6. The preheating switch is turned OFF.
water is below the specified water tempera-
2 ture, the contacts of the APS water tempera- 7. If the glow plug or APS fuel injection nozzle
5 ture sensor close and the water temperature system are short circuited with the ground,
z sensor ON signal is input to the controller. the lamp will light up until the short circuit is
canceled. If the lamp does not go out when
2. Under the above conditions, if the preheating the preheating is completed (after 12 sec-
switch is turned ON, the controller sends elec- onds have passed), or the lamp goes out
tricity to the glow plug to heat it. and then lights up again, stop the engine
When the glow plug is being heated, the and check for any short circuit with the
preheating pilot lamp lights up. ground.
3. After the preheating time for the glow plug 8. If the preheating switch is turned ON when
has passed, the lamp goes out to show that the engine cooling water temperature is
the glow plug has been heated sufficiently to above the specified temperature, the lamp
actuate the APS. lights up for 12 seconds, and then flashes.
In this case, the glow plug is not actuated.
4. After the preheating lamp goes out, if the
starting switch is turned to the START posi-
tion, the APS fuel injection nozzle inside the
intake manifold is switched ON/OFF (IO times/
set) to spray fuel.
5. When the engine cooling water tempera-

ture goes above the specified temperature,
the APS water temperature sensor contacts
open, and the action of the glow plug and
APS fuel injection nozzle is stopped. When
this happens, the preheating lamp flashes
at 1 Hz to show that the preheating has been
completed.
lo- 132-3
@
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM
Panel switch ,c _____ ______\

/’
/’
/’
A’
/’
T/C output shaft

Transmission Steering clutch speed sensor
(4 pulses/rev.)
F19702049
TORQUE CONVERTER LOCK-UP CONTROL CIRCUIT
Panel switch Lock-up display lamp

---__ .._I_
r 1
Lock-up controller
L/U valve source
L/U valve signal
3 T/C speed (+)
3 T/C speed (-1

,3 T/M oil press.
I sen*or
qGiF-&
Battery 24V
Battery relay Lock-up Torque converter Transmission
solenoid speed sensor oil pressure
sensor F19702050
D275A-2 10-133
OUTLINE
l The torque converter lock-up control system
uses a controller and the signals from two sen-
sors to automatically locks up the torque con-
verter according to the load on the machine.
When the torque converter is locked up, the dis-
play lamp at the front of the operator’s compatt-
ment lights up.
FUNCTION
l When the lock-up switch on the panel switch is
pressed, the switch contact is closed and it is
connected to the ground. Electricity from the
battery passes through the fuse and flows to the
lock-up relay coil in the relay box, and closes the
lock-up relay contacts.
When this happens, the electricity from the bat-
tery passes through the fuse and enters the
lock-up relay, flows to the lock-up controller,
and becomes the power source.
l The lock-up controller receives signals from the
transmission oil pressure sensor and torque
converter speed sensor. It connects and cuts the
lock-up solenoid and display lamp from the
ground to switch the lock-up ON/OFF.
The lock-up is switched ON-OFF if the signals
from the two sensor fulfill the following condi-
tions.
t Lock-up ON (solenoid excited)
When both of the following two conditions are
satisfied (AND circuit)
Above 1170 rpm
Transmission oil pressure:
Above 19.5 kg/cm’
* Lock-up OFF (solenoid deactivated)
When either of the following two conditions are
satisfied (OR circuit)
Below 11 IO rpm
Below 15 kg/cm2
1o-1 34 D275A2
SENSOR
Torque converter speed sensor
@.I^;)
\ \
i 2 3
561FO3114
2. Flange l The torque converter speed sensor is installed
3. Sensor to the speed sensor gear of the torque conver-
ter output shaft.
The rotation of the gear teeth generates a
pulse voltage and sends a signal to the control-
ler.
Transmission oil pressure sensor
17MF02082
1. Switch FUNCTION
2. Tube l The transmission oil pressure sensor is in-
3. Wire stalled to the transmission control valve. If the
4. Connector oil pressure is above the set pressure it is ON,
and if it is below the set pressure it is OFF, and
a signal is sent to the controller.
D275A-2 1o-1 35
MACHINE MONITOR SYSTEM
(with SSC system)
Mode selection panel Monitor display Panel
Sensor signal
I:_;
!
Sensors
I!5 Lamp sisnal
Power source
Buzzer sianal
1
Buzzer
I--I:
&
0
Caution
(central warnina lamp)
Battery SWD03775
l The machine monitor system uses sensors . The machine monitor system consists of the
installed at various parts of the machine to monitor panel, sensors, auxiliary controller,
observe the machine condition. It processes warning lamp, alarm buzzer and power
this information swiftly and displays it on source.
the panel to keep the operator informed of l The monitor panel, auxiliary controller, and
the machine condition. sensors are connected with wiring har-
The information displayed on the panel can nesses, and the power supply for the moni-
be broadly divided into the following cat- tor panel is taken from the battery through
egories. the auxiliary controller.
1. The monitor group, which informs the If any abnormality occurs in the machine
operator when there is any abnormality (detected by the sensors), the monitor and
in the machine warning lamp flash and the buzzer sounds
2. The gauge group (coolant temperature, to protect the machine.
torque converter oil temperature, fuel
level), which always displays the condi-
tion of the machine.
D275A-2 1o-137
a
MONITOR PANEL
Mode &itches Monitor SWD03776
1. Engine oil level 6. Battery charge 11. Torque converter oil tem-
2. Radiator water level 7. Electronic system perature
3. Fuel level 8. Engine oil pressure 12. Hydraulic oil temperature
4. Torque converter oil tem- 9. Radiator water level 13. Engine preheating
perature 10. Engine cooling water 14. Service meter indicator
5. Engine cooling water tem- temperature 15. Service meter
perature
OUTLINE
. The monitor panel consists of the monitor 2) The CHECK items go out when the en-
portion, which gives out warning when any gine is started. (To judge if the engine
abnormality occurs in the machine, and the is running or not, the system checks if
gauge portion and service meter, which al- the engine oil pressure has risen or if
ways indicate the condition of the machine. the voltage from the alternator is more
The monitor and gauge portions each have than IOV.)
microcomputers that process the signals
from each sensor and display the results. 3. CAUTION
A liquid crystal display is used. The caution items are checked from the time
For details of the items displayed on the the engine is started until the time the en-
monitor and gauge portions, see the table gine is stopped.
on the next page. If there is any abnormality, the item flashes,
and the warning lamp also flashes.
OPERATION If any item in CAUTION 2 flashes, the alarm
1. Power switched on (starting switch ON) buzzer also sounds.
1) All items on the gauge and monitor light * The monitor and warning lamps flash in an
up for 3 seconds. ON-OFF cycle of approx. 0.8 sec.
2) The warning lamps light up for 2 sec- * The flashing cycle of the monitor may
onds and the alarm buzzer sounds for 1 change slightly if the ambient temperature
second. is low (approx. -1O’C or below), but this is
2. CHECK items not an abnormality.
1) After lighting up as explained in Section
1, if there is any abnormality in any
CHECK item, that item flashes.
1 O-138 D275A-2
0
MONITOR PANEL DISPLAY
Display
Symbol Display item Display range Display method
categoq
Radiator water level Below low level Displays when engine is

stopped and starting switch
SAD01479 is ON
Display when normal: OFF
Display when abnormal:
Flashes
CHECK Engine oil level Below low level
SAD01480

Engine oil pressure Below specified pressure Display when abnormal:
Flashes
SAD01481
Battery charge When charge is defectivr > Displays when starting

switch is ON and engine is
SAP00522 running
CAUTION Display when abnormal:
Flashes
SSC controller electronic CAUTION lamp flashes at
When system is abnorma I
system same time
SWD03777
Engine oil pressure Below 49.03 kPa IO.5 kg/cm2 1
SAii1481
Radiator water level Below low level
SAD01479 IIisplays when starting

<switch is ON and engine is
unning
When at highest level
ilisplay when normal: OFF
Engine water temperaturc (108°C or above) on en-
CAUTION : Ilisplay when abnormal:
gine water temperature
I=lashes
gauge (CAUTION lamp flashes and
SAD01482
‘alarm buzzer sounds at
!same time
When at highest level
Torque converter oil (130°C or above) on torque
temperature converter temperature
SAD01483 gauge
iydraulic oil temperature 108°C or above
SAD01484
I
During cold weather, when sheet
switch (preheating switch) on
switch panel is ON, it lights up
Pilot ‘reheating VVhen preheating Ifor approx. 12 seconds. After
1this, it goes out to inform opera-
1tor that preheating is completed.
SWD03805
10-140 D275A-2
0
Display Display item Display range Display method
Symbol
category
108t2%
102 i-;-c
98%
Engine water temperaturN
94%
83%
SAD01482 70%
One place lights up to show

applicable level
Torque converter oil

Gauges temperature
SAD01483
FULL
6/7
5/? All lamps light up below ap-
Fuel level plicable level
4/7
SAD01486 3/7
2/7
Red EMPTY
0 Actuated when alternator is

Hourmeter From 0 to 99999 charged. Advances by 1 hour
fizq for every hour.
Service SKD00631
meter
0
Lights up when service
Service meter indicator Service meter meter is running
SKD00632
D275A-2 10-141
a
MODE SELECTION SYSTEM
* SSC stands for Shoe Slip Control system. The following explanation uses the abbreviation SSC.
REVERSE
limit switch
Ripper leve ‘r
a
Rinner
PPC valve
oil Pressure
switch
Back-up
buzzer
Accelerati
sensor
REVERSE speed ranse signal

SSC controller
FORWARD speed ranse signal

Fuel control lever 1st speed ranae signal
2
A Z
A
Torque converter outaut shaft
Manual throttle : g speed sensor signal (20 Pulse/rev) r\
signal * G z
Iz, 0
-0
Torrue converter Pulse Engine speed sensor sianal
7; 2
sianal (20 ouIse/rev) :3
Decelerator 25
nedal -i- c 1 , eyb;;; i;yete&
;
:
o_ ELPC
Auto lock-un be;bbact’) ) Fuel injection< 1 1(
control 2 _ control’er I lw (&&
z
z
To floor, , ,
frame Engine
actuator
I Lock-un actuation signal I
Transmission oil Pressure sensor signal
SWD03778
10-142 D275A-2
a
The mode selection system consists of the
mode selection panel (with built-in micro-
computer) which selects the operating mode,
the shoe slip controller (with built-in micro-
computer) which governs the engine con-
trol, the ELPC controller which receives the
command from the shoe slip controller and
controls the fuel injection pump, the lock-
up controller which switches the lock-up of
the torque converter ON/OFF according to
the torque converter dividing pulse output
by the shoe slip controller, and various sen-
sors.
The mode selection system automatically
carries out engine control to match the op-
erating mode selected by the operator, and
acts to reduce fuel consumption, extend the
life of the track shoes, and reduce the fre-
quency of operation of the deceleration.
The engine control modes consist of the
economy mode control used when dozing,
the SSC control used when ripping, and the
reverse slow mode control, which can be
used for either operation.
The lock-up control mode is the same as
the conventional lock-up function. It cannot
be selected in combination with the above
modes.
D275A-2 10-143
0
Operation of mode selection system
. It is possible to select the five modes individually or in combination to carry out work under the
optimum conditions for the type of work.
Open Lode Mode actuation conditions Actuation, features of mode

tion ;witch
. Automatically switche: 1. WHen torque converter approaches stall range or when
P,3;OFF according to the
gear is shifted, lock-up is turned OFF; when there is light
load, lock-up is turned ON.
ON OFF 2. Possible to use at all speed ranges
L
I I 3. Impossible to select combined operation with other mode
Torque
converter 1,170rpm
4. Suitable for dozing operations where there is compara-
output or above tively little change in load.
0 shah
speed
TraIE- 1.5MPa
1.9MPa
mi$o” 19.5kgfcmZ}{15kg/cmzl
or above or below
pressure
t I
When transmission is al When economy mode ((1) or (2)) and shoe slip control
Fl with economy mode are set in combination, economy control is carried out
switch (1) or (2) ON when the transmission is shifted to Fl, and slip control is
carried out when the ripper lever is operated and the
switch is turned ON.
0 The engine output can be controlled to 2 levels without
operating the engine deceleration.
Mode (1): 90% (at 2.4 km/h)
Mode (2): 70% (at 2.4 km/h)
At neutral, the engine speed is reduced to partial speed.
When transmission is a 1. The engine output can be controlled to partial without
RI, R2, R3 operating the engine deceleration.
0 Engine speed when in traveling reverse: 1,400 - 1,850rpm
2. Set speed when traveling in reverse
RI, R2, R3: 71 - 94% of full throttle
-
When the following con- To prevent the machine from starting suddenly when it
ditions are fulfilled moves off, modulation is carried out.
1. When transmission is The SSC controller controls the engine output according
at Fl to the drawbar pull characteristics (see Rockbed selec-
2. After ripper DOWN, tion below) selected by the operator from the drawbar
ripper TILT lever is pull characteristics (set to 5 levels), and prevents the
operated and limit occurrence of slippage.
switch is turned ON When this happens, if the ripper DOWN signal is input,
the SSC controller reduces the drawbar pull characteris-
.-i? tics by 40% and controls the engine output.
Q
Q The SSC controller takes the drawbar pull immediately
.-
u 0 before slippage occurs when the shoe slip ratio is 25% or
more as the maximum and carries out control of the
engine output. When this happens, if the ripper TILT or
ripper UP signal are input, the SSC controller increases
the drawbar pull characteristic by approx. 30 - 60% and
controls the engine output.
At neutral, the engine speed is reduced to partial speed.
Interconnected with
1. When the SSC control is turned ON, selection mode 131
shoe slip control and
lights up.
is turned ON to the
load and condition 01 2. The selection is made 1 ti 3 ti 5 according
the bedrock.
Ir When the above modes are set, it is possible to operate the fuel control lever and decelerator
pedal. In such cases, the engine output control is carried out according to the minimum value
command from the controller command, throttle command, and deceleration command.
10-144 D275A-2
0
MODE SELECTION PANEL
1. Lock-up mode switch

2. Economy mode switch
3. Reverse slow mode switch
4. SSC control mode switch
5. Rockbed selection mode switch (hard)
6. Rockbed selection mode switch (soft)
SHOE SLIP ON
Outline
l The mode selection panel has 6 mode se-
lection switches. The selection mode
changes each time the switches are pressed.
The LED lights up to display the existing
condition.
D275A-2 10-145
a
INITIAL SET SWITCH
1. ELPC controller
2. SSC controller
3. Initial set switch
4. Monitor auxiliary controller
I98FO2043- I
.
Outline Normal mode pattern (when switch is OFF)
The initial set switch is used to set the mode
setting to a constant mode pattern. If the
Item Actuation
initial set switch is operated and the start- I
ing switch is turned ON, all the switches on
the mode selection panel will be automati- Lock-up mode
cally set to one of the mode patterns shown
in the chart on the right. 2
Economy mode
Even after the mode pattern is set, it is pos- 3
sible to select the mode freely.

Reverse slow
The normal mode pattern in the chart on
the right is the pattern set when the initial
set switch is OFF (the normal condition SSC control
when the machine is shipped from the fac-
tory). It is the mode pattern suited to dig- F&ked selection
ging bedrock and dozing operations.
The initial set mode in the chart on the right
is the pattern set when the initial set switch
is turned ON (connector CNSOI-(11) on the . Initial mode pattern (when switch is ON)
mode selection panel is connected to the
chassis ground). This mode pattern is suit- Item Actuation
able for specialized operations with blasted
rock.
The condition inside the n in the actua-
tion column in the chart on the right is the
mode set when the starting switch is turned
ON.
Reverse slow OFF H w
SSC control OFF HW
Rmo;$ked selection 1~2++4tt5
lo-146 D275A-2
0
SSC CONTROLLER
(r
0 0
L
‘;
SED01409
1. Self-diagnostic display LED
Function
1. The SSC controller uses the input signal 4. When the mode selection panel lock-up
from the acceleration sensor to calculate the mode signal is input, it sends the torque
travel speed of the machine in relation to converter output shaft speed pulse (20 pulse/
the ground. In addition, it inputs the torque rev) as it is to the lock-up controller.
converter speed sensor signal and calcu- 5. The SSC controller has a self-diagnostic
lates the shoe speed. From these data, it function, and if there is any abnormality in
detects the shoe slip ratio. the input or output system, the 2 LEDs flash
2. Next, it inputs the engine speed sensor sig- to display the problem.
nal and torque converter speed sensor sig-
nal, and calculates the drawbar pull.
3. It uses the results of the calculations in Steps
1 and 2 above together with the mode se-
lection signal from the monitor panel and
the transmission oil pressure sensor signal
to calculate the optimum engine speed. It
then sends a signal to the ELPC controller
as the SSC control command.
D275A-2 10-147
0
SENSORS
ENGINE SPEED SENSOR
SEW00289
1. Magnet
2. Terminal
3. Case
4. Boot
5. Connector
TORQUE CONVERTER SPEED SENSOR
@*g)
D
F
D 2 Structure of circuit
c3 1
SBDo1545
I. Connector
2. Flange
3. Sensor
lo-148 D275A-2
0
Transmission F oil pressure sensor
Transmission 1st oil pressure sensor
Structure of circuit SW003806
1. Switch
2. Tube
3. Wire
4. Connector
Work equipment control lever (ripper) limit switch

Backup alarm switch
Neutral safety switch
SJD02655
1. Plunger 6. Cap
2. Microswitch 7. Roller
3. Plug 8. Stopper
4. Ball 9. Diaphragm
5. Bearing IO. Connector
D275A-2 10-149
0
ACCELERATION SENSOR
Acceleration Deceleration
-
1. Plate
2. Sensor portion
-O- Amp
3. Wire
4. Connector
SWD03781
Outline
l The acceleration sensor is installed under
the front of the operator’s cab.
l With the acceleration sensor, the position
of the ball inside the sensor changes ac-
cording to the acceleration.
Inside the sensor, there is a coil that detects
the position of the ball. This is amplified by
the amp and is sent as a voltage change to
the SSC controller.
l The input and output characteristics of the
sensor are shown in the diagram on the
rig ht.
Acceleration (G)
SWD03782
10-150 D275A-2
0
ENGINE CONTROL SYSTEM
17MF02083
1. Manual potentiometer Outline

2. Deceleration pedal . Engine control is carried out for the follow-
3. Mode selection panel, monitor panel ing two systems.
4. Panel switch 1. When the fuel control lever and decelerator
5. ELPC controller pedal are operated, they control the fuel
6. Shoe slip controller injection pump through the linkage and
7. Fuel control lever ELPC actuator.
8. Relay box 2. When mode selection system is actuated
9. Torque converter lock-up controller The necessary information for the shoe slip
10. Battery relay controller enters, the processed manual
11. Battery command is sent to the ELPC controller,
12. ELPC actuator drives the ELPC actuator and controls the
13. Fuel injection pump fuel injection pump.
D275A-2 10-151
a
ELPC CONTROLLER
CNSM I
1 SED01418
1. Self-diagnostic display LED
No. 1Input/Output 1 Signal No. 1Input/Output 1 Signal
I.1 Input 1 Power source (+) 12. Input GND

2.1 - I- 13. - -
3. output Proportional solenoid (+I 14. ( output 1 Proportional solenoid H
4. - - 15.1 - I -
5. Input Feedback signal 16. output Feedback power source (-)
6. output Feedback power source (+I 17. - -

7. output Manual power source (+I 18. output Manual power source (-1
a. Input Manual command 19. output Accelerationsensor power source (-1
9. Input Shoe slip command 20. - -

10. - - 21. output Alarm signal
11.1 - I -
D275A-2
Outline
l The ELPC controller receives the manual sig- (Input sianail (Outnut signal)
nals shown in the diagram on the right, car-
ries out internal processing, and sends a
Starting snitch *
signal to the ELPC actuator. (Dower source)
Control function of controller

flanuai Potentiometer
1. Engine speed set function using manual (desceleration sienall
potentiometer
l An output signal is sent according to
the angle of the manual potentiometer
so that the ELPC actuator output lever L________________J
rotation angle matches manual com-
mand voltage 0. ELPC feedback
botentioneter c
l Rotation angle @I gives feedback to the tvotentioaeter sionalf
controller according to the ELPC feed- 4
I I
back potentiometer signal, and always SV002540
displays the actuation of the ELPC ac-
tuator.
ELPC Valve
2. Engine speed control according to shoe slip output lever
control command (throttle signal) rotation anale
l The ripper controller indirectly controls @

the engine speed according to the shoe ELPC controller
output characteristice
slip command because of the mode se-
lection system control.
l The ELPC controller receives the signal
from the manual potentiometer and the
shoe slip command (throttle signal) from
the shoe slip controller, and controls the
engine according to the low engine
speed signal (high voltage) (it sends a
signal to the ELPC actuator).
(Example)
When the transmission is at neutral, output characteristic
even if the fuel control lever is set to the SVD02541
FULL position, if the economy mode has

been selected, the engine speed is auto-
matically reduced to partial speed.
For details, see SHOE SLIP CONTROL.
ELPC Valve
output lever
rotation anofe
I ELPC controller
output characteristice
3 Ful I
%
_
VI
~ ld,ina -~----------_-~-----
.-
_
8 stop
1
I
I
I I ,
1. 1 1. 6 2. 5 ssc
command
voltage
SVD02542
D275A-2 10-153
0
ELPC ACTUATOR
SVD02543
1. Feedback potentiometer 10. Input spool

2. Manual potentiometer 11. Pilot spool
3. Proportional solenoid 12. Spring
4. Output shaft 13. Stopper
5. Input shaft 14. Output spool (piston)
6. Output control spring 15. Joint
7. Load piston 16. Output lever
8. Output control spool
9. Input lever
10-154 D275A-2
0
15 14 13 12 II IO ‘9
A-A
D-D E-E
SVD02544
Outline
(1) When the fuel control dial is operated, the trol the fuel injection pump through output
potentiometer resistance changes. This sig- lever (16) and the link. In addition, a signal
nal is sent to the ELPC controller through is sent to the ELPC controller from feedback
ripper controller and the processed current potentiometer (1) according to the rotation
command from the controller is input to of output shaft (41, and the actuation of the
proportional solenoid (3). ELPC actuator is observed.
The proportional solenoid generates a pro- (2) When mode selection is selected, if the throt-
pulsion force which is in proportion to the tle signal from the shoe slip controller is a
current command, moves spool (81, and sets low-speed command, proportional solenoid
the oil pressure at port PI. Input spool (IO) (3) is driven according to the throttle signal,
and pilot spool (11) move to a position regardless of the position of input lever (91,
where this oil pressure PI and spring (12) and controls input spool (IO), output spool
are in balance. Output spool (14) follows (141, and the fuel injection pump.
this and moves in the same direction to con-
D275A-2 10-155
0
MANUAL POTENTIOMETER
1. Shaft
2. Potentiometer
3. Tube
4. Wire
1 2 3 4 5 5. Connector
x t--====
I
SBD02367
Function
l The manual potentiometer is installed to the l When the decelerator pedal is moved, shaft
opposite side of the ELPC actuator input le- (I) of the manual potentiometer is rotated
ver. The decelerator pedal and ELPC actua- through the link, ELPC actuator input lever,
tor input lever are connected by a link. and input shaft, and the resistance changes.
A constant voltage is applied between pins 1
- 3 of the potentiometer, and a voltage sig-
nal corresponding to the position of the fuel
control lever is sent to the ELPC controller
from the No. 2 pin.
FEEDBACK POTENTIOMETER
I. Potentiometer
2. Wire
3. Tube
4. Connector
SVDO2545
Function
l The feedback potentiometer is installed to l When the ELPC actuator output lever (fuel
the opposite side of the ELPC actuator out- injection pump governor lever) is rotated by
put lever. The fuel injection pump governor the command from the ELPC controller, the
lever and ELPC actuator output lever are con- rotating body of the feedback potentiometer
netted by a link. is rotated through the output lever and out-
put shaft, and the resistance changes.
A constant voltage is applied between pins 1
- 3 of the potentiometer, and a voltage sig-
nal corresponding to the position of the out-
put lever is sent through the amplifier to the
ELPC controller from the No. 2 pin.
lo-156 D275A-2
a
PROPORTIONAL SOLENOID
l The proportional solenoid generates a pro-
pulsion force according to the command MPa
current from the ELPC controller as shown (ka/cm*l
in the diagram on the right.

l The propulsion force generated by the pro-
portional solenoid acts on pressure control
spool (8) and produces the oil pressure
shown in the diagram on the right. There-
fore, by controlling the command current, --) Current (A)
the propulsion force can be changed and
the oil pressure controlled. SVD02546
Operation
1. When proportional solenoid is continuous
l If electric current flows from the ELPC con-
troller to proportional solenoid (31, the pro-
portional solenoid generates a propulsion
force proportional to the current. When this
happens, the propulsion force of the pro-
portional solenoid and the sum of the pro-
pulsion force from the oil pressure at port
PI applied to load piston (7) and the reac-
tion force of pressure control spring (6) are
balanced and the pressure is adjusted.
At this point, the oil pressure at port PI is
determined by the balance of the force push-
ing input spool (IO) to the left and the reac-
tion force of spring (121, so the stroke of SVD02547
input spool (IO) is controlled.
2. When proportional solenoid is not continu-

ous (when there is disconnection in com-
mand circuit)
l If no current flows to the proportional sole-
noid, and pressure control spool (8) is
pushed back by the reaction of pressure
control spring (61, so no oil pressure is gen-
erated at port PI. However, when the fuel
control lever is operated, if it is operated to
the FULL position, input spool (IO) and pilot
spool (11) move to the right to follow the
movement of input lever (9) because of the
reaction force of spring (12). As a result of
this, output spool (14) and. joint (15) also
move to the right.
l When the fuel control lever is at the SLOW
or STOP position, input lever (9) directly SVD02548
pushes input spool (IO) and pilot spool (II)
to the left. As a result of this, output spool
(14) and joint (15) also move to the left.
D275A-2 10-157
0
OPERATION OF ELPC ACTUATOR
Fuel control lever operated SLOW + FULL
(Engine at low idling)
5’ SW003794
When fuel control lever (17) is operated,

shaft (18) of manual potentiometer (2) is
rotated by the link and input shaft (5), and
the resistance value changes.
This signal is sent to the ELPC controller,
and the processed current command from
the controller enters proportional solenoid
(3).
The solenoid moves spool (8) in proportion

to the current command and sets the oil
pressure at port PI to the specified pres-
SWD03795
sure.
Pilot spool (11) and input spool (IO) of the
ELPC valve move to the right in the direc-
tion of the arrow until oil pressure PI and
spring (12) are balanced. When this hap-
pens, the circuit between orifice a of piston
(14) and passage c closes, and the circuit
between orifice b of pilot spool (1 I) and
chamber B opens. The oil from the power
train pump always enters chamber A. The
circuit between orifice a and passage c is
closed, so the oil pressure rises.
The oil in chamber B passes through orifice
b and flows to chamber C. It then flows
from port T to the drain circuit, so the oil
pressure in chamber B goes down.
Therefore, piston (4) is pushed to the right
by the oil pressure in chamber A, moves to
the position where the circuit between ori-
c bT \ \
12 II IO
fice a and passage c opens (in other words, SWD03796
the point where the rod of joint (15) and the
left end of pilot spool (11) contact), and
stops.
lo-158 D275A-2
a
When piston (14) is pushed out to the right
in the direction of the arrow, joint (151, which
forms one unit with the piston, also moves
to the right, so the throttle lever of the fuel
injection pump is moved to the FULL posi-
tion.
If the fuel control lever is operated continu-
ously, the above operation is repeated and
the engine runs at full speed.
In addition, the action of the oil pressirre in
chamber A also reduces the operating ef-
fort of the fuel control lever.
When the fuel control lever is stopped at a
fixed point, piston (14) of the ELPC valve
stops at a point where the circuit between
SWD03797
orifice a of chamber A and passage c is
open.
At this point, the passage from orifice b (in
other words, the passage to the drain cir-
cuit) is closed, and at the same time, oil
from passage c enters chamber B, so the oil
pressure rises.
When this happens, the difference in pres-
sure between chambers A and B (in other
words, the pressure moving piston (14) to
the left or right) disappears, so the piston is
held in the same position.
Therefore, the engine speed can be held
constant to match the amount that the fuel
control lever is operated.
D275A-2 10-159
0
2. Fuel control lever moved stopped + slow
(Engine stopped)
stop SWD03798
SIOW
SW003799
. When fuel control lever (17) is moved from

the STOP position to the slow position, in-
put lever (9) rotates and the reaction force
of spring (12) moves ELPC valve input spool
(IO) and pilot spool (11) to the right in the
direction of the arrow, following input lever
(9). However, the engine at this point is
stopped, so no oil pressure acts on the ELPC
valve. Pilot spool (11) uses the protruding
portion at the left end to move piston (14)
and joint (15) directly to the right. This
moves throttle lever (18) of the fuel injec-
tion pump to the slow position.
lo-160 D275A-2
0
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM
c_________________
Mode selection Panel /’ ‘.
,’ -\
,’ ‘.
,’ ‘.
‘.
‘\
‘\
‘\
‘.
‘.
SSCcontroller \
Pressure sianal
Transmission oil
Torque converter
_-_-___ output shaft
30r
pu 1se/rev)
SWDO3800
TORQUE CONVERTER LOCK-UP CONTROL CIRCUIT DIAGRAM
Lock-up
display lamp
relay solenoid speed sensor Pressure sensor SWD0380 1
D275A-2 lo-161
a
Outline
With the torque converter lock-up control
system, the torque converter lock-up is op-
erated automatically according to the load
on the machine by the controller and signal
from the two sensors.
When the torque converter is locked up, the
display lamp at the front of the operator’s
seat lights up.
When the starting switch is turned to the
ON position, the contacts of the lock-up re-
lay inside the relay box close and power is
supplied to the lock-up controller.
The torque converter speed sensor is con-
nected to the SSC controller, and inputs a
pulse signal corresponding to the torque
converter speed to the SSC controller. The
SSC controller sends the input pulse signal
according to the signal from the mode se-
lection panel (the signal for the lock-up ON/
OFF switch) to the lock-up controller, or
stops the system.
The lock-up controller receives the torque
converter speed signal from the SSC con-
troller and transmission oil pressure sen-
sor, and connects or disconnects the con-
nection of the lock-up solenoid and display
lamp to the ground to turn the lock-up ON
or OFF.
The lock-up is turned ON or OFF when it
fulfills the following conditions for the two
sensors.
When lock-up is ON
When both of the following conditions are
fulfilled (AND circuit):
1,170 rpm or more
1.9 MPa (19.5 kg/cm*} or more
When lock-up is OFF

When either of the following conditions are
fulfilled (OR circuit):
1,110 rpm or less
1.5 MPa (I 5 kg/cm*) or less
lo-162 D275A-2
0
20 TESTING AND ADJUSTING
Standard value table for engine.. ............... 20- 2 Adjusting of brake pedal linkage . . .. . .. .. . . . . . . . 20-30
Standard value table for chassis ................ 20- 3 Adjusting of work equipment control
Standard value table for electrical linkage . .. . . .. . . . .. . . . . . . . . .. . . . . . . .. .. .. . . . .. . . .. . . . . .. . . . . . 20-32
judgement.. .............................................. 20- 9 Adjusting clearance of idler . . .. . . . . . . .. . . .. . .. . . 20-35-I
Table of tools for testing, adjusting Measuring speed at torque converter stall . . . . 20-36
and troubleshooting ............................... 20-I 1 Measuring speed at torque converter stall
Testing and adjusting belt tension.. ........... 20-13 + hydraulic pump relief . .. . . . .. .. . . .. . . . .. . . . . . . . 20-37
Adjusting valve clearans ............................. 20-14 Measuring power train oil pressure .. . . . . . . . . 20-38
Measuring compression pressure .............. 20-15 Testing and adjusting work equipment main
Measuring blow-by ...................................... 20-16 relief pressure . . . . . .. .. . . . . . . .. .. . . . . . . . . . . . .. .. .. . . .. . 20-41
Adjusting fuel injection timming ................ 20- 17 Bleeding air from hydraulic cylinder .. . . . .. . . 20-42
Measuring exhaust color.. ........................... 20- 18 Measuring linkage inside cylinder .. .. . . .. . . . . . 20-43
Measuring engine oil pressure ................... 20-19 Checking location of cause of hydraulic
Measuring engine speed ............................. 20-19 drift of blade and ripper . . .. . .. . . . . .. . . .. . . . .. . . . 20-44
Measuring boost pressure .......................... 20-20 Procedure for simple test of steering brake
Measuring exhaust temperature ................ 20-21 performance .. . . . . . .. . . .. .. . . .. . .. . . . . . . . . . . . .. . .. . . .. . . 20-45
Adjusting of fuel control linkage ................ 20-22 Procedure for testing sensor . . . . . . . . .. . . .. .. . . .. . . 20-46
Adjusting of fuel control linkage Testing and adjusting ELPC valve
(with SSC system) ............................... 20-22-I potentiometer (with SSC system) . . .. . . 20-48-I
Adjusting of gear shift lever linkage.. ....... .20-24 Troubleshooting . . . . . . . .. . . . . . . . . .. . .. . . . . .. . . . . .. .. .. . . . . . 20-49
Adjusting of steering clutch linkage .......... 20-28
* The following precautions are necessary when using the STANDARD VALUE TABLE for testing and
adjusting, or for troubleshooting.
1. The values in the table are for new machines, and obtained for reference to value for new
machines and the values when shipping from the factory. Therfore, they should be used as target
values for judging the progress of wear, or when repairing the machine.
2. The values for judging failures are based on standards when shipping the machine from the
factory, and on the results of various tests. These values should be used as reference together with
the repair condition and operating record of the machine to make judgements on failures.
3. The values in the table should not be used for judging claims.
a When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install
the safety pins and block the tracks.
a When working in groups, use agreed signals and do not allow unauthorized persons near the
machine.
a When checking the water level in the radiator, wait for the water to cool. Do not remove the
radiator cap while the water is hot. Boiling water may spurt out.
a Be careful not to get caught in rotating parts.
D275A-2 20-l
a
STANDARD VALUE TABLE FOR ENGINE
Serial numbers 10001 - 10167
Engine S6D170-1
Unit Standard Permissible

Item Measurement conditions
value value
High idling 1,960 2 50 1,960 + 50

Engine speed Low idling wm 600 k 50 600 2 50
Rated speed 1,800 2 50 -
Exhaust temperature
Whole speed range
(turbocharger inlet
(ambient temperature: 20°C) “C Max. 650 Max. 700
port temperature)
Boost pressure kPa Min. 120 Min. 108

At rated output {Min. 9001 {Min. 810}
{mmHgI
At sudden acceleration Bosch Max. 6.0 Max. 8.6

Exhaust gas color
At high idling index Max. 1.0 Max. 2.0
Intake valve 0.4

Valve clearance Exhaust valve mm 1.0
(at cold)
Oil temperature: 40 - 60°C
MPa Min. 2.86 Min. 1.97
Compression pressure Engine speed: 210 - 250 rpm
(SAEBO oil) {kg/cm*1 {Min. 29) {Min. 20) 8
At rated output Max. 5.9 5

Blowby pressure kPa Max. 2.9
(Water temperature: Operating range) {Max. 6001 z
‘mmH20) {Max. 3001
(SAESO oil)
(Water temperature: Operating range)
At high idling (SAESO) 0.3 - 0.49 Min. 0.25
13.0 - 5.0) {Min. 2.5)
At low idling (SAE30) Min. 0.15 Min. 0.7
MPa
Oil pressure {Min. I.51 {Min. 7.01
{kg/cm*1
At high idling (SAEIOW) 0.25 - 0.44 Min. 0.18
12.5 - 4.5) {Min. 1.8}
At low idling (SAE 1 OW) Min. 0.1 Min. 0.07
{Min. 1.0) {Min. 0.7)
Oil temperature Whole speed ranoe (inside oil Dan) “C 80 - 110 Max. 120
Fuel injection timing B:T.D.C. “(de@ 38 + 1 38 * 1
Deflection when pressed with finger force -

Alternator belt tension 15
of approx. 58.8 N 16 kg}
Air conditioner compressor Deflection when pressed with finger force -

13 -17
belt tension of approx. 98 N {IO kg}
mm
Fan belt tension Dimension A:

(auto tension) 50 f 5
17MF02140
( 1: For reference
20-2
@
Engine S6D170-2
Unit Standard Permissible

Item Measurement conditions
value value
High idling 1,960 -c 50 1,960 5 50

Engine speed Low idling vm 600 2 50 600 2 50
Rated speed 1,800 2 50 -
Exhaust temperature
Whole speed range
(turbocharger inlet
(ambient temperature: 20°C) “C Max. 650 Max. 700
port temperature)
Boost pressure kPa Min. 120 Min. 108

At rated output {Min. 900) {Min. 810}
ImmHgI
At sudden acceleration Bosch Max. 6.0 Max. 8.0

Exhaust gas color
At high idling index Max. 1.0 Max. 2.0
Intake valve 0.4 -

Valve clearance Exhaust valve mm 1.0 -
(at cold)
Oil temperature: 40 - 60°C
Compression Engine speed: 210 - 250 rpm MPa Min. 2.86 Min. 1.97
pressure
(SAEBO oil) {kg/cm21 {Min. 29) {Min. 20)
At rated output
Blowby pressure kPa Max. 2.9 Max. 5.9
G (Water temperature: Operating range)
[mmH201 {Max. 3001 {Max. 600)
(SAE30 oil)
(Water temperature: Operating range)
At high idling (SAESO) 0.3 - 0.49 Min. 0.25
(3.0 - 5.0) {Min. 2.5}
At low idling (SAE30) Min. 0.15 Min. 0.7
MPa
Oil pressure {Min. 1.5) {Min. 7.0}
{kg/cm21
At high idling (SAEIOW) 0.25 - 0.44 Min. 0.18
(2.5 - 4.51 {Min. 1.8}
At low idling (SAEIOW) Min. 0.1 Min. 0.07
{Min. l.O} {Min. 0.71
Oil temoerature Whole speed range (inside oil pan) “C 80 - 110 Max. 120
Fuel injection timing B.T.D.C. “(de@ 22 22
Deflection when pressed with finger force

Alternator belt tension 15
of approx. 58.8 N (6 kg}
Air conditioner compressor Deflection when pressed with finger force

13 -17
belt tension of approx. 98 N {IO kg}
mm
Fan belt tension - -

(auto tension)
( 1: For reference
20-2-l
63
STANDARD VALUE TABLE FOR CHASSIS
Classi Standard Permissible

Check item Conditions Unit
ficatio value value
l Engine oil pressure:

Torque converter within operating range
l Engine oil temperature: 1,580 f 50 Min 1,510
stall speed
within operating range
l Power train oil temperature: rpm
70-80°C
Torque converter stall
l Hydraulic oil temperature: 1,375 f 50 Min 1,240
+
45-55X
hydraulic relief speed
l No. of speed range : F3
Engine: low idling
90 * 20 90 z!z20
l Center of - full throttle
Fuel control lever
lever knob Engine: low idling
60 f 20 60*20
- stop
l Center of pedal
Decelerator pedal 25 * 5 25 Z!Y5
l Engine: full throttle - Low idling
Between each
l Engine stopped 35 * 5 35 * 5
speed range
Gear shift lever
l Center of lever
F-R 61 f6 61 f6
knob
l Engine low
Full stroke 147.5 f 7.5 147.5 f 7.5
idling
Steering lever
l Center of lever Until clutch is fully 55 f 5 55 + 5
knob disenaaaed Play: Max. 5 Play: Max. 5
l Engine low
Full stroke lOOf 100+5
idlina
Brake pedal
To point where brake
l Center of pedal pressure becomes mm 80 k 5 80 f 5
0 ka/cm*
l Engine low
idling HOLD - RAISE
70 f 7 70 f 7
l Center of HOLD - LOWER
Blade control lever
lever knob
l Hydraulic oil HOLD - LEFT TILT
temperature: 55 f 6 55+6
HOLD - RIGHT TILT
45 - 55°C
l Engine low
idling HOLD - RAISE
55 + 6 55 + 6
l Center of HOLD - LOWER
Ripper control lever
lever knob I
l Hydraulic oil HOLD - TILT IN
temperature: 55 dz6 55 z!z6
HOLD - TILT BACK
45 - 55°C I
Engine: low idling

12.5 f 2.5 Max. 18
- full throttle
l Center of Engine: full throttle 1
Fuel control lever 11+3 Max. 16
lever knob - low idling
Engine: low idling
17f3 Max. 27
- stop
l Engine speed
kg
850 f 50 rpm Engine: full throttle
Decelerator pedal 10.5 f 2.5 Max. 17
l Center of - low idling
pedal
l Engine stopped 4.8f1.8 Max. 7

Gear shift lever
l Center of
3fl I Max. 5
lever knob
20-3
Classi,
ficatior
Check item Conditions
Until clutch is fully

I I Unit
Standard
value I
Permissible
value
l Engine low 3.3 + 0.8 Max. 7

idling disengaged
Steering lever
l Center of Until machine turns
721 Max. 10
lever knob when brake is aDDlied
l Engine: low idling
Brake pedal l Engine stops or stalls with one brake 38 III 4 Max. 45
l Center of pedal
t
l Engine low
HOLD - RAISE 4.8 f 0.8 Max. 8
idling I I
l Center of lever
Blade control lever
knob HOLD - LOWER kq 3.3 + 0.8 Max. 8
l Hvdraulic oil I-I
temperature: HOLD - LEFT TILT
3.3 + 0.8 Max. 6
45 - 55°C HOLD - RIGHT TILT I I I
I c
l Engine low
idling HOLD - RAISE
1 1 3.3f0.8 1 Max.6
l Center of lever HOLD - LOWER
Ripper control lever
knob F I
l Hydraulic oil HOLD - TILT IN
temperature: 3.13 f 0.8 Max. 6
HOLD - TILT BACK
45 - 55°C
Radiator shutter Close -+ Open 15+3 -
control lever Open -+ Close 6rt3 -
Torque converter Low idling 0.5 - 2.0 0.5 - 2.0 (v

relief pressure (inlet)
Full throttle 91: 91; z
z
Torque converter Low idling 0.5 - 2.0 0.5 - 2.0
outlet pressure
Full throttle 5.5 2 A:: 5.5 + A:;
Lock-up Low idling 0 0

clutch ~-
Torque converter Full throttle 13 +:, 13 +:,
lock-up pressure
Stator Low idling 23 - 27 23 - 27
clutch
Full throttle 27 f 2 27 f 2
Transmission main
27 + 2 Min. 24
relief pressure
Transmission modu-
27 f 2 Min. 24
lating pressure
l Oil temperature in power train:
Transmission reduc-
70 - 80°C 21.5 f 1.5 21.5f 1.5
ing pressure
l Engine speed: full throttle
Transmission lubri- Low idling Min. 0.1 Min. 0.1
cation pressure 2.0 f 0.5 2.0 f 0.5
Full throttle
Low idling kg/cm2 25 * 2 Min. 22

Steering clutch operat-
ing pressure
Full throttle 27 + 2 Min. 24
Low idling 25 f 2 Min. 22

Brake operating
pressure
&z-----l 27 & 2 Min. 24
I
Ripper pin-puller
Blade lifting pressure l Hydraulic oil

Blade tilting pressure temoerature: Low
Ripper lifting pressure 45 i 55°C Full throttle
I
20-4
0
Check item Standard Permissible
Conditions Unit
ficatic value value
Posture of work equipment

Low
8-13 Max. 26
idling
z
z
Full
3-5 Max. 6
1 I throttle
Blade speed (lift) I I
197FO1547
Low
1 .o - 1.5 1.0 - 1.5
l Hydraulic oil tempera- idling
z
ture: 45 - 55°C
l Blade: no load g-
-J
l From ground to maxi- Full
1.0 - 1.5 1 .o - 1.5
mum height throttle

Low
8-13 Max. 17
5 idling
I=
t
!Y Full
3-4 Max. 6
throttle
Blade speed (tilt)
197FO1549 Low
5 6-10 Max. 16
idling
i=
l Hydraulic oil tempera-
ture: 45 - 55°C z
l Blade: no load oc Full
2.5 - 3.5 Max. 5
l Left tilt - Right tilt throttle

Low
8-12 Max. 15
2.5 - 3.5 Max. 5
qipper speed (lift) 197FO1549
) Hydraulic oil tempera- Low

1.5 - 2.5 1.5 - 2.5
ture: 45 - 55°C idling
E
1 Shank set at bottom 1-
hole 9
) From ground to maxi- Full
1.5 - 2.5 1.5 - 2.5
mum height throttle
work equrpmenr
Low
12- 18 Max. 21
idling
z
Full
4.5 - 5.5 Max. 6.5
throttle
tipper speed (tilt)
197FO1550
1 Hydraulic oil tempera- y Low
8-12 Max. 15
ture: 45 - 55°C idling
1Shank set at bottom 2
hole 3
1 From tilt back - F Full
3-4 Max. 6
tilt in throttle
20-5
Classi- Standard Permissible
ficatior value value

Pitch 2.5
dump IO.6 degl4.3 s
Pitch 3.0
back IO.6 deg/3.5 s
legree
Pitch speed
/set
l Hydraulic oil temperature: 45 - 55°C

l Blade: no load
l Pitch dump - pitch back
l Full throttle

7.1
Left tilt
80.6 deg14.3 s
Dual tilt speed Negree
lsec
7.1
Right tilt
80.6 degf4.3 s:
Semi
1,135
17MF02142 U dozer
Dual tilt
l Hydraulic oil tempera- mm
ture: 45 - 55°C
l Blade: no load
U dozer 1,215
l Left tilt - Right tilt
l Full throttle

ture: 45 - 55°C Engine
l Lower the blade from low Max. 6 Max. 12
the maximum height, idling
and measure the time
Time lag (blade)
taken from the point
when the blade touches Engine
the ground to the point full Max. 1.5 Max. 2.0
where the idler is throttle
raised from the ground
sec.
ture: 45 - 55°C
l Lower the ripper from the maximum
height, and measure the time taken
Time lag (ripper) Max. 1.0 Max. 1.5
from the point when the ripper touches
the ground to the point where the
sprocket is raised from the ground
l Engine full throttle
20-6
Classi- Standard Permissible
fication value value
Hydraulic drift
(blade lift)
!EtE& 197FO1551 Max. 200/l 5 Max. 400/l 5
l Engine stopped
l Center of blade cutting edge; from
height of 800 mm to ground
Hydraulic drift 197FO1552 Max. 3015 Max. 10015

(machine moves l Hydraulic oil temperature: 45 - 55°C
down) l Engine stopped
l Blade pushed down, movement at
center of idler
Posture of wgrk equipment
LEFT TILT Max. 3015 Max. 8015
Hydraulic drift 197FO1553 mmlmir

(blade tilt) l Hydraulic oil temperature:
45 - 55°C
l Tilt blade to raise machine,
engine stopped immedi- RIGHT TILT Max. 3015 Max. 80/5
ately to reach ground
l Measure retraction of
tilt cylinder
Hydraulic drift Max. 80/I 5 Max. 160/l 5

(ripper lift) 197FO1554
l Engine stopped
l Ripper point: 500 mm above
the ground
Hydraulic drift Max. 3015 Max. 6015

(machine moves down) 197FO1555
l Engine stopped
l Ripper pushed down movement
at center of sprocket
20-7
Classi
Check item Conditions
ficatioi
F 1st
(3.8 f 0.2) (3.8 f 0.2)
10.7 * 0.6 10.7 + 0.6
F 2nd
(6.7 + 0.3) (6.7 f 0.3)
6.1 z!z 0.3 6.1 f 0.3
F 3rd
(11.8 * 0.6) (11.8 f 0.6)
14.7 IL 0.8 14.7 + 0.8
R 1st
(4.9 + 0.2) (4.9 * 0.2)
l On level surface 8.3 + 0.4 8.3 + 0.4
Engine at full throttle R 2nd
l (8.7 + 0.4) (8.7 f 0.4)
l Engine water tempera-
4.8 +I 0.3 4.8 f 0.3
ture: Inside operating R 3rd
sec. (14.9 f 0.7) (14.9 f 0.7)
Travel speed range
(km/h) 18.9+ 1.0 18.9f 1.0
l Run up distance: F 1st
(3.8 * 0.2) (3.8 f 0.2)
IO-30m
l Measurement distance: 10.4 do 0.6 10.4 I!Z 0.6
F 2nd
20 m (6.9 f 0.3) (6.9 * 0.3)
6.1 f 0.3 6.1 f 0.3
F 3rd
(11.7 f 0.6) (11.7 f 0.6)
14.7 * 0.7 14.7 IL 0.7
R 1st
(4.9 f 0.2) (4.9 f 0.2)
8.1 f 0.4 8.1 f 0.4
R 2nd
(8.9 f 0.4) (8.9 k 0.4)
4.8 + 0.3 4.8 f 0.3
R 3rd
(15.1 f 0.8) (15.1 + 0.8)
20-8
STANDARD VALUE TABLE FOR ELECTRICAL JUDGEMENT
SYS ‘esting
Judgement table
Measurement
Component tonnector No
ten lethod conditions
1) When using the short connector, the followin 1) Engine

results show that the sensor is defective started
CN405
Coolant level sensor
(Male) 1) The following results show that the sensor 1) Starting
is normal switch OFF
I Coolant level normal Max. 1 Q

I
I Coolant level abnormal 1 Min IMP 1
The following results show that the sensor 1) Starting

Coolant temperature is normal switch OFF
sensor CN402 2) Disconnect
(Coolant temperature (Male) CN402
gauge) I Ambient
temoerature I
When normal
I
(coolant
tempera-
Torque converter oil

temperature sensor CN453
35°C
20°C
I Approx.
Approx.
I
29kQ
52kQ
ture gauge)
3) Disconnect
CN453
(Torque converter oil (Male) I I (T/C oil
temperature gauge) 10°C Approx. 80kS tempera-
ture gauge)
1) When CN403 is connected to chassis ground, 1) Engine

the following results show that the sensor is started
defective
Engine oil pressure

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

Min. IMQ
0.7 ka/cm2
I Engine oil pressure

0.7 ka/cm*
under
Max. 1 Q
I
The following results show that the sensor is 1) Starting

normal switch OFF
(Normal temperature 25°C) 2) Disconnect
CN423
Fuel level sensor CN423 CN423 (Male) @ - @

(fuel gauge) (Male)
Full Approx. 109 or less
Empty Approx. 859
20-9
sys- Measurement
Component Connector No. ~e~h~~ Judgement table
tern conditions
I I
I I
1) When CN452 (female) is connected to chassis 1) Engine
ground, the following results show that the started
SF
52 sensor is defective
Hydraulic oil CN452

temperature sensor (Male)
I ; I 1) The following
is normal
results show that the sensor 1) Starting
switch OFF
1) When CN404 (female) is contacted to chassis 1) Starting

ground, the following results show that the switch ON,
8:
Engine oil level CN404

sensor (Male)
I I
1) The following results show that the sensor 1) Starting
& switch OFF
is normal
g
9
0)
.E Engine oil level normal Max. 1 R
;
:
Engine oil level abnormal Min IMR
r”
20-10
TABLE OF TOOLS FOR TESTING, ADJUSTING AND
TROUBLESHOOTING
Test measurement item Symbol Part No. Part Name I Remarks
Digital display:
Engine speed A 799-203-8001 Multi-tachometer L: 60 - 2,OOOrpm
H : 60 - 19,999rpm
Water temperature,
oil temperature, i3 799-101-6000 Digital temperature gauge -50 - 1,200”C
exhaust temperature
- -
Pressure gauge:
799-101-5001 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
125, 60, 400, 600 kg/cm2}
1
Oil pressure C
Digital hydraulic tester Pressure gauge: 68.6 MPa
790-261-1201
{700 kg/cm21
-
2 799-401-2320 Hydraulic gauge 1.0 MPa {IO kg/cm21
- -
Boost pressure D 799-401-2310 Pressure gauge 199.9 kPa I1500 mmHg1
0 - 6.9 MPa (0 - 70 kg/cm21

1 795-502-1210 Compression gauge
Kit Part No.: 795-502-1205
Compression pressure E
2 795-502-1350 I -
1 799-201-1504 Blowby cheker I -
Blowby pressure F
2 799-201-1590 Gauge 0 - 9.8 kPa (0 - 1000 mmH,OI
i
Commercially Intake valve: 0.4 mm;
Valve clearance G Feeler gauge
z available exhaust valve: 1.0 mm
I
z j Discoloration: 0 - 70 %
I
(with standard color)
z 1 799-201-9000 Handy smoke checker (Discoloration x l/IO = Bosch
Exhaust color H index)
Commercially -
2 Smoke meter
available
Commercially -
Operating force I available Push-pull scale
I
Commercially -
Stroke, hydraulic drift J available
Commercially -
Work equipment speed K Stopwatch
available I
799-601-7100 T-adapter kit For those owning 799-601-2500
Troubleshooting of wiring
L 799-601-7000 is possible
harness, sensor
799-601-7070 Adapter SWP14
Troubleshooting of volt- Commercially -

M
aqe, resistance value available
Measuring wear of
sprocket tooth P 791-627-1130 Wear gauge
Dial gauge is commercially

Fuel injection timing Q 795-471-1200 Gauge assembly available
20-11
@
TESTING AND ADJUSTING BELT TENSION
Serial No . : 10001 - 10167
1. Testing fan belt tension

0 An auto-tensioner is installed, so check 1
that the dimension of the tension spring
b$FdA = 50 k 5 mm when the belt is re-
I 4 ?
1. Adjustment nut
2. Washer
3. Tension spring
4. Adjustment bolt
5. Tension pulley
6162F291
A. Protrusion of adjustment bolt I
0”
Et
0’
2. Testing and adjusting alternator belt tension
Testing
l Check the deflection of the belt when it
is pressed at approx. 58.8N (6 kg) at a
midpoint between the alternator and ac-
cessory drive pulley.
1
* Deflection: 15 mm
Adjusting Alternator belt

1. Loosen alternator assembly mounting bolt
(1) and belt tension adjustment bolt (2).
2. Using a pipe, move the alternator to adjust
the belt tension. Tighten the adjustment
bolt first, then tighten the alternator
mounting bolt. 569F102
20-l 3
@
Serial No . : 10168 and up
1. Testing and adjusting alternator belt tension

Testing
. Check the deflection of the belt when it is
pressed at approx. 58.8 N (approx. 6 kg} at a
midpoint between the alternator and acces-
sory drive pulley.
* Deflection: 15 mm
Adjusting
1) Loosen alternator assembly mounting bolt
(I) and belt tension adjustment locknut (2).
21 Turn adjustment nut (3) to adjust the ten-
sion of the belt to the standard value.
3) After adjusting the belt tension, tighten
locknut (2), then tighten alternator assembly
mounting bolt (1).
20-13-l
@
ADJUSTING VALVE CLEARANCE
* Adjust the clearance between the rocker lever

and crosshead as follows:
1. Remove the cylinder head cover.

2. Rotate the crankshaft in the normal direction
to align the 1.6 TOP line on vibration damper
(1) with pointer (2) to set the No. 1 cylinder at
compression top dead center. When rotating,
check the movement of the valves.
3. When No. 1 cylinder is at compression top Valve arrangement
dead center, adjust the valves marked 0.
When No. 6 cylinder is at compression top
dead center, adjust the valves marked 0.
TDD00723
4. To adjust the clearance, insert feeler gauge G

between rocker arm (3) and crosshead (4),
and adjust with adjustment screw (5) until the
clearance is a sliding fit. Then tighten locknut
(6) to hole the adjustment screw in position.
m Locknut: 68.8 z 9.8 Nm {S t 1.0 kgm)
* After tightening the locknut, check the

clearance again.
5. Next, rotate crankshaft one turn in the normal

direction and adjust the valve clearance of
the remaining valves marked 0.
* After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 120” each time and adjust the
clearance of the valves of each cylinder ac-
cording to the firing order.
Firing order: l-5-3-6-2-4
Yl k
TWD01232
20-14
a
A Be careful not to touch any hot places when
installing or removing the measuring tools.
* Raise the temperature of the cooling water to

the operating range before measuring.
1. Adjust the valve clearance.

For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Remove the nozzle holder assembly of the cy-

linder to be measured.
j, Be careful not to let dirt or dust get inside.
3. Install tool E2 in the mount of the nozzle

holder assembly, then connect tool El to tool
E2.
Sr Coat the tip of tool E2 with a small amount
of oil.
4. Set tool A to the pick-up port of the ta-

chometer.
5. Place the fuel control lever in the NO INJEC-

TION position. Crank the engine with the
starting motor and measure the compression
pressure.
8
Z
6 A If the fuel control lever is not placed at
the NO INJECTION position, fuel will
spurt out.
A When
pressure,
measuring the compression
be careful not to touch any
hot parts or rotating parts.
* Measure the compression pressure at the
point where the pressure gauge indicator
remains steady.
* When measuring the compression press-
ure, measure the engine speed to confirm
that it is within the specified range.
* After measuring the compression press-
ure, install the nozzle holder assembly.
20-15
* Raise the coolant temperature to the opera-
ting range before measuring.
1. Install tool Fl to the tip of engine breather

hose (I), then connect it to tool F2.
2. Run the engine at rated output, and measure

the blow-by pressure. Adapter
A When measuring, be careful not to

touch anv hot Darts or rotatina Darts. Nozzle
* The blow-by should be measured with the
engine running at rated output. -
17MF02143
0 When measuring in the field, a similar
value can be obtained at stall speed.
0 If it is impossible to check at rated output
or stall speed, measure at high idling. I Fl
In this case, the blow-by value will be

about 80% of the value at rated output.
* Blow-by varies greatly according to the
condition of the engine. Therefore, if the
blow-by value is considered abnormal,
check for problems connected with defec-
tive blow-by, such as excessive oil con-
sumption, defective exhaust gas color,
and prematurely dirty or deteriorated oil.
17MF02144
20-16
ADJUSTING FUEL INJECTION TIMING
Serial No . : 10001 - 10167
1. Rotate the crankshaft in the opposite direc-

tion in 40 to 50” from No. 1 cylinder at com-
pression top dead center.
2. Rotate the crankshaft in the normal direction,

and align pointer (2) correctly with the 38” I.J
line on vibration damper (1).
3. Disconnect fuel injection pipe (3) of No. 1 cy-

linder.
4. Remove delivery valve holder (4), take out

spring (5) and delivery valve (6), then install
delivery valve holder (4) again.
5. Place the fuel control lever at the FULL posi-

tion.
* When the coupling is rotated, the injection
time is changed as follows.
Turn TOWARDS cylinder block to AD-
VANCE timing.
Turn AWAY from cylinder block to RE-
TARD timing.
6. Loosen the bolt in the oblong hole of the

laminated coupling and operate the priming
E: pump while moving the coupling. Stop at the
point where the fuel stops flowing from the
:
6 delivery valve holder.
7. Remove delivery valve holder (4), assemble

delivery valve (6) and spring (5), then install
delivery valve holder (4) again.
m Coupling mounting bolt:
88.3 + 4.9 Nm I9.0 d 0.5 kgm}
QGE Delivery valve holder:

112.8 + 4.9 ill.5 f 0.5 kgm}
8. Connect fuel injection pipe (3).

m Sleevew nut:
21.6 2 2.0 12.2 f 0.2 kgm1
I Oblong hole 6162F663

1. Remove the tube between the air cleaner

Komaclone and the muffler.
2. Remove the injection pump coupling cover.
3. Remove the head cover, disconnect spill tube
(I) and delivery tube (2) of the No. 1 piston,
then remove No. 1 nozzle holder assembly
(3).
4. Align No. 1 cylinder with the compression
top dead center line (1:6).
* When doing this, check that the fuel in-
jection timing line on the fuel injection
pump is near the line on the fuel injec-
tion pump body.
5. Set dial gauge Q to the nozzle holder hole
where the nozzle holder assembly has been
removed. (See the diagram.)
6. Set the scale on dial gauge Q to 0 when the
piston is at the top dead center.
* Rotate the crankshaft in the normal di-
rection and in the reverse direction in
turn to align the top dead center.
Ir Record the value indicated by the short
indicator on the dial gauge.
7. Rotate the crankshaft approx. 45” in the re-
verse direction from the No.1 cylinder TOP
position.
8. Rotate the crankshaft again slowly in the
normal direction and set to specified dimen-
sion “c”.
* Specified dimension c: 6.51 d 0.2 mm
* Always rotate the crankshaft in the nor-
mal direction to align the position.
* Continue to rotate in the normal direc-
tion, and when the No.1 cylinder reaches
the TOP (top dead center) position (the
indicator on the dial gauge starts to ro-
tate in reverse), check that the dial gauge
reading is 0 r 0.2 mm. If it is not within
0 f 0.2 mm, carry out from Step 6 again.
_..~
9. Check that fuel injection timing line “a” on BED00346
the fuel injection pump is aligned with line
“b” on the coupling.
20-17-l
@
10. If the lines are not aligned, loosen bolt (4) in
the oblong hole, move the coupling to align
the lines, then tighten the bolt.
20-17-2
8
MEASURING EXHAUST COLOR
0 When measuring in the field where there is

no air or electric power supply, use tool Hl;
when recording formal data, use tool HZ.
* Raise the coolant temperature to the opera-
A Be careful not to touch any hot parts when

removing or installing the measuring tools.
Measuring with HI.

1) Install filter paper to tool Hl.
2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly,
and operate the handle of tool HI at the
same time to collect the exhaust gas on the
filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.
Measuring with H2.

1) Insert probe 0 into the outlet port of the ex-
haust pipe (I), and tighten the clip to secure it
to the exhaust pipe.
2) Connect the air hose and the socket of the
probe hose accelerator switch to tool H2.
* Keep the pressure of the air supply below
1.47 MPa {I5 kgm2}
3) Connect the power cord to the AC socket.
* When connecting the cord, check that the
power switch of’tool H2 is OFF.
4) Loosen the cap nut of the suction pump, and
fit the filter paper.
17MF02147
* Fit the filter paper securely so that the ex-
haust gas cannot leak.
5) Turn the power switch of tool H2 ON.
6) Accelerate the engine suddenly, and depress
1 Hz
the accelerator pedal of tool H2 at the same

time to collect the exhaust gas color on the
filter.
7) Place the filter paper used to catch the ex-
haust gas color on top of at least IO sheets of
unused filter paper inside the filter paper
holder, and read the value shown.
//
17MF027 48
20-18
8
MEASURING ENGINE OIL PRESSURE
*Raise the coolant temperature to the opera-

1. Remove pressure measurement plug (1) (PT

l/8), then install oil pressure gauge C (IO kg/
cm2).
2. Start the engine, and measure the oil press-

ure at low idling and high idling.
FO2150
6
MEASURING ENGINE SPEED
A Be careful not to touch any hot parts

when removing or installing the measuring
tools.
* Measure the engine speed under the follow-

ing conditions:
1) Coolant temperature:
Within operating range
2) Power train oil temperature: 70 - 90” C
3) Hydraulic temperature: 45 - 55” C
1. Remove cap (1) from the speed pick-up port,

then install the adapter of tachometer A.
2. Connect tachometer A to the adapter with the
cable.
A When measuring the engine speed, be

careful not to touch the rotating parts or
hot parts.
3. Start the engine and measure the engine

speed at high idling and low idling.
Sr When measuring items other than above (tor-
que converter stall, torque converter stall +
hydraulic pump relief), see the measurement
procedure for each item.
20-19
MEASURING BOOST PRESSURE
A Be careful not to touch any hot parts

when removing or installing the measuring
tools.
1. Remove boost pressure measurement plug

(1) (PT1/8), then install the coupler inside oil
pressure gauge kit C.
2. Connect the oil pressure measurement hose

to the coupler and pressure gauge N (14.7
kPa {I,500 mmHg)).
A When measuring the pressure, be care-

ful not to touch the rotating parts or
hot parts.
Note: Operate the engine speed at midrange
or above, and use the self-seal portion
of the gauge to bleed the oil inside the
hose.
0 Insert the gauge about half way, repeat
the action to open the self-seal portion,
and bleed the oil.
Sr If there is oil inside the hose, the gauge

will no work, so always bleed the oil.
3. Run the engine at the rated speed and read

the gauge indicator.
I 17MF02153
20-20
8
MEASURING EXHAUST TEMPERATURE
A The temperature sensor is installed to the
exhaust manifold, so if the machine is being
operated, wait for the manifold temperature
to drop before installing the sensor.
Raise the coolant temperature to the operat-
ing range before measuring.
Remove the adiabatic plates.

(Serial No.:10168 and up) :
Remove plug (1) from the exhaust manifold, /
and install temperature sensor (2).
l Temperature sensor: 6215-11-8180
(cable length 610 mm) or
6215-11-8170 17MF02154
(cable length 490 mm)
Connect to digital temperature gauge B with
the wiring harness.
Measurement procedure
1. When measuring with the torque converter
stalled
X-type connector (2Pinl
* The conditions are only for torque conver- Temperature sensor
ter stall, so when measuring the exhaust
temperature, the core of the sensor will
heat up and the torque converter will
overheat before a stable value is obtained.
1) Raise the exhaust temperature by using
s: full stall (torque converter stall + hydraulic
BLD00675
pump relief) (standard value: Approx.
: 650°C).
6
2) In the above conditon, cancel the hy-
draulic rleief, and carry out only torque
ocnverter stall. (If the temperature starts
to go down, or goes up without going
down, repeat step 1) to raise the set tem-
perature.)
3) Note the stable temperature when the
temperature starts to go down.
2. When measuring the maximum value for the

exhaust temperature
Carry out actual work and measure the maxi-
mum value during operation.
* Use the peak mode (it can store the maxi-
mum value in memory) of the temperature
gauge function.
Tempera- Stable reading
ture t
Note:
The exhaust temperature varies greatly ac- Exhaust temper-
ature at torque
cording to the ambient temperature (tem- converter stall
When measured only
perature of the engine intake air), so if any with torque converter
abnormal value is obtained, carry out tem-
perature compensation.
* Compensation = Measured value +
2 (converted ambient temperature - am-
Full stall Torque converter -Time
bient temperature) + overheat
* For the D275A-2, the converted ambient Torque con- 1 1 _
verter stall BKD00676
temperature is taken as 20” C.
20-2 1
@
ADJUSTMENT OF FUEL CONTROL LINKAGE
1) Make the length between the pins of rod

(1) 637 mm, and interconnect lever (2)
and friction clutch (3).
2) Fix fuel control lever (2) at a position
where clearance A between friction
clutch (3) and idling set spring box (4) is
0 mm.
3) With the friction clutch in the condition in
Step I), set lever (5) installed to the en-
gine fuel injection pump to the idling PO-
sition.
4) In this condition, set rods (6), (7), (8) and
(9) to the standard length, and intercon-
nect them.
* Standard length of rod (6): 887 mm
(7): 986 mm
(8): 559 mm
(9): 845 mm
* To adjust for the parts tolerance and
assembly tolerance, turn the turn-
buckle attached to rod (7), and adjust
the length to interconnect rod (7).
F17M02010
5) With decelerator pedal linkage rod (IO)
not interconnected, pull fuel control lever
(2) towards the rear of the machine.
Check that lever (5) of the engine fuel in-
jection pump contacts the FULL stopper.
6) Keep the lever in this position, and turn
FULL stopper (11) until it contacts the fuel
control lever. Then turn the stopper back
3
two turns, and lock it in position.
7) With decelerator pedal linkage rod (IO)
not interconnected, push fuel control
lever (2) towards the front of the ma-
chine. Check that lever (5) of the engine
fuel injection pump contacts the STOP
stopper.
8) With the lever in this position, turn stop
adjustment bolt (12) attached to idling set
Clearance E-t_
spring box (4), and adjust clearance B to 0
mm. Then turn the bolt back one turn,
and lock it in position.
9) Set fuel control lever (2) at the full throttle
position, and set so that clearance C at
the decelerator pedal is 0 mm, and clear-
ance D at the end of decelerator pedal
linkage rod (10) is also 0 mm.
10) Start the engine, set the throttle lever to
850 _+ 50 rpm, then adjust with the turn-
8
buckle of rod (10) so that clearance C is 0
E mm.
6
11) Run the engine at high idling, and adjust
with rod (IO) so that clearance D is 0 mm.
Run the engine at high idling, and adjust
154F21114
with adjustment bolt (13) so that clear-
ance E is 0 mm, then lock in position with
the nut.
F17M02011
20-23
ADJUSTING FUEL CONTROL LINKAGE
(WITH SHOE SLIP CONTROL)
1) Set the distance between the pins of rod (1) to

630 mm, then connect throttle lever (2).
2) Set the throttle lever to the idling position.

* Move the throttle lever towards the idling
position. The point where idling stopper
clearance A is 0 mm is the idling position.
3) Connect rods (3), (41, and (5) so that the dis-

tance between the pins is as shown below.
j, Rod length (3): 887 mm
Rod length (4): 300 mm
1 TWD01234
11 18 10
17MF02158
20-23- 1 D275A-2
0
4) Move throttle lever (16) 90 mm towards the FULL 7
position and bring it into contact with FULL stop-
per (15).
(There is no need to lock it)
TWD01236
5) insert rotation adjustment dowel pin (04205- Dowel Pin for

10830) into the ELPC valve input lever portion, rotation
Solenoid /adjustment
fix the input lever in position, and connect rods
(12) and (13).
Rod length (12): 232 mm Input lever
TWD01237
Governor
12
TWD01238
6) Set the distance between the pins of rod (11) to I ,lOOmm

854 mm, then connect engine governor lever Full
(17) and the center hole of lever (IO) (length of position
lever: 90 mm).
7) Adjust rod (12) so that engine governor lever

(17) contacts the FULL stopper.
D275A-2 20-23-2
a
8) With the throttle lever at the FULL position, keep
the rotation adjustment dowel pin inserted, start
the engine, measure the engine speed, and ad-
just rod (12) so that the engine reaches full
speed.
li Engine full speed: 1960 f 50 rpm
* Check that loose spring (18) deflects at least
1 mm.
* Check that governor lever (17) is in contact
with the governor FULL stopper.
9) Remove the rotation adjustment dowel pin, re-
turn the throttle lever to the low idling position,
and adjust with rod (13) or (5) so that the speed
is the low idling speed.
* Low idling speed: 600 f 50 rpm
IO) Move the throttle lever gradually to the FULL
position, and fix FULL stopper (15) in the guide
portion at the point where the engine speed
reaches the full speed measured in Step 8.
11) Stop the engine, turn the starting switch OFF,
then remove the engine speed sensor connec-
tor.
12) Start the engine, set the throttle lever to the
FULL position, turn the SSC switch ON, run for
approx. 10 seconds, then check that the engine
speed is 660 - 930 rpm. If the engine speed is
not within the above range, adjust again as fol-
lows.
l When less than 660 rpm
i) Set the position of the hole in lever (IO)
to 80 mm, and connect rod (II).
ii) Carry out the adjustment again from Step
6 to Step 10.
l When more than 930 rpm
i) Set the position of the hole in lever (IO)
to 100 mm, and connect rod (II).
ii) Carry out the adjustment again from Step
6 to Step 10.
TWD01240
L
20-23-3 D275A-2
0
13) Connect the engine speed sensor connector.
14) After adjusting the speed, turn FULL stopper
(15) of throttle lever (16) back one turn and fix it
in position.
* Leave room to spare at the full end.
15) Remove connector CNSOG at the turn frame left
end, start the engine, move the throttle lever
gradually to the STOP position, and stop the
engine. Check that the governor lever is in con-
tact with the STOP stopper, push the stopper
bolt in to bring it into contact, then turn it back
one turn and fix it in position. TWD01236
16) Start the engine, set the throttle lever to 850 ?
50 rpm, then adjust with the turnbuckle of rod
(4) so that clearance B is 0 mm.
17) Run the engine at full speed and adjust rod (4)
so that clearance C is 0 mm.
18) Run the engine at full speed and adjust with
adjustment bolt (22) so that clearance D is 0
mm, then lock with the nut.
Stopperbolt
Tiahten until it
contacts stopper bolt.
then loosen 1 turn and
Locknut
TWD01242
TWDO I243
D275A-2 20-23-4
a
ADJUSTMENT OF GEAR SHIFT LEVER LINKAGE
--
2
3
llMF02184
20-24
Sr Tighten the locknuts of the rods and ca-
bles securely, and bend the cotter pins se-
curely.
w Locknut (14), (15): 7.25 f1.75 kgm
* Speed selector lever (1) and direction se-

lector lever (2) are installed to the trans-
mission control valve. The speed position
and direction position of each lever are
determined by the detent inside the valve.
1) Set lever (1) in the N position, and connect

gear shift push-pull cable (3) to bracket (4)
and lever (1).
2) In this position, adjust the mounting height
of the switch so that neutral safety switch
(5) is pushed in 1.5 mm.
* Movelever(l)@+@+@+@
@ + 0. Check that the push-pull cable
moves the correct distance.
3) Set lever (2) in the REVERSE position, and

connect direction selector push-pull cable
(6) to bracket (4) and lever (2). 17MF02160
In this condition, adjust the mounting
height of the switch so that backup alarm
switch (7) is pushed in 1.5 mm.
1.5 mm 17MF02161
20-25
4) S.et gearshift lever (8) to the N position (N
position of change guide (9)), and put
safety lock lever (IO) in the LOCK position.
* If the LOCK position of the safety lever
does not match the position of the
change guide, adjust the length of rod
(11).
5) Secure push-pull cables (3) and (6) to

bracket (17).
6) Adjust so that the amount of protrusion of
push-pull cables (3) and (6) is as follows.
* Speed (3): 157 mm
Directional (6): 130 mm
7) Turn the turnbuckle and connect push-pull

cables (3) and (6) to rods (12) and (13)
(with the turnbuckle screwed in approx. 5
mm).
j, Position of speed lever (8): FORWARD
and 2nd position.
* After adjusting all the parts of the linkage,
check that gear shift lever (8) moves the
correct distance for all eight positions.
(FORWARD: @-+@-0-0; REVERSE:
@I-@-Q-Q.
* Check that when the gear shift lever is put
in the N position for FORWARD and
17MF02162
REVERSE, it cannot move @ + @ + @
when the safety lock lever is in the lock
position.
17MF02163A
20-26
Co
ADJUSTMENT OF STEERING CLUTCH LINKAGE
45 nlm
147.5+10 mm
9
1
1 c!
a _
197F417
20-28
* Tighten the lock nuts of the rods and cables
securely, and bend the cotter pins securely.
1. Adjust the length of stopper bumper (2) so

that steering lever (1) is 45 mm from the front
face of the guide box.
2. Keep the protrusion of push-pull cable (3)

above the floor frame at 157 mm, and inter-
connect rod (4) and cable (3).
3. Push steering levers (5), (6) installed to the

steering brake valve towards the rear of the
machine at 1 - 2 kg.
With the rods in contact with the spool inside
the valve, interconnect push-pull cable (3)
and rod (7).
4. After interconnecting all the parts of the link-

age, if the play of steering lever (1) is more
than 5 mm, screw in yoke (8) at the rear of
push-pull cable (3) to adjust the length and
remove the play.
5. After adjusting all parts of the linkage, pull

the steering lever fully and check that it
8
travels 147.5 rtr 7.5 mm. Check also that there
z is a clearance between the steering lever and
6
the guide box.
* The distance the steering lever travels is
determined by the contact with the stop-
per of the spool inside the steering valve.
When the steering lever is pulled fully,
check that the lever on top of the valve al-
ways moves the full stroke (Full stroke =
32 mm).
20-29
ADJUSTMENT OF BRAKE PEDAL LINKAGE
197F417A
20-30
j, Tighten the lock nuts of the rods and cables
securely, and bend the cotter pins securely.
1. With brake pedal (1) depressed, pull up park-

ing lever (2) and lock the brake pedal.
Adjust the length of rod (3) so that the brake
pedal moves a distance A = 95 f 5 mm.
2. Push lever (4) towards the rear of the ma-

chine at 1 - 2 kg. When it contacts the spool
inside the brake valve lightly, interconnect
rods (5), (6).
* When doing this, adjust the length of rod
(6) so that there is no play of the connect-
ing pin at applied side.
3. After adiustino all the parts of the linkage, de- I 1
press brake pedal (1) fully and check that the

distance the brake pedal travels is A = 100 f
5 mm. Check also that brake valve lever (4)
travels a distance of 20 - 22 mm.
* The distance the brake pedal travels is
determined by the contact with the stop-
per of spring box rod (7) installed to the
bottom of the pedal. If the travel of the
brake pedal is not adjusted to the speci-
fied range, the linkage and brake valve
may be acting the stopper. This means
that there is excessive load on these parts
and the necessary braking force cannot be
197F419
obtained. This may also cause failures in
the brake system.
4. After connecting and adjusting all linkages,

depress the brake pedal, pull parking lever (2)
up and lock the pedal.
In this condition, check that the left and right
brake oil pressures are “0”.
For details of the place and method of
measuring the oil pressure, see MEASURING
OIL PRESSURE.
20-3 1
ADJUSTMENT OF WORK EQUIPMENT CONTROL LINKAGE
1. ADJUSTMENT OF BLADE CONTROL LINKAGE
197F420
20-32
1. Set blade control lever (1) at HOLD position,
and set blade lock lever (2) at LOCK position
to hold blade lever in position.
2. In this position, interconnect rods (3), (4), (5)

and (6).
jr Standard length of rod(3): 171 mm
(4): 190 mm
(5): 485 mm
(6): 556 mm
* To adjust length of each rod, turn the turn-
buckle attached to rods (5) and (6). Do not
move levers (7), (8) connected to the con-
trol valve to interconnect rods (5), (6).
3. After interconnecting all parts of the linkage,

move lock lever (2) between the LOCK and
FREE positions in turn, and check that rods
(5), (6) do not move.
* If rods (5), (6) move, this means that the
HOLD position of the blade lever does not
match the HOLD position of levers (7), (8)
on the valve. When the lock lever is at the
LOCK position, levers (7), (8) on the valve
are always pulled.
f: 4. After adjusting all parts of the linkage, move

the blade control lever to RAISE, LOWER,
5
E; FLOAT, LEFT TILT, and RIGHT TILT. Check
that the movement of levers (7), (8) on the
valve are distances L, to L,.
* Travel of lever (L,): 23.4 mm
(LJ: 23.4 mm
(LJ: 14.6 mm
(LJ: 15.6 mm
(L,): 15.6 mm
197F421
20-33
2. ADJUSTMENT OF RIPPER CONTROL LINKAGE
I
I II
197F422
20-34
1. Set ripper control lever (1) at HOLD position,
and set ripper lock lever (2) at LOCK position
to hold ripper lever in position.
2. In this position, interconnect rods (3), (4), (5)

and (6).
(4): 190 mm
(5): 557 mm
(6): 538 mm
* To adjust length of each rod, turn the turn-
buckle attached to rods (5), (6). Do not
move levers (7), (8) connected to the con-
trol valve to interconnect (5), (6).
3. After interconnecting all parts of the linkage,

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

the ripper control lever to RIPPER RAISE, RIP-
PER LOWER, RIPPER TILT, and RIPPER TILT
BACK. Check that the movement of levers
(7), (8) on the valve are distances L, to L4.
* Travel of lever (L,): 15.6 mm
(LJ: 15.6 mm
(LJ: 15.6 mm
(LJ: 15.6 mm
* For machines with a giant ripper, check
that connector CN263 of pin puller switch
(9) is connected.
20-35
ADJUSTING CLEARANCE OF IDLER
A If idler side guide (1) and guide plate (2) are

worn, and there is play to the side, or the
idler is at an angle, adjust as follows.
1. Adjustment in side direction

1) Drive the machine for 1 - 2 m on flat
ground, then measure clearance A (left,
right, inside, outside: 4 places).
2) If clearance A is more than 3 mm, remove

bolt (3) and (4), then take out shim (5), and
adjust as follows.
Clearance of one side: Max. 0.5 mm e 17MF02863
* Type of shim: 0.5 mm, 1.0 mm
20-35-l
0
CONVERTER STALL
* Measure the stall speed under the following

condition.
0 Coolant temperature : Within operating
range
0 Power train oil temperature : 70 - 90°C
0 Hydraulic oil temperature : Min. 50°C
A Make sure that there is no one near the ma-

chine before starting measurements.
1. Install tachometer A. Red

For details, see MEASURING ENGINE SPEED. r
\I
2. Depress the steering brake firmly and move
the gearshift lever to F3.
3. Set the fuel control lever to FULL, run the en-

gine at high idling, and stall the torque con-
verter.
4. When lamp A at the top of the green range of

the torque converter oil temperature gauge Green 1
lights up, return the gearshift lever to neutral, L
17MF02164
and lower the oil temperature until lamp B
lights up.
5. Repeat Steps 2) - 4) three times.
6. Repeat Steps 2) - 4) to stall the torque con-

verter.

the torque converter oil temperature gauge
lights up, wait for 5 - IO seconds, then
measure the engine speed.
* After completion of the measurement, return
the gearshift lever swiftly to neutral, and run
the engine at high idling to lower the oil tem-
perature.
A, Precautions
ver-ter
when relieving the torque con-
1) Depress the decelerator pedal before pull-

ing the fuel control lever to the FULL posi-
tion.
2) Release the decelerator pedal to run the
engine at high idling. However, for safety
reasons, always keep your right foot on
the decelerator pedal until the completion
of the measurement operation.
20-36
MEASURING SPEED AT TORQUE CONVERTER STALL
+ HYDRAULIC PUMP RELIEF (FULL STALL)
Ir Measure the stall speed under the following

condition.
0 Coolant temperature : Within operating
range
0 Power train oil temperature : 70 - 90°C
l Hydraulic oil temperature : Min. 50°C
A Make sure that there is no one near the ma-

chine before starting measurements.
1. Install tachometer A.
For details, see MEASURING ENGINE SPEED.
2. Depress the steering brake firmly and move Red

the gearshift lever to F3.
\I
3. Set the fuel control lever to FULL, run the en- A

gine at high idling, and stall the torque con-
verter.
4. When lamp A at the top of the green range of B

lights up, return the gearshift lever to neutral,
and lower the oil temperature until lamp B Greez
lights up. I
17MF021t
8 5. Repeat Steps 2) - 4) three times.
z
6 6. Repeat Steps 2) - 4) to stall the torque con-
verter, and at the same time, set the ripper
control lever to the RAISE position to relieve
the circuit.

lights up, wait for 5 - IO seconds, then
measure the engine speed.
* After completion of the measurement, return
the gearshift lever swiftly to neutral, and run
the engine at high idling to lower the oil tem-
perature.
Note: If this measurement is carried out im-

mediately after measuring the torque
converter stall speed, the measure-
ment can be carried out by performing
Steps 1) - 6) once.
A Precautions
verter
when relieving the torque con-
1) Depress the decelerator pedal before pull-

ing the fuel control lever to the FULL posi-
tion.
2) Release the decelerator pedal to run the
engine at high idling. However, for safety
reasons, always keep your right foot on
the decelerator pedal until the completion
of the measurement operation.
20-37
MEASURING POWER TRAIN OIL
A Stop the machine on level ground, lower the

work equipment to the ground and apply
the parking brake.
When measuring the hydraulic pressure,

remove all the sand and dirt from around the
nipple and plug.
Raise the power train oil temperature to at
least 70°C before measuring.
Refer to the diagram and table below to in-

stall oil pressure gauge C to the nipple for the
circuit to be measured.
Table of centralized pressure pick-up port posi-

tions and gauges to use when measuring hy-
draulic pressure
Gauge
Measurement location
(kg/cm*)
1. Right brake actuating pressure 60
I 2 Left brake actuating pressure 60
I 3 ” Rrght clutch actuating pressure 60
I 4 Left clutch actuating pressure 60
I 5 Transmission reducing pressure 60
I 6 Transmission modulating pressure 60
7. Torque converter stator clutch pressure 60
8. Torque converter lock-up pressure 25
I9 Torque converter outlet pressure 10
I 10 Torque converter inlet pressure 25

11'
I 11 Transmission lubricating pressure 10
17MF02165
20-38
1. Measuring torque converter oil pressure 2. Measuring transmission oil pressure
Measuring torque converter inlet port and 1) Measuring modulating and rotating clutch
outlet pressure reducing pressure (clutch circuit pressure)
i) Install oil pressure gauge C to torque i) Install oil pressure gauge C to modulat-
converter inlet pressure measurement ing pressure measurement nipple (6)
nipple (10) and outlet pressure and reducing pressure measurement
measurement nipple (9). nipple (5).
ii) Set the gearshift lever at neutral, and Measure the hydraulic pressure when
measure the torque converter inlet port the clutch is actuated with the engine
pressure and outlet port pressure with at low idling and high idling when the
the engine at low idling and high idling. gearshift lever is operated to all the po-
sitions given below.
Measuring torque converter lock-up press- ii) Measure the modulating pressure with
ure the gearshift lever at neutral.
i) Install oil pressure gauge C to torque * Before carrying out the following
converter lock-up pressure measure- measurements, pull the steering levers
ment nipple (8). (left and right) fully and apply the park-
ii) Set the gearshift lever at neutral, turn ing brake securely.
the lock-up mode switch ON, and iii) Place the gearshift lever at Fl.
measure the torque converter lock-up Measure the modulating pressure and
pressure with the engine at low idling reducing pressure.
and high idling. iv) Place the gearshift lever at F2.
* Start the engine, turn the lock-up mode Measure the modulating pressure.
switch ON, then gradually raise the en- v) Place the gearshift lever at F3.
gine speed. Measure the modulating pressure.
When doing this, check that the lock-up vi) Place the gearshift lever in RI.
lamp lights up, and at the same time Measure the modulating pressure.
the lock-up oil pressure rises. * Before returning the steering levers,
Reference: place the gearshift lever in neutral,
Engine speed when lock-up actuation then move the steering levers slowly.
starts (lamp lights up): 1110 - 1170 rpm
Combination of speed range and clutches
Measuring torque converter stator clutch * No. 5 (1st) is the rotating clutch.
pressure
i) Install oil pressure gauge C to torque
converter stator clutch pressure
measurement nipple (7).
ii) Set the gearshift lever at neutral, turn
the lock-up mode switch OFF, and
measure the torque converter stator
clutch pressure with the engine at low
idling and high idling.
20-39
2) Measuring transmission lubricating oil
pressure
i) Remove lubricating oil pressure
measurement plug (11) (PT1/8), and in-
stall oil pressure gauge C.
ii) Place the gearshift lever at neutral, and
measure the lubricating oil pressure
with the engine at low idling and high
idling.
Note: The oil pressure differs greatly be-

tween high temperature and low
temperature, so warm up the oil
throughly before measuring.
For details, see MEASURING EN-
GINE SPEED AT TORQUE CONVER-
TER STALL.
3. Measuring steering clutch pressure
1) Install oil pressure gauge C to left nipple

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

(2) and right nipple (1) for measuring the
steering brake oil pressure.
2) Place the gearshift lever at neutral, and
measure the oil pressure with the engine
at low idling and high idling with the steer-
ing levers not operated.
-j, Check also that the oil pressure is 0 kg/
cm2 with the engine at high idling both
when the steering levers are pulled
fully and when the brake pedal is
locked with the lock lever.
20-40
TESTING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF
PRESSURE
A Stop the machine on level ground, lower the

work equipment to the ground and apply the
Small pump
relief valve
parking brake. \
* When installing the oil pressure gauge,

remove all the sand and dirt from around the
plug.
0 Measuring pressure
1) Remove plug (PT1/8) (1) (for large pump)

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

pump.
0 Operate the blade tilt cylinder to the
end of its stroke to relieve the circuit,
then measure the oil pressure with the
engine at low idling and high idling.
Large pump
reliel valve i
17MF02185
0 Adjusting pressure
* If the result of measuring the work equipment

main relief pressure shows that the value is
not within the standard value, adjust as fol-
lows.
1) Remove cover (1).

2) Loosen locknut (2), and turn adjustment
screw (3) as follows to adjust.
Jr TO RAISE pressure, turn CLOCKWISE
TO LOWER pressure, turn COUNTER-
CLOCKWISE
* One turn of the adjustment screw ad-
justs the pressure by approx. 24.8 kg/
cm2.
i 3
197F430
20-41
BLEEDING AIR FROM HYDRAULIC CYLINDER
j, When operating the hydraulic cylinders for

the first time after replacing or reassembling
the cylinders or piping, always bleed the air
from the hydraulic cylinders as follows:
1) Start engine and run at low idling for ap-

prox. 5 minutes.
2) Run the engine at low idling, and raise and
lower the blade or ripper 4 - 5 times.
* When operating the hydraulic cylinder,
stop the piston rod 100 mm from the
end of its stroke. Do not relieve the cir-
cuit under any circumstances.
3) Run the engine at high idling and repeat

Step 2), then run the engine at low idling
and operate the piston rod to the end of
its stroke to relieve the circuit.
20-42
0 If the hydraulic drift exceeds the standard
value, check if the cause of the hydraulic drift
is in the cylinder or in the control valve.
* Oil temperature when measuring:

45 - 55°C
Measurement posture
1. Blade tilt cylinder, ripper tilt cylinder

0 Fully extend the rod of the cylinder to be
measured, and lower the tip of the blade
or ripper to the ground.

0 Remove the shank pin and extend the lift
cylinder fully.
* The blade lift cylinder has a built-in piston

valve, so measurement is impossible.
Measuring
1) Disconnect the head piping, and block the

piping at the chassis end with a blind
plate.
A Be careful not to disconnect the pip-

ing at the bottom end.
Start the engine, run the engine at high id-

ling, and apply the relief pressure to the
bottom end of the cylinder.
Wait for 30 seconds, then measure the
amount of leakage over the next 1 minute.
20-43
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF
BLADE AND RIPPER
* If hydraulic drift occurs in the blade and rip-

Blade lift cylinder
per (cylinder), check as follows to see if the
cause is in the cylinder packing or in the con-
trol valve.
1. Inspection posture
1) Blade lift cylinder circuit

Extend the blade to raise the chassis.
2) Blade tilt cylinder circuit 197FOl552
Extend the tilt cylinder rod fully (maximum

tilt), then extend the blade to raise the I
chassis. ( Blade tilt cylinder
n
3) Ripper lift cylinder
Extend the ripper to raise the rear of the
chassis from the ground.
4) Ripper tilt cylinder
2. Inspection
Set the cylinder of the circuit to be

checked in the inspection posture, then
stop the engine.
* For details of the inspection posture,
see Item 1) - 4).
Ripper lift cylinder
Operate the control lever in the direction
extend the cylinder rod.
If the downward movement becomes
fast, the packing is defective.
If there is no change, the control valve
is defective.
If the pressure in the accumulator has
been removed, run the engine for ap- I97FO I555
prox. 10 seconds to charge the accu-
mulator before carrying out the oper-
ation.
Ripper tilt cylinder
Reference: If the cause of the hydraulic drift

is in the packing, the speed of
downward movement in the
above operation will become fas-
ter for the following reasons.
1) With the work equipment in the posture

given above, (holding pressure applied to
the bottom end), the oil will leak from the I 17MF02166
bottom end to the head end. However,

the volume at the head end is smaller than
at the bottom end (proportional only to the
3) When the pressure becomes balanced, the
area of the rod), so if the oil flows in from
speed of downward movement becomes
the bottom end, the internal pressure at
slower. In this condition, if the lever is
the head end will rise.
operated as shown above, the circuit at
2) If the internal pressure at the head end
the head end is connected to the drain cir-
rises, a balance will be made in proportion
cuit (the bottom end is closed by a check
to this at a certain pressure (this differs ac-
valve), and the oil at the head end flows to
cording to the amount of leakage).
the drain circuit to increase the speed of
downward movement.
20-44
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE
PERFORMANCE
* Carry out the measurement under the follow-

ing conditions.
0 Coolant temperature:
Within operating range
0 Power train oil temperature: 70 - 90°C
1. Stop the machine on a flat road surface with

the blade and ripper in the travel posture.
2. Run the engine at low idling, depress the

brake pedal securely, and place the gearshift
lever at F2.
3. Depress the decelerator pedal and pull the

I 17MF02167
fuel control lever to the FULL position.
4. Release the decelerator pedal gradually, raise

the engine speed to high idling, and check
that the machine does not move.
A During the measurement, keep your

right foot on the decelerator pedal, and
if the machine starts to move, quickly
depress the decelerator pedal and re-
turn the gearshift lever to neutral.
Note: If this test is carried out in Fl, an ex-

8
cessive load will be brought to bear on
z the brake. For this reason, never use
i;
Fl; always use F2.
20-45
PROCEDURE FOR TESTING SENSORS
1. Radiator water level sensor
1) Stop the engine, turn the starting switch

OFF, and remove the sensor from the radi-
ator.
2) Put the test pin of the tester in contact
with the sensor connector.
3) Move the sensor float up and down, and
measure the resistance between terminals
1 and 2.
* Judgement
Condition When normal
Float up Max. 1 Q
Float down Min. 1 M 8
1. Float
0 The relationship between the sensor and 2. Switch
the position of the float is as follows. 3. Connector
Float above specified level: CLOSED (ON)
Float below specified level: OPEN (OFF)
i i 56lFO3177
2. Engine oil level sensor

OFF, and remove the sensor from the en-
gine.
2) Connect a T-adapter to the sensor connec-
tor.
3) Move the sensor float up and down, and
measure the resistance between terminal
1 and the bracket.
j, Judgement
Condition When normal
Float up I Max. 1 R
Min. 1 M Q 1. Connector
Float down I
2. Bracket
3. Float
l The relationship between the sensor and 4. Switch
the position of the float is as follows.
Float above specified level: CLOSED (ON)
Float below specified level: OPEN (OFF)
f Down Structure of circuit
I97FO2077
20-46
3. Engine oil pressure sensor
1) Stop the engine and turn the starting

switch OFF.
2) with the sensor still installed to the engine,
disconnect the wiring harness from the
sensor. 1 2 3 4 5 6
3) Measure the resistance between the termi-
nal and the chassis with the engine \\I///
@ @
stopped and with the engine running.
* Judgement
Condition of sensor
Engine stopped
Engine running
I
When normal
Min. 1 M 8
Max. 1 R 1. Plug
2.
0
Contact ring
202FO5 I 75
3. contact
0 The relationship between the sensor and
4. Diaphragm
the oil pressure is as follows.
5. Spring
Oil pressure above 0.7 kg/cm*:
CLOSED (ON) 6. Terminal
Oil pressure below 0.7 kg/cm2:
OPEN (OFF)
4. Engine water temperature, torque conver-

ter oil temperature sensor

OFF, and remove the sensor from the en-
gine or torque converter.
2) Measure the resistance between terminals
1 and 2 with the sensor at about the same
temperature as the ambient temperature.
* Judgement
Ambient temperature When normal
35°C Approx. 29 KR
I I
20°C Approx. 52 KQ
I I
10°C Approx. 80 KS
1. Connector
2. Plug
3. Thermistor
I96FO2046
20-47
5. Hydraulic oil temperature sensor

OFF.
2) With the sensor still installed to the piping
at the suction side of the hydraulic pump,
disconnect the wiring harness from the
sensor.
3) Measure the resistance between terminal
1 and the ground.
* Judgement
Condition of sensor When normal
Between terminal 1
Max. 1 Q 1. Switch
and ground I 2. Case
3. Wire
4. Connector
Structure of circuit ISSFO2047
6. Fuel level sensor
1) Stop the engine and turn the starting

switch OFF.
2) With the sensor still installed to the fuel
tank, disconnect the wiring harness from
the sensor.
3) Measure the resistance between terminals
1 and 2.
* Judgement
Condition of fuel I When normal
Full I Approx. 10 R
Empty I Approx. 85 R
F91702223
20-48
TESTING AND ADJUSTING ELPC VALVE POTENTIOMETER
Sr Use the following procedure to carry out testing

and adjusting of the potentiometer set condi-
tion and adjustment when the potentiometer has
been replaced.
-. // /
17MF02867
. ._. ._ _.
1. Disconnect rods (I) and (2) connected to tne
input and output levers of the ELPC valve.
2. Testing and adjusting manual (input) potentiometer

I) Connect the wiring harness checker to the
connector (CNSM4) of manual potentiometer
(3).
2) Turn input lever (4) counterclockwise until it
stops.
3) Turn the power on, measure the voltage be- cNsM4
tween pins No. 2 and 3 of potentiometer (31,
and check that it is within the standard value. TWP01245
Standard voltage: 2.5 + 0.01 V
I TWD01246
D275A-2 20-48-l
0
I
4) If the voltage is not within the standard value,
loosen mounting bolts (5) of the potentiometer,
and move the oblong hole portion to adjust to
within the standard value.
TWP01247
3. Testing and adjusting feedback (output)

potentiometer
I) Connect the wiring harness checker to the
connector (CNSMP) of feedback potentiometer
(6).
2) Turn output lever (7) counterclockwise until
it stops.
3) Turn the power on, measure the voltage be-
tween pins No. 2 and 3 of potentiometer (61,
and check that it is within the standard value.
Standard voltage: 1.58 & 0.05 V
I TWPOl248
TWD01249
4) If the voltage is not within the standard value,

loosen mounting bolts (8) of the potentiometer,
and move the oblong hole portion to adjust to
within the standard value.
4. After installing and adjusting the potentiometer,

connect rods (I) and (2).
Sr Adjust the linkage.
For details, see ADJUSTING FUEL CONTROL
LINKAGE.
TWP01250
20-48-2 D275A-2
a
TROUBLESHOOTING
Point to remember when troubleshooting .......................................................................................... 20- 50

Sequence of events in troubleshooting ............................................................................................... 20- 51
Rrecautions when carrying out maintenance ..................................................................................... 20- 52
Handling connectors .............................................................................................................................. 20- 59
Checks before troubleshooting ............................................................................................................. 20- 60
Method of using matrix troubleshooting chart ................................................................................... 20- 62
Method of using troubleshooting chart.. ............................................................................................. 20- 66
Type of connector and position of installation ................................................................................... 20- 69
Connector position drowing ................................................................................................................. 20- 71
Connection table for connector ............................................................................................................ 20- 72
Electrical circuit diagrams for each system ........................................................................................ 20- 81
Troubleshooting of engine.. .................................................................................................................. 20- 85
Troubleshooting of hydraulic, mechanical system ............................................................................. 20-I 05
Troubleshooting of electrical system ................................................................................................... 20-123
Troubleshooting of electrical system (with SSC system) ............................................................... 20-I 40-I
Troubleshooting of machine monitor system.. ................................................................................... 20-I 41
Troubleshooting of shoe slip controller, ELPC controller system (G mode) ................................... 20-201
D275A-2 20-49
0
POINTS TO REMEMBER WHEN TROUBLESHOOTING
A 0 Stop the machine in a level place; and check that the safety pin, blocks, and parking brake are se-
curely fitted.
0 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.
0 Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
0 When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
0 When removing the plug from a location which is under pressure from oil, water, or air, always re-
* lease the internal pressure first. When installing measuring equipment, be sure to connect it
properly.
0 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 ques-
tions to form some idea of possible cases of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not

hurry to disassemble the components. 2) Check the CHECKS BEFORE STARTING
If components are disassembled immediately items.
any failure occurs: 3) Other inspection items.
0 Parts that have no connection with the 4) Other maintenance items can be checked
failure or other unnecessary parts will be externally, so check any item that is con-
disassembled. sidered to be necessary.
0 It will become impossible to find the cause
of the failure. 4. Confirming failure
It will also cause a waste of manhours, parts, 0 Confirm the extent of the failure yourself,
or oil or grease, and at the same time, will and judge whether to handle it as a real
also lose the confidence of the user or oper- failure or as a problem with the method of
f:
ator. operation, etc.
For this reason, when carrying out trouble- * When operating the machine to reenact :6
shooting, it is necessary to carry out thor- the troubleshooting symptoms, do not
ough prior investigation and to carry out carry out any investigation or measure-
troubleshooting in accordance with the fixed ment that may make the problem
procedure. worse.
2. Points to ask user or operator 5. Troubleshooting

1) Have any other problems occured apart 0 Use the results of the investigation and in-
from the problem that has been reported? spection in Items 2 - 4 to narrow down
2) Was there anything strange about the ma- the causes of failure, then use the trouble-
chine before the failure occurred? shooting tables (matrix) to locate the posi-
3) Did the failure occur suddenly, or were tion of the failure exactly.
there problems with the machine condi- * The basic procedure for troubleshoot-
tion before this? ing is as follows.
4) Under what conditions did the failure 1) Start from the simple points.
occur? 2) Start from the most likely points.
51 Had any repairs been carried out before 3) Investigate other related parts or in-
the failure? formation.
When were these repairs carried out?
61 Has the same kind of failure occurred be- 6. Measures to remove root cause of failure.
fore? 0 Even if the failure is repaired, if the root
cause of the failure is not repaired, the
3. Check before troubleshooting same failure will occur again.
1) Check for symptoms of any abnormality in To prevent this, always investigate why
the machine. the problem occurred. Then, remove the
root cause.
20-50
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office,shop ,=
fl n m Jobsite
step1
1Examination, confirmation of symptoms j RIngI Ring1
1) When a request for repairs is received,
first ask the following points:
0 Name of customer
0 Type, serial number of machine
0 Details of jobsite, etc.
2) Ask questions to gain an outline of the
problem.
0 Condition of failure
0 Work being carried out at the time
of the failure
0 Operating environment
0 Past history, details of maintenance,
etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
step 3
\
Preparation
1)
of troubleshooting
Look at the table of troubleshooting

tools
tools
,m
in the shop manual and prepare the
I
necessary tools.
0 T-adapter
0 Hydraulic pressure gauge kit, etc. l Pinpoint locations of failure (carry out
2) Look in the parts book and prepare the
necessary replacement parts.
I Before
repair
0
0
starting
simple
Check before
Other
troubleshooting,
failures.
check items
starting items
locate and
2) See the Troubleshooting Section of the

shop manual, select a troubleshooting
flowchart that matches the symptoms, and
carry out troubleshooting.
I i 0
Re-enacting failure
Drive and operate the machine to confirm

the condition and judge if there is really a
I failure.
step 4 1 Step5
1 Go to jobsite 1
of failure
I
0 Was there anything strange about
the machine before the failure occurred?
0 Did the failure occur suddenly?
0 Had any repairs been carried out before
the failure?
20-5 1
To maintain the performance of the machine over
a long period, and to prevent failures or other
troubles before they occur, correct operation,
maintenance and inspection, troubleshooting, and
repairs must be carried out. This section deals
particularly with correct repair procedures for me-
chatronics and is aimed at improving the quality
of repairs. For this purpose, it gives sections on
“Handling electric equipment” and “Handling hy-
draulic equipment” particularly hydraulic oil).
1. PRECAUTION 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 disconnect-
ing one wire from another wire, and protector
or tubes used for protecting the wiring. Com-
pared with other electrical components fitted
in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore,
during inspection and repair operations they
are frequently removed and installed again,
so they are likely to suffer deformation or
damage. For this reason, it is necessary to be
extremely careful when handling wiring har-
nesses.
F20505201
Main failures occurring in wiring harness

(1) Defective contact of connectors
(defective contact between male and fe- Improper insertion
male)
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- F20505202
faces.
20-52
(2) Defective compression or soldering of
connectors Improper compressio
The pins of the male and female connec-
tors are in contact at the compressed ter-
minal or soldered portion, but there is ex-
cessive force on the wiring, and the plat-
ing peels to cause improper correction or
breakage. F56103079
(3) Disconnections in wiring

If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or
a heavy object hits the wiring, the com-
pression of the connector may be lost, or
the soldering may be damaged, or the wir-
ing may be broken.
F20505204
(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.
The connector is designed to prevent
water from entering, but at the same time,
&
if the water does enter, it is difficult for it
to be drained. Therefore, if water should F20505205
get into the connector, the pins will be
short-circuited by the water, so if any
water gets in, immediately dry the connec-
tor or take other appropriate action before
passing electricity through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating
surface between the male and female
pins, the oil will not let the electricity pass,
so there will be defective contact.
If there is oil or grease or dirt stuck to the
connector, wipe it off with a dry cloth or
blow dry with air, and spray it with a con-
tact restorer.
jr When wiping the mating portion of the
connector, be careful not to use ex-
cessive force or deform the pins.
F20505206
20-53
* If there is water or oil in the air, it will
increase the contamination of the
points, so clean with air from which all
the water and oil has been removed.
2) Removing, installing, and drying connectors

and wiring harnesses.
Disconnecting connectors
(1)Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires.
For connectors held by a screw, loosen
the screw fully, then hold the male and fe-
male connectors in each hand and pull
apart. For connectors which have a lock
stopper, press down the stopper with your
thumb and pull the connectors apart.
F20505207
(2) Action to take after removing connectors

After removing any connector, cover it
with a vinyl bag to prevent any dust, dirt,
oil, or water from getting in the connector
portion.
F20505208
Connecting connectors
(1) Check the connector visually.
a. Check that there is no oil, dirt, or water
stuck to the connector pins (mating
portion).
b. Check that there is no deformation, de-
fective contact, corrosion, or damage
to the connector pins.
c. Check that there is no damage or
breakage to the outside of the connec-
tor.
Sr If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the wir-
ing with a dryer, but be careful not to
make it too hot as this will cause short
circuits.
* If there is any damage or breakage, re-
place the connector.
20-54
(2) Fix the connector securely.
Align the position of the connector cor-
rectly, then insert it securely.
For connectors with lock stopper
Push in the connector until the stopper
clicks into position.
Cliks into position
(3) Correct any protrusion of the boot and any

misalignment of the wiring harness F20505209
For connectors fitted with boots, correct

any protrusion or the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its cor-
rect position.
j, When blowing with dry air, there is
danger that the oil in the air may cause
improper contact, so clean with air
from which all the water and oil has
been removed.
Drying wiring harness

If there is any oil or dirt on the wiring har-
F20505210
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 follows.
(1) Disconnect the connector and wipe off the
water with a dry cloth.
* If the connector is blown dry with air,
there is the risk that oil in the air may
cause defective contact, so avoid blow-
ing with air.
F20505211
(4 Dry the inside of the connector witha a
dryer.
If water gets inside the connector, use a
dryer to dry the connector.
* Hot air from the dryer can be used, but
be careful not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connec-
tor.
F20505212
20-55
(3) Carry out a continuity test on the connec-
tor.
After drying, leave the wiring harness dis-
connected and carry out a continuity test
to check for any short circuits between
pins caused by water.
j, After completely drying the connector,
blow it with contact restorer and reas-
semble.
T-adapter
3) Handling control box F20505213

(1) The control box contains a micro-com-
puter and electronic control circuits.
These control all of the electronic circuits
on the machine, so be extremely careful
when handling the control box.
(2) Do not open the cover of the control box

unless necessary.
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or F20505214

a vinyl bag
(5) During rainy weather, do not leave the

control box in a place where it is exposed
to rain.
(6) Do not place the control box on oil, water,

or soil, or in any hot place, even for a
short time. (Place it on a suitable dry
stand)
(7) Precautions when carrying out arc welding

When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controlb box. Fit
an arc welding ground close to the weld-
ing point.
F20505216
20-56
2. POINTS TO REMEMBER WHEN
HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disas-
sembling 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 confirm the performance
after repairs, so it is desirable to use unit ex-
change. Disassembly and maintenance of hy-
draulic equipment should be carried out in a
specially prepared dustproof workshop, and
the performance should be confirmed with
special test equipment.
F20505217
3) Sealing openings
After any piping or equipment is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left open
or is blocked with a rag, there is danger of
dirt entering or of the surrounding area being
made dirty by leaking oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of
it, or take it back with you for disposal.
F20505218
4) Do not let any dirt or dust get in during re-

filling operations.
Be careful not to let any dirt or dust get in
when refilling with hydraulic oil. Always keep
the oil filler and the area around it clean, and
also use clean pumps and oil containers. If
an oil cleaning device is used, it is possible to
filter out the dirt that has collected during
storage, so this is an even more effective
method.
F20505219
20-57
5) Change hydraulic oil when the temperature
is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together
with the oil, so it is best to change the oil when
it is still warm. When changing the oil, as
much as possible of the old hydraulic oil must
be drained out. (Do not drain the oil from the
hydraulic tank; also drain the oil from the filter
and from the drain plug in the circuit.) If any
old oil is left, the contaminants and sludge in it
will mix with the new oil and will shorten the
life of the hydraulic oil.
Flushing operations
After disassembling and assembling the 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 spe-
cified hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment F20505220
(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 ultrafine (about 3 ,~4 particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
F20505221
20-58
HANDLING CONNECTORS
1. When removing the connectors from the

clips, pull the connector in a parallel direction
to the clip.
* If the connector is twisted to the left and
right or up and down, the housing may
break.
205FO5609
8 205FO5610
r
I-
6 2. When disconnecting male and female con-

nectors, release the lock and pull in parallel
with both hands.
* Never try to pull out with one hand.
205FO5611
3. When the wiring harness clamp of the con-

nector has been removed, always return it to
its original condition and check that there is
no looseness of the clamp.
I 205FO5612
20-59
CHECKS BEFORE TROUBLESHOOTING
T Item
Judgement
standard
-
Remedy
1. Check fuel level Add fuel

2. Check for dirt or water in fuel - Clean, drain
3. Check hydraulic oil level - Add oil
4. Check hydraulic oil strainer - Clean, drain
5. Check power train oil level - Add oil
6. Check engine oil level (level of oil in oil pan) - Add oil
7. Check cooling water level Add water
8. Check condition of dust indicator Clean or
replace
9. Check for loose or corroded battery terminals or wires - Tighten or

replace
10. Check for loose or corroded alternator terminals or wires Tighten or
replace
11. Check for loose or cooroded starting motor terminals or wires Tighten or
replace
12. Check for abnormal noise or smell - Repair
13. Check for oil leakage - Repair
14. Bleed air from system - Bleed air
15. Check battery voltage (engine stopped) 20 - 30 v Replace

16. Check level of battery electrolyte - Add or
replace
17. Check for discolored, burnt, or bare wiring - Replace
18. Check for missing wiring clamps, hanging wires Repair
19. Checks for water leaking onto wiring (check carefully for water Dry area
leakage at connectors and terminals) around
connector
20. Check for broken or corroded fuses - Replace
!I. Check alternator voltage (engine running at over half throttle) After running Replace
engine for
several
minutes
27.5 - 29.5 v
!2. Noise when battery relay is operated. - Replace
(Turns starting switch ON - OFF)
20-60
METHOD OF USING MATRIX TROUBLESHOOTING CHART
This troubleshooting chart is divided into three

sections: questions, check items, and trouble-
shooting. The questions and check items are
used to pinpoint high probability causes that can
be located from the failure symptoms or simple
inspection without using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections $9 + @ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under 0 in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of 0 that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-62
The basic method of using the troubleshooting chart is
as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with 0
Check each of the [Questions] and [Check items] in
turn, and marked the 0 or 0 in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for that
item to make final confirmation of the cause.
-*1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark the
_, Cause column with A to use as reference for
locating the cause of the failure. However, do
not use this when making calculations to narrow
down the causes.
*2. Use the A in the Cause column as reference for
[Degree of use (Operated for long period)] in
the [Questions] section as reference. As a rule,
do not use it when calculating the points for lo-
cating the cause, but it can be included if
necessary to determine the order for trouble-
shooting.
Confirm recent repair history

*1
Degree of “se Operated for long period A A
*2 A
20-63
0 Example of troubleshooting when exhaust gas is black
Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symp-
toms have causal relationship with this problem: [Exhaust gas slowly becomes black], [Power slowly
became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
l Insufficient intake of air
l Improper condition of fuel injection
l Excessive injection of fuel
20-64
I
1 Five causes 1
Step 1
1 Clarify the relationship between the three symp- 1
toms in the [Questions] and [Check items] section
and the five Cause items in the vertical column.
I
Three symptoms
A A A
Steo 2
I-
Add up the total of 0 and 0 marks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element: 000
(2) Air leakage between turbocharger and
head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: g
(5) Worn piston ring, cylinder:
Step 3
The calculations in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item
marked 0. The Remedy is given as [Clean], so
carry out cleaning, and the exhaust gas color
should return to normal.
20-65
METHOD OF USING TROUBLESHOOTING CHARTS
1. Category of troubleshooting code number
Troubleshooting code No. Component
H-00 Power train, work equipment (Hydraulic, mechanical system)
E-00 Electronic system
M-00 Machine monitor
2. Method of using troubleshooting table

@ Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the problem
with the machine.
@ Distinguishing condition
Even with the same problem, the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the troubleshooting chart is further divided into sections
marked with small letters (for example, a)), so go to the appropriate section to carry out trouble-
shooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check
item.
@ Method of followinn troubleshooting chart
Check or measure the item inside the box, and according to the answer follow either the YES line
or the NO line to go to the next box. (Note: The number written at the top right corner of the
box is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will lead fi-
nally to the Cause column. Check the cause and take the action given in the Remedy column on
the right. 8
Below the box there are the methods for inspection or measurement, and the judgement values. z
If the judgement values below the box are correct or the answer to the question inside the box is 6
YES, follow the YES line; if the judgement value is not correct, or the answer to the question is
NO, follow the NO line.
Below the box is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling
is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be
damaged. Therefore, before starting inspection or measurement, always read the instructions
carefully, and start the work in order form item 1).
@ General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top of the
page and marked with *. The precautions marked * are not given in the box, but must always be
followed when carrying out the check inside the box.
@ Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details,
see TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.
@ Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number
connection table, so when carrying out troubleshooting, see this chart for details of the onnector pin
number and location for details of the connector pin number and locations for inspection and
measurement of wiring connector number 00 appearing in the troubleshooting flow chart.
20-66
Example 1
@ M-3. When starting switch is ON (engine stopped), CHECK items shown abnormality
@ al Abnormality in radiator water level
. Radiator water level monitor flashes
0
Cause Remedy
YES Defective radiator water

Replace
lever sensor.
Does radiator YES 3 YES Defective monitor module. Fii?DlPX

water level monitor _
go off? Is resistance bet-
ween CN-1 (female)
2 - (5) and chassis
ground less than Defective contact, or discon-
. Connect short lQ? nection in wiring harness
connector to Is resistance bet- between CN405 (female) (1) After inspection,
CN405 (female).
L
wee” CN405 (fe-
male) (2) and _ . Disconnect CN-1. NO
- CN202 (11 - CN201 (1) repair or replace
e Turn starting - CNlOl (2) - CN421 (3)
switch ON. NO chassis ground less - CN-1 (female) (51.
8 than 1 Q?
2 Defective contact or discon-
b l Disconnect CN405. nection in wiring harness After inspection,
6 NO between CN405 (female1 (21 repair or replace
and chassis ground.
@ * Before carrying out troubleshooting, check that all the related connectors are properly inserted.
jr Always connect any disconnected connectors before going on the next step.
20-67
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
* $~I~J.~~?RESS column in this table shows the address in the connector position drawing (3-dimensional
Connec- Connec- No. ADD- Connec- Connec- No. ADD.

Place of use Place of use
tor No. tor type of pins RESS tor No. tor type I of pins I RESI
Intermediate connector D7
CNI AMP040 12 Monitor panel B6 CN364 (without cab)
intermediate connector
CN2 AMP040 8 Monitor panel B6 CN371 C6
(without cab)
Caution lamp, lock-up
CN3 MIC 5 Monitor panel 84 CN372 A7
lamp (without cab)
Int;;yaiate connector
CN4 M 2 Monitor panel 85 CN391 18
Caution lamp, lock-up

CN5 M 2 Monitor panel B5 CN399 G9
lamp (with cab)
CNlOl SWP 14 Intermediate connector G2 CN401 Intermediate connector G2
Engine water temperature E7

CN102 X 4 APS nozzle, glow plug D7 CN402 sensor
CN403 Engine oil pressure sensor G2
CN404 1 X ( 1
CN422 X 2 Intermediate connector I8
CN423 X 2 Fuel sensor H9
CN151 X 3 Neutral safety switch I8
CN153 SWP 6 Intermediate connector H3
CN161 SWP 6 Starting switch B8 CN464 X 4 Auxiliary controller C6
CNI 62 X 3 Auxiliary controller c7 CN465 Connector 1 Caution buzzer D8
CN201 X 4 Intermediate connector Dl CN466 Connector 1 Caution buzzer D7
CN202 X 4 Intermediate connector Dl CN622 SWP 8 Lock-up controller I4
CN653
CNSOl
CN224 X 2 Pin-puller solenoid J7 CNSOZ
CN241 X 3 Intermediate connector F8 CNS03
CN242 M 1 Working lamp (right) E7 CNS04 Riooer UP switch
CNSOS Ripper tilt switch
CN361 SWP 14 Intermediate connector J4
CN362 SWP 8 Intermediate connector J4 CNSIO SWP 14 Intermediate connector H2

Transmission FORWARD Hg
CNSl2 X 2 oil pressure switch
20-69
I I I
ADD- Connec- ADD-
Place of use Place of use
I RESS I tor No. RESS
1 CNSMI 1 MIC 1 21 1 ELPCvalve controller I ~8 I

CNSM2 X 3 Feedback potentiometer F8
CNSMB X 2 Solenoid G8
I CNSM4 I X 1 3 I Throttle potentiometer I ~8 I

CNSM5 X 2 Engine speed sensor E7
CNSSI MIC 13 SSC controller D8
CNSS2 MIC 17 SSC controller D7
1 CNSSB 1 X 4 1 Acceleration sensor I F8 I
20-70
CONNECTOR POSITION DRAWING
CN653
CN452
CN423
CN263 CN399
I CNS12
/ CNSOS I I i
ZY AA / / -I I I
CNl
CN422
crJ3g1 -_.___
\ CFj251
CN622
N451
CN62
, / Cd404c’103
17MF02166
............................................................ ....................
p:.:.:.:+:.:.:.:.:.:.:.:.:C~--
...............
. ~G:~~l
................ ~.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:::::::::::jljjii
.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:
.................................................
.......................................
:~!:~:~:i:!:i:i~:i~~.~~~ c ...
““““““‘~ : : : : ...........................
:~::~::::i::::::::::::::~,~~:~.:.:.:.:
..........................................
B
..........................................
............................................
:y:::::::::::::::::::::::::::::::::::::::
i:i:#:~:i:i:~:i::::::::::::::~~:::~:~::: D F :::::::::::::::::::::::::::::::::::::::::::
........................A. ........................ H ...........................................
:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:+:, J I
20-71
CONNECTION TABLE FOR CONNECTOR
NO. Oi b X TYPE CONNECTOR

Pins Male connector Female connector
205FO5309 205FO5310
205FO5311 205FO5312
/
2
205FO5313 205FO5314
1 3
4 2
205FO5315 205FO5316
20-72
T
M TYPE CONNECTOR
No. o f
205FO5317 205FO5318
205FO5319 205FO5320
205FO5322
1 3
El
205FO5323 205FO5324
20-73
No. of
Pin
T Male connector
M TYPE CONNECTOR
Female connector
1 4 4 1
/ \
3 6
205FO5325 205FO5326
20-74
AMP040 TYPE CONNECTOR
No. c,f
Pins T Male connector Female connector
8
- \
5 1
1 5
F56103083 F56103084
12 6
12
I \
1 ‘7 i i
F561 03085 F56103086
8 16 16 8
/
16
\\
i 9
205FO5335 205FO5336
20-75
S TYPE CONNECTOR
No. c
4 a
205FO5327 205FO5328
1 6 6 1
10
205FO5329 205FO5330
6 1
12
6 1 li s
205FO5331 205FO5332
16 7 a i
16
a 1 16 7
205FO5333 205FO5334
20-76
SWP TYPE CONNECT&
No. c
4 1
205FO5339
H
8
I I
205FO5340
1 5 5 1
\ I
4 8
205FO5341 205FO5342
14 8 11 11 8 4 1
14
i lb i4
F56103087 F56103088
20-77
F
MIC CONNECTOR
No. of
142F411 142F410
13
142F413 142F412
6
17
F7
I I
142F415 142F414
1 11
12 21
21
142F417 142F416
20-78
CONNECTOR
Total
Pins Male (mating portion protrudes) Female (mating portion is inset)
195FO5128 195FO5129
20-79
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
MACHINE MONITOR (except preheating, APS system)
Torque converter Hydraulic oil Radiator Engine oil Starting Starting Starting
oil temperature temneratur Fuel level water Pressure Engine oil Radiator water Alternator motor
jVb_pnerator’s cab is installed ______
sensor esensor temperature sensor level sensor level sensor
sens or Central warnina lamp ,
warnine lamp
Buzzer sianal
_ Monitor Panel
I
hi--- Monitor module
_____-__-__-__------
r +l(
__ ) _.._
Lighting signal I
1’2\ [GND
Power source (+I

GND
Stating signal
Charge amount R
ill I I I I I Radiator water level
Engine oil level
Engine oil pressure
I I I I
I I I
““!/OS\ t Hydraulic oil temperature
--
Enain water tennerature
I I Torque converter oil temperature
Fuel level
Preheating selector GND
I I CN121 I ,., -.--

warn’ns
I-__
lamp
I
Buzzer
____________________I
En-b
a E Serviice
___________-__-__-__ meter
t Lighting signal
GND
3’
Battery relax
I
j T;/ 1 cnarae amount x
-a
N Lock-us Relay box 0 BR a
a I I I ’ 04 GND
y 0
0 40
3
@ I t 05
gi 0 20
I
I 10
,o 0
'""P~S'_arY~_Y!~~____________________; TDD00706
20-8 1
0
APS SYSTEM
Serial No . : 10001 - 10167
I
APS controller
r-------7
APS fuse No. 16
53
Monitor module
D9
0.5
:t
I I 1 1.25
I
J I I Panel switch IC
0.75 m pwJerro”rce
0.75 I I
Panel switch GND
Ii
I I I I II II04
0.5 APS relay
I u
’ 1Kn
l*,I
n APS pilot OH
013
0.5 II
,012
i-l Starting switch R2 01I
OIC
II 1 II09
17MF03001
20-82
@
Start ins motor Safety switch
zzzl
L
Nozze I
Nl03 N151
?elav box APS water

-_-_-__.______________-_-_-______.-.-_-_ -_-_-_-_-------.-_ sensor
1
Safety relay _
_-_-__
Fuse__
r---
I
I
,^.5 ^^.
i1 IUH
9
c ZUA
11
j CNl21
CN451
__________________~_onit_arm_odul
I I I I I lb8 Ilndl II I
r r__________.-_-_-_-_-_- 1
I
I LZ / I
I 44 I I I lbiilliiall I I I
0
-I
.-
I
0141
0151
016 1
Grow 9
017
018
..I9
mo
1
I
I
2u CN4 CNl
I
a CN2
I
J2
Panel switch
I I CN361 I
Starter snitch
APS oilnt
L-
- Ll
L___-_______.__L__1
APS controller Relay
7-
77 TDD00709
20-82-l
@
SSC CONTROL, ELPC CONTROL
MODE SELECTION ELECTRONIC SYSTEM DIAGRAM
CN251 (X)
a Back-up alarm
limit switch
I Transmission
forward oil
CNS07 (X) Pressure switch
OaIIerY IN>L”“A.L,
(option C2OOX2) 4
1 AEXI.25P "E" j AEXO.85P 1 - ,,, ,, AEXIOOR (1201

Fusible IinktGOA) CN421 (SWP)
1 .\rnnn,tn.-.\
II . AVSO.85LW II. [ISneed+

AVZL
Acceleration CNSSJ (XI
I AVSO.85LY 11.; ;&need-
CN122 (SWP)
CNSM5 (XI I
Engine speed CNSOG (SWP)
sensor
xx xx I I
,,A~~.858
For SSC
actuator CNSM4
7
Lx!!
7
AVSO.85Le
I
* 5 5
'Sianal5V _~ , ,. AVSO.85BW
AVSO.85GW . 6 6
02 2+ -9 1 7 3
7 GND w3 3. AVSO.858 x >c.,
8 8
. o 3 9
10
11
&AVBS------------~
AtSMA)
,3. AVBSO.15W ;
I”. AVBSO.758 ,7------ ______---------------_.
1I________________-------- SWP)
I CNSMJ
; i I
" \_a
0 Motor At+) II,,\\ ,,llAVBSO.75W T!
TWD01251
20-82-2 D275A-2
0
Shoe siio control specifications
SSC Panel (when key is ON)
Monitor Panel
Ripper LOWER CNS03 (Xl CNSOS (MI ON-OFF available switch
switch Caution buzzer AVSO. 58 . c
1Monitor Panel - , COM . 3 3. AVSO. 858
Monitor auxiliary controller Shoe slip
/ AVSO. 5LY .; ;+
@ NC 02 20 :K,’ control Ier (SSC)
1 NO . , ,c AVSO. 85GW
Torque converter speed t-1
Ripper RAISE CNS04 (XI Ens i ne speed f-1
switch Throttle(t5V)
COM m
-’ Throttle signal
NO Rockbed selection mode
Torque converter speed (+I
Ripper TILT CNS05 (X) Ens ine speed (+I
switch Acceleration sensor (8V)
COM II-?\’
NC Acceleration sensor (GNO)
NO Acceleration sensor (sianal)
1 SSC command
Economy mode B
Economy mode A
Transmission F switch
Ripper TILT switch
CN42 1 RIoper RAISE switch
Ripper LOWER switch
Back-up alarm switch
System abnormality output
Power supply (+24V)
AVSl. 25B .
;4 ;;. GNO
AVSO. 5LW ~
15 15. Slip control
AVSO.85BrR .,D ,B.
I I Transmission 1st switch
Reverse slow switch
II IIIIII AVBSo’75W
!*3 3.1 Solenoid drive
,
I I
XX xx I I I I
i’llll, AVSo’85GW
!*i 1 5.1 F/B notentiotsienal)
AVSJ. t)SLgW
9.
,OC_AVSO.____ - ’r------ -3’
I3___/____ i__
-I-l--l-- SSC command
GNO
Solenoid drive(-)
F/B Potent io (-)
Input potent io (-1
AVSo.85B 1.19 \ l&I Sensor GND
Alarm output
Starting switch
TWDO 1252
D275A-2 20-82-3
a
TORQUE CONVERTER LOCK-UP SYSTEM DIAGRAM
Transmission
;;;t;;ess”re CN652 (X) Front disnlav(For non cab)

I., 1.I AVSO.85BrY
2 2.1 AVSO. 858 1 CN364 (XI CN371 (X) CN372 (X)
I .3 3e1AVSO. I .3 3
rI
AVSO. 85LW AVSO. 85LW
I xx I I AVSO.
65LYL4 1 4 85LY
1.4 4 Lock-up
Torque converter I Iamp
speed sensor CN651 (XI
Shoe sl in control Ier (SSC)
%Z,’
CN653 (XI
AVSO. 85LY I. I* Torque converter speed (-)
Lock-UP CN 122 (SWP) AVSO. 85LW 1. ; 8. Torque converter speed(t)
solenoid AVSI. 258 . . AVSl. 258 I
1 AVSo’5GW
6 6.
94
AVSO. 85LW . 7 7. AVSO. 85LW
AVSO. 85LY . 8 8. AVSO. 85LY
4. Lock-up switch
Plus for lock-up
CNSOG (SWP) ---‘I4 14. GND
Shoe slip control specifications

Monitor Panel
~__________._.._.__..-.._.._..-__
/
1
AVSO. 5BR .
Relax box
AVSO. 5B .;
1 l Power SUPPIY (24V)
2 GND
I AVSO. 5GW . 3 3.
l
Lock-up switch
/ AV20Rt100) 1 ,
Monitor auxiliary
z CN362 (SWP)
i &
CNl21 (Mic) I AVSO. 858
+24v output
AVSO. 85LW
Front disnlav(For cab)
I
CN39
1 (M i c) CN399 (x1
AVSO. 85LW I, I
AVSO. 85LY 1. 17 17.1 -++4 1.3 3 Lock-up 1
Battery (NS200X2)
- , 18 18 4 lamp /
Battery relax (600AX2) Fusible
(opt ion C2OOX2)
I ink
/
AEX40B
\A~i00B _ ,I ,l,l AExlooR (120)
r
1 AVLL
77h7
GND TWD01253
20-82-4 D275A-2
0
PANEL SWITCH SYSTEM (except APS system)
Right working lamp

.
CN2.22
-_
z
c >sl
Left working lamp
Right rear lamp
Right lamp
-‘
7
Left rear lamp
Left lamp
-_
2
Relay box
Workina
la
r
Panel switch
To monitor panel
352 wq------]
power source CNl
Head lamp mitcb
:-I
Auxiliary controller
(monitor power source)
ttuo
17MF02173
20-83
RELAY BOX ELECTRICAL CIRCUIT DIAGRAM
Serial No. : 10001 - 10127
CN 362
CN361
12345678
I Ill I
II I I I
il
CNl21
197FO2085-1
20-84
8
017M02
0. 75
I. 25 IIIIIIIIIIIIIII Workino IamP
0.5r- I
l._-
I
I I I III1
1.25 / \‘
,_____
__.
25Service lamPI
12. 0 Preheating !
m 0. 75
I. 25
I I I
1-_--l
I I
I I
I I I III
I I
017M02
TROUBLESHOOTING OF ENGINE
s- 1 Starting performance is poor. ..................................................... 20- 86

s- 2 Engine does not start ........................................................... 20- 87
s- 3 Engine does not pick up smoothly .................................................. 20- 90
s- 4 Engine stops during operations .................................................... 20- 91
s- 5 Engine does not rotate smoothly ................................................... 20- 92
S- 6 Engine lacks output ............................................................ 20- 93
s- 7 Exhaust smoke is black. ......................................................... 20- 94
S- 8 Oil consumption is excessive. ..................................................... 20- 95
s- 9 Oil becomes contaminated quickly. ................................................. 20- 96
S-IO Fuel consumption is excessive. .................................................... 20- 97
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down ........................ 20- 98
S-l 2 Oil pressure lamp lights up ....................................................... 20- 99
20-100
s-13 Oil level rises.................................................................
s-14 Water temperature becomes too high. ............................................... 20-101
s-15 Abnormal noise is made. ........................................................ 20-102
S-16 Vibration is excessive ........................................................... 20-l 03
20-85
S-l Starting performance is poor
(Starting always takes time)
General causes why starting performance is poor.

0 Insufficient supply of fuel
0 Insufficient intake of air
0 Improper selection of fuel (particularly in winter)
(At ambient temperature of -10” C or below,
use ASTEM D975 No. 1)
0 Defective electrical system
j, Battery charging rate
7g time A A A
newow3 QQ 00 000
I Q Q @
2 Indicator lamp does not light UP I I I I I I
ven when iniection pump
1 When compression pressure is measured, it is found to be low I l 1l I

When air cleaner element is inspected directly, it is found
to be clogged 1
When fuel filter, <trainer are inspected directly, there are found
to be clogged 0 0
When feed pump strainer is inspected directly, it is found

to be clogged 0
APS combustion portion does not become warm a
ml
.z
Voltage is 26 - 30V between alternator terminal
and terminal E with engine at low idling
B
Yes 0
NO 0
8
Either specific graviol of electrolyte or voltage of battery
f 0
is low
$
2 Speed of some cvlinders does not chanae when owratina _ 0
E on reduced cylin&rs
When check is made using delivery method, injection timing

is found to be incorrect 0
When control rack is pushed. it is found to be heaw or does

not return (when blinb plug at rear of pump is remdved, it
can be seen that plunaer control sleeve does not move1 I I I I I I I I I I I I.1
When fuel cap is inspected directly, it is found to be clogged
Overflow valve is stiff, remains open
When engine oil is inspected directly, it is found to have high
20-86
S-2 Engine does not start.
0 Engine does not turn
General causes why engine does not turn
0 Internal parts of engine seized

* If internal parts of the engine are seized, carry
out troubleshooting for “Engine stops during
operations”.
0 Failure in power train
0 Defective electrical system
When starting switch is

turned START, pinion
moves out, but
When starting switch is turned to START, pinion does not
Specific gravity of electrolyte, voltage of battery is low
For the following conditions 1) - 4). turn the starting switch -0

OFF, wnnect the cord, and carry out troubleshooting at ON ox
1) When the terminal B and terminal C of starting switch ,p
P are connected, engine starts 8$
‘G -eZ-
8 2) When terminal B and terminal C of starting motor
6W
5 are connected, engine starts 4 .;
4 3) When terminal B and terminal C of safety relay g;
a are connected, engine starts
c z-
4) When terminal of safety switch and terminal B of t
starting motor are connected, engine does not start :
u-
When ring gear is inspected directly, tooth surface is found
to be chipped
20-87
0 Engine turns but no exhaust smoke comes out.
(Fuel is not being injected)
General causes why engine turns but no exhaust smoke comes out.
l Supply of fuel impossible

0 Supply of fuel is extremely small
0 Improper selection of fuel (particularly in winter)
When fuel filter is drained, fuel does not come out @

When engine is cranked with starting motor,
1) No fuel comes out even when fuel filter air bleed
E plug is loosened @ 00 C3
.E
% 2) No fuel spurts out even when injection pipe sleeve
nut is loosened @@,Q 0
2
0
Rust and water are found when fuel tank is drained hh
20-88
0 Exhaust smoke comes out but engine does not
start (Fuel is being injected)
General causes why exhaust smoke comes out but

engine does not start
0 Lack of rotating force due to defective

electrical system
0 Improper selection of fuel (particularly
in winter)
1 Confirm recent reoair historv
1 Degree of use of machine 1 Operated for long period A A A A
@@
heard from
@
e
.g Engine oil must be added more frequently
:
z
to Operation Manual
When engine is cranked with starting motor,

1) Little fuel comes out even when injection pump
E sleeve nut is loosened 0 0
.E
2) Little fuel comes out even when fuel filter air
% @@ @
bleed plug is loosened
e
0
There is leakage from fuel piping @
When exhaust manifold is touched immediately after starting
engine, temperature of some cvlinders is low @
I When furl fil+rr is drsinrd no fwd comes c-m+ I

I
I
1
I
I
I
I
I
1
I
I
I
I
I
I
I
I
I
I
I
I
Ihl
1-1
I
I
When fuel control lever is moved, injection pump lever does
not move Q
1
When head cover is removed and inspection is made directly,
it is found to be abnormal I I I I I I T-I
en control rack is pushed, it is found to be heavy, or does I I I I
P
‘G
x-
5
4
a
YE
When nozzle holder is inspected directly, it is found

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

to be cloaqed
Play, stiffness in fuel control linkage

T
When engine oil is inspected directly, it is found to have high
20-89
S-3 Engine does not pick up smoothly
(Follow-up is poor)
General causes why engine does not pick up smoothly
l Insufficient intake of air

0 Improper condition of fuel injection I I
0 Improper fuel used
0 Defective injection pump
I.1 I I I I I I I I I
6 When compression pressure is measured, it is found to be low

<
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be outside

standard value
When fuel cap is inspected directly, it is found to be clogged
20-90
S-4 Engine stops during operations
General causes why engine stops during operations
0 Seized parts inside engine

0 Overheating
* If there is overheating and insufficient out-
put, carry out troubleshooting for over-
heating
0 Failure in power train
* If the engine stops because of a failure in
the power train, carry out troubleshooting
for the chassis.
Condition when
:
Try to turn by hand using

barring tool
20-91
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly
0 Air in fuel system

0 Defective governor mechanism
Condition of hunting
20-92
S-6 Engine lacks output (no power)
Measure the speed of the engine to determine if the

problem is in the engine or the chassis.
General causes why engine lacks output
0 insufficient intake of air

0 Improper condition of fuel injection
0 Improper fuel used
(if non-specified fuel is used, output drops)
0 Lack of output due to overheating
* If there is overheating and insufficient output
carry out troubleshooting for overheating.
No pulse in injection pipe (all or part) (weak)
When feed pumpstrainer is inspected directly, it is found

to be clogged
Speed of some cylinders does not change when operating on

reduced cylinders
20-93
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

l Improper condition of fuel injection
l Excessive injection of fuel
Colorof exhaust gas

I I IC3l I I I I I I I I I
harger is rotated by hand, it is found to be heavy
20-94
S-8 Oil consumption is excessive (or exhaust smoke is blue)
j, To prevent the oil from leaking up or down, do not run the engine
at idling for more than 20 minutes continuously.
(Both low and high idling)
General causes why oil consumption is excessive
. Abnormal combustion of oil

. External leakage of oil
. ear
W of lubrication system
When intake manifold is removed, dust is found inside
When head cover is removed, inside is found to be abnormally

dirty
20-95
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
. Oil change interval too long
Abnormally excessive 63 I loI lolol I I >’
Oil filter caution lamp stays on even when oil pressure rises
When oil filter is inspected, metal particles are found 0
Engine oil temperature rises quickly t

Oil is above H level on oil level gauge
20-96
S-l 0 Fuel consumption is excessive
General causes why fuel consumption is excessive
. Leakage of fuel
. Improper condition of fuel injection
0 Excessive injection of fuel
Condition of fuel consumption
20-97
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
. Internal leakage in lubrication system

. Internal leakage in cooling system
:
Excessive air bubbles inside radiator, spurts back I@,(@,(
u Power train oil is cloudy white 0
Pressure-tightness test of oil cooler shows there is leakage I.1 I I.1 I I I
20-98
S-12 Oil pressure lamp lights up (drop in oil pressure)
General causes why oil pressure lamp lights up
0 Leakage, clogging, wear of lubricating system

. Defective oil pressure control
. Deterioration of oil due to overheating
l Improper oil used (improper viscosity)
* Standards for engine oil selection
8
H
I-
Condition when oil pressure
When oil filter is inspected directly, it is found to be clogged 00 0

0
When oil pan is removed and inspection is made directly, it is .;
E? found to be abnormal 0.0
‘G 8
8 Oil pump rotation is heavy, there is play 2
0
5
P :
There is catching of relief valve or regulator valve, spring or
4 08 j
valve guide is broken
e
I-
When oil level sensor is replaced, oil pressure sensor lamp goes
O”t
) Wlyn oil pressure is measured, it is found to be within standard/ I I I I I I I I I I 1-l;
20-99
S-13 Oil level rises
jr If there is oil in the cooling water, carry out

troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
0 Water in oil (cloudy white)

. Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
Exhaust smoke is white
When enaine is first started, draw of water come from muffler
Leave radiator cap open. When engine is run at idling, an abnormal numbe
of bubbles arxxar. or water swrts back 1 I
Water pump breather hole is clogged with mud
When water DU~D breather hole is cleaned. water comet out i
Oil level goes down in damper chamber
Enaine oil smells of diesel fuel
20-100
S-l 4 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high
l Lack of cooling air (deformation, damage of

fan)
0 Drop in heat dissipation efficiency
l Defective cooling circulation system
0 Rise in oil temperature of power train
* Carry out troubleshooting for chassis.
Water temperature gauge

S-l 5 Abnormal noise is made
j, 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
I Confirm recent repair history
When compression pressure is measured, it is found to be low l

4 I I I I I I I I I I I I
When turbocharger 1s rotated by hand, it is found to be heavy 0
When gear cover is removed and inspected directly, it is found to
be abnormal 0 0
Speed of some cylinders does not change when operating on

P reduced cvlinders 0
.&
8 When control rack is pushed, it is found to be heavy, or does not

return 0
f
; Injection pump test shows that injection amount is incorrect
20-l 02
S-l 6 Vibration is excessive
* If there is abnormal noise together with the

vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)

l Improper alignment
l Abnormal combustion
Condition of vibration
20-l 03
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
Table of failure modes and causes. ........................... ........ ........ ........ 20-I 06
H- 1 Brakes do not work. ................................. ........ ........ ........ 20-l 07
H- 2 Machine does not turn ............................... ........ ........ ........ 20-I 08
H- 3 There is travel deviation .............................. ........ ........ ........ 20-I 09
H- 4 Machine turns only in one direction ...................... ........ ........ ........ 20-I 10
H- 5 Time lag is excessive ................................ ........ ........ ........ 20-l 11
H- 6 Machine travels only in one direction ..................... ........ ........ ........ 20-I 11
H- 7 Machine does not move .............................. ........ ........ ........ 20-I 12
H- 8 Machine does not move in any speed range ................ ........ ........ ........ 20-I 14
H- 9 Torque converter oil temperature is high .................. ........ ........ ........ 20-I 16
H-l 0 Abnormal noise from around hydraulic pump ............... ........ ........ ........ 20-I 18
H-II Blade RAISE speed slow or work equipment lacks power. ...... ........ ........ ........ 20-I 18
H-l 2 Ripper lift speed slow, or lacks power. .................... ........ ........ ........ 20-I 20
H-13 Excessive hydraulic drift of blade. ....................... ........ ........ ........ 20-I 21
H-14 Excessive hydraulic drift of ripper ....................... ........ ........ ........ 20-121
H-l 5 Torque converter lock-up does not work. .................. ........ ........ ........ 20-I 22
H-16 Pin-puller cylinder does not work. ....................... ........ ........ ........ 20-I 22
8
E
6
20-l 05
TABLE OF FAILURE MODES AND CAUSES
(ELECTRIC, HYDRAULIC, MECHANICAL SYSTEMS)
Torque converter Work equipment
3 There is travel deviation. 00 000 - H- 3
4 Machine turns only in one direction (lever operated). 00 0 0 - H- 4
5 Time lag is excessive 0 00 0 - H- 5
6 Machine travels only in one direction (forward or in reverse) 0 0 0 - H- 6
7 Machine does not move. (2nd, 3rd. engine running) 00000 00000 - H- 7
8 Machine does not move in any speed range. 00000 00000 - H- 8
9 Torque converter oil temperature is high. 0 0000 00000000 - H- 9
IO Abnormal noise from around hydraulic pump. 00 0 - H-10
1 Blade RAISE speed slow or lacks power. 0 000 0 0 - H-l 1
2 Ripper lift speed slow. 0 0000 - H-l 2
3 Excessive hydraulic drift of blade 00 - H-13
4 Excessive hydraulic drift of ripper 0 00 - H-14
5 Torque converter lock-up does not work. 00000 0 0 0 0 0 E-S1 H-l 5
6 Torque converter lock-up display is abnormal. 00 E-S2 -
7. Torque converter lock-up fuse 8 is blown. 0 E-S3 -
8 Pin-puller cylinder does not work. 00 E-l H-l 6
9 Preheating fuse 11 blows. 0 0 0 E-2 -
!O Actuation of APS is defective. 0000 0 E-3 -
!I When light switches are turned ON, lamps do not light up. 0 0 00 E-4 -
12 When light switches are turned OFF, lamps do not go out. 0 0 00 E-5 -
13 Panel switch does not work (abnormality in panel switch E-6 -

power source) 0 000
20-106
H-l Brakes do not work.
* Check the power train oil level before starting troubleshoooting.
’ See Note 1. Defective seal of clutch piston ReplaCe

I I
Is oil pressure in
- brake, clutch circuit -
NO normal? YES Does brake valve
- spool nlO”z?
smoothly?
3
* See Table 1.
Defective actuation of spool Repair or replace
When brake linkage NO
is adjusted, does
_ condition become -
NO normal?
Defective adjustment of
I Adjua
l See TESTING linkage
AND ADJUSTING. NO
8
z‘0 Note 1: Depress the brake pedal fully, place the transmission in IV, and pull the steering lever on one side
fully. When the engine speed is raised gradually from deceleration slow (stall) to high idling, the
machine must not move.
Table 1
1 Oil pressure (left and right)
Conditions
Engine speed:
Brake pedal not
depressed
Brake pedal
depressed
20-107
H-2 Machine does not turn. (Machine can travel only in a straight line.)
Cause Remedy
ES -
See H-l
Is clutch
YES
Seized clutch disc, plate Replace
disengaged?
4 YES
Defective seal of clutch piston ReplaCe
*See Notes 1 and 2. IT
‘See Table 1.
Defective actuation of spool Repair or replace
’
When steering link-
I age is adjusted,
does condition
NO become normal?
L Defective adjustment of Adjust
*See TESTING linkage
AND ADJUSTING.
8
Note 1: Raise the chassis with the blade and ripper, run the engine at low idling, and place the trans- 2
b
mission in F3 (R3). When the steering lever on one side is pulled, the track must stop. 6
Note 2: Travel in Fl (RI) with the engine at low idling. When the steering lever on one side is pulled
slowly, the machine must stop or must turn slowly.
Table 1
Oil pressure (kg/cm*)

Conditions
Clutch Brake
0 273~2
Engine speed:
Steering lever not High id’ing (left and right) (left and right)
operated 0 25 k 2
Low idling
(left and right) (left and right)
Engine speed: High idling Right: 0 Right: 27 + 2

Left: 27f 2 Left: 0
Left lever
Steering Low idling Right: 0 Right: 25 f 2
Left: 25f2 Left: 0
lever
operated Right: 27 f 2 Right: 0
Engine speed: High idling
Left: 0 Left: 27+ 2
Right lever
Low idling Right: 25 k 2 Right: 0
Left: 0 Left: 255 2
20-l 08
H-3 There is travel deviation.
Cause Remedy
1 YES
See H-l. -
Is clutch
disengaged?
See H-2. _
* See Notes 1 NO
and 2.
Note 1: Raise the chassis with the blade and ripper, run the engine at low idling, and place the trans-
mission in F3 (R3). When the steering lever on one side is pulled, the track must stop.
Note 2: Travel in Fl (RI) with the engine at low idling. When the steering lever on one side is pulled
SI slowly, the machine must stop or must turn slowly.
H
b
6
20-109
H-4 Machine turns only in one direction (lever operated).
Cause Remedy
YES Worn brake disc, plate, Repair

2 scuffing
YES Is clutch, brake

- pressure normal? -
3 YES Defective seal of clutch
Repair or replace
chamber
l_
- * See Table 1. Does valve spool
- move smoothly? -
Is adjustment of NO
steering linkage _
normal? Repair or replace
Defective actuation of spool
NO
.
* See TESTING
AND ADJUSTING.
Defective linkage Adjust
Table 1:
Oil pressure (kg/cm?)

Conditions
Clutch Brake
27 + 2
Engine speed:
Steering lever not High id’ing (left ant right) (left and right)
operated 0 25 f 2
Low idling
(left and right) (left and right)
Right: 0 Right: 27 k 2
Left: 27+ 2 Left: 0
Left lever
Right: 0 Right: 25 f 2
Steering Low idling
Left: 25*2 Left: 0
lever
operated Right: 27 f 2 Right: 0
Left: 0 . Left: 27+2
Right lever
Low idling Right: 25 ? 2 Right: 0
Left: 0 Left: 25* 2
20-110
H-5 Time lag is excessive.
Remedy
YES Defective transmission valve

Repair or replace
l Defective actuation of spool
4 YES
Defective hydraulic pump Replace
Is free length of
main relief valve
l Engine speed: - spring normal? _
YES IS adjustment of High idling NO Does valve spool
- gear shift lever - l Oil pressure: move smoothly?
linkage normal? 27 !c 2 kg/cm? Defective spring, clogged
1 Replace or clean
. Free length of NO with dirt
spring: 120.3 mm
* See TESTING
Is brake free from AND ADJUSTING. Defective adjustment of
dragging? linkage
NO
* See Note 1.
See H-l.
-
NO
Note 1: When the chassis is raised with blade and ripper, the track should move with the engine at low id-
ling and the transmission in F3 (R3).
H-6 Machine travels only in one direction (forward or in reverse).
* Conditions: Oil pressure is normal (27 + 2 kg/cm2)
Cause Remedy
1 YES Defect inside transmission,

or defective valve Repair or replace
Is adjustment of
war shift linkaae ‘L
Defective adjustment of Adjust

linkage
* See TESTING NO
AND ADJUSTING.
20-111
H-7 Machine does not move. (2nd, 3rd engine is running)
YES
YES_ Is modulating
pressure normal?
4
l Engine speed:
YES_ Is main relief
High idling
. Oil pressure:
pressure normal? NO
27 + 2 kg/cm?
. Engine speed:
8 YES
Is brake free of drag-
IES High idling
ging when traveling
in Fl (Rl)?
- l Oil pressure:
El- 8
Does gear shift lever

27 rt 2 kg/cm2
N0 z
6
YES enter position nor-
- mally? * Free length of NO
Is adjustment of link- spring: 120.3 mm
1 age normal?
L
* See TESTING R
Is parking brake AND ADJUSTING.
released?
Table 1
Engine speed:
Steering lever not
operated
Engine speed: High idling Right: 0 Right: 27 f 2

Left: 27f2 Left: 0
Left lever
Steering Low idling Right: 0 Right: 25 + 2
Left: 25+2 Left: 0
lever
operated Right: 27 5 2 Right: 0
Left: 0 Left: 27f2
Right lever
Low idling Right: 25 f 2 Right: 0
Left: 0 Left: 2522
20-112
Cause Remedy
7 YES
Repair or replace
YES
-(l....“.::.rr:H-
Defective steering clutch -

(See H-2)
* See Table 1. NO
Is oil pressure at
torque converter
outlet normal?
l
Engine speed:
High idling
011 pressure:
L
NO
Defect inside torque
cOn”erter
Repair or replace
5 - 7 kg/cm2
Repair or replace
Defective pump R62pl.Xe
Defective spring, spool Replace or repair,

scuffing, clogged with dirt Clean
-
Brake dragging (See H-l)
linkage 4djust
4djust
linkage
20-113
H-8 Machine does not move in any speed range.
Sr Check the power train oil level before starting troubleshoooting.
YES
YE S
pressure normal?
3
. Engine speed:
High idling
pressure normal? . Oil pressure:
27 + 2 kg/cm2
Is free length of main

relief valve spring
. normal?
Does valve spool
move smoothly?
l Free length of NO
spring: 120.3 mm
Table 1
I 1 Oil pressure (left and right)

(kg/cm*)
Conditions
Clutch Brake
Engine speed: High idling 0 27 f 2

Brake pedal not
depressed
Low idling 0 25+_2
Brake pedal
depressed
20-l 14
Cause Remedy
‘ES Defect Replace

inside steering
clutch
6
YES_ Is steering clutch .

pressure normal?
5 Replace
Defective steering clutch
* See Table 2. SeaI
Is oil pressure at
- torque converter -
outlet port normal? [\
Adjust
l Engine speed: * See TESTING NO Defective adjustment of
High idling AND ADJUSTING. linkage
^..
l “II pressure:
27 * 2 kg/cm2 I
Defect inside torque Repair or replace
NO
converter
Defective transmission valve Repair or replace
Defective pump Replace

scuffing, clogged with dirt clean
Defective adjustment of Adjust

linkage
Defective brake (See H-l) -
Table 2
Oil pressure (kg/cm2)

Conditions
Clutch Brake
Engine speed:
Steering lever not High id’ing (left an”d right) (left%: fight)
operated
Steering
lever
operated tnglne speea: I-llC
Rigt
20-115
H-9 Torque converter oil temperature is high.
* Check the power train oil level before starting troubleshooting.
YES
YES IS engine speed at

- F3 stall normal?
3 l Engine speed:
1580 * 50 rpm
NO
YES IS main relief
2
8 YES
YES IStOrq”e C0”“WtW
_ oil temperature sen- _
SOT normal? Is free length of main
1 relief valve spring
- normal?
NO goes valve spool
l Remove oil pressure move smoothly?
Is brake free from sensor.
dragging? _ l Check resistance Free length of
V&E.
l NO
spring: 120.3 mm
* See Note 1.
Note 1: When the chassis is raised with blade and ripper, the track should move with the engine at low id-
ling and the transmission in F3 (R3).
20-l 16
Cause Remedy
Defective cooling system _

(see Engine Volume)
7 YES Transmission clutch slipping ReplaCe

l Increase in engine output Adjust
YES Does transmission

_ output shaft stop -
with operation in
6 Item 4?
Steering clutch slipping R&W?
* Remove the case NO
YES IS pressure at torque at the rear of the
converter inlet/outlet - transfer to check.
port normal?
5
rl
1 ’ _
-
=__:__ ____,’
L,,!j,,lc: >prru.
1 1 Defect inside torque I Repair or replace
CO”“WtW
Does machine stop High idling NO
- with operation in - . Torque converter
Item 4? Inlet port: 7 - 10 kg/cm2
Outlet port: 5 - 7 kg/cm’
- Brake disc slipping Repair or replace

NO
Defective pump R@Xe
l Air leaking in through joint Tighten
in suction circuit
Replace or repair,
Defective spring, spool
scuffing, clogged with dirt clean
Defective oil temperature %DlWX

sensor
11 Brake dragging (See H-l)
20-117
H-10 Abnormal noise from around hydraulic pump.
* Check the hydraulic oil level before starting troubleshooting.
YES
i Is air being sucked YES

- into hydraulic pump -
suction circuit?
3
- Is strainer clogged? -
NO
4 YES
When hydraulic oil

- is strained, are metal -
NO wear particles found?
NO
H-11 Blade RAISE speed slow or work equipment lacks power.
A Check the hydraulic oil level before starting troubleshooting.
Note: Check for any modification of the blade.
YES
I
4
YES Is hydraulic drift

- normal when lever -
is at HOLD?
3-p
P . Engine stopped NO
l Hydraulic drift of
YES Is pump discharge

_.___.
hl.adC=.
200mml15 min
2
6 YES
H
l Engine speed:
YES Does cylinder extend High idling When relief valve is
- and contract - l Oil pressure: adjusted, does pump
smoothly? 210 ‘To kg/c”? NF discharge pressure
return to normal?
L I 1
. Engine speed: NO
Is adjustment of
High idling
blade control linkage
l Oil pressure:
210 ‘7, kg/cm2
. Pressure adjustment
= See TESTING for 1 turn: 24.8 kg/cm2
AND ADJUSTING.
NO
20-118
I Cause Remedy
Defecrive seal
l Lowe piping clamp Tighten
. Damaged O-ring
Clogged strainer
Defective pump RePlaCe
Inspect again
Operate for a short time and
(according to
look for any change in the
change in condi-
condition
tion)
Improper oil AL?PlWt?
Cause Remedy
Defective actuation of valve

. Defective actuation of
unload valve Replace parts
l Defective actuation of
check valve
5 YES Excessive leakage inside

valve Replace
I
l Leakage inside lift valve
When cylinder head
circuit is blocked,
does amo”nt O+
I
hydraulic drift return
to normal? Excessive leakage inside
cylinder ReplaCe
NO l Defective piston seal
Defective relief valve Clean or replace
Defective pump Replace
Air in circuit Bleed air
Defective linkage Adjust
20-l 19
H-12 Ripper lift speed slow, or lacks power.
Sr Check the hydraulic oil level before starting troubleshooting.

-)r If the relief pressure is not normal, go to failure mode H-II (blade RAISE speed slow) and adjust the re-
lief pressure.
Cause Remedy
YES Defective main spool of Hi

valve (including shuttle valve) ?eplace
3
h
YES Is hydraulic drift of
ripper lift cylinder
normal?
4 YES Defective fixed differential
valve of Hi valve ?ep1ace
l Engine stopped
. Hydraulic drift:
YE3 Is ripper tilt speed

normal? Defective cylinder piston seal Rt?plXX
NO
I
1 Tilt 5 YES
FULL: 4.5 - 5.5 sec. Defective shuttle valve R&W2
SLOW: 12 - 18 sec.
Tilt back
Is adjustment of FULL: 3 - 4 set Is blade lift cylinder
ripper control linkage SLOW: 8-lzSeCN speed normal? 6 YES
Defective Lo valve pilot
circuit Repair
Is Lo valve pilot
* See TESTING l Blade speed pressure normal?
AND ADJUSTING. RAISE:
FULL (3 - 5 set)
SLOW (8 - 13 Carry out troubleshooting -
LOWER: l Engine speed: NO of Items 3 and 6 of H-l 1
FULL (1 - 1.5set) High idling
SLOW (1 - 1.5 set) l Oil pressure:
210 r:, kg/cm2
Defective linkage 4djust
N’
20-120
H-13 Excessive hydraulic drift of blade
Cause Remedy
1 YES Excessive leakage inside valve

l Leakage inside blade lift Replace
VdW
When hose at cylinder
end is blocked, does _
hydraulic drift return
to normal?
Excessive leakage inside
cylinder Replace
l Engine stopped. NO . Defective piston seal
l Hydraulic drift:
Max. 200 mm/15 min
H-14 Excessive hydraulic drift of ripper
I Cause
I Remedy
2 YES
Defective ripper Lo valve Replace
I . ..I
When oil line bet-
ween npper LO valve
YES and ripper Hi valve is
- blocked, does hydra- -
1 lit drift return to
_ normal?
1 Defective ripper Hi valve Replace
. Hydraulic drift: NO
Nhen hose at cylinder Max. 80 mm/15 min
?nd is blocked, does _
lydraulic drift return
0 normal?
1 Engine stopped. Excessive leakage inside

) Hydraulic drift: cylinder Replace
Max. 80 mm115 min P.I~ a r,s<ar+i.,~ nic,nn CPQI
I””
20-121
H-l 5 Torque converter lock-up does not work.
* When actuation of lock-up solenoid is normal

(if it is abnormal, see E-Sl)
Cause Remedy
2 YES
Defective lock-up clutch Replace or repair
drive normal?
I Defect inside torque converter Repair

l Speed range: F3
Is torque converter l Stall speed:
lock-up pressure 1580 * 50 rpm
normal? 4 YES
Defective selector valve Replace or repair
l Engine speed: YEI Is operation of lock-

High idling UD solenoid SDOOI c
l Oil pressure:
13+1
_O kg/cm2
31
Scuffing of spool Replace or repair
R I Is main relief
pressure normal? u
QO
5 YES
Defective pump
l Engine speed: I_
High idling
l Oil pressure: - normal?
27 * 2 kg/cm2 N Does valve spool
move smoothly?
l Free length of NO scuffing, clogged with dirt Clean
spring: 120.3 mm
H-l 6 Pin-puller cylinder does not work.
A When actuation of pin-puller solenoid is normal

(if it is abnormal, see E-l)
Cause Remedy
YES
Defective pin-puller cylinder Repair or replace
h
YE Does pin-puller
solenoid valve spool
move by hand?
1
I Defective spool of pin-puller Replace
sole- NO solenoid valve
l Disassemble
Is transmission main noid valve.
relief pressure
normal?
l Engine speed:
High idling
Go to H-7
-
l Oil pressure:
27 + 2 kg/cm2
20-l 22
TROUBLESHOOTING OF ELECTRICAL
SYSTEM
E- 1 Pin puller cylinder does not work ........................................................................................... 20-124

E- 2 Preheating fuse No.1 1 is blown (Serial No. : 10001 - 10167) ............................................. 20-125
E- 3 Defective operation of APS (Serial No. : 10001 - 10167). .................................................... .20-126
a) Even when panel preheating switch @ is pressed, the APS pilot q on

the monitor panel does not light up .. . . ..__....................__.................................................. 20-126
b) When panel preheating switch m is ON, the APS pilot q on the monitor
panel lights up, but it does not go out within the range of 60 - 100 seconds . . . . . . . . .. 20-128
cl Approx. 80 seconds after panel preheating switch is turned ON, APS pilot q
goes out, but starting performance is poor (glow plug works normally) . . . .._............. 20-130
d) The engine can be started with the APS, but when the starting motor stops,
the engine stops also . .. . .. . .. . . .. . . . . . . .. . . . .. . . . . . . . . . . .. . . . . . . .. . . .. . .. . . . . . . . .. . . . . .._.................................... 20-I 32
e) APS does not stop . . .. . . .. . . .. . . . . . . . .. . . . . . . . . . . . .. . . . .. . . . . . . . .. . .. .._.............................................. . . . . . . . .. . 20-133

E- 3 Defective operation of APS (Serial No. : 10168 and up) . . . . . . . .. . . . . . . . .. . .. . .. . . . . .. .. . . . .. . . .. . . . . . . . .. . . . . . 20-I 34-l
a) APS pilot q on monitor panel does not light up when preheating switch
@ on panel is pressed .. . . . . . .. . . .. . . ..___..................._._._............................................... 20-134-I
b) APS pilot q on monitor panel does not go out even when more than
12 seconds has passed after lighting up . .._..................................................................... 20-134-4
b-l. APS pilot stays lighted up (glow plug system short circuited) ._._................._...._._ 20-134-4
b-2. APS pilot flashes (disconnection in APS water temperature sensor) . . . . . .. . . . .. . . . . . . 20-134-4
c) APS pilot q on monitor panel lights up when starting switch is at START

(short circuit with ground in nozzle system) . . . . . .. . . . . . . . . .. . . . . . . .. . . . . .. . . . . .. . . . . . . . . . . .. . . . .. .. . . . .. . . .. . 20-I 34-5
d) APS does not work (When there is no abnormality in Items a) - c) for Defective
operation of APS) .. . . . . .._...................................._..............................................._................. 20-I 34-6
d-l. Disconnection in C signal input system . .. . . . . .. . . . . . . . . .. . . . . . . .. .. . . .. .. . . .. . .. . . . . . . .. . . . .. . . . . .. . . . .. . 20-134-6
d-2. Disconnection in glow plug system . . .. .. . . .. . .. . . . .. . . .._................................................... 20-I 34-8
d-3. Disconnection in nozzle system . . .. . . . . . . . .._._.....................__.......................................... 20-134-g
e) APS does not stop even when water temperature is above 20°C
(short circuit with ground in APS water temperature sensor system) . . .. . .. ..__............. 20-134-10
E- 4 Even when the light switch is turned ON, the lamps do not light up ............................... 20-135
a) Head lamp switch m ........................................................................................................ 20-135
b) Rear lamp switch @j ......................................................................................................... 20-136
c) Working lamp switch @ ................................................................................................... 20-I 37
E- 5 Even when the light switch is turned OFF, the lamps do not go out.. .............................. 20-138
a) Head lamp switch ............................................................................................................... 20-I 38
b) Rear lamp switch ................................................................................................................ 20-138
c) Working lamp switch .......................................................................................................... 20-138
E- 6 Panel switch does not work. - Abnormality in panel switch power source.. .................... 20-139
20-123
@
E-l Pin puller cylinder does not work (For giant ripper)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* After checking, connect the disconnected connectors and relays again immediately unless otherwise specified.
I Cause Remedy
I
Defective operation of
solenoid valve (spool)
Y
Defective solenoid Replace

- Disconnect CN224. j NO
1
is voltage disconnection in wiring bar.
between CN224 4 YES
ness, Or short circuit between
(1) and (2) Is resistance CN263 (female) (2) - CN122
20 - 3ov7 (3) - CN224 (female) (1).
YES between CN263
(male) (1) and (2)
* Turn starting
asshown Table 27
switch ON. 3 1 Defective pin puller switch Replace
* Turn pin puller Is voltage * Disconnect CN263. NO
switch ON. CN263
between
- (female) (1) and -
har-
’ chasis ground Disconnection
“ass, or short
in wiring
circuit between
20 - 3ov7 5 YES
* Turn starting zx I%%] 1: j.and

Is voltage
switch ON. between CN162 _
_
* Turn pin puller (2)
NO ;;a~&;:)~and
switch OFF.
Defective supplementary See Trouble-
system. shooting for
controller
* Turn starting NO monitor
switch ON, (M-l ).
Table 1 Table 2
Between CN224 At pin puller switch

40 - 80&-l 1 Cl or below
(1) - (2) I
I I ON I
Between CN224 At pin puller switch
1 Ml or above 1 s2 or above
(l), (2) and chassis OFF
I I 1
I I J
E-l Related electrical circuit diagram
Supplementary
.controller CN162
- -
I "H \-
CN263 CN 122 CN224
Pin-puller switch
Pin-puller
solenoid
F19702206
20-l 24
E-2 Preheating fuse No. 11 is blown
Serial No. : 10128 - 10167
* Always connect any disconnected connectors before going on the next step.
1 C2tJ.W Remeday
3 YES I
I
Wiring harness between relay
1161 (4) - R3 - heater relay Ll,
Iepair or replace
2 YES Is resistance and between connector [5] (3)
betweenCNl21 - Rl - heater relay Ll inside
r&v box short circuiting with
chassis ground, or defective
-{Es $~~~~and --Tnd more than 1 M Q? -
relay
- .l-3QP)
I
ground more than 0 Turn starting switch
1 MQ. l Turn starting switch OFF.
t OFF. l Disconnect CN121.
1 I Wiring harness between relay
l Disconnect CNl21.
l Turn starting witch
1 1161 (31 - R4 - connector [41 (11
OFF. - connector 151 (2) - R4. R2 -
NO epair or replace
CN121 (4). (19)inside relay box
short circuiting with chassis
ground
Wiring harness between CNl21

I (4). (191 - CNlOl (11, (11) -
I epair or replace
CN102 (1). (4) - glow plug 1.
NO qlow plug 2 short circuiting
with chasdis ground
8 I Wiring harness between L2 and

epair or replace
fuse 11 inside relay box short
E NO
circuiting with chasks ground
6
E-2 Related electric circuit diagram
CNl02 Glow 1
r
Timer
II Glow 2
20-125
8
E-3 Defective operation of APS
Serial No . : 10128 - 10167
a) Even when panel preheating switch g UF is pressed, the APS pilot on the monitor panel
0
does not light up.
Only when water temperature is below 2O’C.
If the red lamp for the switch also does not light up when the preheating switch is pressed, the panel switch is
defective.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
YES
2 I
Isvoltage 4 YES
YES between CN361
- (13) and chassis - Is voltage be-
ground YES tween connec-
16-ZOV? 3 - tar (51 (1) and -
* Turn starting chassis ground
switch ON. Is voltage 16-ZOV?
* Turn preheat- between con- * Turn starting NO
ing switch ON. NF ;ztc&r, [,“I(?& - switch ON.
* Within 30 set
of turning pre-
* Turn starting heating switch ON.
switch ON. NO
* Turn preheat-
ing switch ON.
YES
6
1
I
minal L2 inside
Is voltage
0 Turn starting
between CN121
switch ON.
(4). (19) and
chassis ground
IF: -%-Iv,
* Turn starting
switch ON. YES
* Turn preheating
switch ON.
* Turn starting
switch ON.
NO
Cause
See M-4 a)
Defective contact or discon-

nection in wiring harness be-
tween connector [5] (1) and
CN361 (13).
3efective timer
Defective contact, or discon-

tween connector [5] (2). (31 -
Rl, R2.
Defective heater relay

contact. or disconnection in
wiring tiarness between
heater relay Ll - Rl, R3.
defective contact, or discon-

section in wiring harness
>etwee” fuse 11 and L2
nside relay box.
Defective preheating relay

[201.

nection in wiring harness
YES between preheating relay
[201 socket (4) - connector
10 3
[Sl (2). (l)-CN362 (6) -
Is resistance be-
CN261 (6) - panel switch.
YES wee” co”“%t‘,r
-;;!, [yle) (1) -
9
Is voltage be- * Disconnect [6] ~ Defective heater relay.
NO
- rz”szt (3) -
and chassis
ground 20--nOV? Defective contact or discon-
tween relay [201 socket (3) -
. Turn starting relay [15] socket (2) - J3.
switch ON.
11 YES
tween J3 - preheating relay
Is resistance
[20] socket (2). (1) - CN121
between APS water
_ temperature sensor _ (13) - CNlOl (12) - CN106.
CN106 and chassis
groundless than 1 Q.,
Defective APS water tempera-
ture sensor, or defective
* Disconnect CN106. NO grounding.
20-l 27
OL7-C
b) When panel preheating switch I 0 is ON, the APS pilot %T on the monitor panel lights up, but
I
it does not go out within the range of 60 - 100 seconds.
* Always connect any disconnected connectors before going on the ,next step.
* If.the abnormality is only in the display, go to M-4.
l When the APS pilot (preheating monitor) goes out in lessthan 60 seconds.
Cause Remedy
,YES
Defective timer Replace
1 1
between CN121 Defective contact, or discon-
2 YES Repair or
H
between Ll - Rl * R3. replace
chassis ground R2’R4 -CN121 (4). (19)
When terminals of inside relay box.
resIstor 1 and rer,si-
tars 2 Ins,** relay
switch ON. box ar* remove*, I‘
NO rer,*tence of both re-
* Turn preheating
slstor. less than la?
switch ON. Defective resistor (resistor
with resistance of more than Replace
NO lsl,.
l When the APS pilot (preheating monitor) does not go out even
after 100 seconds.
Defective timer. Replace
Defective cOntact or diwon-

nection in wiring harries*
Repair or
* Turn starting NO replace
switch ON.
* Turn preheating
switch ON.

YES between RZI- CN121 (4) Repair or
* Turn starting 7 t or R4 -CN121 (19) inside replace
switch ON. relay box.
. Turn preheating
switch ON. Defective contact or discon-
between CN121 (4) (19) - Repair or
CNlOl (1). (llkkN102 replaCf3
(1). (p)‘-glow plug 1, glow
Plug 2.
Defective glow plug (glow

plug with resistance of more Replace
than 3a2).
20-128
c) Approx. 80 seconds after panel preheating switch is turned ON, APS pilot & goes out, but starting
El
performance is poor (glow plug works normally).
t Only when water temperature is below 20°C.
t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on the next step.
YES
ES
- Remove
and cm104
CN103
I
1 I
Does head lamp
work normally
‘when relay [16]
is inserted in socket
of relay [14]?
I
l Turn starting
switch ON.
l Turn head lamp
switch ON.
NO
20-130
Cause
Defective APS nozzle fuel

system
9 YES
Defective APS controller

~~~ tween Connector (41 (5). (6)
and CN121 (7). (10).

tween CN121 (2) and connec-
and CN104. NO tor [4] (4).
’ Remove relay 1161.
’ Put starting switch
at START position.
* Turn starting Defective contact or discon-

switch ON. nection in wiring harness be-
* Turn preheating tween connector (41 (1) - R2,
switch ON. Connector [4] (7) - J2.

* Hemove CN103 l nection in wiring harness
NO between CN121 (2)l-
and CN104.
c~ioi (~)‘-cNIo~ (1).
* Put starting switch
at START position,
Disconnection in fuse
NO
11 YES between CN121 (7) (lO)l-
II y2y31)~(7). (8)‘_ ch1102
Defective nozzle (nozzle with

‘esistance value not within
3 - 5s2).

tween relay (161 socket (4) -
R3, (3) - R4.

tween relay [16] socket (1)
snd relay (201 socket (1).

vxtion in wiring harness
xtween CN161 (3) and
3N361 (12).
defective starting switch
Defective preheating backup

relay (161.
20-131
d) The engine can be started with the APS, but when the starting motor stops, the engine stops also.
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on the next step.
t When checking the operation of the nozzle, the monitor gives a mistaken display (low engine oil pressure warning),
but this is not an abnormality.
Cause Remedy
Y 40 abnormality in electrical After inspec-

ystem; defective fuel system. tion, repair
Can operating
sound be heard
from nozzle when
battery relay BR
is connected to R?
. Connect battery
4
1
2
Y e Iefectlve APS controller.
kfective contact, or discon-

wction in wiring harness be-
wee” CN121 (12) and connec
Replace
relay BR to R . Connect battery

II voltape between :or [41 (3).
with crocodile relay BR to R with
CN121 (12) and
clip. chsrrll wound 20 _ crocodile clip.
. Turn starting -i3ov when b-t- * Turn starting
witch ON. NO tery relay BR Ir switch ON.
. Turn preheating connected to R?
switch ON. . Connect battery 4 YES
jee M-5 a) Abnormality in
relay BR to R with :harge amo”nt.
crocodile clip.
* Turn starting
No{xH-
Repair or
nection in wiring harness replace
NO between CN121 (12) - CNlOl
(9) - CN105.
E-6 d) Related electrical circuit diagram
Relay box
F91702208
20-132
e) APS does not stop
0 Th! operation of the APS is normal, but the APS does not stop even when the water temperature goes above 20°C.
* Check when the engine water temperature is above 20°C.
Cause Remedy
3 YES Defective preheating relay
[201.
Contact of + 24V with wiring

harness between preheating
relay [201 (4) and connector
[61 (21.

[20] (1) and CN121 (13) short
circuiting with chassis ground.
Wiring harness between

. Disconnect CN121. CN121 113) - CNlOl 1121 -
CN106 ;hdrt circuiting with
chassis ground.
Defective APS water tempera.

ture se”sor.
l APS operates even though panel preheating switch is not pressed.
3 YES
Defective panel switch.
Is resistance be-
YES wee” CN261
2 c (male) (6) and _
chassis ground Wiring harness between
IS resistance be- more than 1 MFi-l? CN362 (female) (6) and CN261
YES tween CN362 (male) (6) short circuiting with
* Oisconneci NO
- (male) (6) and - chassis ground.
CN362.
chassis ground
more than lM11’ *
Disconnect
1 CN261.
* Disconnect Wirina harness between
Does operation of connector 161. CN362 (male) (6) and connec-
APS stop when * Disconnect CN362. No tor 161 (11 short circuitina with
connector [61 is ch&& ground.
disconnected? Contact of + 24V with wiring
4 YFS harness between glow plug
1.2 - CN102 (1) (4) - CNlOl
(1) (11) - CN121 (4) (19) -
Ll and L2 inside resistor R2. R4 - .
Rl R3.
relay box more
Defective heater relay.

* Remove heater NO
relay.
20-133
E-3 Related electrical circuit diagram
APS SYSTEM
Serial No. : 10001 - 10167

5 Monitor module
Panel switch z
starting
mcltor 6 Starting switch
@-j- I-----
Alternator
a
n
0
t
Relay bo x
I
17MF02177
20-l 34
@
E-3 Defective operation of APS
a) APS pilot )‘1161 on monitor panel does not light up when preheating switch m on panel
is pressed
* When an abnormality occurs and the system returns to normal when the connector has been
disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the
connector connected, the system has been reset.
Only when the water temperature is below 20°C.
It is possible to carry out troubleshooting when the cooling water temperature is above 20°C by
short circuiting the APS water temperature sensor.
Check that fuses 9 and 11 inside the fuse box are normal.
Always turn the starting switch OFF before disconnecting the connector or connecting the T-
adapter (or socket).
20-l 34-1
@
3 YES
,
Is voltage
YES between CN2 (5)
and chassis
ground normal?
-12-30V NO
* Turn starting
switch ON.
ground normal? * 12 seconds after turning preheating
switch ON. 4 YES
-12-30V
Is voltage between
* Turn starting
switch ON. connector 151(l)
and (4) inside relay
* 12 seconds after N 1
turning box normal?
preheating *12-30V NO
switch ON. * Turn starting
switch ON.
- 12 seconds after
turning
1
YEIS
1
Is voltage between
CN121 (4). (19) and
-20 30 v
chassis ground
normal? * Turn starting
7 switch ON.
-ll-14v voltage between
Is -Turn preheating
-Turn starting YES relay terminal L2 switch ON.
switch ON. - (inside relav box)
-Turn preheating ;“,r;r;i” ground 1
switch ON.
,20-30V
Turn starting
6 switch ON.
YE between CN261
I-
NO
- Preheating
switch:
12 YES
ON: Max. 1 V
OFF:20-30V Is voltage
* Turn starting between CN261
switch ON. NO (6) and (2)
5 normal?
Is voltage -2O-30V NO
between CN362 -Turn starting
r (6) and (2) switch ON.
normal? -Turn preheating
I
switch OFF.
*20-30V 14 YES
* Turn starting f
switch ON.
* Turn preheating
switch OFF.
-IO-IOOR NO
* Turn starting
connector 161(2) switch OFF.
- Disconnect
and chassis ground
connector [61.
I
*20-30V
NO
-Turn starting
switch ON.
* Turn preheating
switch ON.
20- 134-2
@
Cause Remedy
-
See M-4 a)
Defective contact, or
disconnection in wiring
lepair or
harness between CN2
eplace
(female) (5) and CN361
(female) (13)
harness between lepair or
connector 151 (female) (4) eplace
inside relay box and
CN361 (male) (13)
Defective APS controller leplace
Defective APS controller leplace

between connector
(inside relay box) disconnection in wiring
harness between lepair or
connector [51 (female) (1) eplace
NO inside relay box and
chassis ground
connector 151. disconnection in wiring
11 YES lepair or
harness between relay eplace
Is resistance
switch OFF.
mween relay
I terminal Ll and connector
YE 141 (female) (1) inside
-terminal Ll and LZ -
relay box
inside relay box
10 normal?
Defective relay contact Zeplace
4
Isresistance - Max. 1 R NO
between connector - Disconnect
[dlWnale)(l) and (2) terminals Ll and L2.
NO inside relay box *Turn starting switch ON.
normal? *Turn preheating switch
I I
-IO- 1OOR
ON.
-Turn starting I Defective relay coil Zeplace
switch OFF. NO
- Disconnect
connector 161.
disconnection in wiring Repair or
harness between relay replace
terminal L2 and fuse 11
, inside relay box
Defective panel switch Replace
Repair or
harness between CN362
replace
(female) (6) - CN261 (6) -
panel switch
Repair or
-I harness between
connector 161 (female) (I) replace
inside relay box and
CN362 (male) (6)
Defective relay coil Replace
harness between Repair or
connector 161 (female) (21 replace
inside relay box and fuse
9 inside relay box
20-134-3
8
b) APS pilot on monitor panel does not go out even when more than 12 seconds has
passed after lighting up
* When an abnormality occurs and the system returns to normal when the connector has been
* Only when the water temperature is below 20°C.
* it is possible to carry out troubleshooting when the cooling water temperature is above 20°C by
t Check that fuses 9 and 11 inside the fuse box are normal.
* Always turn the starting switch OFF before disconnecting the connector or connecting the T-
* Before carrying out troubleshooting, check that all the related
connectors are properly inserted. Remedy
* Always connect any disconnected connectors before going on
the next step. Wiring harness between
CN121 (male) (4),(19) and
b-l. APS pilot stays lighted up (glow plug system short circuited) connector 141 (female)
Y== (2),(3) inside relay box
?epair or
.eplace
chassis ground
between CN121 Wiring harness between

(female) (4). (19) CN121 (female) (4),(19) -
YES CNlOl (l),(ll) - CN102 3epair or
.eplace
-0.8-1.3R
I
Is resistance
between CN 102
- (female) (l),(4) short
circuiting with chassis
. Turn starting
switch OFF. Replace
- Disconnect
CN121. -0.8-1.3R
. Turn starting
switch OFF.
- Disconnect
CN102.
b-2. APS pilot flashes (disconnection in APS water temperature

sensor) Cause Remedy
Ir It is normal if the lamp flashes when the water temperature is
above 20°C.
Defective APS controller qeplace
3 YES harness between CNl06 - qepair or
connector [51(2) Is resistance CNlOl (12) - CN121
.eplace
(female) (13)
1
tE S between CN121
relay box normal? - (female) (13) and -
* Max. 0.5 V Is resistance chassis ground as disconnection in wiring ?epair or
+ Turn starting shown in Table I?
between CN106 harness between CN121 ‘eplace
switch ON. (water temperature (male) (13) and connector
* Turn starting NO
N0 end) and chassis switch OFF. 151(female) (2) inside
Reference: around as shown relay box
* Disconnect
The voltage i Table I? CN121.
when the water Defective APS water
* Turn starting 3eplace
temperature is NO temperature sensor
switch OFF.
above 20°C is 7 -
* Disconnect
IOV.
CN106.
Table 1
( Coolant temperature Resistance value
I Below 20°C I Max. 1 Q I

I Above 20°C ( Min. 1 MR I
20-l 34-4
@
APS pilot on monitor panel lights up when starting switch is at START (short circuit
with ground in nozzle system)
When an abnormality occurs and the system returns to normal when the connector has been
Cause Remedy
Defective APS controller
YE Wiring harness between

CNl21 (male) (7) and
connector [41 (female) (4)
Repair or
inside relay box short
circuiting with chassis
z 1.5-2.5R
. Turn starting
ground
between CNl21 switch OFF.
(female) (7) and Wiring harness between
Disconnect
CN121 (female) (7) -
connectors [41
‘ES CNlOl (7) - CN102 Repair or
.1.5-2.5R and 151.
(female) (2) short replace
. Turn starting circuiting with chassis
switch OFF.
Is resistance ground
. Disconnect between CN102
CNl21. Wiring harness between
(male) (2) and (3)
normal? I 4 YES CN102 (male) (2) and Repair or
nozzle short circuiting replace
. 1.5 2.5 R with chassis ground
* Turn starting FH_
switch OFF.
- Disconnect Defective nozzle
CN102. *3-5R NO
-Turn starting
switch OFF.
* Remove nozzle.
xl- 134-5
@
d) APS does not work (when there is no abnormality in Items a) - c) for Defective operation of
APS)
d-l. Disconnection in C signal input system
YES
YES
nozzle actuation
switch is turned
YES
2
- Disconnect
CN103 and Is voltage between
CN104. connector 151(3)
-Turn preheating NO and (1) inside raiav
switch ON. box normal?
*Turn starting 4
switch to START. -lo-3ov
- Disconnect 3 YES
CN103 and
between CN121
switch ON. ground normal?

* Starting switch to _
*lo-3ov
START.
* Disconnect
CN103 and ground normal?
. CN104.
-IO-3ov
* Turn preheating
- Disconnect
switch ON.
Is voltage CN103 and CN104.
* Starting switch to I
between CN361 *Turn preheating
START.
NO (3) and chassis switch ON.
NO
ground normal? - Starting switch to
4
*IO-3ov START.
7 YES
- Disconnect
CN103 and CN104. Is voltage
. Turn preheating between CN161
switch ON. NO (4) and chassis
- Starting switch to ground normal?
START. *lo-3ov NO
. Disconnect
CN103 and CN104.
*Turn preheating
switch ON.
- Starting switch to
START.
20-134-6
@
Cause I Remedy
Go to Trouble-
Defective APS nozzle fuel shooting S-l
system and S-2 for
engine
Go to d-2. Defective contact of glow PLUG system.
harness between CN121 Repair or
(male) (2) and connector replace
[51 (female) (3) inside
relay box
i- disconnection in wiring
0 Repair or
6 YES harness between CN121
(female) (2),(3) - CN451 replace
Is resistance
_ between CN151 _ (7),(8) - CN151 (female)
(male) (1) and (3) (l).(3)
normal? Defective safety switch Replace
. Gear shift lever NO
N: Max. 1 R
. Gear shift lever at
any position
except N: Min. 1 MR
* Turn starting switch
OFF. Defective contact, or
* Disconnect CN151. disconnection in wiring
harness between CN361 Repair or
(male) (3) and CNl21 replace
(male) (3)
disconnection in wiring Repair or
harness between CN361 replace
(female) (3) and CN161
(female) (4)
Defective starting switch Replace
20-134-7
8
d-2. Disconnection in glow plug system
* Before starting, carry out d-l. Disconnection in C signal input system first.
* Check if there is abnormality in installation of glow plug.
Go to d-3. Defective
YES
-contact of nozzle
3 system.
Is resistance
YES between CN102
- (malehl),(4) and - Defective contact, or
chassis ground 4 YES disconnection in wiring
normal? - harness between CN102
2 Is resistance
between each (male) (l),(4) and glow
.0.8-1.3R
Is voltage No glow plug and - plug
* Turn starting
YES between CN102 chassis ground
_ switch OFF.
- (l).(4) and normal?
- Disconnect K Defective glow plug
chassis ground -0.8. 1.3R
1 CN102.
normal?
* Turn starting switch
Is voltage .ll-14v OFF. Defective contact, or
between CN121 . Turn preheating * Disconnect glow plug disconnection in wiring
(4Lf19) and terminal. harness between CN102
switch ON.
chassis ground (female) (l),(4) - CNlOl
* Turn starting NO
normal? (l),(ll) - CN121 (female)
switch ON.
(4).(19)
-ll-14v
-Turn preheating Defective contact, or
5
switch ON. disconnection in wiring
YES
Is voltage between harness between
-Turn starting
connector I41 connector I41 (female)
switch ON.
L (2).(3) inside relay (2),(3) inside relay box
NO box and connector and CN121 (male) (4),(19)
f51 (1) inside relay
box normal? Defective APS controller
NO
.ll-14v
-Turn preheating
switch ON.
* Turn starting
switch ON.
20-134-8
@
d-3. Disconnection in nozzle system
* Before starting, carry out d-l. Disconnection in C signal input system and d-2. Disconnection in
glow plug system first.
Cause Remedy
YES disconnection in wiring Iepair or
4- harness between CN102 ,eplace
Is resistance of (male) (2),(3) and nozzle
YES nozzle as
individual part
3 normal?
Is voltage Defective nozzle FIeplace

-3-50
NO
between CN102 * Turn starting
(male) (2) and - switch OFF.
chassis ground * Disconnect nozzle
normal? terminal.
2 0.4 - 5 v disconnection in wiring
Disconnect harness between CN102 Ftepair or
YI between CN121 CN103 and CN104. NO (female) (2) - CNlOl (7) - replace
(7) and chassis . Turn preheating switch ON. CN121 (female) (7)
. Starting switch to START. Defective contact, or
*0.4-5v disconnection in wiring
harness between CN121 Ftepair or
* Disconnect
(male) (7) and connector r eplace
CN103 and
1 CN104. I41 (female) (4) inside
* Turn preheating N relay box
Is resistance switch ON.
Defective APS controller FXeplace
between CN102 * Starting switch to
(female) (3) and START.
chassis ground . Disconnect CN103 and CN104.
nnrmal?
~
. Turn preheating switch ON.
-Max. 1R . Starting switch to START.
* Turn starting
switch OFF.
1’
* Disconnect 6 YES harness between CN102 FXepair or
CN102. (female) (3) and CN121 replace
Is voltage
‘betweenCN121 (female) (IO)
(male) (IO) and Defective contact, or
N chassis ground disconnection in wiring
normal? harness between CN121 Fsepair or
(female) (IO) - J2 inside r eplace
- Max. IQ NO
* Turn starting relay box - chassis groun d
switch OFF.
. Disconnect
CN121.
20-134-9
@
e) APS does not stop even when water temperature is above 20°C (short circuit with ground in
APS water temperature sensor system)
Cause Remedy

CN121 (male) (13) and
YES Repair or
connector [51 (2) inside
2 I replace
relay box short circuiting
Is voltage with chassis ground
YE between CN121
1 (13) and chassis
around normal? Wiring harness between
CN106 - CNlOl (12) -
I Repair or
between CN 106 .7-1ov CN121 (female) (13) short
replace
-Turn starting NO circuiting with chassis
ground normal? switch ON. ground
-Turn preheating switch ON.
.7-1ov
Defective APS water
* Turn starting Replace
temperature sensor
switch ON.
*Turn preheating
switch ON.
20-134-10
@
E-3 Related electrical circuit diagram
N’S SYSTEM
Monitor nodul _
_Q2
0
Safety switch CN151 %0
ADS
Pilot L
ureheatino 40
signal
1
Panel switch
1
Starting motor
Starter switch
4
-FJ-
-_-_
CNl61
1
CNlO
APS controller
---------I
GND
Water temperature switch
Starting motor C
Preheating Iamp
TDD00710
20-134-11
@
E-4 Even when the light switch is turned ON, the lamps do not light up
a) Head lamp switch g 10

cl
* When fuse No.14 is normal
(If fuse No.14 is blown, check if the wiring harness between fuse No.14 - relay [13] [141 (3) (4) ‘- lamp is in
contact with the chassis ground.)
Cause
YES
Defective relay on side that
31 does not light up (Defective
Does condition contact).
YES become normal
-when relay [131 -
or 1141 is 4 YE Defective lamp, or defective
replaced? ?ls voltage contact with ground.
between
_ CN203 (I) or _
NO CN204 (1) and
chassis ground nection in wiring harness
20 - 3OV? between lamps and relay on
NC
2 . Turn starting side that does not light up.
switch ON.
Are lamps that
. Turn head lamp
switch ON.
on one side

nection in wiring harness be.
..-
tween fuse 14 and relay [13]
P41 (31.
Of Panel switch
* Turn starting
YES Defective relay on side that
switch ON. 6p does not light up (Disconnec-
* Turn head lamp
Are lamps tion in coil).
switch ON,
YES that do
not light up on -
5 one side only? 7 YEE
Do red lamps of Do lamp light UP
other switches _ when CN261 (3) _
NO is grounded to
chassis?
-I- nection in wiring harness be-
* Turn starting * Turn starting NO tween relay 1131[14] (1) -
switch ON. switch ON. CN362 (3) - CN261 (male) (3).
* Turn other * Turn head lamp
switches ON. switch OFF.
* Connect
T-adapter to
CN261.
See E-6 (panel switch power

Nk BOUrce system).
20-135
0O0:
*
b) Rear lampswitch 0
When fuse No.1 3 is normal
(If fuse No.13 is blown, check if the wiring harness between fuse No.13 -relay [171 1181 (3) (a)- lamps is in
contact with the chassis ground.)
Cause Remedy
Defective relay on side that

YES
does not light up (Defective
contact).
Does condition
when relay [171

4 YES Defective lamp, or defective
contact with ground.
Is voltage bet-
ween CN243 (1) a
CN223 (1) and
;hgaywy;und Defective contact or discon-
between lamps and relay on
* Turn starting NO side that does not light up.
switch ON.
Are lamps
YES * Turn rear lamp
that do
switch ON.
not light UP on
one side only?

NO tween fuse 13 and relay [171
[I81 (3).
1
* Turn starting
switch ON. YES Defective relay on side that
* Turn rear lamp. does not light up (Disconnec-
switch ON. 61
tion in coil).
1 Are lamps I I
s ;

1 I IL tween relay [171 [181 (1) -
’ Turn startina * Turn
startina NO CN362 (4) - CN261 (male)
switch ON. - switch ON. - (4).
. Turn other * Turn rear lamp
switches ON. switch OFF.
’ connect
T-adapter to
CN261.
See E-6 (panel switch power

*ource system).
NO
20-136
c) Working lamp switch Iz AC?
* When fuse No.12 is normal
(If fuse No.12 is blown, check if the wiring harness between fuse No.12- relay [221 (3) (4)-lamps is in contact
with the chassis ground.)
Cause Remedy
YES Defective lamp, or defective

31 contact with ground.
Isvoltage
between
YES
- CN242 (1) or _
CN221 (1) and
chassis ground
20 - 3ov7 Defective contact or discon-
* Turn starting
switch ON. NO
CN242 (1) orCN221 (1) and
CN121 (female) (21).
* Turn working
lamp switch ON.
2
Are lamps
Y that do
YES
not light up on Defective relay [22] (Oefec-
one side only? 4 tive contact).
Does condition
_ become normal
NO I”hen relay 1221
1s replaced?
tween fuse 12 - relay [22]
NO (3) (4) - CN121 (male) (21).
Panel switch
. Turn starting
switch ON. YES
Defective relay [221 (Olscon-
* Turn working
6 . nection in coil).
lamp switch
ON.
Does condition
YES become normal _
5 when relay [221 7 YE!
is replaced? Defective panel switch.
00 red lamps of \Does
other switches UP when CN261
light/up? NO (5) is grounded
NO Defective contact, or discon-
to’chassis?
* Turn starting * Turn starting tween relay [221 (1) - CN362
NC
switch ON. switch ON. (5) - CN261 (male) (5).
* Turn other * Turn working lamp
switches ON. I switch OFF.
- Connect
T-adapter to
CN261.
I SeelE-6 (panel switch power

source system).
NO
20-l 37
E-5 Even when the light switch is turned OFF, the lamps do not go out
a) Head lamp switch w
Cause Remedy
3 YES
Defective relay
Do lamps go out
YES when relay is
2 - removed on side -
where lamps do
not go out7 Contact of + 24V with wiring
YES Are lamps that do harness between relay [131
- not go out on one
* Turn starting NO
[14] (4) and lamps.
switch ON.

1 [131 [141 (1) - CN362 (3) -
NO CN.261 (male) (3) short circuit-
Does red lamp ing with chassis ground.
Of Panel switch -
go out7
* Turn starting
Defective panel switch,
* Turn head lamp
switch OFF.
b) Rear lamp switch

0
g 0:
3 YES
Defective relay.
YES
SH-

harness between relay [171
* Turn starting NO
[la] (4) and lamps.
switch ON.

[171 [181 (1) - CN362 (41 -
NO CN261 (male) (4) short circuit-
Does red lamp of ing with chassis ground.
panel switch go -
out?
. Turn starting
switch ON.
NO
* Turn rear lamp
switch OFF.
c) Working lamp switch @ Defective contact, or discon-

3 YES nection in wiring harness be-
tween relay [221 (1) - CN362
Is resistance
(5) - CN261 (male) (5).
yEL between relay [22]
2 (3) and (4) more
than 1 Ma?
YES Does IamP 90 Out 3efective relay [22]
* ri2yjlpve relay NO
7 when relay [22] -
is removed7
Defective contact or
1 disconnection in wirinq
* Turn starting
harness between rela;[221
switch ON. NO (4) - CN121 (21) - left and
Does red lamp of
right lamps.
panel switch go -
out?
. Turn starting
switch ON. Defective Panel switch.
NO
* Turn working lamp
switch OFF.
20-138
E-6 Panel switch does not work. -Abnormality in panel switch power source
(Even when the switch is pressed, the red lamp for that switch does not light up.)
* When fuses No.9 and 15 are normal

If fuse is blown, check for short circuit with chassis ground in wiring harness between fuse No.9’- (2) pin of each
relay, fuse No.9 - CN362 (1) - CN261 (panel switch), or fuse No.15 - CN162 (1) (supplementary controller)
* When the battery is normal.
.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Remedy
3 YES
Defective panel switch. teplace
IS “Okage between
j
_ CN261 Ill and (2120 _ Defective contact, or discon-
- 3OV? nection in wiring harness be-
tween fuse 9 and (2) of each
Turn starting 1 relay, or between fuse 9 -
NO
switch ON. CN362 (1) -
CN261 (1) (2) -
CN362 (2) - chassis ground.
Defective safety relay (121 . Seplace

* Turn starting Does condition
switch ON.
- CN361 (7) - safety relay’

[121 (1). (2.
YES Defective contact or discon- Repair or

nection in wiring har”e*s replace
between CN464 (1) and
CN361 (7).
5
ISvoltage
between
CM64 11) and chass,s -
ground 20 - 3OV?
6 YES Defective supplementary
Replace
controller.
Turn start,&! Is voltage between
SWltChON - CNl62 (1) and _
NO chassis ground
20 - 3OV? Defective contact or discon- Repair or
nection in wiring harness replace
between battery terminal (+)
* Turn starting NO -CN361 (lo)- CN162 (1).
switch ON.
20-l 39
E-4, E-5, E-6. Related electrical circuit diagram
Workhng lamp (R H.)

CN242
:
:
/
Workong lamp 1L.H 1
Head lamp 03 Hi
Redr lamp 1L.H.)
Head lamp 1R.H I
Relay box
Panel switch
F19702203A
20-l 40
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(MODE SELECTION ELECTRONIC SYSTEM WITH SSC SYSTEM)
(WITH SSC SYSTEM)
Table of failure modes and causes (mode.selection electronic system) . . . . . . . . . . . . .. . . . . . . .. .. . . .. . . . .. . . . . 20-I 40-2
E-S1 Torque converter lock-up does not work (lock-up display lamp does not light up) ....... 20-140-4
E-S2 Torque converter lock-up display is abnormal .................................................................... 20-I 40-7
a) Lock-up display lamp does not go out ........................................................................... 20-I 40-7
b) Lock-up display lamp lights up but lock-up is not actuated ........................................ 20-140-7
E-S3 Blown fuse No. 8 of torque converter lock-up relay inside relay box ............................. 20-140-8
E-S4 Mode does not switch when economy mode is pressed
(monitor panel LED is normal) ........................................................................................... .20-140-9
E-S5 Reverse slow is not actuated when REVERSE slow switch is pressed
(monitor panel LED is normal) .......................................................................................... 20-I 40-10
E-S6 Shoe slip control is not actuated when shoe slip control switch is pressed
(monitor panel LED is normal) .......................................................................................... 20-I 40-I 1
E-S7 Selected level does not change when rockbed selection mode switch is pressed
(monitor panel LED is normal) .......................................................................................... 20-I 40-I 2
E-S8 Engine cannot be controlled, engine stalls, engine cannot be started .......................... 20-I 40-13
E-S9 Shoe slip is not detected when shoe slip control is ON ................................................. 20-I 40-I 4
E-S10 Starting modulation does not work when shoe slip control is ON ................................ 20-I 40-15
E-S1 1 There is no up/down of drawbar pull by using ripper lever
when shoe slip control is ON ............................................................................................ 20-140-15
E-S12 Abnormality in ripper UP, DOWN, TILT signal, REVERSE signal ................................... 20-140-16
D275A-2 20- 140- 1

0
(MODE SELECTION SYSTEM)
2. Mode does not switch when economy mode

000 00
switch is pressed
3 REVERSE slow is not actuated when

0
’ REVERSE slow switch is pressed
4 Shoe slip control is not actuated when

000 00
’ shoe slip control switch is pressed
5 Selected level does not switch when

’ rockbed selection mode switch is pressed
6 Engine cannot be controlled, engine stalls,

0 00 0
. engine cannot be started
, Shoe slip is not detected when shoe slip

. control is ON
0
8 Starting modulation does not work when

00
* shoe slip control is ON
g There is no up/down of drawbar pull by using

000
’ ripper lever when shoe slip control is ON
,. Abnormality in ripper UP, DOWN, TILT signal,

0000
. REVERSE signal
20-140-2 D275A-2
0
Switch module
For abnormalities in
machine monitor system,
go to Troubleshooting
(YES/NO) M-OX
E-S1 Torque converter lock-up does not work (lock-up display lamp does not light up)
When the torque converter is locked up, an input signal is being re-
ceived from the SSC controller, so check for any error in the function of
the SSC system, and check that there is no failure code displayed on
YES
the SSC controller.
Always turn the starting switch OFF before disconnecting any connec-
tor to connect the T-adapter (or socket adapter).
When connecting a T-adapter, connect the male and female; when
connecting a socket, connect to the part specified inside ( 1.
Always connect any disconnected connectors before going on the next
step.
Connectors CN364, CN371, and CN372 become connectors CN391 and YI
CN399 on machines equipped with a cab.
. Start engine.
* Turn lock-up
switch ON.
- Transmission:
Table 1 Neutral
* Short circuit
between CN622
(2) and (5)
NO
YE
(Tolerance: +O.lV)
* Turn starting
switch OFF.
YIES
* Turn starting
switch ON.
Table 2 NO
Between (I) and (2) 1 40 - 80 V 1

3 Between (l)(2)
Min. 1 MQ
Is vokaga between and chassis
YES_ CN121 (II) and _
chassis ground 20 NO
-3ov7
* Turn starting YES
switch ON. -
I
by[151isrepbced. 17 YES
2
isvokagebetween
YI YES
tween CNSS2 (4)
* Turn starting
* Turn starting * Turn starting NO
switch ON.
switch ON. switch ON.
1
* Turn lock-up
switch ON. c
* Turn starting NO
tween CNSOl (3) switch ON.
* Turn starting
switch ON. NO
* Turn lock-up
switch ON.
20-140-4 D275A-2
a
Cause 3emedy
7 YES
Defective lock-up display lamp Ieplace
Iefective contact or disconnectior

n wiring harness between CN121
11) - CN122 (7). CN622 (7) - CNlPl sepair or
8). CN122 G’L (8) - CN364 (3), (4). ,eplace
- Start engine. NO
:N371 (3), (4) - CN371 (3), (4)
* Turn lock-up switch ON.
:N372 (3). (4)
* Transmission: Neutral
YES
- Short circuit between Defective lock-up controller teplace
CN622 (2) and (5)
19
Is vottage be- Defective contact or discon-
tween CN622 section in wiring harness be
YE! YES Iepair or
(I) and (3) more - ween CN622 (1) (3) - CNSOE
eplace
than 0.5V (AC
10 111) (14) - CNSSI (I), CNSSi
range)?
P Is voltage be- 112)
- Start engine. tween CNSSP YES
* Run at high L (12) and (14) - Defective shoe slip controller Ieplace
11 P
idling. NO more than O-5V
(AC range)? Is voltage be-
. T&;cocDk-Nup Defective contact or discon-
tween CNSSI
* Start engine. - (I) and 18)more - 12 YES section in wiring harness be.
3epair or
8
u
* Run at high NO than 0.5 V (AC ween CNSSI (female) (l)(8).
Is voltage be- - .eplace
idling. range)?
Is resistance
be . tween CN651 CNS06 (l)(4) - CN451 (4)(5)
tweenCN622lfe * Turn lock-up * Start engine. _ (l)andt2)mo-e _ ZN651 (female) (l)(2)
male) (2) and (5) switch ON. * Run at high NO thaha,W (AC
less than 1 M idling. Defective torque converter
seplace
* Turn lock-up * Stan engine. NC speed sensor
* Start engine. switch ON. - Run et high
idlino.
13 YES Defective transmission oi

qeplace
pressure sensor
Isresistamebe
tWeJlCN622ffe
male) (2) and f5l Defective contact or discon,
N lessthan IQ? nection in wiring harness be, ?epair or
f Connect short NO tween CN622 (female) (2L (5 veplace
connector to - CN652 (I), (2)
CN652 (female).
Defective contact or discon
qepair or
nection in wiring harness be,
peplace
tween CN622 (female) (7L (8
- (male) (I) and - - CN653 (1). (2)
(2) as shown in
Table 2? Defective lock-up solenoid qeplace
. ;urnt;a&Fg NO

nection in wiring harness be qepair or
tween CN121 (female) (11) veplace
CN622 (4)(5) -chassis grounc
Defective lock-up relay [I51 Replace
Defective contact or disconnec

tion in wiring harness be&veer Repair or
fuse No. 8 - k&up relay [I5 replace
(3)(4) - CN121 (male) (11)
nection in wiring harness be Repair or
tween CN362 (female) (7) replace
CN122 (male) (6)

‘ion in wiring harness betweer, Repair or
use No. 9 - lock-up relay [151 eplace
2)(l) - CN361 (male) (7)
)efe&e contact or disconnec-

lepair or
ion in wiring harness between
eplace
:NSOl (3) and CNSS2 (4)
30 to M-12
D275A-2 20-140-5
a
7 r
E-S2 Torque converter lock-up display is abnormal
Turn the starting switch OFF before connecting or disconnecting a T-adapter (or socket).
When connecting a T-adapter, connect the male and female; when connecting a socket, connect to
the part specified inside ( 1.
Connectors CN364, CN371, and CN372 become connectors CN391 and CN399 on machines equipped
with a cab.
a) Lock-up display lamp does not go out Cause Remedy
short circuit with chassi:

ground in wiring harness be
ween CN622 (female) (7)
1 YES ZN153 (3) - CN653 (female) (2 3epair 01
)r between CN622 (female) (7 ,eplace
Is resistance be-
CN122 (8) - CN364 (4) - CN37’
tween CN622 (fe-
4) - CN372 (female) (4)
male) (7) and chas-
sis more than 1 MQ?
Defective lock-up controller qeplace
* Turn starting NO
switch OFF.
* Disconnect CN622.
b) Lock-up display lamp lights up but lock-up is not actuated
2 YES ;;eo;ir
Defective hydraulic system
Is voltage be- nspection
YES tween CN622 (7) _
and (8) as shown
in Table I?
Defective lock-up controller leplace
- Start engine. NO
* Transmission:
Neutral Table 1
mi
* Turn lock-up
switch ON.
* Short circuit
between CN622
(2) and (5).
s Disconnect CN622. (Tolerance: +0.5V)

%ctive contact or disconnec-
on in wiring harness between
3 YES Iepair or
:N622 (female) (7) - CN153 (3)
eplace
Is resistance be- I CN663 (2)(l) - CN153 (2) -
tweet-rCN653 (male) :N622 (female) (8)
ND (1) and (2) 40 - 80 D?
)efective lock-up solenoid leplace
* Disconnect CN653. ND
D275A-2 20-140-7
0
E-S3 Blown fuse No. 8 of torque converter lock-up relay inside relay box
Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter
(or socket adapter).
When connecting a T-adapter, connect the male and female; when connecting a socket, connect to
the part specified inside ( 1.
Connectors CN364, CN371, and CN372 become connectors CN391 and CN399 on machines equipped
with a cab.
I Cause Remedy
Short circuit with chassis

YES ground in wiring harness be- Repair 01
tween fuse 8 inside relay box replace
1 - lock-up relay [I51 socket (3)
Does fuse 8 blow Short circuit with chassis

when starting _ YES ground in wiring harness be qepair of
switch is turned tween CN121 (male) (11) - replace
ON? 2 lock-up relay [151 socket (4).
Is resistance be-
tween CN121 (fe
- male) (11) and -
NO chassis ground
3 YES
more than 1 MQ? Is resistance be- ~ Defective lock-up controller Replace
* Disconnect CN121. tween CN622 (fe-
- male) (4) and - Short circuit with chassis
NO chassis ground ground in wiring harness be-
more than 1 MQ?, - tween CN121 (female) (11) - 3epair or
CN622 (male) (4) - CN122 (7)
- Disconnect CN622. No - CN364 (3) - CN371 (3) -
CN372 (female) (3)
E-S2, E-S3. Related electrical circuit diagram

With cab
r- - .-
CN391 CN399 Lock-up display
cN372 Lock-up display lamp
Lock-up
con^troller
+24y
Lock-up
valve
? i 3 i Lock-&Ienoid
Valve
power
source
CN362
Relav box
Lock-up relay
q
CN121
In
q
I Safety relay
197F01512A
20-140-8 D275A-2
0
E-S4 Mode does not switch when economy mode is pressed (monitor panel LED is
normal)
[Check for any error in the function of the SSC system and for
Cause Remed)
any failure code displayed on the SSC.1
* Before carrying out troubleshooting, check that all the re-
lated connectors are properly inserted.
* Always connect any disconnected connectors before go-
ing on the next step.
3 YES
w GotoA
Are ripper lever
YES signal and trans
2 - mission REVERSE
signal normal?
Is voltage be- So to E-S12 -
YES tween CNSS2 (3) * Go to item in NO
- - (14), (2) - (14) as - Troubleshooting
1 shown in Table I? Iefective contact or discon-
E-S12.
Is voltage be- section in wiring harness be- qepair 0
- Turn starting
tween CNSOI (4) _ :ween CNSOI (4)(5) and .eplace
switch ON. NO
- (2). (5) - (2) as :NSSZ (3)(2)
* Turn economy
shown in Table I?
mode switch ON.
- Qr$-$~$y -
30 to M-12
- Turn economy No
mode switch ON.
Table 1 YES
Defective shoe slip controller Replace
Iefective contact or disconnec-
:ion in wiring harness between
3NSS2 (male) (5) - CN421 (14).
3N451 (13) - CNSIZ (female1 Repair 0
J)(2) CN451 (14) - chassis replace
ground, or between CNSS2 (141
CN122 (6) - chassis ground
* Brake Defective transmission FOR- Replace
* When gearshift WARD oil pressure switch
lever is at F:
- Start engine. NO
* Run at low idling.
IO-3ov
* Brake
* When gearshift
* When gearshift lever
lever is at N:
is at F: Min. 1 MQ
o-1v
* Start engine.
is at N: Max. 1 fi
* Run at low idling. Defective contact or disconnec
* Brake lion in wiring harness between
. Whengeanhii ZNSS2 (male) (16) - CNSO6 (131 Repair
YES o
lever is at Fl: CN451 (12) - CNS07 (female1
10 - 30 v :1)(2) - CN451 (14) - chassis replace
* When gearshi ground, or between CNSSZ (141
lever is at N: CN122 (6) - chassis ground
O-IV I Defective transmission 1st oil
Replace
* Start engine. NO oressure switch
* Run at low idling.
* Brake
* When gearshift lever is at Fl: Min. 1 MQ
* When gearshift lever is at N: Max. 1 R
E-S4. Related electrical circuit diagram
Mode selection switch

--
Transmission 1st oil

pressure switch
Transmission FORWARD oil

pressure switch
197F01513
D275A-2 20-140-9
0
E-S5 Reverse slow is not actuated when REVERSE slow switch is pressed (monitor
panel LED is normal)
[Check for any error in the function of the SSC system and for any failure code displayed on the SSC.1
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
I Cause Remedy
3 YES
I t -GotoA
YES Is transmission
2 - REVERSE signal -
normal?
Is voltage be- Go to E-S12 -
YES tween CNSS2 _ * Go to item in NO
(Il$and (14) 0 - Troubleshooting
1 Defective contact or discon-
E-S12.
Is voltage be- - Turn starting nection in wiring harness be 3epair or
tween CNSOI (6) - switch ON. NO tween CNSOI (female) (6) eplace
and (2) 0 - 1 V7 * Turn REVERSE CNSS2 (female) (17)
slow switch ON.
* Turn starting -
switch ON. Go to M-12
NO
- Turn REVERSE
slow switch ON.
A
+iiiiiq(l,ytiem Defective shoe slip controller
has beenreset
qeplace
E-S5 Related electrical circuit diagram
Mode selection switch SSC controller
REVERSE slow
CNSOI CNSS2
REVERSE ~10~
1 I
GND
i _-I
197F01514
20-140-10 D275A-2
0
E-S6 Shoe slip control is not actuated when shoe slip control switch is pressed
(monitor panel LED is normal)
[Check for any error in the function of the SSC system and for
Cause 3emedy
any failure code displayed on the SSC.]
* Before carrying out troubleshooting, check that all the re-
Sr Always connect any disconnected connectors before go-
_ . *
Are npper lever
3l YES GotoA
YES signal and trans-

2 - mission REVERSE
signal normal?
YES Is voltage be- Go to E-S12 -
* Go to item in NO
- tween CNSSl -
Troubleshooting
1 (15)-(14)0-Iv?
E-S12. Defective contact or discon-
Is voltage be- - Turn starting nection in wiring harness be- Iepair or
tween CNSOI (7) - switch ON. NO tween CNSOl (7) and CNSS2 eplace
and (2) 0 - 1 V7 * Turn shoe slip (15)
control switch ON.
Turn starting
I Go to M-12 -
switch ON.
NO
Turn shoe slio
control switch ON.
YES
Defective shoe slip controller 3eplace
tion in wiring harness between
CNSSZ (male) (5) - CN421 (14).
6 YES CN451 (13) - CNS12 (female1 lepair or
Is resistance be- (1)(2) - CN451 (14) - chassis eplace
* Start engine. tween CNSl2 _ ground, or between CNSS2 (141
* Run at low idling. ND (male)(I) and(2) - CN122 (6) - chassis ground
* Brake normal? _ Defective transmission FOR
* When gearshift Ieplace
* Start engine. ND WARD oil pressure switch
lever is at F:
. Run at low idling.
10 - 30 v
. Brake
* When gearshift
lever is at N:
is at F: Min. 1 MR
o-1v
. When gearshift lever
* Stan engine.
is at N: Max. 1 R
. Run at low idling. pefeyztive,conpct or di?onnec
* Brake tlon In wrnng hXneSS DeNveer
* When gearshii CNSS2 (male) (16) - CNSO6 (131
7 YES 3epair 01
lever is at Fl: - CN451 (12) - CNS07 (female1
lo-3ov Is resistance be- (1)(2) - CN451 (14) - chassis ,eplace
- When gearshii tween CNS07 ground, or between CNSS2 (141
lever is at N: - (male) (1) and (2) - - CN122 (6) - chassis ground
0 - 1 Y No normal?
Defective transmission 1st oil
Ieplace
* Start engine. . NO pressure switch
: ;;ik; low rdlrng.
* When gearshift lever is at Fl: Min. 1 MR

- When gearshift lever is at N: Max. 1 .Q
SSC controller
Transmission 1st
oil pressure switch
Transmission FORWARD oil

pressure switch
197F01515
D275A-2 20-140-11
0
E-S7 Selected level does not change when rockbed selection switch is pressed
(monitor panel LED is normal)
[Check for any error
any failure code
Before carrying
in the function of the SSC system and for
displayed on the SSC.1
out troubleshooting, check that all the re-
r Cause Remedl

Always connect any disconnected connectors before go-
Go to E-S12 -
- (14) as shown Troubleshooting
E-S12. Defective contact or discon-
+^.+:..-
-1 nection in wiring harness be- qepair 0
tween CNSOl (9) tween CNSOI (9) and CNSSP .eplace
and (2) as shown
* Turn shoe slip control switch ON.
. Switch rockbed_ __ __. _. mode.
celectinn _- -
* Turn starting 1 E%D;izoG;de selection
qeplace
switch ON.
NO
* Turn shoe slip
control switch
ON.
- Switch rockbed YES
p Defective shoe slip controller Replace
selection mode. 5
Defective contact or disconnec-
S Is voltage be- tion in wiring harness between
- tween CNSS2 (5) - S YES CNSS2 (male) (5) - CN421 (14) -
and (14) normal? _ CN451 (13) - CNSIZ (female) Repair 0
Is resistance be- (1)(2) - CN451 (14) - chassis replace
. Start engine. _ tween CNSIZ _ ground, or between CNSS2 (141
. Run at low idling. NO (male)(1) and (2) - CN122 (6) - chassis ground
* Brake normal? _ Defective transmission FOR-
* When gearshift Replace
* Start enaine. ND WARD oil pressure switch
lever is at F:
. Run at low idling. I
IO-3ov
* Brake
* When gearshift
. When gear&ii lever
lever is at N:
is at F: Min. I MR
O-IV
- When gearshift lever
. Start engine.
isatN:Max.lQ
* Run at low idling. Defective. contact or disconnec-
. Brake tcon rn wtnng narness oetween
* When gear&ii YES CNSS2 (male) (16)- CNSO6 (131 Repair o
lever is at Fl: 7
- CN451 1121 - CNS07 (female1
IO-30v replace
Is resistance be- (l)(2) - CN451 (14) - chassis
. When gear-shift tween CNS07 ground, or between CNSSZ (141
lever is at N: - CN122 16) - chassis ground
o _ , v No ;;;;$? and f2)
Defective transmission 1st oil
Replace
* Start engine. . NO pressure switch
: ;yaRzt low tdllng.
* When gearshift lever is at Fl: Min. 1 MR

* When gearshift lever is at N: Max. 1 R

Table 1
K-G
r’::$$A””
ssc cant--“--
Rockbed g
n
~F&++--j
(Tolerance: t O.lV)
0
Torque
converter speed ’ CN421 CN4!
Transmission
L F
GND , CNSOI
Transmission @-
1st switch CNSSZ
197FOl516
20-140-12 D275A-2
0
E-S8 Engine cannot be controlled, engine stalls, engine cannot be started
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
4 YES Defective fuel injection pump, Repair 0

engine system replace
YES Is output lever rc-
- tating angle as -
shownin Table l?
3 . Tz;ctaoag No Defective ELPC controller Replace
Is voltage be-
yEs tween CNSMI _ * Start engine.
(8)(9)(5) - (12) as * Move throttle lever
shown in Table I? Hi-Lc- Stop. 5 YES Go to G,, G,2
2 Is voltage be-
. Turn starting
switch ON. tween CNSSI (4)
Is LED display on
YI No (13) - (II) as -
- shoe slip control- - * Start engine.
shown in Table I?
ler normal? - Move throttle - Defective shoe slip controller Replace
lever Hi-Lo-Stop. NO
* Turn starting
switch ON.
* Turn shoe slip
control switch
ON.
* Turn starting s Start engine.
switch ON.
* Turn shoe slip
control switch I
ON.
- Start engine.
E-S& Related electrical circuit diagram

Table 1
SSC controller
% The FULL position is taken as 09
CN421
hlpur
7-l-l CE potentiometer
ack
iometer
L____.-.J
17MF02179
D275A-2 20-140-13
0
E-S9 Shoe slip is not detected when shoe slip controller is ON
[Check for any failure code displayed on the SSC.]

Cause qemedy
4 YE:
Defective shoe slip controller teplace
mr
H
Does problem
appear again?
IL System has been reset -
CNSSl (12) and NC
Table 1 when an-
2 1 lgle ofacceferation 11
sensorischanged7 1 Defective contact or discon
* Remove lepair or
CNSS3 (2) and (3) I tween CNSS3 (female) (2)
YI as shown in Table acceleration ND eplace
sensor. CNSlO (2) - CNSOG (7)
1 when angle of
. Turn starting CNSSI (female) (12)
acceleration sen-
switch ON.
* Remove
tween CNSS3 (1) acceleration
sensor. Defective acceleration sensor leplace
* Turn starting IO
* Turn starting
switch ON. iepair or
tween CNSS3 (female) (l)(3).
eplace
NO CNSIO (l)(3) - CNS(6)(8)
CNSSl (female) (1O)Ul)
Table 1
CNSSS
1.25 V
(2) - (3)
CNSSI
(12) - (11) 1+25v
I I
(Tolerance: ~k0.3V)
SSC controller
I-I
ieration sensor
‘Acceleration sensor
(8V)
Acceleration sensor
(signal)
,Acceleration sensor
(GND)
197FOl518
20-140-14 D275A-2
0
E-S10 Starting modulation does not work when shoe slip controller is ON
E-S11 There is no up/down of drawbar pull by using ripper lever when shoe slip
controller is ON
[Check for any failure code displayed on the SSC.1
Cause qemedy
2 YES
Defective shoe slip controller 3eplace
YES Does problem
appear again?
System has been reset -

NO
* Go to item in Go to E-S12 -
Troubleshoot- NO
ing E-S.12.
D275A-2 20-140-15
0
E-S12 Abnormality in ripper UP, DOWN, TILT signal, REVERSE signal
[Check if any failure code is displayed on the SSC.]
Sr Always connect any disconnected connectors before going on the next step.
1
Is lighting up of
LED display on
SSC as shown in
Table I? t 5 YES
+yGJH-
NO
YES
- See Table 1.
Turn starting
switch ON.
Operate gearshift ,j!zz&&-
lever to REVERSE.
Does transmis-
sion REVERSE
switch ON. NO
* Operate gearshift
lever to REVERSE.
* See Table 1.
YES
8,
If ripper UP display
. . *
10
N
NO
Table 1. Check of ripper lever signal, transmission

REVERSE signal YES
1 Individual 1 SSC LED display 1
operation Green LED Red LED
Transmission in
FORWARD 0 0
NO
Ripper UP 6 0
Ripper DOWN 6 0
Ripper TILT 0 al” If ripper TILT dis-
play is given when
Transmission in _...._.
REVERSE 0 d gearshift lever is _..jO5 is
operated to FOR- 1disconnected?
I I
WARD
* Do not operate two levers at the same time.
NO
l Procedure
1) Turn starting switch ON. YES
2) Select Economy mode 2.
3) Turn shoe slip control switch ON.
4) Select Rockbed selection 1. /
* Turn starting
switch ON. I
- Operate NO
gearshift lever to
FORWARD.
20-140-16 D275A-2
0
I Cause Remedy
Normal (system has been re- -

set)

nection in wiring harness for Adjust,
signal which is not displayed repair, or
or defective adjustment oi replace
limit switch

nection in wiring harness be- Repair or
tween CNSS2 (female) (9) - replace
CS06 (IO) - CN451 (IO) -
CN251 (male)
7 YES
Defective backup alarm switch Replace
Is voltage be-
tween CN252 (fe-
- male) and chassis Defective contact or discon
ground 20 - 30 V? nection in wiring harness be. Repair or
tween CN252 (female) - CN451 replace
- Turn starting ND
(6) - CN121 (8) -fuse No. 10
switch ON.
9 YES Defective adjustment of posi- Adjust
Does condiion be- tion of ripper UP switch
come normal when
ripper UP switch
positionis adjusted?
Defective ripper UP switch
NO
ground in wiring harness be Repair or
tween CNS04 (female) (3) ant replace
CNSS2 (female) (7)
11 YES Defective adjustment of posi,

Adjust
Dces mndiion be tion of ripper DOWN switch
come normal when
- iipflsrD(sIMJswitch
positionisadjusted!
Defective ripper DOWN switch Replace
NO
Short circuit with ground ir
wiring harness betweer Repair or
CNS03 (female) (3) ant replace
CNSSZ (female) (8)
13 YES Defective adjustment of posi Adjust

Dces condition be tion of ripper TILT switch
mrnenorrnalwhen
ripper TILT swkch
1p&ion isadjusted?] Replace
- Defective ripper TILT switch
NO

ground in wiring harness be Repair or
tween CNS05 (female) (3) ant replace
CNSSL (female) (6)
jGHHisytiern Defective shoe slip controller
has beenreset
Replace
16 YES
Defective backup alarm switch Replace
Is voltage be-
- tween CNSS2 (9) - Contact of +24V with wirinc
and (14) 0 - 1 V7 harness between CN25j Repair or
(male) - CN451 (IO) - CNSOt replace
* Turn starting No (10) - CNSSZ (female) (9)
switch ON.
* Operate gearshift lever
to REVERSE.
. Disconnect CN251.
D275A-2 20-140-17
0
E-SIO, E-Sll, E-S12. Related electrical circuit diagram
CNS05
Ripper tilt switch

SSC controller
Ripper tilt Ripper UP switch
Ripper UP
Ripper DOWN
i
I 9
5
Backup alarm
Ripper DOWN switch
1
GND I4
J Backup alarm
switch
Relay box
197F01519
20-140-18 0275A-2
0
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
Table of failure modes and causes . .. . . . . .. . . . . .. . . .. . . . . .. . . . . . . . . . . . .. . . . .. . . . . .. . .. . . . . .. . . . . .. .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . . . . 20-I 43
M-l No display appears on the monitor panel when the starting switch is ON .. . . . . .. .. . . .. . . . . . . . . . 20-144
M-2 When starting switch is turned ON, monitor panel lamps all stay on and do not go out . . . 20-144
M-3 When starting switch is ON (engine stoped), CHECK items show abnormality . . . . . . .. . . . .. . . . . . . . 20-145
a) Abnormality in coolant level -

SC) . . .. . . . . .. . . . . . . .. . .. . . . . .. . .. .. .. . .. . . . . . . .. . . . . . . . . . . . .. .. .. . . . . . .. . . . . . . . . . . . . . 20-I 45
re(,nl
b) Abnormality in engine oil level 6

SC) . . . . . . . .. . . . .. . . . .. . . . . . .. .. . . . . . . . . . . . . . . . .. . . . . .. . . . . .. . .. . . . . . . . . . . . . .. . . . 20-I 46
,“001‘10
M-4 Abnormality in preheating 01111 .. . . . . . . . . . . .. .. . . . . . . . . .. .. .. . .. . .. . . .. .. .. . . . . . . .. . . . . .. . .. . .. .. .. . . . .. . . . . . . .. . . . .. . . . .. . . 20-I 47

1”00>101
a) Preheating monitor does not light up . .. . . . .. . . . . . . .. . . .. . . . . . .. . ... .. . .. . .. . . . . . . . . . . . . . . . . . .. .. . . . . .. . .. . . . . . . . . . . . .. 20-147
b) Preheating monitor stays light up . . .. . . .. . . .. . . . . .. .. . . . .. . . .. . . . . .. . . .. . . . . . . . . . . .. . . .. .. . . .. . . . . . .. . . . . . .. . . . . . .. . .. . . . 20-147
M-5 When starting switch is ON and engine is stoped, CAUTION items flash . . . . . .. .. . . . .. . . . .. . . . . . . 20-148
Charge level flashes .................................................................................................... 20-I 48
Engine oil pressure flashes.. ....................................................................................... 20-I 48
Coolant level flashes ................................................................................................... 20-I 48
Coolant temperature flashes ....................................................................................... 20-I 48
Torque converter oil temperature flashes .................................................................. 20-I 49
Hydraulic oil temperature flashes ............................................................................... 20-I 49
g) Electronic system abnormality flashes ........................................................................... 20-151-I
M-6 Abnormality in buzzer.. ............................................................................................................... 20-152

a) CAUTION items are flashing, but does not sound .............................................................. 20-I 52
b) No abnormality display is given on monitor, but buzzer sound.. ..................................... .20-152
M-7 Abnormality in warning lamp ................................................................................................... 20-I 53
a) CAUTION items are flashing, but lamps do not flash ........................................................ 20-I 53
b) No abnormality display is given on monitor, but lamp light up ...................................... -20-153
M-8 Abnormality in gauge ................................................................................................................. 20-I 54
a) Abnormality in coolant temperature gauge ........................................................................ 20-1.54
b) Abnormality in torque converter oil temperature gauge .................................................... 20-I 55

c) Abnormality in fuel level gauge ........................................................................................... 20-I 56
M-9 Service metor does not move after engine is started .......................................................... .20-l 57
M-10 Panel lighting monitor panel does not light up ...................................................................... 20-I 58
M-l 1 After starting switch is turned ON, display LED does not light up
even when mode selection switch is pressed ....................................................................... .20-159
M-12 LED on panel is normal, but there is no output from mode selection switch module ..... 20-160
M-13 LED on mode selection switch panel does not flash when lighting switch is ON ............ 20-161
M-l 4 Defective initial setting .............................................................................................................. 20-I 62
a) Initial setting cannot be made when initial set switch is ON .......................................... 20-I 62
b) Initial setting is made when initial set switch is OFF.. .................................................... .20-162
D275A-2 20-141
a
(MACHINE MONITOR, MODE SELECTION SWITCH)
Sensors
Causes
?Z
I11
Z! i;; fZ!?
=I
Failure mode
0
Monitor panel display is not given when
1.
starting switch is turned ON
0
2 When starting switch is turned ON, all

’ monitor panel lamps light up and do not go out
Abnormality is display in Check before starting item

3.
when starting switch is at ON position (engine stopped)
4. Abnormality in preheating display
5. CAUTION item flashes when engine is started 00 0 00 0
6. Abnormal in buzzer
7. Abnormality in warning lamp
8; Abnormality in gauge 000
g Service meter does not move

0
’ after engine is started
0. Monitor panel lighting does not light up 0
After starting switch is turned ON, display LED does not

1. 0 0
light up even when mode selection switch is pressed
2 LEDs on panel are normal but there is no

. output from switch module
,3. When lighting switch is ON,

LEDs on panel do not dim
Initial setting cannot be made when initial set switch is ON

14.
Initial setting is made when initial set switch is OFF
0
20-142 D275A-2
a
Monit :01
I I
rroubleshootinc
- am
- -
F
.o
3
8
r’
E &z 8
2 _c
0) 2 0
.E s? 2
E i 4 2 E
z _m t
E E ii
-ii
l-0
=
z z
rr
: 5 z
.E
g
.e ‘5
5 E 5 &
-
0
-
0
-
u
-2 -
S
-
UY
3 0 M-l
- - - - - -
0 M-2
- - - - - -
0 M-3
- - - - - -
0 M-4
- - - - - -
3 0 M-5
- - - - - -
0 0 M-6
- - - - - -
0 0 M-7
- - - - - -
0 M-8
- - - - - -
0 M-9
- - - - - -
3 3 0 M-10
- - - - - -
1 3 M-l 1
- - - - - -
1 3 M-12
- - - - - -
3 1 0 M-13
- - - - - -
3 M-14
- - - - - -
D275A-2 20-143
0
M-3 When starting switch is ON (engine stopped), CHECK items show abnormality
(Liquid levels is normal for check items before starting)
t Always connect any disconnected connectors before going on the next step.
a) Abnormality in coolant level 8

/_
l Coolant level monitor flashes
Cause Remedy
After inspedtion
YES Defective coolant level sensor. repair or
1 sensor replace accord-
ing to table
1 of standard
1values
Does coolant 3 YES
Defective monitor module. Replace
level monitor - Is resistance
go Off? yES between CNl
2 - (female) (5) and -
chassis ground less nection in wiring harness
. Connect short
Is resistance than Q-L?
connector to
between CN405 - ~@~e~%$%J$ G%J?LF$F-
CN405 (female). _ (female) Q) and _ * Disconnect \CNl NO
* Turn starting
NO chassis ground less
switch ON.
than lSZ7
Defective contact or discon- After inspec-
* Disconnect CN405. . nection in wiring harness tion, repair
between CN405 (female) (2) or replace
NO
and chassis ground.
2
E M-3 a) Related electrical circuit diagram
6
CN I
CN201 CNIOI CN421

Monitor panel
t t
Down Up F19702211
Coolant level sensor
-
561 FO3177A
3. Connector
20-145
b) Abnormality in engine oil level
l Engine oil level monitor flashes.
h
Cause Remedy
After inspec-
Defective engine oil level
YES tion sensor,
. sensor or defective
repair or
chassis ground. replace accord-
1 ing to table
of standard
Doer engine oil
2 YES VallleS
level monitor go - Is resistance Defective monitor module. REplaCe
off? between CN 1
P (female) (6) and -
- NO chassis ground Defective contact. or discon-
* Ground CN404
(female) (1) to less than la? nection in wiring harness be-
After inspec-
tion, repair
chassis. Disconnect CNl. NO tween CN404 (female) (1) - or replace
* Turn starting CN401 (4) - CN421 (5) - CNl
switch ON. (female) (6).
M-3 b) Related electrical circuit diagram
CN I
Engine oil
level sen*or CN404 CN401 CN421
Monitor panel
1 1
197FO1522
Engine oil level sensor
F19702213
20-146
M-4 Abnormality in preheating m
* When operation of the APS is normal (if it is abnormal, carry out troubleshooting E-6 first.)
a) Preheating monitor does not light UP
Cause
YES
Defective monitor module.
* Turn starting Defective contact, or discon-

switch ON. nection in wiring harness be-
* Turn preheating I tween connector [51 (female)
switch ON. N” (1) - CN361 (female) (13) -
CN2 (female) (5). or defective
bimetal timer.
b) Preheating monitor stays lighted up

‘ES harness between connector
[51 (female) (1) - CN361 (13)
- CN2 (5), or defective
bimetal timer.
off when CN2 is
disconnected?
* Disconnect CN2. Defective monitor module.

NO
M-4 Related electrical circuit diagram
Relay box
CN36l
Check module
I97FO I523
20-147
M-5 When starting switch is ON and engine is started, CAUTION items flash
(When there is no abnormality in the CHECK items or engine)
a) m Charge level flashes
2 YES
YES Is voltage between
_ CNl (4) and
chassis ground Defectlve contact or disconnec-
1 20 -3ov7 tion in wiring harness between Repair or
alternator tekinal R - CN107 - replace
Is voltage between * Start engine. NO CN105 - CNlOl 19)-
alternator * Engine at half battery relay tern&l R - CN122
terminal R and throttle or more.
chassis ground
(1)- CNl (female (4).
20 -_,3OV?
. Start engine.
* Engine at half
throttle or Replace
more. NO
b) +& Engine oil pressure flashes Remedy

After inspec-
tion sensor.
F repair or
YES replace accord-
Defective engine oil pressure
1 I sensor system. ing to table
of standard
YalUeS
Does display go
off when CN403 -
is disconnected?
2 YES
Is resistance
1 Defective monitor module. Replace
between CN 1
* Disconnect CN403.
(female) (7) and -
* Start engine. Wiring harness between CN403
NJ chassis ground
morelthan 1 MA-L? - CN401 (3) - CN421 (4) - Repair or
1 CNl (female) (7) short circuiting replace
* Disconnect CNl. ND
with chassis ground.
* Turn starting
switch OFF.
* Disconnect CN403.
c) 0 Coolant level flashes
-- See M-3 a)
4
$
Coolant temperature flashes r Cause Remedy
After inspec-
2 YES DefectIvecoolant temperatur tion sensor.
se”sor system. repair or
Does display go
YE Ioff when short replace accord
. cOnnectOr Is ing to table
connected tcl of standard
CN402 (female)? V&_VZS
’ Connect short NO Defective monitor module. Replace
connector to
CN402 (female).
* Start engine.
*start
* Engine
engine.
at half
throttle or more.
20-148
Torque converter oil temperature flashes
Sfter inspec-
:ion sensor.
epair or
.eplace accord-
2 YES Defective torque converter
oil temperature sensor ng to table
Does display go system. ,f standard
YES off when short lalues
- connector is
connected to
CN453 (female)7
1 -NO
. Connect short
connectclr to
Is torque converter CN453 (female).
oil temperature _ . Start engine,
gauge within red
range?
* Start engine.
* Engine at half
throttle or more.
jji Defective monitor module.
Hydraulic oil temperature flashes

Cause Remedy
After inspec-
tion sensor,
YES Defective hydraulic oil repair or
1 ’ temperature sensclr system.
replace accord-
Does display go ing to table
off when CN452 of standard
is grounded to 2 YES values
chassis7 Defective monitor module. FlepkX3
Is resistance
P between CNl
. Disconnect
_ (female) (8) and _
CN452, and
ground (fema,ej NO chassis ground Defective contact, or discon-
less than 1 a7 nection in wiring harness be-
(1) to chassis. tween CNl (female) (8) -
* Start engine. * Disconnect CNl. NO CN421 (12) - CN451 (3) -
- Ground CN452
CN452 (female).
to chassis.
* Turn starting
switch OFF.
20-149
M-5 a) Related electrical circuit diagram
CN I
Monitor Alternator
0
module terminal R
Service
F19702215
CNI CN421 CN401

Engine oil pressure sensor
CN403
Monitor
module
F19702216
If the condition is es shown in the table below, it is normal
Engine oil pressure 0.5 kg/cm2 or above No continuity
I Engine oil pressure below 0.5 kg/cm’ Continuity I
M-5 d) Related electrical circuit diagram
CN2 CN42 I CN401 CN 402 Coolant temperature

sensor
Monitor
module
F19702217
If the condition is es shown in the table below,

it is normal
Coolant temperature sensor
IILL
F19702218
M-5 e) Related electrical circuit diagram
Torque converter
CNOFjl CN453 nil +amn0rs+,,m ..,%“r.-.v
Monitor
module
F19702219
If the condition is as shown in the table below,
it is normal.
M-5 fl Rerated electrical circuit diagram
Hydraulic oil
CNI CN421 CN451 CN452 temperature sensor
Monitor 3
F
7TJT
198FO2242
I 2 4
U w-71
SAD01536
1. Switch
2. Case
3. Wire
4. Connector
D275A-2 20-151
0
g) Electronic system abnormality flashes
Cause I3emedy
F:ailure in shoe slip controller

-( 20 to Troubleshooting for G. -
FvlODE
YES
-c )efective monitor module
Is voltage
tween CNI (9)
2i/
be-
and (2) 0 - 1 V?
t Fleplace
-C Iefective shoe slip controller
CDefective contact or discon

r section in wiring harness be- Ftepair 01
* Connect NO r ween CNI (female) (9) andI replace
T-adapter to C:NSS2 (female) (II)
CNSS2.
* Short circuit
between CNSS2
(1 I) and (14).
M-5. g) Related electrical circuit diagram
Monitor panel
I-lCNl
I
,
Electronic system
abnormality
CNSSE r
-1
System abnormality
output
GND
GND
_I
197 FO1530
20-151-l D275A-2
0
M-6 Abnormality in buzzer
* Of the CAUTION items, the buzzer will not sound if there is an adnormality in the charge level.
a) CAUTION items are flashing, but buzzer does not sound.
1 YES
Defective monitor module. ReplaCe
Does buzzer
sound when CN2

tree” CN454 (male) (1) -
NO CN465 - buzzer - CN466 -
CN2 (female) (EL or defective
chassis. buzzer.
* Turn starting
switch ON.
b) No abnormal display is given on monitor, but buzzer sound.

Cause Remedy
I
1 YES
Does buzzer stop

when CN2 is
removed?
Wiring harness betwee” CN2
(female) (8) and CN466 Repair or
- Remove CN2. ON short circuiting with chassis replace
* Turn starting ground, or defective buzzer.
switch ON.
Monitor supplementary
cO”trOller
+24V
#
I
I I
CN464
CN465
( 1
Buzzer
CN466
Monitor
module
CN2 F91702220
20-152
M-7 Abnormality in warning lamp
a) CAUTION items are flashing, but lamps do not flash.

* Check visually to confirm that there is no disconnection
in the lamp. (If the lamp bulb is blown, replace the bulb.)
Remedy
1 YES
Does lamp light
up when CN2
(female) (7) is _
connected to Defective contact or discon-
chassis ground? nection in wiring harness
between CN2 (female) (7)
’ Ground CN2 NO - CN364 (2 - CN371 (2)
(female) (7) to -CN372 (2 1*(l) - CN371
chassis. (1) - CN364 (1) - CN464.
* Turn starting
switch ON.
8
5 b) No abnormal display is given on monitor, but lamp lights up
6

I
Does lamp go out
when CN2 is
removed?
Wiring harness between CN2
(female) (7) - CN364 (2) - Repair or
* Remove CN2. NO CN371 (2) - CN372 (2) rePlaCe
short circuiting with chassis
’ Turn starting
ground, or defective lamp.
switch ON.

with cab
_-___-,
CN372
Caution
Lamp
198FO2270
20-153
M-8 Abnormality in gauge
a) Abnormality in coolant temperature gauge

l Engine coolant temperature gauge shows abnormally low temperature.
Cause Remedy
After inspec-
tion sensor,
repair or
replace accord-
1 YES Defectwe coolant
H
ing to table
temperature sensor system
DOBS temperat”re of standard
display go off when values
Short COnnectOr IS Defective contact or discon-
connected to CN4027
between CN402 (female)
(1) - CN401 (1) - CN421 Repair or
* Connect Short NO (1) - CN2 (female) (11, Or replace
connector to CN402 between CN402 (female) (2)
Ifemalel. - CN401 .~.
(21 - CN421 (2)
-chassis ground.
* Turn start!ng switch ON.
l Engine coolant temperature is not displayed
Cause Remedy
I ifter inspec-
t ion sensor.
r epair or
1 YES Defective coolant I eplace accord-
temperature sensor system.
i ng to table
Ic)f standard
\/alues
CN402 (female) (I) - Repair or
CN401 (1) -CN421 (1) - replace
* Disconnect NO CN2 (female) (1) short
connector of circuiting with chassis ground.
CN402 (female).
* Turn starting
switch ON.
M-8 a) Related electrical circuit diagram
CN2 CN421 CN401 CN402

Coolant temperature sensor
198FO2239
If the condition is as shown in the table below,
it is normal
F19’702218
20-154
b) Abnormality in torque converter oil temperature gauge
l Torque converter oil temperature gauge shows abnormally
low temperature.
After ~nspec-
tion sensor.
repair or
replace accord-
1 YES Defective torque converter ,ng to table
oil temperature sensor
Does temperature wstern. of standard
display go off values
when short
connector is con- Defective contact or dixon-
nected to CN4537 Repair or
between CN453 (female) (1)
replaCe
-CN451 (1) - CN421 (8)
* Connect short NO -CN2 (female) (2). or
connector to I between CN453 (2) - CN451
CN453 (female). (2) - CN421 (2) -chassis
* Turn starting ground.
switch ON.
0 Torque converter oil temperature is not displayed.

Cause Remedy
lfter inspec-
:ion sensor,
xpair or
1 YES Defective torque converter replace accord-
oil temperature sensor ng to table
Does temperature system. ,f standard
gauge display ralu?S
appear when
CN453 is Wiring harness between
removed? CN453 female) (1) -
CN451 I 1) - CN421 (8) -
- Disconnect NO CN2 (female) (2) short
connector of circuiting with chassis
CN453 (female). ground.
* Turn starting
switch ON.
Torque converter
CN2 CN421 CN451 CN453 oil temperature sensor
Monitor
module
F19702221
If the condition is es shown in the table below,
it is normal.
Oil temperature
58”SOT
F19702218
20-155
c) Abnormality in fuel level gauge
l Fuel gauge always displays FULL.
Cause Remedy
After inspec-
tion sensor,
repair or
YES replace accord-
Defective fuel level sens0r
1’ system. ing to table
of standard
Does fuel gauge VIIUBS
display go off? - 2 YES Repair or
_.. .-. ,., replace
(3) short circuiting.with
. Remove CN423 chassis ground.
Does fuel gauge
(fuel level N< display go off? -
SWWX).
* Turn starting
switch ON. Defective monitor module. Replace
* Remove CN2 NO
* Wait for approx.
1 min. *ITurn stamng switch ON.
* Waltforapprox. 1ml”
0 Fuel level is not displayed.

Cause Remedy
After inspec-
tion sensor.
YES
ia
repair or
Defective fuel level sensor
replace accord-
r
svstem.
ing to table
of standard
Is FULL display ValUeS
given7 2 YES
Defective monitor module. ReplaCe
Is resistance
- between CN2
* Remove CN423 I (female) (3) and -
(fuel level NO chassis ground Defective contact or discon-
SellSOr). less than 15-Z? nection in wiring harness Repair or
. Connect short between CN423 replace
(female) (1)
connector. . Connectshort NO -CN422 (1) - CN421 (7)
* Turn starting COnnectOr to -CN2 (female) (3).
switch ON. CN423 (female)
(1) (2).
M-8 c) Related electrical circuit diagram
CN2 CN421 CN422 CN423

Monitor Fuel level
module sensor
F19702222
Level sensor
F19702223
20-156
M-9 Service meter does not move after engine is started
Cause Remedy
YES
See M-5 a) -
1
Does charge
abnormality -
display flash? 2 YES
Defective service meter. REplfdCe
Is voltage between
* Start engine.
- CN3 (1) and (4) -
NO 20-3OV?
Defective contact or dircon-
nectlon in wiring harness Repair or
beNyya CN122 (I) and replace
’ start engine. NO
M-S Related electrical circuit diagram
CN I
Monitor Alternator
module T 0 terminal R
CN3
Batteryrelay
Service
meter F91702224
20-l 57
M-10 Panel lighting for monitor panel does not light up (Liquid crystal display is
normal)
l Check visually to confirm that there is no disconnection in the lamp. (If the lamp bulb is blown, replace the bulb.)
l \hE.henfuses No. 5 is normal
(If fuse is blown, check for short circuit between CN361 (female) (8) - CN4 (11, CN5 (1)).
Cause Remedy

1 YES nection in wiring harness be-
tween CN4 (1) and CN361 (8).
Is voltage between or between CN5 (1) and CN361
CN361 (8) and _ (6).
chasis ground
20 - 3OV?
1;
jee E-7,
* Turn starting NO
switch ON.
M-l 0 Related electrical circuit diagram.
Relay box
CN4 CN361
8
Monitor --F
module
H.H. working
Fuse 6
CN5
F91702225
20-158
M-II After starting switch is turned ON, display LED does not light up even when
mode selection switch is pressed
a) Does not light up for any switch
l When monitor panel display is normal (if it is abnormal, go to M-1)
Cause Remedy
Defective mode selection

Replace
switch module
Is voltage
be-
tween CNSOl
(female) (1) and
nection in wiring harness be- Repair or
tween CN464 (1) - CNSOl (fe- replace
* ConnectT- NO
male) (I), or between CN464
adapter to (4) - CNSOI (2)
CNSOI (female).
- Turn starting
switch ON.
b) Does not light up for some switches

(Note that the rockbed mode switch does not work when the shoe slip control is OFF.)
Cause IRemedy
M-l 1. Related electrical circuit diagram
CNSO I CN464
Iefective
,
mode
witch module
Sub controller
+24V output
selection
IFleplace
Switch
,module
GND
CNI
Monitor
module
197FOl535
D275A-2 20-159
0
M-12 LED on panel is normal, but there is no output from mode selection switch
module
Cause Remedy
After
One of signal wires below is
inspection,
in contact with +24V (check
repair or
all wires)
replace
M-12. Related electrical circuit diagram
CNSOI CNSS2
Mode selection
switch module
I98FO225 I
20- 160 D275A-2

0
M-13 LED on mode selection switch panel does not flash when lighting switch is ON
Cause I3emedy
2 YES Defective mode selection

Is voltage be- switch module ’ Fleplace
YI tween CNSOl
1 - (female) (IO) and - Defective contact or discon
(2) 20 - 30 VI nection in wiring harness be FIepair 01
* Connect T- NO tween CNSOI (female) (1011 r eplace
adapter to and CN361 (8)
CNSOI (female).
* Turn starting switch ON.
. Check visually. Go to M-10 -
IO
CNSOI CN361
Relay box
Switch module
CNSOP
Bulb for mode

lighting
Bulb for monitor panel

lighting
Bulb for service meter

lighting
197FO1536
D275A-2 20-161
0
M-14 Defective initial setting
a) Initialsetting cannot be made when initial set switch is ON
Cause Remedy
1 YES jefective mode selection

ieplace
witch module
Is there continuity
between CNSOI _
jefective contact or discon-
Eyale) (11) and
section in wiring harness be. lepair or
ween CNSOl (11) -CNSOS(lI eplace
* Turn starting NO initial set switch - CNSOS (21
switch OFF. chassis ground
- ConnectT-
adapter to
CNSOI (female).
* Turn initial set
switch ON.
b) initial setting is made when initial set switch is OFF

Contact of chassis ground
1 YES tih wiring harness between iepair or
:NSOl (11) - CNSOS (1) - ini- eplace
Is there continuity
between CNSOl al set switch
(female) (11) and -
(2P Iefective mode selection
teplace
- Turn starting NO witch module
switch OFF.
* Connect T-
adapter to
CNSOl (female).
* Turn initial set
switch OFF.
CNSOI CNSOS
module Initial set switch
198FO2253
20-162 D275A-2
0
TROUBLESHOOTING OF SHOE SLIP CONTROLLER,
ELPC CONTROLLER SYSTEM
(G MODE)
Shoe slip
controller
ELPC
controller
Display when normal d (> : Rapid flashing (5 times/set)
.20-202
G-l
I65 I [Abnormality in engine] is displayed.. .....................................................
G-2 [Abnormality in acceleration sensor power source] is displayed ........ 20-203
G-3 [Abnormality in torque converter speed sensor] is displayed ............. 20-204
G-4 [Abnormality in engine speed sensor] is displayed.. ............................. 20-205
[Abnormality in economy mode selection] is displayed ....................... 20-206
[Abnormality in control mode selection] is displayed .......................... 20-207
G-7 [Abnormality in acceleration sensor] is displayed ................................. 20-208
[Abnormality in ripping mode selection] is displayed .......................... 20-209
G-9 [Abnormality in ELPC controller] is displayed.. ...................................... 20-210
GmYebwFW
G-10
L-J
l ee
GCSlYedmREd
[Abnormality in sensor power source] is displayed .............................. 20-211
G-II
GMllW
L-J
l oe
GmYekwRxl
[Abnormality in feedback potentiometer] is displayed ......................... 20-212
G-12
cl I I
de ooe
GlWlY&WR&
[Abnormality in input potentiometer] is displayed ............................... 20-213
G-13
I-- l eo
GmYdb.vFkd
[Abnormality in shoe slip control command] is displayed ................... 20-214
G-14
Ioeo I [Disconnection, short circuit in solenoid system] is displayed ............ 20-215
G-15 [Abnormality in shoe slip controller] is displayed ................................. 20-216
G-16
u L-l
Green Red
00
GCBlY&.VW
000
[Abnormality in power source] is displayed.. ......................................... 20-217
D275A-2 20-201
a
GCBlRed
G-l
I I
5 6 [Abnormality in engine] is displayed
Cause Remedy
Carry out troubleshooting ac-

1 YES -
cording to abnormality dis-
Is ELPC control- play on ELPC controller
ler giving abnor- -
mality display? Mechanical failure between Repair or
ELPC valve - link system - gov- replace
NO
ernor system
20-202 0275A-2
0
G-2 ‘zz [Abnormality in acceleration sensor power source] is displayed
u
Cause Remedy
2 YES
Defective controller Replace
YES Is same abnor-
- mality display -
1 given again?
Is voltage be- * Turn starting NO
tween CNSSI (11) - witch ON.
and(10)7-9V?
3 YES
Defective acceleration sensor Replace
* Turn starting
Is voltage be-
switch ON.
- tween CNSSB (I) - Short circuit with ground OI
NO and (3) 7 - 9 V? short circuit in wiring harness
Repair or
between CNSSI (IO) - CNSOE
* Turn starting NO replace
(6) - CNSIO (I) - CNSS3 (I),
switch ON.
or contact with other wiring
harness
G-2. Related electrical circuit diagram
Shoe slip controller
ration
Acceleration sensor (8V)
Acceleration sensor (signal)
Acceleration se
I_
197FOl518
D275A-2 20-203
a
Green
0
R&d
G-3 . 5 [Abnormality in torque converter speed sensor] is displayed
Cause Remedy
3 YES
Defective controller Replace
vfHu--
2
Is resistance be-
1again?
I INO System has been reset -
YES tween CNSSl he- _ * Start engine. Defective contact, disconnec-
male) (8) and chas- -I tion, or short circuit with ground
1 sis min. 1 MQ? NO in wiring harness between
Is resistance be- YES CNSSI (1) - CNSO6 (I) - CN461 Repair or
* Turn starting
tween CNSSI _ (5) - CN651 (2). or between replace
switch OFF. CNSSl (8) - CNSO6 (4) - CN461
(female) (I) and YES
(8) 480 - 1,000 M (4) - CN651 (1). or short circuit
4 with other wiring harness
* Turn starting Is resistance be- Defective speed sensor Replace
switch OFF. tweet CNfEl (male) _
~0 (2) and (1) 480 -
l.oxrR?
* Turn starting Defective speed sensor Replace
switch OFF. NO
I Torque converter speed t-) Torque converter

speed sensor
Torque converter speed (+)
I98FO2255
20-204 D275A-2
0
G-4
uGreen
O 5
Red
[Abnormality
Sr Before carrying out troubleshooting,

in engine speed sensor] is displayed
check that all the related connectors are properly inserted.

j, Always connect any disconnected connectors before going on the next step.
Cause Remedy
3 YES
Defective controller qeplace
I I I

Defective contact, disconnec-
tion, or short circurt with ground
in wiring harness between
5 YES CNSSI (2) - CNSO5 (2) - CNSIO Repair or
* Turn starring 1 I- I I
tween CNSSI 15) - CNSM5 (21, or between replace
switch OFF.-
(female) (2) and CNSSI (9) - (4) - CNSO5 (5) -
YES CNSIO (4) - CNSM5 (I), or short
4I i-
circuit with other wiring harness
I.
. Turn starting
Defective speed sensor 3eplace
switch OFF. * Turn starting NO
* ConnectT- switch OFF.
adapter to
CNSSl.
* Turn starting Defective speed sensor Replace
switch OFF. NO
Engine speed
sensor
197FO1537
D275A-2 20-205
0
G-5 [ 6 6 1 [Abnormality in economy mode selection] is displayed
Cause Remedy
YES Defective shoe slip mode set-

Replace
ting panel
3 YES
. Turn starting l- s/j-

tween CNSS2 switch ON. NO
(female) (2)(3) - System has been reset -
NO
* Turn starting
Short circuit between chassis
switch OFF.
I and wiring harness with de- Repair or
* Disconnect
NO fective resistance, or contact replace
CNSOI.
with other wiring harness
r-7
Shoe slip controller Mode selection panel switch
CNSSE
I
Economy mode B Economy mode IB ’
1
Economy mode A Economy mode A
197FO1538
20-206 D275A-2
0
q
GreenRed
G-6 Q d [Abnormality in control mode selection] is displayed
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Remedy

VI
1 Defective shoe slip mode set Replace

switch ON. NO :ing panel
* Turn lock-up
tween CNSS2 We switch OFF.
male)(2) (3) (15) (17) . Turn economy
mode OFF.
* Turn shoe slip
* Disconnect control OFF.
CNSOI. - Turn REVERSE Short circuit with chassis ir
slow OFF. Niring harness with defective Repair or
. Turn starting
switch ON. NO resistance, or contact witt replace
zther wiring harness
Shoe slip controller Mode selection panel switch
I-I
Economy mode B Economy mode ,B
Economy mode A Economy mode #A
,Shoe slip control switch Shoe slip control switch
Reverse slow Reverse slow
Lock-up switch Lock-up switch
GND
197FO1539
D275A-2 20-207
a
Green
L-l
Ped
G-7 l 6 [Abnormality in acceleration sensor] is displayed
Cause 3emedy
2 YES
3efective shoe slip controller leplace
Is abnormality
YE
display given
again?
NO
5 YES
Defective acceleration sensor Ieplace
Is resistance be-
CNSSl (12) and YE6 tween CNSS3 ffe- _ Short circuit, defective contact,
4- male) (2) and or disconnection in wiring har-
- CNSS3 (3) 4.7 KQ? ness between CNSSl (11) and iepair or
* Turn starting YES Is voltage be- _ - CNSSJ (3). or between CNSSl eplace
switch ON. _ tween CNSS3 (2j _ * Turn starting NO (12) and CNSS3 (2). or contact
* Set machine switch OFF. with other wiring harness
and chassis 0 V7
horizontal. 3
- Connect Wring harness between fepair or
. Check that 3NSSl (12) and CNSS3 (2) in
Is voltage be- T-adapter to NO eplace
acceleration :ontact with other wiring har-
meen CNSS3(1) - CNSS3 (female).
sensor is N * Turn starting less
and (3) 7 - 9 V7
properly ~ switch ON.
6 YES defective contact, disconnec lepair or
installed. * Turn starting :ion, or short circuit in wiring eplace
switch ON. Is resistance be narness between CNSSI (101
tween CNSS3 (fe _ snd CNSS3 (I)
~5 male) (3) and chas-
sis less than 1 R? Defective contact or discon- sepair or
nection in wiring harness be
eplace
* Turn starting NO tween CNSSI (11) and
switch OFF. CNSS3 (3)
r-7
CNSS I CNSOG CNSIO CNSS3
I A.::Fatic
Acceleration sensor (SW
Acceleration sensor (signal)
Acceleration sensor (GND)
197FO1518
20-208 D275A-2
a
G-8
*
u GreenRed
0 6 [Abnormality in ripping mode selection] is displayed
Ir Always connect any disconnected connectors before going on the next step.
Cause 3emedy
2 YES
Iefective shoe slip controller ieplace
YE Does abnormal-
iw appear again?
NO
1
. Is voltage E
between CNSSl YES 3efective shoe slip mode set-
0”;;” (11) 0.6 - Is resrstance oe- :ing panel teplace
tween CNSSl He
. Is v&age YES male) (6) and (11). _
or ix+ween CNSSZ Short circuit with chassis or shon
between CNSSS YES 4-
(15) and (14) (female) (15) and :ircuit with other wiring harness
Is voltage between c n wiring harness between lepair or
7 lessthan lV? (14) min. 1 MCI?
:NSSl (6) - CNSOl (9). or be eplace
CNSSI (6) and (II), _ NO
- TschtaaFg Is resistance be- or between CNSS2 * Turn starting ween CNSS2 (15) - CNSOI (7)
tween CNSSI (fe- (15) and (14) 0 V? switch OFF.
. Turn shceslip male) (6) and - * Disconnect CNSOI. Short circuit with other wiring
control switch ON. * Disconnect 3epair or
CNSOl (female) ,amess in wiring harness be.
* Select mode I- 5. (9). or between CNSOI. Nveen CNSSl (6) - CNSOl (9). OI ,eplace
NO
N CNSSZ (female) * Turn starting oetween CNSSZ (15) - CNSOl VI
(15) and CNSOl switch ON.
Defective contact or discon tepair or
nection in wiring harness witt eplace
NO defective resistance

_- Mode selection panel switch
I-I
Shoe slip control switch
GND Shoe slip control switch r
Rockbed selection mode
Rockbed selection mode
Acceleration sensor
I (GND) -l- *
I_L
197FO1540
D275A-2 20-209
0
G-9 m ,m [Abnormality in ELPC controller] is displayed
YES
Go to other than G-9 -
I
1 I
El-iL
Is shoe slip con-
troller giving ab
nonalii display?
* Turn starting
switch ON.
NO
- tween CNSSI (4)
NO
3efective shoe slip controller
Disconnection, short circuit in

seplace
and(ll)2-3V? 3 ND tepair or
wiring harness between
eplace
* Turn starting Is voltage between CNSSl (4) and CNSMl (21)
switch ON. - CNSMI (21) and -
YES (12)2-3V?
. Defective ELPC controller teplace
* Turn starting YES
switch ON. -
jCNSS2
I Acceleration
sensor (GND)
- I
ELPC controller
-
ICNSSI
Warning output
20-210 D275A-2
0
G-10 E/, PI [Abnormality in sensor power source] is displayed
j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause 3emedy
Defective ELPC controller Fieplace
tween each pin -

System has been reset
* CNSMl i-I, - (18):
. CNSMl(6) - (16): Defective wiring harness ir

YES
system with defective resist
’ FIepair or
. CNSMl (71 (6) - replace
chassis: Min. 1 ante
Defective potentiometer in
* Turn starting
switch OFF.
system with defective resist- FIeplace
NO ance
* CNSMI female
sis: Min.‘1 MR?
- Turn starting
switch OFF.
. CNSM4 male
* CNSM2 male
G-10, G-II, G-12. Related electrical circuit diagram
CN421
Input
potentiometer 1-l
ack potentiometer
potentiometer
FeedbacktSig’
potentiometer H
4
17MF02181
D275A-2 20-211
a
G-II El, r] [Abnormality in feedback potentiometer] is displayed
Cause temedy
4 YES
Iefactive ELPC controller leplace
G[

eacn pm normaIr NO
2u
I
- CNSMl (7) - (18):
Is resistance be-
I 4-6M 5
r
defective wiring harness in
tween._each pin I
I
* CNSh4lV7)-cha+
sis Min. 1 MQ? I
I tween each pin nor- system with defective resist-
ance
lepair or
eplace
1
Is resistance be-
tween each pin -I 3efective input potentiometer leplace
normal? ,
. CNSMP (1) - (3): - Turn starting
11 kQ switch OFF.
* CNSM2 (I) - (2): * CNSX4 male IIefectivewiring harness in
iepair or
system with defective resist-
* Turn starting eplace
. &%M2 (2) - (3): NIO 3nce
switch OFF.
* CNSMl female
Idefective feedback potenti- leplace
r>meter
NO
* Turn starting
switch OFF.
. CNSM2 male
20-212 D275A-2
0
G-12 El, I”,‘;;“,“/ [Abnormality in input potentiometer] is displayed
Cause 3emedy
4 YES
mr Defective ELPC controller leplace

NO
2
IIs resistance be-
Defective wiring harness in
i iepair or
system with defective resist-
eplace
once
* Turn starting * CNSM2 (I) - (3):
switch OFF.
Defective feedback potenti-
ieplace
ometer
* CNSM4 (1) - (3):

. CNSX4 male Defective wiring harness in
{epair or
;ystem with defective resist-
* Turn starting ,eplace
N once
switch OFF.
. CNSMI female
3efective input potentiometer leplace

* Turn starting
switch OFF.
- CNSM4 male
D275A-2 20-213
0
3%3lY&Wl?&
G-13 16.1, l l O [Abnormality in shoe slip control command] is displayed
Ir The battery voltage should be 20 - 30 V.

* The ELPC voltage between CNSMI (I) and (12) should be 20 - 30 V.
Cause qemedy
YES
1
Defective ELPC controller ?eplace
VI
n NO
L Defective contact, disconnec-

1 3epair or
* Turn starting tion, or short circuit in wiring
switch ON. NO harness between CNSSI (131 eplace
tween CNSSl and CNSMI (9)
(13) and (11) 0.9
4 YES
* Turn starting Defective shoe slip controller seplace
switch ON. Does abnormality
ND appear again?

NO
Shoe slip controller ELPC controller
Sensor GND
SSC command
Acceleration sensor (GND)
SSC command
20-214 0275A-2
0
G-14 El, m [Disconnection, short circuit in solenoid system] is displayed
* If there is a short circuit or disconnection when engine is running:

1) Engine speed rises, then becomes manual operation.
2) Engine does not stop.
Ir When engine is stopped:
1) Engine starts but becomes manual operation.
_ 2) Engine does not stop.
AStop the engine. (push the fuel lever of the fuel injection pump to the NO INJECTION position.)
before carrying out the inspection.
Cause qemedy
2
Is resistance- be- 3YES >efective ELPC controller 3eplace
tween each pin of
, YES CNSMl (female)
I- and between each - Disconnection in wiring har-
pin and chassis as less of applicable pin No.
CNSMI - CNS08 - CNSIO -
:NSM3}
Defective solenoid
* Disconnect
CNSMB.
CNSMI CNSIO CNSM3

ELPC solenoid
ELPC controller
17MF02182
Table 1
pi
D275A-2 20-215
0
q
Green
Red
G-15 l l [Abnormality in shoe slip controller] is displayed
* The battery voltage should be 20 - 30 V.

* Check that fuse No. 4 is normal.
If it is blown, repair or replace the wiring harness between CNSS2 (13) - CNSMI (1 j(2) - CN361 (1 I).
Cause Remedy
2 YES
YES YES Does abnormal-

.kY appear again?
1 4
Is voltage be- Is resistance be- NO
tween CNSSP YES tween CNSS2 0% _
male) (14)anddms- Defective contact or discon-
(13) and (14) 20 - -
sislessthan 1M nection in wiring harness be Repair or
30 v? 3
tween CNSSP (14) - CN122 (61 replace
. Turn starting
Is voltage be- * Turn starting NO - chassis ground
tween CNSS.2 _ switch OFF.
switch ON.
NO :b”’ ;gndWyhassls Defective contact or discon
5 YES nection in wiring harness be Repair or
tween CNSS2 (13) - CNSMl replace
* Turn starting 1 (1X2) - CN361 (II)
switch ON.
nection in wiring harness be Replace
tween fuse No. 4 inlet ant
* Turn starting No
battery terminal (+I
switch ON.
Shoe slip controller Relav box

.-
Power source
CNSSZ jjFF
i @ 7
(24V)
GND 4
I
I
L_ 1 Battery
ELPC controller I
I Starting switch
17MF02183
20-216 D275A-2
0
[Abnormality in power source] is displayed
* Check that fuses No. 1 and 4 are normal.

If they are blown, short the wiring harness between fuse No. 4 - CN361 (11) - CNSS2 (13) - CNSMI
(I I,(2).
It The battery voltage should be 20 - 30 V.
I Cause Remedy
Is voitage between Replace

CNSSZ (13) - (14).
CNSMI (l)(2) - (12)
Repair or
* Turn starting
replace
switch ON.
* Turn starting
Y
-1 LtEZe battery relay
Repair or
replace

‘ES Repair or
tween starting switch BR -
5 CN161 (2) - CN122 (5) - bat- replace
1Is voltage be- tery relay BR
. Turn starting tween starting _ --i
switch ON. 6 YES
- Defective starting switch Replace
. Is voltage be-
. Turn starting _ tweenCN361(1) _
switch ON. NO and chassis 20 - Defective contact or discon-
30 W _ nection in wiring harness be Repair or
ND tween CN161 (1) - CN361 (1) - replace
fuse No. 1
Shoe slip,controller Relay box

--- --
CN361
Fuse
CNSSP
Power source
-@4d) @ =
GND
@--- 1
__I
ELPC controller
1 ,I
I
Starting switch
Power source
(24W Sub controller
GND
17MF02103
D275A-2 20-217
0
30 DISASSEMBLY AND ASSEMBLY
Method of using manual ............................ .30- 3 ENGINE

Precautions when carrying out operation . . 30- 4 Removal .................................................. 30-32
Special tool list ............................................. 30- 6 Installation .............................................. 30-34
STARTING MOTOR DAMPER
Removal. ................................................. 30-13 Removal .................................................. 30-35
Installation .............................................. 30-13 Installation .............................................. 30-36
ALTERNATOR Disassembly .......................................... .30-37
Removal ................................................. .30-l 4 Assembly ................................................ 30-38
Installation ............................................. .30-l 4 POWER TRAIN UNIT
ENGINE OIL COOLER Removal .................................................. 30-40
Removal .................................................. 30-15 Installation .............................................. 30-42
Installation ............................................. .30-15 Disconnection ......................................... 30-43
TORQUE CONVERTER OIL COOLER Connection ............................................. 30-45
Removal ................................................. .30-16 PTO, TORQUE CONVERTER
z Installation .............................................. 30-16 Disconnection ........................................ .30-46
FUEL INJECTION PUMP Connection ............................................. 30-47
Removal ................................................. .30-17 TORQUE CONVERTER
Installation .............................................. 30-17 Disassembly ........................................... 30-48
WATER PUMP Assembly ............................................... .30-53
Removal .................................................. 30-18 PTO
TURBOCHARGER Assembly ................................................ 30-63
Removal .................................................. 30-19 TORQFLOW TRANSMISSION
Installation ............................................. .30-19 Disassembly ........................................... 30-68
NOZZLE HOLDER Assembly ................................................ 30-78
Removal ................................................. .30-20 STEERING CASE
CYLINDER HEAD Assembly ............................................... .30-94
Removal ................................................. .30-2 1 STEERING CLUTCH, BRAKE
Installation .............................................. 30-25 Disassembly ........................................ .30-100
FUEL TANK Assembly ............................................. .30-104
Removal ................................................. .30-26 TRANSFER GEAR HOUSING
Installation .............................................. 30-26 Disassembly ........................................ .30-108
RADIATOR AND FRONT GUARD Assembly ............................................. .30-l 10
Turning over.. ........................................ .30-27 TORQUE CONVERTER VALVE
Installation ............................................. .30-27 Removal ............................................... .30-l 12
RADIATOR Installation .......................................... ..30-112
Removal ................................................. .30-28 Disassembly ......................................... 30-I 14
Installation .............................................. 30-28 Assembly ............................................. .30-l 16
RADIATOR GUARD TRANSMISSION CONTROL VALVE
Removal .................................................. 30-29 Removal ............................................... .30-l 17
Installation ............................................. .30-31 Installation .......................................... ..30-117
Disassembly ....................................... ..30-118
Assembly ............................................. .30-l 19
30-l
@
STEERING CONTROL VALVE PIVOT SHAFT
Removal ................................................ 30-120 Removal ................................................ 30-195
Installation ............................................ 30-120 Installation ............................................ 30-195
Disassembly ........................................ .30-122 EQUALIZER BAR
Assembly .............................................. 30-I 22 Removal ................................................ 30-196
SCAVENGING PUMP Installation ............................................ 30-198
Removal ................................................ 30-124 EQUALIZER BAR SIDE BUSHING
Installation ............................................ 30-124 Removal ................................................ 30-199
POWER TRAIN PUMP Installation ............................................ 30-200
Removal ................................................ 30-125 SUSPENSION CUSHION
FINAL DRIVE Installation ............................................ 30-20 1
Removal ................................................ 30-126 SEGMENT TOOTH
Disassembly ......................................... 30-I 28 Installation ............................................ 30-202
Assembly .............................................. 30-136 HYDRAULIC PUMP
TRACK FRAME Removal ................................................ 30-203
Removal ................................................ 30-148 Installation ........................................... .30-203
Installation ............................................ 30-148 BLADE LIFT VALVE
IDLER YOKE Removal ................................................ 30-204
Reinoval ............................................ .30-148-l Installation ............................................ 30-204
Installation ........................................ .30-148-2 Disassembly ......................................... 30-206
RECOIL SPRING Assembly .............................................. 30-208
Removal.. .............................................. 30-149 BLADE TILT, RIPPER LOW VALVE
Installation ........................................ .30-150-3 Removal .... _........................................... 30-210
Disassembly ...................................... 30-150-4 Installation ............................................ 30-2 10
Assembly ........................................... 30-150-4 Disassembly ......................................... 30-212
IDLER Assembly .............................................. 30-214
Removal ................................................ 30-152 RIPPER HIGH VALVE
Installation ............................................ 30-152 Removal ................................................ 30-216 z
Disassembly ........................................ .30-153 Installation ............................................ 30-216
Assembly .............................................. 30-154 Disassembly ......................................... 30-218
TRACK ROLLER Assembly .............................................. 30-220
Removal.. .............................................. 30-156 BLADE LIFT CYLINDER
Disassembly ......................................... 30-157 Installation ............................................ 30-222
Assembly .............................................. 30-158 BLADE TILT CYLINDER
CARRIER ROLLER Removal ................................................ 30-223
Removal ................................................ 30-I 59 Installation ............................................ 30-223
Installation ............................................. 30-159 RIPPER LIFT CYLINDER
Disassembly ......................................... 30-160 Removal ................................................ 30-224
Assembly .............................................. 30-161 Installation ............................................ 30-224
TRACK SHOE RIPPER TILT CYLINDER
Removal ................................................ 30-163 Removal ................................................ 30-225
Installation ........................................ .30-l 63-2 Installation ............................................ 30-225
Overall disassembly ........................... .30-164 HYDRAULIC CYLINDER
Overall assembly ................................ .30-169 Disassembly ......................................... 30-226
Press-fitting jig dimension table Assembly .............................................. 30-228
for link press .................................. 30-184 WORK EQUIPMENT
Field disassembly of one link ............. 30-185 Removal ............................................... .30-231
Field assembly of one link.. ............... .30-187 Installation ............................................ 30-232
Disassembly of master link ............... .30-189 Disassembly ........................................ .30-233
Assembly of master link .................... .30-191 Assembly .............................................. 30-235
PIVOT SHAFT TWISTING SEAL RIPPER
Removal ................................................ 30-194 Disassembly ......................................... 30-236
Installation ............................................ 30-194 Assembly .............................................. 30-237
30-2
0
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given for
the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked m, and the same
mark is olaced after the relevant step in the removal procedure to indicate which step in the installa-
tion procedure it applies to.
(Example)
REMOVAL OF 0 0 0 ASSEMBLY . . . . . . . . . Title of operation
A .................................. operation
Precautions related to safety when carrying out the
1. xxxx (1) ........................... Step in operation

* ................................ Technique or important point to remember when re-
moving XXXX (1).
2. A A A (2): . . . . . .._................ m Indicates that a technique is listed for use
during installation
3. 0 Cl q 0 assembly (3)
:
n . . . . . . .._...................... See Lubricant and Coolant Table
INSTALLATION OF 0 0 0 ASSEMBLY .... Title of operation
l Carry out installation in the reverse order to removal.
m.............................. Technique used during installation
* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Technique or important point to remember when in-
stalling A A A (2).
l Adding water, oil . . . . . . . . . . . . . . . . . . Step in operation
* .............................. Point to remember when adding water or oil
Q .......................... Quantity of filling oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are
given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precau-
tions when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (A,, etc.) that appear in the
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
0
PRECAUTIONS WHEN CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.

. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors
. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws alternately.
l Befor removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
* Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end)
Plug (nut end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 0737650422 07221-20422 (Nut), 07222-00414 (Plug)
05 ] 07376-50522 ] 07221-20522 (Nut), 07222-00515 (Plug)
06 1 07376-50628 /07221-20628 (Nut), 07222-00616 (Plug)
10 1 07376-51034 107221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal Sleeve head
Flange (hose end) Split flange
number (tube end)
04 07379-00400 07378-l 0400 07371-30400
05 07379-00500 07378-l 0500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
A
i
n Taper l/8 -0
-a ?a
1 7
L
-
ZOZF2001
2. Precautions for installation operations
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with antifriction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
. When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the
direction of the hook.
. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
* When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 100
mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
* When using the machine for the first time after repair or long storage, follow the same procedure.
$ 3. Precautions when completing the operations

6
. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the
engine to circulate the water through the system. Then check the water level again.
. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
. If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed
for repair, always bleed the air from the system after reassembling the parts.
* For details, see TESTING AND ADJUSTING, Bleeding air.
. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related
parts.
30-5
0
SPECIAL TOOL LIST
Nature of work Symbol Parts No. Part Name Q’ty Remarks
791-654-I 100 Remover 1

Removal of radiator
A 790-I 01-2102 Puller (30 t) 1 Removal of
guard assembly
guard pin
790-I 01-l 102 Pump 1
791-600-I 100 Installer assembly 1
195-12-11210 Plate 1
Installation of IPress-in of
B
dumper Assy 790-I 01-4200 Puller (30t) 1 ,dumper bearing
790-I 01-l 102 Pump 1
Disassembly, assembly 790-413-I 010 Bracket 1

of torque converter IFor overseas
assemblv 790-501-5200 Repair stand 1
790-415-I 011 Bracket 1

IFor overseas
790-501-5200 Repair stand 1
IRemoval of No.5
791-615-I 130 Push tool 1 I:lutch piston
Disassembly, assembly Installment of snap
of TORQFLOW 791-615-I 200 Ring assembly 1
I-ing of No. 4 carrier
transmission
assembly Installment of snap
791-615-1101 Ring assembly 1
I.ing of No. 2 and 3
(3peration check of
799-301-I 600 3il leak tester 1
(:lutch piston
Disassembly and
f3emoval of cluth
assembly of steering 791-622-I 1 IO 3racket 1
kxa ke Ass’y
case Ass’y
790-337-I 032 _ifting tool 1

Removal, installation 791-627-I 210 ‘late 1 fRemovable of final
of final drive F -c drive Ass’y
assembly 791-627-I 320 shackle 2
0101 O-52090 3olt 2

-
791-627-I 400 3emover assembly 1
-r Removal of’
1 790-I 01-2102 Puller (30 t) 1
sprocket bearing
790-I 01-l 102 Pump 1
790-431-1801 Remover assembly 1

Disassembly, assembly 1 IRemoval of
791-627-I 260 Plate
of final drive G 2 Irubber bushing
assembly 790-I 05-I 100 Cylinder (30 t) 1
790-I 01-l 102 Pump 1
791-627-I 600 Remover assembly 1

-1 qemoval, press-
3 790-I 01-2102 Puller (30 t) 1
_I iitting of carrier
790-I 01-l 102 ‘ump 1 Ilin
30-6
Co
Nature of work Symbol 1 Parts No. Part Name W Remarks
791-627-l 200 Remover assembly 1 1 1
4 790-I 01-2102
790-I 01-l 102
Fitting of pinion
5 791-627-I 250 Guide 1
and gear

Press-fittings of
6 790-I 01-2102 Puller (30 t) 1
center bearing
Disassembly, assembly G 790-I 01-l 102 Pump 1
of final drive assembly
Press-in of
7 790-I 01-2102 Puller (30 t) 1
carrier pin
790-I 01-l 102 Pump 1

_ Press-fitting of
8 790-I 01-2102 Puller (30 t) 1
_ sprocket bearing
790-I 01-l 102 Pump 1
z
9 791-627-I 280 Installer
I 1
I Installation of
floating seal
791-630-I 300
2 Removal, installation
6 of recoil spring H 790-I 01-2102
assembly
790-I 01-l 102
791-685-8500
or
790-434-I 700
Disassembly,
I 791-775-I 110 Spacer I 1 I
assembly of recoil
spring assembly 791-635-3160 Extension I 1 I
790-I 01-l 600 Cylinder (70 t) I 1 I
790-I 01-l 102 Pump I 1 I
791-630-I 200
1 790-I 01-2102
790-I 01-l 102
Assembly of front 791-630-I 400

J
idler assembly w hiss-i-zf floating
2 790-I 01-2102
790-I 01-l 102
Installation of
3 791-515-I 520 Installer 1
floating seal
30-7
0
track roller assembl
Assembly of track
roller Ass’y
Disassemby and
assembly of track
roller Ass’y
g
Removal of center ?
z
bar bushing
791-650-I 800 Remover & installer 1

Replacement of equalizer Press-in of side
790-I 01-2102 Puller (30 t) 1
side bushing P - spherical bushing
790-I 01-l 102 Pump 1
790-502-I 003 1
1 Repair stand
790-5&3000 1
790-I 02-3802 Multi wrench 1 Removal of cylinder

2 -
1 head nut
790-I 02-3300 Wrench
Disassembly and Expansion of

0 3 790-720-I 000 Expander 1
piston ring
assembly of hydraulic
cylinder 796-720-I 670 Ring 1 Blade lift _E
1 cylinder
07281-01279 Clamp 5
796-720-I 690 Ring 1 Blade tilt and -z

4 ripper lift %
07281-02169 Clamp 1 cylinder
%
796-720-I 690 Ring 1 ym
Ripper tilt +
07281-01919 1 cylinder
Clamp z
30-8
a
Nature of work Symbol Parts No. Part Name Remarks
Removal of pin plug of

lubricated track link I W
I
791-646-7531
I
Remover
I ’ I
Cleaning of pin of
lubricated truck link
X
I 791-660-7460
I
Brush
I
1
I
For washing pin
Installation of pin plug of Y 791-646-7900 Push tool 1 For lage plug

lubricated track link Z 791-932-I 1 IO Push tool 1 For small plug
Installation of seal of
KA 791-632-I 030 Push tool 1 For F3 type seal
lubricated track link
Air tightness check of

KB 791-601-I 000 Oil pump Ass’y 1
lubricated track link
Filling of lubricated track 791-646-8002 Lubricator 1

KC
link with oil 791-601-I 000 oil pump assembly 1
I I I
790-434-I 1 IO Adapter II I
790-434-l 610 buide I 1 I
1
195-32-61210
0101 O-51 440

Bolt
1Bolt
I I
I
2
2 I
Shoe bolt may be
used
790-101-1102 I Pump I ’ I
2
790-I 01-4300 I Cylinder I 1 1150tons
791-685-9510 I Frame I 1 I
791-685-9520 I Frame I 1 I
791-685-9530 1Rod I 1 I
791-685-9550 1Nut I 1 I
791-685-9560 1Bolt I 4 I
I ’ I
Track link KD 3
remover 790-434-I I 20 I Adapter
0101 O-51 030 1Bolt I 1 I
04530-I 2030 I Eye bolt I 1 I
790-101-1102 I Pump I 1 I
790-I 01-4300 Cylinder 1 150 tons
791-685-9540 Rod 1
4
791-685-9550 Nut 2
791-685-9510 Frame 1
5
791-685-9520 Frame 1
30-9
0
Nature of work Symbol Parts No. Part Name Remarks
KD
Track link
remover
Track link <E

Installer
30-10
0
Nature ofwork Symbol PartsNo. Part Name Q'ty Remarks
-
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
791-685-9540 Rod 1
791-685-9550 Nut 3
791-685-9560 Bolt 4
791-126-0150 Adapter 1
4
01010-51030 Bolt 1
791-685-9620 1Extension I 1 I
791-680-5550 1Guide I 1 I
790-434-1140 IAdapater I 1 I
791-680-9630 1Adapter I 1 I
790-101-1102 ~Pump I 1 I
790-101-4300
Track link KE 5 790-434-1160

Installer
s1 791-685-9510
E 791-685-9520 Frame
0
791-685-9530
791-685-9540 Rod
791-685-9550 Nut
791-685-9560 Bolt
6 791-126-0150 Adapter
790-434-1150 Guide
790-434-1120 Adapter
01010-51030 Bolt 1 I
790-434-1160 Guide I 1 I
790-101-1102 Pump I 1 I
790-101-4300 Cylinder I 1 1150tons
790-101-1102 Pump 1
7
790-101-4200 Puller 1 30tons
-
30-11
0
Nature of work Symbol Parts No. Part Name o’tv Remarks
KIT
791-680-9801 Remover & installer 1
For lubricated type
Track link
remover & 790-I 01-l 102 Pump 1
KF
installer
790-I 01-4200 Puller 1 30 tons
790-I 01-4300 Cylinder 1 150 tons
30-12
0
REMOVAL OF STARTING MOTOR ASSEMBLY
A Disconnect the cable from the negative

terminal of the battery.
(-)
Disconnect wiring (1) and (2).
Disconnect wiring connector (3).
Remove starting motor assembly (top) (4).
Remove starting motor assembly (bottom)

(5).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
. Carry out installation in the reverse order to
removal.
30-l 3
@
REMOVAL OF ALTERNATOR ASSEMBLY
Serial No. : 10001 - 10167
a- Drsconnect the cable from the negative H ter-

minal of the battery.
1. Disconnect wiring (I 1.
2. Remove adjustment bolt (2).
3. Remove fan belt cover (3).
4. Remove mounting bolt and nut (4).
5. Remove belt (5). a
6. Remove alternator assembly (6).
F19703003
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial No. : 10001 - 10167
l Carry out installation in the reverse order to

removal.
pq
* Adjust the alternator belt tension.
For details, see TESTING AND ADJUSTING.
30-14
@
REMOVAL OF ALTERNATOR ASSEMBLY
I
ADisconnect the cable from the negative (-1 ter-
minal of the battery.
1. Disconnect wires (I) and (2).

2. Loosen mounting bolts (3) of alternator assem-
bly.
3. Loosen locknut (4), then rotate adjustment nut
(5) and remove V-belt (6).
4. Remove bolts (7) and (31, then remove alterna-
tor assembly (8) together with belt cover. a
z
zz
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial No.: 10168 and up
- Carry out installation in the reverse order to

removal.
Adjusting tension of alternator belt

* Adjust the tension of the alternator belt.
30-14-l
@
REMOVAL OF ENGINE OIL COOLER ASSEMBLY
Serial No. : 10168 and UD
1. Drain cooling water.
2. Remove adiabatic covers (I), (21, and (3).

* The adiabatic covers are installed to Serial
No. 10168 and up.
3. Remove turbocharger outlet tube (I).
4. Remove torque converter oil cooler connector

(2).
5. Remove engine oil cooler assembly (3).
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY
removal.
. Refilling with water

* Add water to the specified level from filter
port, and run the engine to circulate the
water through the system. Then check the
water level again.
30-l 5
@
REMOVAL OF TORQUE CONVERTER OIL COOLER ASSEMBLY
Serial No . : 10001 - 10167
2. Remove cover (1).
3. Disconnect heater hose (2).
4. Remove engine oil cooler drain plug assem-

bly (3).
5. Disconnect torque converter oil cooler inlet

and outlet hoses (4) and (5).
6. Remove torque converter oil cooler connec-

tor (6).
7. Remove torque converter oil cooler assembly

(7).
&I kg Torque converter oil cooler assembly:

75 kg
F19703004
INSTALLATION OF TORQUE
CONVERTER OIL COOLER
ASSEMBLY
Serial No . : 10001 - 10167

removal.
l Refilling with water

* Add water to the specified level from filler
water level again.
30-l 6
@
REMOVAL OF TORQUE CONVERTER OIL COOLER ASSEMBLY
1. Remove engine underguard.

2. Drain coolant.
3. Open engine right side cover (I) and remove
side cover (2).
4. Remove side covers (3), then remove side cover
stay.
5. Remove water inlet tube (4).
6. Remove water outlet tube (5).
7. Disconnect oil inlet hose (6).
8. Disconnect oil outlet hose (7).
9. Sling torque converter oil cooler assembly (81, I CED01240
remove mounting bolts, then lower assembly to
remove.
&I kg Torque converter oil cooler assembly :

75 kg
zs INSTALLATION OF TORQUE
CONVERTER OIL COOLER
ASSEMBLY
Serial No . : 10168 and up

removal.

Add water to the specified level, and run the
engine to circulate the water through the sys-
tem. Then check the water level again.
30-l 6-1
8
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY
Serial No. : 10001 - 10167
* Close the fuel supply valve.
1. Disconnect 4 fuel supply hoses (1).
2. Disconnect fuel control rod (2).
3. Remove lubrication tubes (3) and (4).
4. Disconnect 6 fuel injection tubes (5). m
5. Remove injection pump coupling cover (6).
6. Remove coupling bolts (7).
7. Remove fuel injection pump assembly (8).

a
L%kg Fuel injection pump assembly: 30 kg
z
zs
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
Serial No . : 10001 - 10167

removal.
a
w Sleeve nut:
22.1 2 2.5 Nm i2.25 + 0.25 kgm}
w Fuel injection mounting bolt:

53.9 f 19.6 Nm I5.5 = 2.0 kgm}
* Adjust the fuel injection timing.

30-17
8
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY
1. Open engine left side cover (I), then remove

side covers (2) and (31, and side cover stay.
2. Close fuel supply valve.
3. Remove bracket (4), oil level gauge (51, and fuel

control rod (6). m
4. Disconnect 4 fuel hoses (7).
5. Remove lubrication tubes (8) and (9), and boost CED01332

compensator tube (IO).
6. Disconnect 6 delivery tubes (II).
7. Remove coupling cover (12).
8. Loosen mounting bolts (13) at drive shaft end

and remove 4 pump mounting bolts (14).
9. Remove fuel injection pump assembly (15) to-

gether with coupling. m
r+ kg Fuel injection pump assembly : 30 kg
INJECTION PUMP ASSEMBLY

removal.
m
* Adjust the fuel control rod.
For details, see TESTING AND ADJUSTING,
Adjusting fuel control linkage.
m
* Adjust the injection timing.
Adjusting fuel injection timing.
* Bleed the air from the fuel circuit.
30-l 7-l
@
ROMOVAL OF WATER PUMP ASSEMBLY
Serial No. : 10001 - 10167
2. Remove torque converter oil cooler connec-

tor (1).
3. Remove water tube (2).
4. Remove water pump assembly (3).
INSTALLATION OF WATER
PUMP ASSEMBLY
Serial No . : 10001 - 10167
. Carry out installation in the reverse or-

der to removal.

* Add water to the specified level from
filter port, and run the engine to circu-
late the water through the system. Then
check the water level again.
30-18
@
REMOVAL OF WATER PUMP ASSEMBLY
1. Drain coolant.
2. Open engine right side cover (I), then remove

side covers (2) and (3), and side cover stay.
3. Remove torque converter oil cooler connectors

(4) and (5).
4. Remove water tube (6).
5. Remove water pump assembly (7).
z INSTALLATION OF WATER
CED01507
z PUMP ASSEMBLY
0

removal.
tem. Then check the water level again.
30-l 8-1
@
REMOVAL OF TURBOCHARGER ASSEMBLY
1. Remove adiabatic covers (II, (2), and (3).
+ The adiabatic covers are installed to Serial
No. 10168 and up.
2. Remove intake connector (1).
3. Disconnect turbocharger inlet hose (2).
4. Remove turbocharger outlet tube (3).
5. Remove turbocharger assembly (4).

I ‘- CEDOl939
r&lkg Turbocharger assembly: 30 kg
INSTALLATION OF
TURBOCHARGER ASSEMBLY
removal.
a
* Fit the gasket with the TOP mark facing up.
m Mounting bolt: 49.0 = 4.9 Nm I5 + 0.5 kgm}
30-19
@
REMOVAL OF NOZZLE HOLDER ASSEMBLY
1. Remove exhaust pipe. (Only for No. 4 to 6.)
& Exhaust pipe: 30 kg
2. Remove radiator top cover and 4 engine side

covers at top on left and right. (Only for No. 4
to 6.)
* For No. 1 - 3, remove only the top left
engine side cover.
3. Lift off hood (3). (Only for No. 4 to 6.)
Pl kg Hood: 85 kg
4. Disconnect Komaclone tube.

Lift off air cleaner assembly (1). (Only for No.
4 to 6.)
& kg Air cleaner assembly: 35 kg
5. Remove cover (2). (Only for No. 1 to 3.)
6. Remove cover (3). (Only for No. 4 to 5.)
7. Remove Komaclone tube (4), then remove

bracket (5). (Only for No. 6.)
8. Remove clamp, then remove fuel injection

pipe (6). (Only for No. 2 to 6.) m
* For No. 1, disconnect.
9. Disconnect spill hose (7), then remove

connection (8).
10. Remove cylinder head cover (9). m
11. Remove nozzle holder assembly (IO). m
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
removal
m
m Sleeve nut:
22.05 + 2.45 Nm I2.25 +. 0.25 kgm)
m
B Cylinder head cover mounting bolt:
31.85 + 2.45 Nm i3.25 + 0.25 kgm}
a
m Nozzle holder mounting bolt:
26.95 + 2.45 Nm I2.75 2 0.25 kgm}
* Tighten the nozzle holder mounting bolts
uniformly.
* Set the nozzle holder with the match mark
facing the front of the engine, then install.
30-20
@
REMOVAL OF CYLINDER HEAD ASSEMBLY
1. Drain coolant.
2. Remove exhaust pipe.
r&l Exhaust pipe : 30 kg

3. Rikove radiator top cover, then remove 4 left
and right engine side covers.
4. Lift off hood.
&I Hood : 85 kg
5. DLiconnect Komaclone tube, and lift off air
cleaner assembly (1).
r&Ikg Air cleaner assembly : 35 kg

9. Disconnect flange (5) of Komaclone tube.
r:
4
2 -
z
10. Remove adiabatic covers (371, (38), and (39).
* The adiabatic covers are installed to Serial
No. 10168 and up.
11. Disconnect turbocharger inlet hose (6).

12. Remove turbocharger outlet tube (7).
13. Remove muffler drain tube (8).
14. Sling muffler, turbocharger, and exhaust mani-
fold as an assembly, the lift off muffler, turbo-
charger, and exhaust manifold assembly (9).
a
&I kg Muffler, turbocharger, exhaust manifold
assembly: 160 kg
15. Remove cover (IO).

16. Remove 6 injection pipes (II).
17. Remove Komaclone tube (12).
18. Remove turbocharger inlet tube (13).
19. Remove bracket (I 4).
20. Disconnect wiring connector (15).

21. Disconnect 2 hoses (16), and move fuel filter
(17) down.
22. Remove 2 tubes (18), then remove corrosion
resistor (19).
23. Remove breather (20).

I
24. Disconnect boost compensation tube (40) at in-
take manifold end.
* The boost compensation tube is installed to
Serial No. 10168 and up.
30-22
@
25. Using eyebolt 0, remove intake manifold as-
sembly (21). m
el
kg Intake manifold assembly : 50 kg
26. Remove spill tube (22) and connection (23).

* In the case of No. 5 and 6, disconnect wiring
connector (24) and ground connection (25),
then remove bracket (26).
/hV I’ 17MFQ2214
27. Using forcing screws 0, remove head cover (27).

m
/-\ 'I 17MF02215_
28. Remove rocker arm assembly (28). m

+ loosen the locknut, then loosen the adjust-
ment screw 2 or 3 turns.
30-23
29. Remove push rod (29).
30. Remove crosshead (30).
31. Remove flange (31).
32. Remove nozzle holder assembly (32).
33. Remove rocker arm housing. m

1) Remove pin (33), the use a bar to lever pipe
(34) and move it.
2) Remove mounting bolts, then remove rocker
arm housing (35).
34. Using eyebolts 0, remove cylinder head assem-

bly (36). m
r+ k’d Cylinder head assembly : 40 kg
30-24
8
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
removal.
@ -i 1
w- Exhaust manifold mounting bolt :
. 1st step: 0 - @: 49 2 9.8 Nm 6 = 1 kgm1
. 2nd step: @I,@: 88.2 d 9.8 Nm
{9 2 1 kgm}
m -@: 110.3 + 12.3 Nm
ill.25 c 1.25 kgm}
& Mounting bolt (2 places marked *) :
Anti-friction compound (LM-P)
17MF02216
w Sleeve nut :
22.1 = 2.5 Nm I2.25 + 0.25 kgm}
m
m Intake manifold mounting bolt :
l 1st step: 0 - @: 24.5 + 4.9 Nm
I2.5 r 0.5 kgm1
l 2nd step: @I - 8: 63.7 f 9.8 Nm
(6.5 + 1.0 kgml
a
w Cylinder head cover mounting bolt :
31.9 + 2.5 Nm I3.25 2 0.25 kgm}
I
I
Clean the oil holes of the mounting bolts
17MF02217
before installing.
Check that the ball of the adjustment screw
is fitted properly into the socket of the push
rod.
* Adjust the valve clearance.
Testing and adjusting valve clearance.
m Rocker arm assembly mounting bolt :
98 = 4.9 Nm {IO 2 0.5 kgm}
w Locknut : 67.7 + 9.8 Nm I6.9 r 1 kgm}
M
* Adjust the crosshead as follows.
1) Loosen the locknut and turn back the adjust-
ment screw.
2) Press down lightly with a finger on the top
of the crosshead and screw in the adjust-
ment screw.
w Locknut:
39.2 c 5.9 Nm (4 f 0.6 kgm}
w Flange mounting bolt :

27 z 2.5 Nm I2.75 d 0.25 kgm1
w Rocker arm housing mounting bolt :

98.1 +. 4.9 Nm {IO f 0.5 kaml
30-25
@
m
* If any rust of more than 5 mm square is
found on the shaft or the thread of the bolt,
replace the head bolt with a new bolt.
* Be careful to check that there is no dirt or
dust on the mounting surface of the
cylinder head or inside the cylinder.
* Check that the grommet does not come out
when installing the gasket.
* Tighten the cylinder head mounting bolts 2
- 3 turns by hand, then tighten in the
6162F311
order given in the diagram.
* After tightening, make one punch mark on
the bolt head to indicate the number of times
it has been tightened.
. If any bolt already has five punch marks,
do not reuse it. Replace it with a new
bolt.
ro1, Mounting bolt :
QEI Cylinder head mounting bolt :
Serial No. : 10001 - 10167

1st step : 77.5 2 14.7 Nm I7.9 = 1.5 kgm}
2nd step : 230.5 + 14.7 Nm (23.5 2 1.5 kgm}
3rd step : 382.5 r 14.7 Nm I39 f 1.5 kgm}
Final tightening torque:
495.2 + 14.7 Nm j50.5 + 1.5 kgm}
Make marks on
Serial No. : 10168 and up cylinder head and bolt
1st step : 98.1 2 9.8 Nm {IO + 1 kgm}
2nd step : 186.3 z 4.9 Nm I19 f 0.5 kgm}
3rd step : Make marks with paint on the bolt
and head, then tighten bolt a further 60”t’zZ.

tem. Then check the water level again. Tighten bolt SO’;!5’
DBD03028
30-25-l
@
REMOVAL OF FUEL TANK ASSEMBLY
1. Remove rear cover (1).
2. Close 2 fuel valves (2).
3. Disconnect hose (3).
4. Remove hose mount brackets (4) and (5) with

hoses still installed.
Disconnect wiring connector (6).
Remove side cover at left side of cab.

’ 17MF02218
Disconnect hose (8).
Lift off tank (9).

* Be careful that the hose bracket does not
get caught when lifting off.
Fuel tank assembly: 1,150 kg

& kg
(When tank is full)
TANK ASSEMBLY liti
-
&
-
= z
I I

removal.
I 198FO2412
30-26
8
TURNING OVER RADIATOR AND FRONT GUARD ASSEMBLY
2. Disconnect radiator outlet tube (I), move it to

side.
3. Remove radiator top cover.
4. Disconnect ground connection (2) and

connector (3).
5. Disconnect aeration hose (4).
6. Disconnect radiator inlet tube of connector

(5).
7. Disconnect hose (6) between radiator and

radiator sub-tank.
8. Sling radiator and front guard assembly, then

disconnect left and right brackets (7) and cap.
Lower radiator and front assembly slowly,

and secure radiator and front assembly (9)
with wire (8).
INSTALLATION OF RADIATOR
AND FRONT GUARD ASSEMBLY

removal.
l Refilling with water

* Add water to the specified level from filler
water level again. I97FO302 I
30-27
0
REMOVAL OF RADIATOR ASSEMBLY
1. For details,
see TURNING OVER RADIATOR
AND FRONT GUARD ASSEMBLY.
2. Remove left and right bottom mounting brac-

kets.
3. Sling radiator assembly, then remove left and

right top caps (2).
4. Raise radiator assembly slowly, then remove

radiator assembly (3).
* Be careful not to damage the core when
removing the assembly. \ I97FO3023
Radiator assembly: 350 kg

I9 kg
INSTALLATION OF RADIATOR
ASSEMBLY

removal.
30-28
0
REMOVAL OF RADIATOR GUARD ASSEMBLY
A Lower the work equipment

ground.
completely to the
1. Sling blade lift cylinder, and remove cap (1)

and shim (2) of piston rod. m
* Check the number and thickness of the
shims, and keep in a safe place.
2. Run engine, and retract piston rod of blade

lift cylinder fully.
* After disconnecting the blade cylinder,
install it to the lock pin on the body to hold
it in position. 1 2
4. Remove radiator outlet hose (3). I
& kg Exhaust pipe: 30 kg
6. Remove radiator top cover and 6 left and

right side covers.
7. Lift off hood.

g Hood: 85 kg
H & kg
f15
z 8. Remove cover, and disconnect 2 blade hoses
(4).
Operate the control levers several times
g
to release the remaining pressure in the
hydraulic piping.
9. Disconnect aeration hose (5) at radiator end.
10. Disconnect radiator inlet hose (6) at radiator

end.
11. Disconnect 2 cooler hoses (7).
30-29
@
Serial No. : 10001 - 10167 Serial No. : 10001 - 10167
13. Loosen fan belt tension adjustment nut (9),

then push tension pulley, and remove fan
belt (IO) from pulley. m
+ Be careful when pushing the tension pul-
ley, as the pulley will rotate.
'162Fl40

13. Loosen tension of tension pulley (91, and
remove fan belt (IO). a
Ir Using a chain block, pull in the direction
shown in the diagram on the right to
loosen the tension of the tension pulley
belt.
IO
CEDOl944
14. Remove lock bolt (I 1).

15. Sling radiator guard assembly, pull out rear
pin (12).
Ir Repeat the operation in the same order
on the opposite side.
* If pin (12) is stiff, disconnect the track
and use tool A to remove pin (12).
16. Using tool A, pull out front pin (13).

J, Repeat the operation in the same order
on the opposite side.
30-30
@
17. Lift off radiator guard assembly (14) slowly.
* Be extremely careful not to damage the
core when removing.
&I kg Radiator guard assembly : 2400 kg
INSTALLATION OF
RADIATOR GUARD
ASSEMBLY
removal.
Adjust so that the play at the spherical

portion in the axial direction is within
0.5 mm, and check that it rotates
smoothly.
Standard shim thickness C : 4 mm
197F381
I
Bleed the air from the cylinder.
For details, see TESTING AND ADJUST-
ING.
Adjust the fan belt tension.

ING.
30-3 1
8
REMOVAL OF ENGINE ASSEMBLY
ADisconnect the cable from the negative (-1

1. Drain coolant.
&I Exhaust pipe : 30 kg

3. Rikove radiator top cover and left and right
side covers.
4. Lift off hood.
&I Hood : 85 kg
5. Rihove 2 cab front steps and intake port
cover.
6. Disconnect starting motor wiring (1).
8. Remove 2 connectors (3) of torque converter
oil cooler.
9. Disconnect radiator outlet hose (4).
Serial No. : 10001 - 10167 Serial No . : 10001 - 10167
IO. Loosen adjustment nut (5) and remove fan

belt (6) from pulley. a
* Be careful when pushing the tension pul-
ley, as the pulley will rotate.
Serial No. : 10168 and up Serial No. : 10168 and up
10. Loosen tension pulley (5) and remove fan

belt (6).
* Using a chain block, pull in the direction
shown in the diagram on the right to
loosen the tension of the tension pulley
belt.
CEDO1945
30-32
@
11. Disconnect radiator inlet hose (7).
12. Disconnect aeration hose (8).
13. Remove 2 covers (9).
14. Disconnect 2 air conditioner hoses (IO).
15. Disconnect wiring connector (I I).
16. Disconnect fuel control rod (12).

17. Disconnect 2 fuel hoses (13).
18. Disconnect ground wire (14).
19. Disconnect 2 wiring connectors (15).
Disconnect Komaclone tube, and lift off air

cleaner assembly (16).
el
kg Air cleaner assembly : 35 kg
21. Remove 2 battery cables (17).

22. Disconnect fuel control intermediate rod (18).
24. Disconnect 2 air conditioner hoses (20).
25. Disconnect 2 heater hoses (21).
26. Disconnect 2 ELPC valve hoses (22).
27. Remove clamp (23) of receiver tank, then

move receiver tank to left.
28. Lift off bracket (24).
r&lkg Bracket : 65 kg
29. Remove damper level gauge (25).

30. Lift off universal joint (26). m
17MF02239 17MF02239
31. Lift off engine assembly (27). m

+ When removing the engine assembly,
check that all wiring and piping has been
disconnected, and use a lever block to
prevent interference with any parts, and
lift off with the front slightly raised.
Be particularly careful to make sure that
the front mount does not hit the radiator
guard mount.
&I kg Engine assembly : 3,000 kg
30-34
(EC
INSTALLATION OF ENGINE
ASSEMBLY
removal.
q Adjust the fan belt tension

ING.
m
w Universal joint mounting bolt :
110.3 f 12.3 Nm III.25 f 1.25 kgm)
a
m Engine mount cap mounting bolt :
926.7 + 103 Nm I94.5 f 10.5 kgm}

Add water to the specified level, and run
the engine to circulate the water through
the system. Then check the water level
again.
30-34-l
8
REMOVAL OF DAMPER ASSEMBLY
1. Using transmission jack 0, remove rear

underguard (1).
Underguard: 360 kg
L+lkg
2. Remove drain plug and drain oil from

damper.
:
u Damper: Approx. 2.1 e
3. Sling universal joint (2), then remove mount-

ing bolts, and remove universal joint. m
I98FO245 I
4. Remove oil level gauge guide (3).
5. Remove mountino bolts and holder (4).

. ,. then
remove coupling T5). 1#21
6. Remove retainer (6).

3
’ I
!
17MF02242 17MF02243
Sling damper cover (7), remove mounting

bolts, then screw in 3 forcing screws and
remove. m
A Set the guide bolt (Q = approx. 200mm)

so that the damper cover will not come
out suddenly.
Damper cover: 60 kg
& kg
8. Using eyebolts 0, sling damper assembly (8),

then remove mounting bolts and lift off. m
A Set the forcing screws (a = approx.

200mm) so that the damper cover will I 17MF02244 11 17MF02245
not come out suddenly.
PI kg Damper assembly: 75 kg
9. Remove bearing (9) from flywheel. m
I 17MF02246
30-35
0
INSTALLATION OF DAMPER ASSEMBLY

removal.
m Universal joint mounting bolts:

11.25 + 1.25 kgm
N~I& Holder mounting bolt thread:

Thread tightener (LT-2)
m Holder mounting bolt:
28.25 + 3.25 kgm
Install damper cover (7) as follows.

1) Using guide bolt (n = 200mm), set the
damper cover in position.
2) Using tool B, press fit bearing.
Use a guide bolt (Q = approx. 200mm) to

position the damper assembly.
r& Fill 50% of the clearance at the

17MF02247
hatched portion in the diagram with
grease (G2-U) (approx. 11 g).
l Refilling with oil

* Add-engine oil to the specified level, and
run the engine to circulate the engine oil
through the system. Then check the water
level again.
30-36
0
DISASSEMBLY OF DAMPER ASSEMBLY
0 Disassembly of damper assembly
1. Set damper assembly to block 0.
2. Remove mounting nut (I), then using forcing

screws 0, remove flange (2).
17MF02249 17MF02250
6. Remove shaft (3).

1
4. Remove rubber (4).
5. Using forcing screws 0, remove flange (5)

from body (6).
5 6
17MF02251 17MF02252
6. Remove seal (7) from flanges (2) and (5).
. Disassembly of damper cover assembly
7. Remove bearing (8) and oil seal (9) from

cover (IO).
8. Remove oil seal (11) from retainer (12).
17MF02255
30-37
0
ASSEMBLY OF DAMPER ASSEMBLY
0 Assembly of damper assembly

Flange
,I
1. Install seal (7) to flanges (2) and (5).
* Install the seal so that the lip is facing the
inside as shown in the diagram.
Seal
I
17MF02256 11 1 17MF02257
I
2. Align bolt holes and install flange (5) to body
(6).
H-XI& Flange mating surface:
Gasket sealant (LG-4)
A Check that there are no dents, rust, oil,

grease, or water on the mating surface,
then coat both the faces of the flange and
body with gasket sealant.
17MF02258
3. Set flange and body assembly to block 0,

then set shaft (3) in position.
Shaft
4. Assemble rubber (4).

!ara
a When assembling the rubber, coat
the whole surface of the rubber, the
outside circumference of the shaft,
and the inside circumference of the
body with grease (G2-LI).
a After assembling the rubber, fill the

Body
clearance between the shaft and
body (16 places) approx. 30% with 17MF02259 17MF02260
grease (G2-LI) (approx. 190s).
5. Install flange (2).
& Flange mating surface:

A Check that there are no dents, rust, oil,

grease, or water on the mating surface,
then coat both the faces of the flange and
body with gasket sealant.
6. Tighten mounting nut (1).
17MF02261
30-38
0
l Assembly of damper cover assembly
7. Using push tool 0, press fit oil seal (11) to

retainer (12).
a Oil seal press-fitting surface:
* Coat the inside surface of the retainer
thinly with gasket sealant, and wipe off
any sealant that is squeezed out.
a Lip of oil seal: Grease (G2-LI)
I 17MF02262 1
8. Using push tool 0, press fit bearing (8) to

cover (IO).
I 17MF02263
9. Using push tool 0, press fit oil seal (9) to

cover (10).
&I?s Oil seal press-fitting surface:

* Coat the inside surface of the cover thinly
with gasket sealant, and’wipe off any seal-
ant that is squeezed out.
&I?+ Lip of oil seal: Grease (G2-LI)
I 17MF02264 1
30-39
0
1. Draining oil
Hydraulic tank: Approx. 95 e
Power train unit: Approx. 120 Q
2. Remove fuel tank assembly.

For details, see REMOVAL OF FUEL TANK
ASSEMBLY.
3. Remove floor frame assembly.

For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
4. Sling universal joint assembly (2), then C17MF02266

remove mounting bolts, and lift off universal
joint assembly. m
5. Remove control lever bracket (3) from frame,

and move it towards power train unit assem-
bly.
6. Disconnect 2 connectors of wiring (4).
7. Disconnect torque converter cooler hose (5).
8. Disconnect hydraulic oil sensor wiring

connector, and remove tube (6).
9 Disconnect 3 hoses (7).
10. Disconnect 5 ripper circuit hoses (8) at valve

end, and move them towards side frame.
11. Disconnect hose (9) between pump and

ripper Hi valve at valve end.
I
12. Disconnect pin puller hoses (IO).
13. Remove fuel hose clamps, and move hoses

(11) to side.
14. Remove mount bolt (12) and mount cap (13).

m
15. Loosen clamp (14), and move it to outside.

m
16. Using forcing screws 0, remove cover (15).
17. Using forcing screws 0, pullout shaft (16).

* If the shaft does not come out, use jack 0
to move the sprocket backwards or
forwards and adjust to a position where
the shaft will come out. i
18. Lift off power train unit assembly (17).

* Be sure to disconnect all wiring and piping
before removing the power train unit
assembly.
kg Power train unit: 3,600 kg

C?l
I98FO2467
I96FO2469 I96FO2470
INSTALLATION OF POWER TRAIN UNIT ASSEMBLY

removal.
m Universal joint: 11.25 f 1.25 kgm
m Mounting bolts: 94.5 + 10.5 kgm

m Mount cap: 94.5 f 10.5 kgm
* Clamp the peaked portion of the coupling

seal securely, and assemble so that the
clamp threaded portion is parallel to the
seat surface of the cap mount.
m Housing clip: 0.675 f 0.175 kgm

* Add oil to the specified level, and run the
engine to circulate the oil through the
system. Then check the oil level again.
30-42
0
DISCONNECTION OF POWER TRAIN UNIT ASSEMBLY
l Remove power train unit assembly.

For details, see REMOVAL OF POWER TRAIN
UNIT ASSEMBLY.
1. Set power train unit assembly (1) on block 0.
2. Remove steering control cables (2) together

with bracket. 1111
3. Remove transmission control cables . (3)

together with bracket. m
4. Disconnect 3 rods (4), and remove bracket

(5).
5. Remove clamps (6) of central pressure

detecting hose at 4 places, disconnect 9
hoses, then remove hose bracket assembly
(7).
* Before disconnecting the hoses, mark with
tags to show their mounting positions.
6. Disconnect wires (8) at connectors, remove

clamps, then remove wiring.
7. Remove pin puller hose (9).
17MF02278
8. Sling hydrualic pump (9), remove mounting
bolts, then remove pump assembly (9)
together with hose.
C?kg Hydraulic pump assembly: 35 kg
9. Remove scavenging pump piping (IO), then

remove oil filler pipe (11).
10. Sling filter assembly (12), remove mounting

bolts, then remove filter assembly.
11. Sling power train pump and strainer assem-

bly (13), disconnect strainer pipe (14) and
clamp bracket (15) of pipe, and remove
mounting bolts, then remove pump and
strainer assembly (13).
& kg Pump, strainer assembly: 55 kg
12. Lift off mount bracket (16). m
Mount bracket: 150 kg

& kg
13. Sling scavenging pump (17), remove mount-

ing bolts, then remove pump assembly.
& kg Scavenging pump assembly: 40 kg
14. Disconnect clamp, and remove gauge tube

(16).
16. Support center of transmission with block @

(height: 500mm).
17. Sling oil pan (20), remove 4 mounting bolts at

bottom and 15 mounting bolts at top, then
remove brackets (21) and (22), and oil pan
(20).
&I kg Oil pan: 110 kg
18. Sling PTO and torque converter assembly

(23), remove mounting bolts, then remove
PTO and torque converter assembly (23).
lf41
I+ kg PRO, torque converter

assembly: 600 kg
* Using a lever block, raise the assembly

horizontally, and disconnect it from the
transmission.
30-44
0
19. Sling transmission assembly (24), remove
mounting bolts, then remove transmissin
assembly (24) from steering case assembly
(25). 24
Transmission assembly: 950 kg
& kg
Sr Use a lever block, and lift off horizontally
from the steering case assembly.
17MF02282
CONNECTION OF POWER
TRAIN UNIT ASSEMBLY
l Carry out connection in the reverse order to

disconnection.
m
g Bend the cotter pin securely.
E )xJ
5
Bend the cotter pin securely.
m
w Rotating part of PTO boss:
Grease (G2-LI)
Using a lever block, raise the PTO and

torque converter assembly horizontally,
align it with the spline on the shaft at the
steering case side, and install.
30-45
0
DISCONNECTION OF PTO, TORQUE CONVERTER ASSEMBLY
1. Remove coupling assembly (1).
2. using forcing screws 0, remove retainer

assembly (2). m 112)
3. Remove shims (3).

A Check the number and thickness of the
Sims, and keep in a safe place.
4. Remove snap ring (4), then remove spacer

(5). m
5. Remove mounting bolts, then using eyebolts

0, sling PTO assembly.
I-
-
17MF02283
6. Using forcing screws 0, remove PTO assem-

bly (6). m
PTO assembly: 300 kg

& kg
4 5
17MF02285
6 17MF02286
30-46
0
CONNECTION OF PTO, TORQUE CONVERTER ASSEMBLY
l Carry out connection in the reverse order Retainer

disconnection.
a
Adjust the clearance between the taper roller
bearings as follows.
1) Set retainer assembly to housing, and
tighten 6 mounting bolts to 1 kgm in turn.
2) Using thickness gauge, measure clearance
a between retainer and housing.
* When measuring, measure at 4 places
(A.
. . B. C. D) around the circumference.
and take the average value as clear- 17MF02287
ance a.
3) Selecting shim thickness
r Remova; tap
* Shim thickness = Clearance a -
(0 to +O.O5mm) D
* The shims are a divided type, so check \ 0 0 /A
the number of shims and make sure
that the shim thickness is the same on
the left and right. 0 0
j, Standard shim thickness t = 0.15, 0.20,
0.5
4) Assemble selected shim thickness, then 0
/ 0 0 \
tighten retainer assembly to specified C B
torque.
:
w Mounting bolt: 6.75 f 0.75 kgm RerAoval tap I98FO2487
Assemble the shim as shown in the diag-

ram on the right so that it does not come
Removal tap
at the position of the retainer removal tap.
A
a Lip of oil seal: Grease (G2-LI)

&I& O-ring: Grease (G2-LI)
Check that the snap ring is fitted securely

in the groove.
Rknoval tap I98FO2488

When assembling the PTO assembly, coat
the P portion of the shaft with anti-friction
compound (LM-P).
30-47
0
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY
1. Torque converter assembly

Set the torque converter assembly (1) to tools
C.
2. Torque converter valve assembly

Remove mounting bolts, then using eyebolts
0, remove valve assembly (2).
* Remove the 6 mounting bolts that are
marked in black.
I I 17MF02288
3. Draining oil
Remove drain plug (3) at 2 places and drain
oil from pump case. 17MF02289 17MF02290 f:
* After draining the oil, tighten the drain 5
plug.
m Plug: 1.15 f 0.15 kgm
4. Lockup clutch, drive case assembly

1) Leaving 2 mounting bolts in place, remove
mounting bolts (4).
a Set so that input shaft is at top, then
remove remaining mounting bolts.
3) Using eyebolts 0, remove off lockup
clutch and drive case assembly (5).
17MF02291
4) Disassemble lockup clutch and drive case

assembly as follows.
i) Remove mounting bolts, then using
forcing screws 0, remove input shaft
(6).
ii) Remove snap ring (7), then remove
plate (8).
17MF02294
30-48
0
iii) Set the clutch housing side facing
down, and set block 0 to turbine.
iv) Using forcing screws 0, disconnect
press-fitting portion of bearing, then
remove turbine (9).
v) Remove mounting bolts, then using

eyebolts 0, remove housing and
piston assembly (10).
* When removing, the piston will fall
out, so support it by hand.
197F.316 17MF02296
vi) Remove piston (11) from housing (12).
vii) Using push tool 0, remove bearing
(13) from housing (12).
I96FO2496 I96FO2497
197F318
15 14 16
viii) Remove 2 discs (14) and 1 plate (15)
from drive case (16) in turn.
* Keep the disk and plate in a flat
place to prevent distortion.
197F319
5. Stator
1) Remove snap ring (17), then remove stator
assembly (18).
li i8 17MF02297
30-49
0
2) Remove snap ring (19), then remove race
(20) from stator (21).
3) Remoe snap ring (22) from stator (21).
I 98FO2502 11 I99FO2500
6. Pump assembly
1) Remove pump assembly (23).
I
17MF02298
2) Remove mounting bolts, then remove

retainer (24). 2,5 ?4
3) Tap with a plastic hammer, and remove
bearing and guide assembly (25) from
pump.
4) Using push tool 0, remove bearing (26)
from guide (27).
17MF02299 17MF02300
__-I
7. Stator clutch housing

Remove mounting bolts, them remove stator
clutch housing (28).
17MFfl7?.1ll
30-50
0
8. Spring , 29
Remove spring (29).
9. Discs, plate
Remove 2 discs (30) and 1 plate (31) in turn.
A Keep the disc and plate in a flat place to
prevent distortion.
do $1 17MF02302
IO. Pin
Remove pin (32).
11. Piston
Remove piston (33).
12. Gear
Remove snap ring (34), then remove gear
(35).
I 17MF02303
13. Stator shaft, shaft assembly

1) Remove mounting bolts (36).
17MF02304
2) Tap stator shaft and shaft assembly (37)

with a plastic hammer to remove from
case (38).
* When removing the stator shaft assem-
bly, set the case in the condition shown
in the diagram.
3) Remove snap ring (39).
5) Using push tool @, remove shaft assembly
(41) from stator shaft assembly (42).
30-51
0
6) Disassemble shaft assembly as follows.
i) Remove snap ring (43), then remove
inner race (44).
ii) Remove collar (45).
,\
iii) Remove bushing (46) from shaft (47).
47
\
I I
I
//////////////y//////////;//
17MF02307
7) Disassemble stator shaft assembly as

follows.
i) Remove snap ring (48).
ii) Using push tool @I, remove bearing
(49) from stator shaft (50).
14. Case
Remove case (38) from tool c.
I98FO25 I5
30-52
0
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
* Clean all parts, and check for dirt or damage.
* Put a few drops of engine oil on the rotating

parts of the fearings, and rotate them several
times.
* Check that the snap ring is fitted securely in

the groove.
* Coat the seal ring thinly with grease (GPLI).
1. Case
Set case (38) to tool C.
i2 t I \\ I98FOZ5 I5
5
z
2. Stator shaf’t assemblv
1) Assemble stator shaft assembly as follows.
14
i) Using push tool, press fit bearing (49).
50
and secure with snap ring (48).
ii) Install seal ring to stator shaft (50).
40
49
17MF02310
2) Install snap ring (39).

3) Tap stator shaft assembly (42) with a plas-
tic hammer, and press fit bearing portion
to case.
I 17MF02311
30-53
0
3. Shaft assembly
1) Assemble shaft assembly as follows.
i) Install bushing (46).
* Expand fit the bushing.
ii) install collar (45).
* Install the collar with the cham-
fered portion of the outside diame-
diameter facing down.
iii) Using push tool, press fit inner race
(44), and secure with snap ring (43).
iv) Install seal ring to shaft (47).
2) Install shaft assembly (41).

jr Using 2 guide bolts (Thread dia. =
IOmm, Pitch = 1.25mm, Length =
60mm), align the oil hole and intall the
shaft assembly.
3) Tighten mounting bolts temporarily.
5) Tighten mounting bolts (36) fully.
a Mounting bolt: Thread tightener

(LT-2)
m Mounting bolt: 6.75 f 0.75 kgm
17MF02312
4. Gear
Fit gear (35) and secure with snap ring (34).
5. Piston
1) Install seal ring to case.
2) Fit seal ring and install piston (33).
* Make sure to assemble the seal ring
facing in the correct direction. Assem-
ble with the side taking the pressure
facing the case as shown in the dia-
gram.
a
Side.receiving pressure i 17MF02304
33 I I 32
17MF02313 I?---
6. Pin
17MF02303
Remove pin (32).
30-54
0
7. Discs, plate I I ?9
install 2 discs (30) and 1 plate (31) in turn.
8. Spring
Install spring (29).
17MF02302
9. Stator clutch housing

Align with dowel pin and fit stator clutch
housing (28), then tighten with mounting
bolts.
j, Make sure that the spring is fitted securely
in the piston and housing hole.
rr\- Mounting bolt: Thread tightener
(LT-2)
a Mounting bolt: 11.25 f 1.25 kgm
8
z
;; 10. Pump assembly
1) Using push tool 0, install bearing (26) to
guide (27).
I 17MF02314
2) Set bearing and guide assembly (25) in

pump, then using push tool, press fit bear-
24
ing portion.
* When assembling the bearing and
guide assembly, align the guide and
pump oil holes.
3) Fit retainer (24), and tighten with mounting
bolts.
* When installing the retainer, align the
retainer and pump oil holes.
fi- Mounting bolt: Thread tightener

(LT-2)
17MF02315 17MF02316
w Mounting bolt: 6.75 k 0.75 kgm
30-55
0
4) Install pump assembly (23).
* When installing the pump assembly,
be extremely careful not to damage
the seal ring assembled to the shaft.
17MF02298
11. Stator assembly

1) Install snap ring (22) to stator (21).
2) Fit race (20) to stator (21) and secure with
snap ring (19).
3) Fit stator assembly (18) and secure with

snap ring (17).
12. Lockup clutch, drive case assembly

1) Assemble lockup clutch and drive case
i) Set turbine (9) to block @,.
li is 17MF02297
ii) Using eyebolts 0, set drive case (16) 7MF02317

to turbine.
30-56
0
iii) Install 2 discs (14) and 1 plate (15) in
turn.
iv) Install seal ring to housing.

v) Fit seal ring to piston (II), and set in
housing (12).
* When installing, be extremely
careful not to damage the seal
ring.
vi) Using eyebolts 0, fit housing and 17MF02318
piston assembly (IO) and tighten with

mounting bolts.
j, When installing, support the piston
by hand to prevent it from falling
out, and set it in position in the
drive case.
Mounting bolt:
Mounting bolt:
11.25 f 1.25 kgm
I96FO2497 196FO2496
vii) Using push tool 0, press fit bearing

(13).
viii) Fit plate (8) and secure with snap ring
(7).
8 7
17MF02319 17MF02320
ix) Using eyebolts 0, fit input shaft (6) 1

and tighten with mounting bolts.
TV?- Mounting bolt:

6
w Mounting bolt:
11.25 k 1.25 kgm
x) Install seal ring to input shaft.
- 17MF02321
30-57
0
2) Using eyebolts 0, set lockup clutch and
drive case assembly (5) to pump.
A Install a guide bolt (Thread dia. = 1 Omm,
Pitch = 1.5mm, Length = 60mm) to the
drive case, align the position of the
drain plug, and set to the pump.
3) Tighten mounting bolts (4).
N-C& Mounting bolt:
m Mounting bolt: 5.5 + 0.5 kgm
13. Torque converter valve assembly

Fit gasket, and using eyebolts 0, install valve
assembly (2).
* Tighten the mounting bolts uniformly in
turn.
14. Torque converter assembly

Remove torque converter assembly (1) from
tool c.
I I 17MF02288
30-58
a
DISASSEMBLY OF PTO ASSEMBLY
1. Idler gear assembly

1) Using eyebolts 0, sling PTO assembly.
plate (1).
17MF02322
3) Face torque converter side down, and set

PTO assembly on block.
4) Remove lubrication tube.
5) Remove mounting bolts, then using forc-
ing screws 0, remove shaft assembly
(2).
6) Remove plug, then using forcing screws

0, remove bearing (3).
7) Remove spacer (4).

8) Remove idler gear assembly (5) and
bearing (6) from bottom.of PTO case.
; 17MF02324 /I 5 17M:2326
9) Remove outer race (7).

IO) Remove snap ring (8).
17MF02326 17MF02327
30-59
0
2. Cover assembly
ing screws 0, remove cover assembly (9).
2) Using puller 0, remove gear assembly

(IO).
3) Using puller 0, remove bearing (11) from
gear (12).
3. Cover assembly
ing screws 0, remove cover assembly
(13).
D---
13---
17MF02329
2) Using puller 0, remove bearing (14).

gear (15).
I98FO253 I l98FO2532
30-60
a
4) Using push tool 0, remove boss assembly
(17) from cage (16).
5) Using forcing screws 0, remove bearing
(19) from boss (18).
17MF02330
JI 17MF02331
4. Scavenging pump drive gear

drive gear (20).
17MF02332
5. Boss
1) Remove snap ring (21)
2) Using push tool, remove boss (22) from
bearing pressfitting portion.
17MF02333

4) Using push tool, remove bearing (24).
30-61
0
6. Bearing, race assembly
1) Using push tool, remove bearing and race
assembly (25).
17MF02336
2) Remove outer race (26). 27

26
7. Sleeve
Remove sleeve (27) from PTO case.
17MF02337
30-62
0
ASSEMBLY OF PTO ASSEMBLY

parts of the bearings, and rotate them several
times.
j, Check that the snap ring is fitted securely in
the groove.
1. Sleeve
1) Face torque conerter side down, and set
PTO case on block.
2) Install sleeve (27) to PTO case.
* Expand fit the sleeve.
2. Bearing race assembly

* Use the bearing and spacer as a set.
1) Using push tool @, press fit outer race
(26).
17MF02338
8
z
2) Set race (28) to press, then using push Press

tool 0, press fit bearing (29).
3) Assemble spacer (30). t ?
4) Usng push tool 0, press fit bearing (31).
-7///////////y/////// 17MF02339
5) Assemble bearing and race assembly (25).

* Assemble the bearing and race assem-
bly with the lip of the race at the
bottom.
6) Assemble spacer (32).

7) Using push tool ($9, press fit outer race
(33).
17MF02340
30-63
0
3. Boss
2) Using push tool, press fit bearing (24) and
secure with snap ring (23).
3) Using a plastic hammer, press fit boss (22)
to bearing from inside of case.
17MF02342
-22
17MF02341
4) Secure with snap ring (21).
17MF02333
4. Scavenging pump drive gear

Install drive gear (20) and tighten with mount-
ing bolts.
AI’+- Mounting bolt:
m Mounting bolt: 6.75 I!I 0.75 kgm
17MF02332
5. Cover assembly
1) Set boss (18) to press, and using push tool
@, press fit bearing (19).
2) Using push tool @, press fit boss assem-
bly (17) to cage (16).
30-64
0
3) Install gear (15), and tighten with mount-
ing bolts.
0. Mounting bolt:
4) Set cover assembly to press, then using

push tool 0, press fit bearing (14).
5) Face torque converter side down, and set

PTO assembly on block.
6) Using eyebolts, fit O-ring and cover
assembly (13), then tighten with mounting
bolts.
* Set the cover assembly to the case,
and tap uniformly with a plastic
hammer to press fit it.
/(i7, O-ring: Grease (G2-LI)
02344
0
6. Cover assemblv
Set gear (12j to press, using push tool 0,
press fit bearing (11).
Press fit gear assembly (10).
* Press fit the gear assembly with the
spling portion on the inside of the gear
at the top.
17MF02345 17MF02346
Using eyebolts, fit O-ring and cover

assembly (9), then tighten with mounting
bolts.
* Set the cover assembly to the case,
and tap uniformly with a plastic
hammer to press fit it.
AXA-. O-ring: Grease (G2-LI)
30-65
0
7. Idler gear assembly
* Match the production number and set
number on the inside and outside of the
bearing and the spacer to make sets when
assembling.
2) Using push tool, press fit outer race (7).
3) Set idler gear (5) to bottom of PTO case.
17MF02327 17MF02326
L
4) Set shaft to press, and using push tool 0,

press fit bearing (3).
I 1 I98FO2549
5) Using bolts 0, fit O-ring and align shaft

assembly (2) with idler gear, and assemble
temporarily.
* Set the shaft assembly to the case, and
tap uniformly with a plastic hammer to
press fit it. Leave approx. 5 mm space
to make it easier to assemble the
spacer and bearing.
H-X&- O-ring: Grease (G2-LI)
6) Using eyebolts, turn over PTO assembly.

7 17MF02349
30-66
0
8) Using copper bar, press fit bearing (6).
I 17MF02350
9) Fit plate (1) and tighten with mounting

bolts.
&IL Mounting bolt:


10) Using eyebolts, sling PTO assembly and
tighten shaft assembly fully.
11) Fit gasket and install lubrication tube.
8. Measuring
1) After completing the assembly, check the
17MF02351
backlash between the idler gear and the
power train pump drive gear and
hydraulic pump drive gear.
2) When measuring, put the probe of the
dial gauge at right angles against the
face of the gear tooth at the tip of the
idler gear. Hold the gear being
measured in place and measure the
readling when the idler gear is moved
backwards and forwards.
* Standard value for backlash:
0.204 -0.516 mm
* Measure at three or more places on
diametrically opposite sides.
30-67
0
DISASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY
* Keep the disc and plates in a flat place to

prevent distortion.
1. Transmission assembly
Set transmission assembly (1) to tool Dl.
I97FO3OU
2. Plate
Remove nut, then remove plate (2) together
with sleeve (3).
3. Cover
Remove mounting bolts, then remove cover
(4).
4. Charging pump assembly

Remove mounting bolts (5), then remove
charging pump assembly (6) together with
seat.
5. Lubrication valve assembly

Remove mounting bolts, then remove lubrica-
tion valve assembly (7).
6. Case
Remove mounting bolts, then use forcing
screws 0 to remove case (18).
* When removing the case, use a chain
block and lift the case off slowly.
17MF02354
30-68
a
7. Input shaft, No. 1 carrier assembly
A Make match marks on each plate and the
housing.
1) Remove tie bolt (9).
2) Using forcing screws 0, disconnect inpu
shaft and No. 1 carrier assembly (IO), use
eyebolts 0 to remove.
A Screw in the forcing screws uniformly
to disconnect the No. 1 carrier assem-
bly.
3) Disassemble input shaft and No. 1 carrier

. Disassembly of input shaft assembly
i) Remove snap ring (11, then remove
No. 2 sun gear (12).
ii) Remove snap ring (13).
iii) Set input shaft and No. 1 carrier assem-
bly to block 0, then tap with copper
hammer to remove input shaft assem-
bly (14).
17MF02357 17MF02358
17MF02359
iv) Set input shaft assembly (14) to press,

and remove bearing (15).
v) Remove spacer (16).

vi) Using push tool, remove No. 1 sun
gear (17) and spacer bearing (18).
30-69
0
vii) Set spacer bearing on block 0, then
use push tool to remove bearing (19)
from spacer (20).
viii) Set spacer bearing on block 0, then
use push tool to remove bearing (21)
from spacer (20).
17MF02363 11 17MF02364
l Disassembly of No. 1 carrier assembly

i) Remove inside snap ring (22).
ii) Set No. 1 carrier assembly on block,
then use push tool @ to remove No. 1
carrier assembly (24) from plate (23).
I97FO3076 I97FO3077 SI
2
iii) Remove spacer (25) from No. 1 carrier

assembly (24).
25,
I97FO3076
iv) Remove snap ring (26) from plate

(23).
v) Using push tool 0, remove bearing
(27).
i3
I97F0307E I 97FO308 Ii
30-70
0
vi) Remove snap ring (28), then remove
collar (29).
vii) Pull out shaft partially, remove ball
(30), then remove shaft (31).
j, Be careful not to lose the ball, and .
keep it in a safe place.
I97FO3083
17MF02365
viii) Remove gear (32) and thrust washer

(33) from carrier, then remove bearing
(34) from gear.
32
/“’
17MF0236E
z
8. Spring
Remove spring (35).
9. No. 1 discs, plates, springs

Remove springs (36), discs (37), and plates
(38) in turn. 36
35
10. No. 1 ring gear 38
Remove No. 1 ring gear (39).
11. No. 1 housing assembly

Using eyebolts 0, remove No. 1 piston (40)
17MF02367
together with No. 1 housing (41).
30-71
0
12. Spring
Remove spring (42).
13. No. 2 discs, plates. springs

(45) in turn.
14. Torque pins

Remove torque pins (46).
\ / 17MF02368
15. No. 2, 3 carrier assembly

1) Using eyebolts @, remove No. 2 and 3
carrier assembly (47) together with ring
gear.
Ir Sling the carrier, then insert a bar in
the ring gear holes and lever the carrier
to remove it.
7 17MF02369
2) Disassemble No. 2 and 3 carrier assembly

as follows.
i) Remove ring (48).
ii) Pull out shaft partially, remove ball (49),
then remove shaft (50).
* Be careful not to lose the ball, and keep
it in a safe place.
17MF02370 197FO3085
iii) Remove gear (51) and thrust washer

(53) from gear.
* The ring is held in position by the inter-
nal pushing force, so do not disas-
semble carrier and ring gear (54).
30-72
0
16. No. 2 ring gear
Remove No. 2 ring gear (55).
17MF02371
17. No. 2, No. 3 housing assembly

Using eyebolts 0, remove No. 2, 3 housing
(57) together with No. 2 piston (56).
17MF02372
18. No. 3 piston

8
Remove No. 3 piston (58).
17MF :02373
19. Spring
Remove spring (59).
20. Guide pin

Remove guide pin (60)

Remove springs (61), discs (62) and plates
(63) in turn. If&
EG =
I
I $1 17MF02374
30-73
a
22. Plate
Using eyebolts 0, remove plate (64).
MF02375

(67) in turn.
24. Torque pins

I 17MF02376

Using eyebolts 0, remove No. 4 piston
together with No. 4 housing (70).
26. Collar
Remove mounting bolts, then remove collar
(71).
17MF02377
I
17MF02378
27. No. 5 clutch assembly

1) Using eyebolts @I, sling No. 5 clutch assem-
bly (72), then tap bottom of output shaft 17MF0237S
with a copper hammer to remove.
30-74
CD
2) Disassemble No. 5 clutch assembly as
follows.
. Disassembly of No. 4 carrier assembly
i) Remove snap ring (73), then remove
No. 3 sun gear (74).
ii) Remove bearing and collar (75).
iii) Set bearing and collar on block 0,
then use push tool‘to remove bearing
(76) from collar (77).
-197F030&3 11 ‘d 17MF02380
78
17MF02381
iv) Using eyebolts @, remove No. 4 carrier

assembly (78) together with No. 4 sun
gear (79). 17MF02382 17MF02383
v) Remove No. 4 sun gear (79).
vi) Remove hub (80).

------lI
A Be careful not to damage the seal
ring when removing.
vii) Remove snap ring (81), then remove
8
collar (82). 81
17MF02384 17MF02385
viii) Remove shaft partially, remove ball

(83), then remove shaft (84).
A Be careful not to lose the ball, and
keep it in safe place.
ix) Remove gear (85) and thrust washer
(87) from gear (85).
30-75
a
x) Remove snap ring (88).
xi) Using push tool, remove bearing (89).
* The ring is held in position by the inter- 89
/
nal pushing force, so do not disas-
semble carrier and No. 3 ring gear (90).
I 17MF02388 1 17MF02389
l Disassembly of output shaft, housing as-

sembly
i) Remove mounting bolts, use forcing
screws @I to disconnect output shaft 91
and housing assembly (91), then use
eyebolts @I to remove.
A Screw the forcing screws in uni-
formly to disconnect the output shaft
and housing assembly.
w 17MF02390
ii) Remove springs (92), discs (93), and

plates (94) from drum (95) in turn.
17MF02391 17MF02392
iii) Set output shaft and housing assembly

in press, and using push tool @,
remove housing assembly (96) from
output shaft assembly (97).
* Set block @ in position to prevent
the housing assembly from falling
out.
I97FO3 IO5
30-76
0
iv) Set housing assembly (96) to press,
then use tool D2 to compress spring.
* Operate the press slowly and push
the spring down uniformly.
v) Remove snap ring (98). then remove
retainer (99), spring (IOO), and piston
(101).
17MF02393 ( 17MF02394 1
vi) Remove snap ring (102), then using

push tool, remove bearing (103).
197F03106 197FO3107
vii) Remove snap ring (104), then remove

bearing (105) from output shaft.
viii) Remove snap ring (106), then remove
bearing (107) from output shaft.
I97FO3 I OE
28. Snap ring

Remove snap ring (108).
108
29. Bearing
Using push tool, remove bearing (109).
30. Collar
Remove mounting bolts, then remove collar
(110).
31. Case
Remove case (11) from tool Dl.
I 17MF02395 17MF02396
30-77
0
ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY

parts of the bearings, and rotate them several
times.
* Coat the sliding surfaces of all parts with
engine oil before installing.
* Install the piston seal ring with the side
receiving the pressure facing the housing,
coat it with grease (G2-LI), and install it
uniformly so that it does not move to one Side receiving pressure
side.
N-^-\~~ Rotation seal ring: Fix in position - I-

l97F337
with grease (G2-LI), and be extremely
careful that it does not get caught
when assembling.
* Check that the snap ring is fitted securely in

the groove.
* Make match marks on each plate and the
housing when disassembling.
1. Case
Set case (111) to tool Dl.
2. Collar
1) Install seal ring to collar. cc2 17MF02397
2) Fit collar (110) and tighten with mounting
bolts.
j, Install the seal ring so that the side
receiving the pressure faces down.
3. Output shaft assembly

Using push tool, press fit bearing (105)
Set output shaft to press, then using push
tool 0, press fit bearing (109).
Install seal ring to output shaft.
Using eyebolts, set output shaft assembly
(97) to case, then using push tool @ press
fit bearing portion.
17MF02398
30-78
0
6) Fit collar (71) an tighten with mounting
bolts.
/?L Mounting bolt:

w Mounting bolt: 6.75 f 0.75 kgm
17MF02400
4. No. 5 clutch assembly

1) Assemble No. 5 clutch assembly as follows.
l Assembly of No. 4 clutch assembly
i) If No. 3 ring gear and No. 4 carrier are
supplied as individual parts, use tool
D3, and with ring (112) compressed,
set No. 3 ring gear (90) on No. 4 carrier,
then tap No. 3 ring gear with a plastic
hammer to assemble.
j, Check that the ring is fitted securely
in the groove.
lS;Fd3I 1511 17MF02401

--__
_
ii) Using push tool, press fit bearing (89)
17MF02402
iii) Assemble bearing (87) to gear (85),

then fit thrust washers (86) to both
ends and set to carrier.
iv) Fit ball (83) and press fit shaft (84).
* Check that the gear rotatessmoothly.
b/acg$d
85
83 17MF0236; 17MF02366
30-79
a
v) Install seal rng to collar.
vi) Install collar (82) and secure with snap
ring (81). 80
* Align the collar with the dowel pin,
and tap with a plastic hammer to
install.
vii) Install seal ring to hub.
viii) Install hub (80) to No. 4 carrier assem-
bly (78).
17MF02385 17MF02403
l Assembly of housing assembly

i) Using eyebolts 0, set drum (95) to
No. 4 carrier assembly.
17MF02404
ii) Install discs (93), springs (92), and

plates (94) in turn.
* No. of discs: 5
Sr No. of plates: 4
* No. of springs: 5
17MF02405 17MF02406
iii) Using push tool, press fit bearing

(103), and secure with snap ring (102).
197FO31 IO
30-80
0
iv) Install seal ring to piston.
v) Set piston (IOI), spring (IOO), and
retainer (99) to housing.
* Set the 3 springs as shown in the
diagram.
vi) Set housing assembly (96) in press,
then using tool D2, compress spring
* Operate the press slowly and press
the spring down uniformly.
/ 17MF02407 1j 17MF02393]
vii) Using eyebolts @, fit housing assem-

bly (96) and tighten with mounting
bolts.
,?_ Mounting bolt:
B Mounting bolt: 18 f 2 kgm
viii) Install seal ring to housing.
17MF02408
I
Using eyebolts @I, set No. 5 clutch assem-
bly (72) to output shaft.
I 17MF02379
Using push tool 0, press fit bearing

portion.
I 17MF02409
30-81
0
5. No. 4 sun gear
Install No. 4 sun gear (79).
6. Bearing, collar
1) Set collar (77) on block 0, then using push
tool, press fit bearing (76).
cd4 17MF02410
I 17MF02411
2) Install bearing and collar (75).

* Install with the collar lip at the top.
u4 17MF02412
7. No. 3 sun gear
Fit No. 3 sun gear (74) and secure with snap
ring (73).

1) Fit seal ring to No. 4 piston, and set in No.
4 housing.
2) Using eyebolts @I, align with dowel pin,
and install No. 4 piston (69) together with
No. 4 housing (70).
* Knock in the area around the dowel pin
with a plastic hammer until there is no
clearance at the contact surface.
9. Torque pins L
_--.
17MFr-17377
Install torque pins (68).

* Length of torque pin: 162 mm I

Install plates (67), discs (66), and springs (65)
in turn.
* No. of discs: 3
A NO. of plates: 3
17MF02376
30-82
0
11. Plate
Using eyebolts 0, align with dowel pin and
install plate (64).

Install discs (62), springs (61), and plates (63)
in turn.
h No. of discs: 3 60
* No. of plates: 2
13. Guide pin

Install guide pin (60).
14. Spring
j, Free height of spring: 91 mm
0” 17MF02374
z
z
15. No. 2,3 housing assembly 56
1) Install seal rings to No. 2 piston and No. 3
piston. \
2) Set No. 2 piston (56) and No. 3 piston (58)
to No. 2 and 3 housing (57).
* Tie the No. 3 piston and housing with
thin wire.
58’ 17MF02413
3) Using eyebolts 0, align with dowel pin

and install No. 2 piston (56), No. 2 and 3
housing (57), and No. 3 piston (58) as one
unit.
30-83
0
16. No. 2 ring gear
Install No. 2 ring gear (55).
* Install with the teeth cut on the inside
facing up.
17. Sleeve 17MF02371

If sleeve (113) has been removed, install to
bolt holes marked % in diagram below with
slit at bottom. r
Slit
% 17MF02415
18. No. 2,3 carrier assembly

1) Assemble No. 2 and 3 carrier assembly as
follows.
i) If ring gear and No. 2, No. 3 carrier are
supplied as individual parts, use tool
D4, and with ring (114) compressed,
set ring gear (54) on No. 2, 3 carrier,
then tap ring gear with a plastic
hammer to assemble.
ii) Assemble bearing (53) to gear (51),

then fit thrust washers (52) to both
50
53 52
30-84
0
__-__
iii) Fit ball (49) and press fit shaft (50).
* Check that the gear rotates smoothly.
iv) Install ring (48).
v) Install seal ring to No. 2 and 3 carrier
assembly.
48
i97FO3085 17MF02370
2) Using_ eyebolts @, install No. 2 and 3

carrier assembly (47) together with ring
gear.
17MF02417
3) Using push tool @, press fit bearing

portion of No. 2 and 3 carrier assembly.
17MF02418
19. Torque pins

install torque pins (46).
* Length of torque pin: 199 mm

Install discs (44), springs (43), and plates (45)
in turn.
* No. of discs: 5
A No. of plates: 4
21. Spring
A Free height of spring: 70 mm 7MF02368
30-85
0
1) Fit seal ring to No. 1 piston and set to No.
1 housing.
and install No. 1 piston (40) together with
No. 1 housing (41).
* Check that the spring is fitted securely
in the piston and the housing hole.
I97FO305 I
23. No. 1 ring gear

Install No. 1 ring gear (39).
* Install with the inside teeth facing up.

Install plates (38), discs (37), and springs (36)
in turn.
* No. of discs: 5
* No. of plates: 5
25. Spring
* Free height of spring: 66 mm 17MF02367
26. Input shaft, No. 1 carrier assembly

1) Assemble input shaft and No. 1 carrier
l Assembly of No. 1 carrier assembly
i) Assemble bearing (34) to gear (32),
then fit thrust washers (33) to both 32
L 17MF02366
ii) Fit ball (30) and press fit shaft (31).

* Check that the gear rotates smoothly.
iii) Fit collar (29) and secure with snap ring
(28).
I97F03083 17MF02365
30-86
0
iv) Using push tool, press fit bearing (27)
in plate (23), and secure with snap
ring (26).
v) install seal ring to plate.
vi) Install spacer (25) to No. 1 carrier
assembly (24).
i4
17MF02419 I97FO3078
vii) Set plate (23) to No. 1 carrier assem-

bly (24), then using push tool @, press
fit bearing portion.
viii) Secure with inside snap ring (22).
I 197FO31 1811 I97F03076
ix) Install No. 1 sun gear (17).

x) Using push tool, press fit bearings
(21) and (19) to spacer (20).
17MF02420
17MF02421 11 1 i’MF02422
xi) Using push tool CD, press fit spacer

bearing (18).
xii) Set spacer (16) in position. 17MF02423 17MF02361
30-87
0
l Assembly of input shaft assembly
i) Using press, press fit bearing (15) to
input shaft.
ii) Press fit input shaft assembly (14) to
No. 1 carrier assembly, and secure with
snap ring (13).
197FO31 IS 17MF02424
iii) Fit No. 2 sun gear (12) and secure with

snap ring (11).
iv) Install seal ring to No 1 carrier assem-
bly.
17MF02357

and set input shaft and No. 1 carrier
assembly (10) in position.
j, Lower slowly and set in position so that
the tip of the input shaft does not hit
the bearing.
* Tap the input shaft with a plastic
hammer to press fit the No. 2 carrier
and bearing portion.
17MF02425 17MF02426
3) Tighten 4 tie bolts (9) uniformly.

4) Tighten remaining tie bolts (9).
w Tie bolt: 26.5 f 1.5 kgm
5) Install seal ring to input shaft.
17MF02427
30-88
0
28. Air check
Using tool D5, check stroke of each piston.
* Air pressure: 5 - 6 kg/cm*
Unit: mm
Piston I Standard stroke
6.6
3 I 4.2
2 I 4.7
1 6.0 17MF02428
29. Case
Fit O-ring, then fit case (8) and tighten with
mounting bolts.
* Lower the case slowly with a chain block.
17MF02429
30. Output shaft bearing

1) Using push tool, press fit bearing (107) to
output shaft, then secure with snap ring
(106).
17MF02430
31. Lubrication valve assembly

Fit O-ring, then install lubrication valve
assembly (7), and tighten with mounting
bolts.
32. Control valve assembly

Fit O-ring, then install control valve assembly
(6) together with seat, and tighten mounting
bolts (5).
Y-X~ Mounting bolt:
m Mounting bolt: 5 f 0.5 kgm 17MF02353
30-89
a!
33. Cover
Fit gasket, then fit cover (4) and tighten with
mounting bolts.
* Remove plug (115), and align the position
of the lever and yoke of the spool.
34. Plate
Fit gasket, then fit plate (2) together with
sleeve (3), and tighten with nut.
35. Transmission assembly I

Remove transmission &sembly (1) from tool
Dl.
I97FO3044
c
30-90
a
DISASSEMBLY OF STEERING CASE ASSEMBLY
Steering valve assembly

Remove mounting bolts, then using shackle
0, remove valve assembly (1).
Clutch, brake assembly

Using tool E, sling clutch and brake assembly,
remove mounting bolts, then remove clutch
and brake assembly (2).
* When removing the clutch and brake
assembly, be careful not to damage the
discs and plates.
* Remove the clutch and brake assembly on
the opposite side in the same way.
17MF02433
3. Shafts
Remove left and right shafts (3).
4. Lubrication tubes
Remove lubrication tubes (4) and (5).
I96FO2646 17MF02434
5. Pipes
* When removing the pipes, be careful not
to damage the O-rings.
1) Remove left and right pipes (6).
2) Remove pipe (7).
17MF02435 17MF02436
6. Seat
0, remove seat (8)
17MF02437
7. Input shaft
2) Remove input shaft (10).
8. Transfer, gear housing assembly

1) Install guide bots 0 to steering case.
2) Using forcing screws 0, pull out housing
assembly.
3) Using shackle 0, remove housing assem-
bly (11).
9. Cage
1) Turn over steering case so that R.H. cage 17MF02438 17MF02439
is at top.
2) Remove mounting bolts, and using forc-
ing screws, remove bearing cage (12),
then remove shim.
3) Remove outer race (13) from bearing
cage.
17MF02440 17MF02441
13
/
17MF02443 17MF02442
30-92
0
4) Remove mounting bolts, then using
eyebolts 8, remove cage (14).
ed ==Q-h=J
17MF02444
10. Bevel gear, shaft assembly

1) Using eyebolts, remove bevel gear and
shaft assembly (15).
2) Assemble bevel gear and shaft assembly

as follows.
i) Remove nut and pull out reamer bolt,
then remove bevel gear (16).
ii) Using puller 0, remove bearings (17)
and (18) from shaft (19). 17MF02445
11. Cage
1) Turn over steering case.
2) Remove mounting bolts, and using forcing
screws, remove bearing cage (20), then
remove shim.
3) Remove outer race (21) from bearing
cage.
17MF02446
I 17MF02449 7MF02448
30-93
0
ASSEMBLY OF STEERING CASE ASSEMBLY
*Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with
1. Cage
Using push tool, press fit outer race (21) in
bearing cage.
17MF02449 1
Assemble shim, then install bearing cage

(20), and tighten with mounting bolts.
* Standard shim thickness: 2mm
m Mounting bolt: 18 f 2 kgm
MF02449
2. Bevel gear, shaft assembly

1) Assemble bevel gear and shaft assembly
as follows.
i) Set shaft (19) in press, and using push
tool @, press fit bearing (18).
ii) using push tool @I, press fit bearing
(17).
17MF0244 17MF02451
iii) Set bevel gear (16) to shaft, then fit

reamer bolt and tighten with nut.
QZT Nut: 18 + 2 kgm
17MF02452
30-94
0
2) Turn over so that R.H. cage of steering
case is at top.
3) Using eyebolts, install bevel gear and
shaft assembly (15).
17MF02445
3. Cage
1) Using eyebolts @, fit cage (14) and tighten
with mounting bolts.
QF Mounting bolts: 18 f 2 kgm
2) Using push tool, press fit outer race (13) to

bearing cage.
17MF02444
I 17MF02443
3) Assemble shims, then fit bearing cage (12)

* Standard shim thickeness: 2mm
17MF02442
4. Adjusting preload
Put push-pull scale @ in contact with tip of
bevel gear teeth, and measure rotating
torque of bevel gear shaft.
* Standard value for rotating torque: 2.2 -
2.8 kg
* Rotate the bevel gear 2 or 3 truns before
measuring the rotating torque.
* If the value is not within the standard
range, adjust as follows.
If torque is too HIGH, INCREASE shim
thickness
If torque is too LOW, DECREASE shim
thickness
30-95
0
5. Transfer, gear housing assembly
1) Install guide bolts @ in steering case.
2) Fit O-ring, then using shackle 0, set
housing assembly (11) to steering case,
w Mounting bolt: 18 + 2 kgm
17MF02454
-_-
6. Adjusting tooth contact, backlash
1) Adjusting backlash
Put the probe of dial gauge 0 in contact
with the tip of the bevel gear teeth at right
angles. Hold the bevel pinion in position,
and read the measurement when the bevel
gear is moved forward and backward.
Sr Standard value for backlash:
0.3 - 0.4mm
* Measure at least six points diametri-
cally opposite around the gears.
I96FO2664
If the result of the inspection shows that the

correct backlash is not being obtained,
r
adjust as follows.
If backlash is too small

Adjust shim at bevel pinion side to
move bevel pinion in direction A; or
adjust shim at bearing cage of bevel
gear shaft to move bevel gear in direc-
tion B.
* Backlashis small I97F342
If backlash is too large

Adjust shim at bevel pinion side to
move bevel pinion in direction A; or
adjust shim at bearing cage of bevel
gear shaft to move bevel gear in direc-
tion B.
* When adjusting the shim at the bearing
cage of the bevel gear shaft, do not
change the preload of the bearing.
Adjust by moving shims from one side
to the other. Always keep the same
total thickness of shims.
* Backlashis large l97F343
30-96
0
2) Checking tooth contact
Testing
i) 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 b a
on the teeth.
ii) Tooth contact should be checked with
no load on the bevel pinion. It should
be in the center of the tooth height.
The tooth contact pattern should be
located 20 to 50% from the small end
“d”, and should cover 30 to 75% of
the length of the tooth.
In addition, there should be no strong
contact at the addendum “a” or
I97F344
dedendum “b” (tip or root of the gear
teeth) or at the big end “c” and small
end “d”.
If the gears are adjusted to this
pattern, the tooth contact will be
correct when load is applied.
a: Addendum e: Width contact
b: Dedendum f: Center of tooth
C: Big end contact
d: Small end
d
Adjustment
If the result of the inspection shows that
the correct tooth contact is not being
obtained, adjust again as follows:
i) If bevel pinion is too far from center
I97F345
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.
l Procedure and adjustment
Adjust the thickness of the shims
at the bevel pinion to move the
bevel pinion in direction A.
Adjust the shim thickness at the
bearing cage of the bevel gear
shaft to move the bevel gear in
direction B. Check the tooth con-
tact pattern and backlash again.
ii) If bevel pinion is too close to center
line of bevel gear.
I97F346
Contact is at the small end of the
concave tooth face of the bevel gear
and the big end of the convex tooth
face.
l Procedure for adjustment
Adjust the thickness of the shims
fl
at the bevel pinion to move the
bevel pinion in direction A. BC
Adjust the shim thickness at the
bearing cage of the bevel gear
shaft to move the bevel gear in
direction B. Check the tooth con-
tact pattern and backlash again.
* When adjusting the bevel gear to A
the right or left, do not change the
preload of the bearing. Adjust by l97F347
moving shims from one side to the
other. Always keep the same total
thickness of shims.
30-97
0
7. Input shaft
1) Assembly input shaft (10) in case.
2) Secure with snap ring (9).
17MF02439
8. Seat
Fit O-ring, then using eyebolts 0, install seat
(8), and tighten with mounting bolts.
9. Pipes
/-“~ O-ring: When installing the pipes,
coat the o-rings thinly with
grease (G2-LI).
1) Fit O-rings to both ends, and install pipe
(7).
2) Fit O-rings to both ends, and intall pipe (6).
17MF02435
10. Lubrication tubes

Fit gaskets and install lubrication tubes (4)
and (5).
17MF02434
30-98
0
11. Clutch, brake assembly
Fit O-ring, then using tool E, set clutch and
brake assembly (2) in steering case, and
tighten with mounting bolts.
When installing the lcutch and brake

assembly, be careful not to damage the
discs and plates.
Install the clutch and brake assembly on
the opposite side in the same way.
12. Shafts
Install left and right shafts (3).
* Procedure for installing shaft
1) Remove plug (22), and screw in bolts
(Thread Dia. = 14mm, Pitch = 2.0mm,
Length = 90mm) to pull in piston and
release brake.
2) Fit right shaft, then rotate bevel gear
and install left shaft.
z
:
‘0
13. Steering valve assembly
Fit gasket, then using shackle 0, install valve
assembly (1).
30-99
0
DISASSEMBLY OF STEERING CLUTCH, BRAKE ASSEMBLY
A Keep the discs and plates in a flat place to

prevent distortion.
DISCONNECTION OF CLUTCH BRAKE

ASSEMBLY
1. Plate
Remove mounting bolts, then remove plate
(1).
2. Collar
Remove collar (2).
3. Plate
Remove mounting bolts, then remove plate
(3).
4. Sleeve
1) Using forcing screws 0, remove sleeve
(4).
2) Using puller 0, remove bearing (5) from
sleeve.
5
17MF02458
5. Clutch, brake assembly I
1) Turn over clutch and brake assembly.

2) Using eyepbolts 0, disconnect clutch
assembly (6) and brake assembly (7).
17MF02459
30-100
0
DISASSEMBLY OF CLUTCH ASSEMBLY
6. Clutch stopper
Remove mounting bolts, then remove clutch 10
/
stopper (8). /
7. Discs, springs, plates

Remove discs (9), springs (10) and plates (11)
in turn.
* No. of discs: 8
No. of plates: 8
17MF02460
II 17MF02461
8. Torque pins
9. Clutch hub
Q, remove clutch hub (13).
12
17MF02462 17MF02463
Plate
ing screws 0, remove plate (14).
2) Remove outer race (15) from plate.
17MF02464 I98FO2675
11. Bearing cage assembly

1) Remove bearing cage assembly (16).
2) Disassemble bearing cage assembly as
follows.
i) Remove mounting bolts, then remove
plate (17).
ii) Remove nut (18).
iii) Remove bearing (19), spacer (20), and
bearing (21) from cage (22).
17MF02465 17MF02466
30-101
0
12. Spacer
Remove spacer (23).
23
13. Clutch cage
1) Using eyebolts 0, remove clutch cage
24
(24).
17MF02467 17MF02468
2) Using puller, remove outer race (25).
17MF02469
14. Piston
Remove piston (26).
15. Belleville springs

Remove Belleville springs (27).
A No. of Belleville springs: 2
1 17MF02470 j
16. Brake hub r Ii

1) Turn over clutch housing
eyebolts @I, remove brake hub (28) from
clutch housing (29).
3) Remove bearing (30) from brake hub (28).
1 2' 17MF02471 /j 17MF02472
30-l 02
0
DISASSEMBLY OF BRAKE ASSEMBLY
17. Brake stopper

Remove mounting bolts, then remove brake
stopper (31).

Remove discs (32), springs (33), and plates
(34) in turn.
* No. of discs: 8
No. of plates: 7
A Keep the discs and plates in a flat place to
17MF02473 17MF02474
prevent distortion.
19. Torque pins

20. Brake cage

z 1) Remove mounting bolts, then using 17MF02475
z eyebolts 0, remove brake cage (36).
z
2) Using puller, remove outer race (37).
38
/
21. Piston
Remove piston (38).
17MF02477 17MF02478

Remove Belleville springs (39).
* No. of Belleville springs: 3
23. Outer race

Using push tool 0, remove outer race (40).
17MF02479
30-103
0
ASSEMBLY OF STEERING CLUTCH, BRAKE ASSEMBLY
Clean all parts, and check for dirt or damage. t
&II& Seal ring: Grease (G2-LI)
Coat the mating surface of the disc and plate

with engine oil.
. ASSEMBLY OF BRAKE ASSEMBLY

I98FO2690
1. Outer race
Using push tool @, install outer race (40).
Install Belleville springs (39).
* Install the Belleville springs as shown in
the diagram below.
17MF02480
17MF02481
1. Piston
Fit seal ring and install piston (38).
17MF02478 17MF02482
4. Brake cage
1) Using push tool 0, press fit outer race
(37).
2) Using eyebolts, fit seal ring, install brake
cage (36) and tighten with mounting bolts.
w Mounting bolt: 11.25 + 1.25 kgm
5. Torque pins
17MF024.83
30-104
0
6. Brake hub
Using eyebolts 0, set brake hub (28) in brake
housing.
a II
Install plates (34). springs (33) and discs (32)
in turn.
* No. of discs: 8
No. of plates: 7
17MF02484 II 17MF02474
8. Brake stopper
1) Fit stopper (31), then tighten with mount-
ing bolts.
m Mounting bolt: 18 -I 2 kgm
* Check that the springs are fitted

securely on the torque pins, then
tighten the clutch stopper.
2) After installing brake stopper, use eyebolts
0 to remove brake hub (28).
2 17MF02485 17MF02486
z
0’
0 Assembly of clutch assembly
9. Brake hub
1) Using push tool @I, press fit bearing (30) to
brake hub (28).
2) Using eyebolts, set brake hub (28) to
clutch hosing (29), then tighten with
mounting bolts.

1) Turn over clutch housing.
17MF02487 17MF02488
2) Install Belleville springs (27).
* Install the Belleville springs as shown in
the diagram below.
26
17MF02489
11. Piston I96FO2660 17MF02470

i
Fit seal ring and install piston (26).
30-105
0
I -lr
12. Clutch cage
3) Using eyebolts 0, install clutch cage (24). (
j 17MF02490 17MF02468

1) Assemble bearing cage assembly as
follows.
i) Using push tool, pres fit bearing (21)
to cage (22).
ii) Install spacer (20).
iii) Using push tool, press fit bearing (19).
iv) Tighten nut (18).
v) Install plate (17), then tighten with
mounting bolts.
m Mounting bolt: 2.5 + 1 kgm
2) Press fit bearing cage assembly (16). I 17MF02466 17MF02465

* Tap the cage assembly with a plastic
hammer to press fit.
14. Plate
2) Install plate (14), then tighten with mount-
ing bolts.
w Mounting bolt:
11.25 f 1.25 kgm
I98FO2675 17MF02491
15. Clutch hub

Using eyebolts 0, install clutch hub (13) and
m Mounting bolt: 5.5 k 2 kgm
16. Torque pins

17MF02463 17MF02462
30-l 06
0
Install plates (II), springs (10) and discs (9) in
turn.
A No. of discs: 8
No. of plates: 8
18. Clutch stopper

Install clutch stopper (8), then tighten with
mounting bolts.
A Check that the springs are fitted securely
on the torque pins, then tighten the clutch
stopper. 11
17MF02461 17MF02460
m Stopper mounting bolt: 18 f 2 kgm
-
l Connection of clutch, brake
assembly
19. Clutch, brake assembly

Using eyebolts 0, set brake assembly (7) in
position on clutch assembly (6).
8 ‘6 17MF02492
z
z
20. Sleeve
1) Using push tool 0, press fit bearing (5) in
sleeve.
2) Fit O-ring and seal ring, then set sleeve (4)
in clutch and brake assembly.
17MF02494
21. Plate
Install plate (3), then tighten with mounting
bolts.
m Mounting bolt: 6.75 + 0.75 kgm
22. Collar
Install collar (2).
23. Plate
Install plate (I), then tighten with mounting
bolts.
I98F02667
30-107
0
DISASSEMBLY OF TRANSFER GEAR HOUSING ASSEMBLY
1. Transfer gear housing assembly

Set transfer gear housing assembly on block.
2. Lubrication tube
Remove lubrication tube (1) together with
block.

1) Remove bearing cage assembly (2).
2) Using push tool 0, remove bearing (3).
- m
17MF02495 17MF02496
4. Drive gear
1) Remove drive gear (4).
2) Using puller 0, remove inner races (5) on
both sides of drive gear.
17MF02497 ;1 17MF02498
5. Lubrication tube
1) Turn over transfer gear housing assembly.
2) Remove lubrication tube (6).
6. Pinion, housing assembly

eyebolts 0, remove pinion and housing
assembly (7).
2) Remove shim (8).
l96FO2698
17MF02499
3) Disassemble pinion and housing assembly

as follows.
i) Remove mounting bolts, then using
forcing screws 0, remove cover (9).
ii) Remove holder (10).
0 I
17MF02500 17MF02501
30- 108
0
iii) Set pinion gear assembly in press,
then using push tool 0, remove
pinion gear (11).
* When removing the pinion gear,
support the bottom of the pinion
gear securely with a wooden
block.
iv) Remove bearing cage assembly (12).
il 17MF02502
4 Using push tool @, remove outer race

(13), bearings (14), and (15), collar
(16) and outer race (17).
* Keep the bearings and collar as a
set.
vi) Remove spacer (18) from driven gear
(19).
198Fl318 (
198FO2703
vii) Remove holder (20).

viii) Using puller 0, pull out inner race (21),
From pinion gear.
17MF02503 11 17MF02504
I
7. Bearings
1) Using push tool @, remove bearing (22).
2) Using puller, remove bearing (23).
30-l 09
0
ASSEMBLY OF TRANSFER GEAR HOUSING ASSEMBLY
+ Clean all parts, and check for dirt or damage.

1. Bearings
1) Using push tool @I, press fit bearing (23).
2) Turn over case, then using push too, press
fit bearing (22).
17MF02506
2. Pinion, housing assembly

1) Assemble pinion and housing assebly as
follows.
i) Press fit inner race (21) to pinion gear.
ii) Install holder (20).
@E Mounting bolt:
28.25 + 3.25 kgm
iii) Set driven gear (19) and spacer (18) to

pinion gear (11).
iv) Using push tool, press fit outer race
(17).
v) Assemble bearing (15), collar (16), and
bearing (14).
vi) Using push tool, press fit outer race
(13).
* Use the bearings and collar as a
set.
I SSFO2705
vii) Set bearing cage assembly (12) on

pinion gear, then using push tool @,
press fit bearing cage assembly.
17MF02508
30-110
0
viii) Install holder (10).
w Mounting bolt:
28.25 + 3.25 kgm
10
17MF02501 17MF02509A
ix) Fit O-ring, then install cover (9) as

follows.
l Tighten cover mounting bolts tempo-
rarily in the order shown in diagram
on right. (Approx. 5 kgm)
l Check clearance A between cover and
cage, and check that it is as follows.
Clearance A: 0.48 f 0.27 mm
* Check that the variation around the
whole circumference is less than 0.05
mm. Check also that the bearing is
completely press fitted and is not at
an angle. 17MF02851
l After checking the above, tighten the
mounting bolts of cover (9) in the

order shown in the diagram on the
right.
w Mounting bolt:
6.75 + 0.75 kgm
7MF02852
2) Assemble shim (8).

* Standard shim thickness: 2mm
3) Fit O-ring, then using eyebolts 0, install
pinion and housing assembly (7).
3. Lubrication tube
Fit gasket and install lubrication tube (6).
30-111
0
4. Drive gear
1) Turn over transfer gear assembly.
2) Using push tool 0, press fit inner races (5)
to both sides of drive gear.
3) Set drive gear (4) in case.
I
\
I98F02707A’ 17MFO2497

1) Using push tool 0, press fit bearing (3).
2) Install bearing cage assembly (2).
6. Lubrication tube
Fit gasket and O-ring, and install lubrication
tube (1).
I 17MF02510 11 17MF02495 )
30-112
0
REMOVAL OF TORQUE CONVERTER VALVE ASSEMBLY
1. Remove floor plate.
2. Disconnect connector (1).
3. Disconnect 4 pressure detection hoses (2).
4. Remove valve assembly (3). m
I-/ m H k-F19802211
z INSTALLATION OF TORQUE CONVERTER VALVE ASSEMBLY

2
removal.
30-113
0
DISASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY
1. Disassemby of lockup valve

1) Remove solenoid valve assembly (1).
2) Remove cover (2), then remove spring (3).
3) Remove cover (4), then remove piston (5).
4) Pull out spool (6).
2. Disassembly of torque converter relief valve

1) Remove cover (7), then remove spring (8).
2) Remove cover (9), then remove valve (IO),
spring (II), and valve (12).
3. Disassembly of main relief valve

1) Remove cover (14), then remove shim (15)
and spring (16).
2) Remove cover (17), then remove valve
(18), spring (19), and valve (20).
4. Disassembly of stator clutch modulation

valve
1) Remove cover (22), then remove piston
(23), and spring (24).
2) Remove ring (25) from body.
(27), spring (28). and valve (29).
5) Remove shim (31) from spool.
5. Disassembly of lockup clutch modulation

valve
1) Remove cover (32), then remove piston
(33), and spring (34).
2) Remove ring (35) from body.
(37), spring (38), and valve (39).
5) Remove spool (41) and shim (42) from
spool (40).
30-114
0
i
l!
17MF02511
30-l 15
0
ASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY
* Clean all parts, and check for dirt or damage. 5. Assembly of lockup valve
Coat the‘ sliding surfaces of all parts with 1) Assemble spool (6).
engine oil before installing. 2) Assemble piston (5) to cover (4), then fit
* Assemble valves (39) and (37), (29) and (27), O-ring and insall cover.
(20) and (18), and (12) and (10) in the direc- 3) Assemble spring (3).
tion show in the diagram so that the valve 4) Fit O-ring and install cover (2).
with the hole in the center is on the inside of 5) Fit O-ring and install solenoid valve assem-
the spool. bly (1).
1. Assemblv of lockuD clutch modulation valve

II Set shim (42) on spool (41), then assemble
to spool (40).
2) Assemble spool (40).
3) Assemble valve (39), spring (38) and valve
(37) to spool, then fit O-ring and install
cover (36).
4) Assemble ring (35) to body.
5) Assemble spring (34).
6) Assemble piston (33) to cover (32), then fit
O-ring and install cover.
2. Assembly of stator clutch modulation valve

1) Assemble shim (31) to spool (30).
cover (26).
4) Assemble ring (25) to body.
6) Assemble piston (23) to cover (22), then fit
3. Assembly of main relief valve

cover (17).
4) Assemble shim (15) to cover (14), then fit
4. Assembly of torque converter relief valve

Assemble spool (13).
Assemble valve (12), spring (11) and valve
cover (9).
Assemble spring (8).
0
-o-_u
-0 T --
/27
Fit O-ring and install cover (7).
30-116
0
REMOVAL OF TRANSMISSION CONTROL VALVE ASSEMBLY
1. Remove operator’s seat (1).
2. Remove suspension assembly (2) together

with turntable.
Suspension, turntable assembly:
& kg
60 kg
3. Remove operator’s seat bottom cover (3).
4. Disconnect brake rod (4). 1111

* Remove the clamp, then move the steer- Y i -
ing control cable to the side. 17MF02513
5. Disconnect 4 wiring connectors (5).
6. Disconnect control cables (6). 1111
7. Remove cover (7) together with sleeve. Iy21
8. Remove inspection plug (8).
9. Remove tube (9), then using forcing screws,

remove control valve cover (10). Iy31
10. Remove 4 bolts (II), then remove valve

assembly (12). m Q
z 17MF02514 17MF025:j
E
0
INSTALLATION OF TRANS-
MISSION CONTROL VALVE
ASSEMBLY

removal.
Kl
Bend the cotter pin securely.
El
a Sleeve O-ring: Grease (G2-LI)
Check through the plug hole in the cover

that the lever and yoke are meshed, then
tighten the mounting bolts.
When installing the cover, if the dowel pin
portion does not go in when it is tapped
vvith a plastic hammer, remove the cover,
correct the meshing of the lever and yoke,
then install again.
30-117
0
DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY
1. Disassembly of modulating valve, quick 2. Disassembly of directional valve, speed

return valve, reducing valve valve
1) Remove snap ring (6), then remove 1) Remove spool (24).
retainer (7), spring (9), shim (8), valves (5), 2) Remove spool (25).
(4), and (2), and spring (3).
2) Remove snap ring (lo), then remove stop-
per (11) and spool (12).
3) Remove snap ring (13), remove stopper
(14), then remove valves (15) and (17),
spring (16), spool (18), shims (19) and (20),
and springs (21) and (22).
4) Remove cover (1) then remove vlave (23).
17MF02518
30-118
0
ASSEMBLY OF TRANSMISSION CONTROL VALVE

1. Assembly of modulating valve, quick return

valve, reducing valve
l)Assemble valve (23), and install cover (1).
2)Fit springs (22) and (21), shims (20) and
(19), and spool (18), then fit valve (17),
spring (16). and valve (15), and secure
with stopper (14) and snap ring (13).
* Standard shim thickness: 1 .Omm
3) Fit spool (12). and secure with stopper (11)
and snap ring (10).
4) Fit valve (2). spring (3). and valves (4) and
(5), then fit spring (9) and shim (8). and
secure with stopper (7) and snap ring (6).
* Standard shim thickness: 2.5 mm
2. Assembly of directional valve, speed valve

1) Install spool (24).
2) Install spool (25).
30-119
0
REMOVAL OF STEERING CONTROL VALVE ASSEMBLY
1. Remove fuel tank assembly.

For details, see REMOVAL OF FUEL TANK
ASSEMBLY.
2. Disconnect 2 yokes (1) of steering control

cable.
3. Disconnect brake rod (2). m
4. Disconnect 2 pin puller hoses (3).
5. Disconnect 4 pressure detection hoses (4).
6. Remove steering valve assembly (5). m
el kg Steering valve assembly: 55 kg
17MF02520
INSTALLATION OF STEERING
CONTROL VALVE ASSEMBLY

removal.
* Bend cotter pin securely.

1121
* Bend cotter pin securely.
m
w Mounting bolt: 11 + 1.5 kgm
30-l 20
0
DISASSEMBLY OF STEERING ASSEMBLY OF STEERING
CONTROL VALVE ASSEMBLY CONTROL VALVE ASSEMBLY
1. Disassembly of check valve * Clean all parts, and check for dirt or damage.
1) Remove block (1). then remove spring (2). Coat the sliding surfaces of all parts with
2) Remove snap ring (3), then remove seat engine oil before installing.
(4) and check valve (5) from valve body
(6). 1. Assembly of brake valve
Assemble piston (37), valve (36), spring (35)
2. Remove lever case from valve body (6). and shim (34) in body (6), then fit O-ring and
install plug (33).
3. Remove bolts (8), then remove spring (9) and * Shim thickness: 6 X 0.5 mm
shim (10).
2. Assembly of clutch valve
4. Remove 3 seat mounting bolts (II), then Assemble valve (32), piston (31), spring (30)
remove seat (12). and shim (29) in body (6), then fit O-ring and
install plug (28).
5. Disassembly of clutch shaft assembly * Shim thickness: 2 X 0.5 mm
1) Remove shaft assembly (13) from body
(6). 3. Assembly of brake shaft assembly
2) Remove nuts (14) and (15), then remove 1) Set guide (26), spring (25), guide (24) and
guide (16), spring (17) and guide (18) from cylinder (23) in shaft (27), then install nuts
shaft (19). (22) and (21).
2) Assemble brake shaft assembly (20) in
6. Disassembly of brakes shaft assembly body (6).
1) Remove brake shaft assembly (20) from
body (6). 4. Assembly of clutch shaft assembly
2) Remove nuts (21) and (22), then remove 1) Set guide (18), spring (17) and guide (16)
cylinder (23), guide (24), spring (25) and in shaft (19), then install nuts (15) and (14).
guide (26) from shaft (27). 2) Assemble shaft assembly (13) in body (6).
z
7. Disassembly of clutch valve 5. Fit O-ring and set seat (12) in postion, then ?
z
Remove plug (28), then remove shim (29), tighten mounting bolts (11).
spring (30), piston (31) and valve (32) from
body (6). 6. Set shim (IO) and spring (9) in position, then
install bolts (8).
8. Disassembly of brake valve * Shim thickness: 1 X 1.0 mm
Remove plug (33), then remove shim (34),
spring (35), valve (36) and piston (37) from 7. Fit gasket and install lever cases (7) to valve
body (6). body (6).
8. Assembly of check valve

1) Set seat (4) and check valve (5) in body
(6), and install snap ring (3).
2) Set spring (2) in body (6), then fit O-ring
and install block (1).
30-122
a
31
30
\
32
iSSFl324
30-123
0
SCAVENGING PUMP ASSEMBLY
1. Drain oil
:
u Power train oil: Approx. 120 Q
2. Open inspection cover of under cover.

* Hold the inspection cover securely, then
remove the bolts and open the cover.
3. Remove pump outlet tube (1).
4. Disconnect pump inlet tube (2).
5. Remove 4 pump mounting bolts, then /

17MF02521
remove pump assembly (3).
& kg Pump assembly: 40 kg
INSTALLATION OF SCA-
VENGING PUMP ASSEMBLY

removal
. Refilling with oil
Add oil to the specified level, and run the
engine to circulate the oil through the system.
Then check the oil level again.
30-124
0
REMOVAL OF POWER TRAIN PUMP ASSEMBLY
1. Remove left and right engine side covers,

then remove left step cover (1) and cab front
cover (2).
2. Disconnect 2 air conditioner hoses (3).
3. Sling torque converter and transmission oil

strainer (4), disconnect 4 connecting bolts
holding to pump, then remove strainer.
4. Remove 2 pump mounting bolts, install guide

bolts 0 (Dia. = 12 mm, pitch = 1.75 mm,
length = 200 mm), and sling pump assembly
(5).
5. Remove remaining 2 pump mounting bolts,

raise pump assembly (5) and pull out to
remove.
f=GzL Power train pump assembly: 40 kg
17MF02524
8
z!
b
s INSTALLATION OF POWER
TRAIN PUMP ASSEMBLY

removal.
Add oil to the specified level, and run the
engine to circulate the oil through the system.
Then check the oil level again.
30-l 25
0
REMOVAL OF FINAL DRIVE ASSEMBLY
1. For detail, see REMOVAL OF TRACK SHOE

ASSEMBLY
2. Using jack 0 (50 ton) and ripper, jack up
machine and set stand 0 (height: approx.
700 mm) under equalizer bar and rear of
chassis.
A Set the stand securely in position
3. Drain oil from final drive case.

:
u Final drive case:
Approx. 43 Q (Each side)
4. Remove covers (I), (2).
6. Using bolts 0, pull out shaft (4) until point

where spline comes out.
* If the shaft will not come out, move the
sprocket backwards or forwards, and
adjust to a position where the shaft will
come out.
7. Leaving 2 or 3 mounting bolts at top from 8

mounting bolts (5) on inside and 17 on
outside, remove mounting bolts.
8. Remove 3 mounting bolts of final drive case

cover, then set tool F and lever block (l/2 t),
and sling final drive assembly (6).
9. Remove remaining mounting bolts, then

move to outside and remove from case.
* Operate a lever block and twist with a bar
to keep the clearance at the mating
surface of the case and final drive case
assembly uniform when removing.
& kg Final drive case assembly: 1950 kg
lO.Remove shaft (4). 17MF02530 17MF02531
30-126
0
INSTALLATION OF FINAL DRIVE ASSEMBLY

removal.
Y-ZIL Mounting bolt:

@Z Mounting bolt: 135 I!I 15 kgm

* Supply engine oil to the specified level
from filler port.
23 Final drive case:

Approx. 43 P (Each side)
30-127
0
DISASSEMBLY OF FINAL DRIVE ASSEMBLY
1. Cover
1) Set final drive assembly on block @
(height: approx. 50 mm).
2) Remove mounting bolts (1) and (2), then
using eyebolts 0, remove cover (3).
17MF02532 17MF02533
2. Hub
1) Remove plate (4).
2) Lift off hub (5).
17MF02534 17MF02535 j g
b
_
3. Sprocket, drum assembly

1) Remove mounting bolts (6), then remove
holder (7).
2) Using eyebolts 0, sling sprocket and drum
assembly (8).
3) Using tool Gl, remove sprocket and drum
assembly together with bearing (9).
I97F359
30-128
0
4) Disassemble the sprocket and drum
assembly
i) Set sprocket and drum assembly on
block (height: 100 mm).
ii) Remove flooting seal (IO).
* Keep the floating seal in a safe
place to protect it from damage.
17MF02538
iii) Remove mounting bolts, then remove

seal (11).
iv) Remove outside drum mounting bolts
(12).
17MF02539 1 17MF02540
v) Remove mounting bolts (13) and (14),

then using eyebolts 0, remove cover
(15).
j 17MF02541 I 17MF02542
vi) Remove mounting bolts, then remove

seal (16).
vii) Remove inside drum mounting bolts
(17).
17MF02543 17MF02544
30-129
0
viii) Lift off inside drum (18).
ix) Using eyebolts 0, remove inner drum

assembly (19) from outside drum (20).
x) Remove outer race (21).
7
18
xi) Weld plate of tool G2 around whole
I98FO2722
circumference of rubber bushing, then
set tool G2 as shown in diagram
below, and pull out rubber bushing
(22).
G2
198Fl412 17MF02545
22mm
,
, 17MF02546 Section A-P 17MF02546
4. Wear guard
Remove mounting bolts, then remove wear
guard (23).
17MF02547
30-130
0
c
5. Cover assembly
1) Remove mounting bolts (24), then using
eyebolts @, remove cover assembly (25).
17MF02549 17MF02550
2) Disassemble cover assembly as follows.

floating seal cage (26).
ii) Remove floating seal (27).
A Keep the floating seal in a safe
------In
place to protect it from damage.
1 17MF02551 11 17MF02552 _I
iii) Remove spacer (28).

iv) Remove bearing (29).
29
20
17MF02553
L
v) Turn over cover, and remove plate (30).

vi) Lift off ring gear (31).
17MF02554 I 17MF02555
30-l 31
0
6. Carrier assembly
1) Using eyebolts 0, remove carrier assem-
bly (32).
2) Set carrier assembly on block (height: 100
mm), and disassemble as follows.
i) Remove spacer (33). 32
I 17MF02556]1 17MF02557
ii) Using puller 8, remove outer race (34).
17MF02558

holder (35).
iv) Using tool G3, remove shaft (36).
v) Remove gear (37), bearing (38), and
spacer (39).
vi) Remove outer race (40) from gear.
40 38
17MF02561 17MF02562
30-132
0
7. Sun gear, shaft assembly
1) Remove sun gear and shaft assembly (41).
17MF02563
2) Disassemble sun gear and shaft assembly

as follows.
il Remove mounting bolts, then remove
plate (42).
ii) Using puller 0, remove bearing (43).
-I
17MF02564 17MF02565

plate (44).
iv) Using push tool 09, remove sun gear
@
(45) from shaft (46).
/
17MF02566 %02567
8. Hub, shaft assembly

1) Remove 18 mounting bolts (47) of shaft.
2) Remove 2 mounting bolts of gear, then
using eyebolts 0, remove hub and shaft
assembly (48).
17MF02569 17MF02569
30-133
0
3) Disassemble hub and shaft assembly as G4
follows.
holder (49).
ii Using tool G4, remove hub assembly
(50) and bearing (51) from shaft assem-
bly (52).
17MF02570
iii) Remove spacer (53), then remove bear-

ing (54) from shaft (55).
iv) Remove outer race (56) and gear (57)
from hub (58).
17MF02572 17MF02573
9. Cage assembly
eyebolts 0, remove cage assembly (59).
2) Remove shim (60).
17MF02574 17MF02575
3) Disassemble cage assembly as follows.

i) Using puller 0, remove outer race (61).
ii) Remove oil seals (62) and (63).
I97F50 I
I98F02738
L
30-134
0
10. Gear assembly
1) Remove gear assembly (64)..
2) Using puller 03, remove beaiing (65) from
gear (66). ..
17MF02576 17MF02i?7
11. Outer race, oil seal

1) Using puller 0, remove outer race (67).
2) Remove oil seals (68) and (69) from case
(70).
I97F502
I98FO274 I
30-l 35
0
ASSEMBLY OF FINAL DRIVE ASSEMBLY
* Wash all parts, then dry them, and check for

dirt or damage. Coat the sliding surfaces of
all parts with engine oil before installing.
1. Oil seal, outer race

1) Using push tool 03, 0, install oil seal (69).
(69).
A Set the upper oil seal with the pressure
side facing up, and the lower oil seal
with the pressure side facing down,
and install.
a Lip of oil seal: Grease (G2-LI) 17MF02578
a Press-fitting surface of oil seal:

A Coat the inside surface of the case

any gasket sealant that is squeezed
out.
-68
17MF02579
2) Using push tool @, press fit outer race

(67).
17MF02580
2. Gear assembly
1) Using push tool @, press fit bearing (65) to
gear (66).
2) Set tool G5 to case, and install gear
assembly (64).
* Do not remove tool 65 until the cage is
installed.
G5
65 I97F405
17MF02581
30-136
a
3. Cage assembly
1) Assemble cage assembly as follows.
i) Using push tools @J and 0, install oil
seals (63) and (62).
* Set the upper oil seal with the pressure
side facing up, and the lower oil seal
with the pressure side facing down,
and install.
/F’~ Lip of oil seal: Grease (G2-LI)
m- Press-fitting surface of oil seal:

17MF02582
* Coat the inside surface of the case
any gasket sealant that is squeezed
out.
62
I 17MF02583
ii) Using push tool @, press fit outer race

(61).
17MF02584
2) Using eyebolts 0, set cage (59) to case,

then tighten 6 mounting bolts.
w Mounting bolt: 1.5 kgm
* Rotate the gear and tighten uniformly,

then remove tool G5 installed at Step
2-2).
30-l 37
0
3) Using thickness gauge 0, as shown in I /I @M easurement
diagram, measure clearances 6E and 6F

between cage @ and case @
4) Set thickness 6 of shim to be inserted
according to table below.
Measurement position @
I I99FO274511 17MF02ii6
30-138
0
5) Assemble shim (60) set in Item 4), and
tighten cage mounting bolts.
w Mounting bolt: 11.25 k 1.25 kgm
17MF02587
4. Hub, shaft assembly

1) Assemble hub and shaft assembly as
follows.
j, The bearing connecting the hub and
shaft is a set, so match the match
symbols and production numbers on
the inner and outer races and inner of inner race
race spacer when assembling. spacer
(ex: K-3)
17MF02588
i) Install gear (57) to hub (58).
QZK Mounting bolt:

28.25 f 3.25 kgm
ii) Using push tool 0, press fit top and
bottom outer races (55) to hub (58).
5-S
17MF02589 17MF02590
iii) Using push tool 0, press fit bearing

(54) to shaft (55).
iv) Assemble spacer (53).
I 17MF02591 17MF02592
30-139
0
4 Set hub assembly (50) to shaft assem-
bly (52), then using tool G6, press fit
bearing (51). r----r
* Rotate the hub when press fitting
the bearing.
17MF02593 17MF02594
vi) Install holder (49).
m- Mounting bolt threaded portion:

w Mounting bolt:
28.25 + 3.25 kgm
17MF02595
2) Using eyebolts 0, raise hub and shaft

assembly (48), then fit O-ring and set to
case.
3) Tighten 18 mounting bolts (47) of shaft.
I 17MF02569 11 17MF02568
5. Sun gear, shaft assembly

1) Assemble sun gear and shaft assembly as
follows.
i) Press fit shaft (46) to sun gear (45).
ii) Install plate (44).
17MF02596 17MF02566
30-140
0
iii) Using push tool @, press fit bearing
(43).
iv) Install plate (42).
17MF02597 17MF02564
2) Set sun gear and shaft assembly (41) to

hub.
6. Carrier assembly I I
1) Assemble carrier assembly as follows. Match symbol Match symbol
of inner or of inner or
The planetary gear bearing is a set, so outer races 1-11 outer races
match the match symbols and produc-
tion numbers on the inner and outer
races and inner race spacer when
assembling.
17MF02598
Install ring and spacer to gear, then

using push tool 0, press fit top and
bottom outer races (40).
30-141
0
ii) Assemble spacer (39) and bearing (38)
to gear (37), and set to carrier.
* Set the direction of assembly of the
gear as shown in the diagram.
38
17MF02562
I
17MF02600
iii) Using tool G7, press fit shaft (36).

* Align the position of the bearing and
17MF02560
spacer holes, and press fit the shaft
slowly.
r
iv) Install holder (35).
* After tightening the bolts, check that
the gear rotates smoothly.
w Mounting bolt: 56 f 6 kgm
v) Using push too 8, press fit outer race

(34).
vi) Assemble spacer (33).
17MF02557
2) Using eyebolts 0, set carrier assembly

(32) to shaft assembly.
* When installing the carrier assem-
bly, be careful not to damage the
bearing. 32
17MF02556
30-142
0
7. Cover assembly
1) Assemble cover assembly as follows.
II
i) Raise ring gear (31), and set to cover.
ii) Install plate (30).
* install the plate with the chamfered
portion on the outside.
17MF0255E 17MF02554
iii) Using tool G8, press fit bearing (29).

iv) Install spacer (28).
v) Using tool G9, install floating seal (27)

to cage.
* When installing the floating seal,
17MF02602 11 17MF02603
remove all grease and oil from the
O-ring and surface in contact with
the O-ring, then dry before install-
ing. 27
* After installing the floating seal,
check that the angle of the seal is
within 1 mm.
vi) Fit O-ring and install floating seal cage
(26).
* Install cork plugs in the trimming
bolt holes.
* Install the floating seal cage with the
notched portion at the bottom as
shown in the diagram.
Gs
17MF02604
17MF02605
30-143
0
2) Fit O-ring, then using eyebolts 8, set
cover assembly (25) to case.
3) Tighten mounting bolts (24).
w Mounting bolt: 56 f 6.0 kgm
17MF02550 17MF02549
8. Wear guard
Install wear guard (23).
m Mounting bolt: 94.5 k 10.5 kgm
17MF02547
9. Sprocket, drum assembly

1) Assemble sprocket and drum assembly as I
follows.
i) Using push tool 0, press fit rubber
bushing (22) in inner drum.
* If thembushing is stiff and will not go
in, press fit with a press.
* Press fit the busing until the end
face of the inner drum and the end
face of the busing are flush as
shown in the diagram.
Bushing Inner drum

I 17MF02607
17MF02608
Y-XI& Press fitting portion of bushing:

anti-friction compound (LM-P)
ii) Install top and bottom outer races (21).

* Expand fit the outer race.
30-144
a
iii) Using eyebolts 0, raise inner assembly
(19), then lower slowly and set on
outside drum (20).
I-----
20
17MF02545
iv) Install inside drum (18).

* Align the dowel pins of the outside
drum and inner drum when install-
ing.
xCL Mounting surface:

I98FO2722
4 Tighten inside drum mounting bolts

(17).
KCL Mounting bolt threaded portion:
w Mounting bolt: 80 f 10 kgm
vi) Install seal (16).
/(il\, Seal mounting surface:

17MF02544 17MF02543
vii) Fit O-ring to inner drum, then using

eyebolts 0, set cover (15) in position,
and tighten mounting bolts (14) and
(13).
w Mounting bolt (14):
28.25 f 3.25 kgm
* Install cork plugs in the trimming

bolts holes.
17MF02542 17MF02541
x) Turn over sprocket and drum assembly
and set on block, then tighten outside
drum mounting bolts (12).
a Mounting bolt threaded portion:

xi) Install seal (7).
RQIL Seal mounting surface:

17MF02540
JL 17MF02539
xii) Using tool G9, install floating seal (10).

* Remove all the grease from the
O-ring and O-ring contact surface,
and dry before installing.
* After installing the floating seal,
check that slope of the seal is less
than 1 mm.
1 17MF02610
2) Using eyebolts 0, set sprocket and drum

assembly (8) to cover.
* Check that there is no dirt or dust on
the sliding surface of the floating seal,
then coat thinly with engine oil.
3) Using tool G8, press fit bearing (9).

* When press fitting the bearing, rotate
the sprocket and drum assembly.
&G&&g
17MF02611
I97F365
30-146
0
4) Fit holder (7) and tighten mounting bolts
(6).
N Mounting bolt: 28.25 + 3.25 kgm
10. Hub
1) Sling hub (3) and install.
2) Install plate (2).
w Mounting bolt: 11.25 I!T1.25 kgm
8
I 17MF02535 17MF02534
I
h
&
0
11. Cover
Using eyebolts 0, install cover (3), then
tighten mounting bolts (2) and (1).
AT?-- Mounting surface:

w Mounting bolt: 28.25 + 3.25 kgm
17MF02533 17MF02532
30-147
0
REMOVAL OF TRACK FRAME ASSEMBLY
1. For details, see REMOVAL OF TRACK SHOE

ASSEMBLY.
2. Using jack (70 ton), raise the machine and set

standard 0 (height: approx. Im) under the
equalizer bar case.
4. Remove holder (2).
5. Remove pivot shaft mounting bolts (3). 0

a7
198F02753 I9gF62754
6. Remove mounting bolts of pivot shaft inside
cover (4), and disconnect cover.
7. Remove pin (5). m

* Sling the track frame assembly, then
remove the lock plate, and knock out the
pin.
8. Lift off track frame assembly (6). 1121

* Use a chain block on the inside of the idler
yoke and adjust to keep horizontal so that
the track frame assembly does not slope
to the left.
* The oil inside the pivot chamber will leak
out, so put a container under it to catch
the oil.
Track frame assembly: 4500 kg

& kg
m
:
u Pivot chamber: Approx. 12~
-0
0
-
INSTALLATION OF TRACK
h
FRAME ASSEMBLY

!I I I98FO2757
removal.
& Pin: Grease (G2-LI)
a Pivot shaft:
w Plug: 15 f 3 kg

* Add engine oil to the pivot case to the
specified level. For details, see INSTALLA-
TION OF EQUALIZER BAR ASSEMBLY.
30-148
0
REMOVAL OF IDLER YOKE
ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
2. Remove scrapers (I), (2), (3), and (4) from side
face of idler.
3. Remove idler assembly.
For details, see REMOVAL OF IDLER ASSEM-
BLY.
4. Drain oil from spring chamber.
+ Drain the oil with a pump.
6 Spring chamber : Approx. 75 ~2 CLD01059
5. Remove idler yoke top cover (5).

6. Disassemble yoke assembly (including idler bo-
gie as follows.
I) Loosen idler yoke mounting bolts (6) gradu- Flange
ally in turn on diagonally opposite sides.
m
* Wrap cloth around the chrome plated
portion to protect the chrome plated por- Plated bushing
tion from being hit and damaged by the

tool.
A To prevent danger, never stand in front
of the yoke assembly.
g The recoil spring inside the recoil cylin- DLD02846
der is applying a pushing force of 363
kN (37 tons) on the yoke, so be careful
not to loosen the mounting bolts sud-
denly. Loosen the mounting bolts gradu-
ally until clearance a between the flange
of the recoil cylinder and idler yoke as-
sembly is 8 - 12 mm.
2) When the bolts are loosened, the torque will

suddenly drop. Check that the spring is not
applying any pushing force on the mount-
ing bolts, then remove all bolts.
* If the torque increases (the pushing force
of the spring is applied) during the loos-
ening operation, stop the loosening op-
eration and disassemble as follows.
Ahscribed
If the torque does not drop during Step 2) de-
above, and the torque when the bolts
are loosened remains large, there is probably
damage to recoil spring set bolt (91, or nut (IO)
at the tip of the shaft has fallen off, so there is
danger that the yoke assembly may fly off to
the front. For this reason, disassemble as fol-
lows.
CLD01062
30-148-l
0
A When disconnecting the yoke assembly and re-
coil cylinder assembly, do not stand in front of
the yoke assembly or behind the recoil cylinder
assembly until safety has been confirmed and
the recoil spring assembly has been removed.
i) Prepare the following parts.

Bolt @ (x6): 791-730-1110
Nut @ (x6): 01580-12722
Washer @ (x6): 01643-32780 (use again)
ii) Remove 6 bolts marked %, then install bolts CKD01063
0, nuts@, and washers @ listed in Step i).

* Check that dimension L is less than 361
mm.
sr Screw in bolts @ until they contact the
bottom of the yoke thread. Yoke
iii) Remove remaining 12 bolts (those not

marked %_).
iv) Hold bolts @ with a wrench to prevent them

from turning, then loosen 2 nuts @ simulta-
neously on opposite sides.
* Be careful not to let the load bea,r on
only one bolt. OK002847
v) When recoil spring is fully extended and

torque has completely dropped in loosening
direction of nut 0, remove bolt 0.
* When clearance b is approx. 165 mm,
the spring is fully extended.
CLD01065
7. Remove idler yoke (7) from recoil cylinder (8).

8
30- 148-2
0
INSTALLATION OF IDLER YOKE
removal.
%2 Spring chamber : Approx. 75 4?

Ir When using waste oil, use oil that does not
include mercury, alkali or any other danger-
ous substance.
m Bolt (6): 1324 i. 147 Nm (135 2 15 kgm)

Sr If the recoil spring holder nut has come off
or fallen out, assemble again.
For details, see ASSEMBLY OF RECOIL
SPRING ASSEMBLY.
30-148-3
0
REMOVAL OF RECOIL SPRING
ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
2. Drain oil from spring chamber. m

* Drain the oil with a pump.
& Spring chamber : Approx. 75 .t
3. Remove idler top cover (1).

17MF02855
4. Remove trunnion (2).
& kg Trunnion : 56 kg
5. Remove outside cover (3) and inside cover (4).

* Remove the inside and outside covers.
17MF02618
6. Remove pins (5). m

* Using tool H, remove the inside and outside
pins.
17MF02619 i-&’ ,(-y 17MF02620
7. Remove idler and recoil spring assembly (6).

Ir Using a lever block, keep the assembly hori-
zontal, and be careful not to damage the oil
seal at track frame (7) end.
& kg Idler, recoil spring assembly : 1500 kg

8. Remove recoil cylinder assembly (6). a
* Disconnect recoil cylinder assembly from
idler yoke assembly (9) as follows.
1) Put idler yoke assembly (9) in contact with
ground, then raise recoil cylinder assembly
(8).
Sr When doing this, check that there is no
damage to the weld of recoil spring case
(8).
+ Wrap cloth around the chrome plated
portion to protect the chrome plated por-
tion from being hit and damaged by the 9 CLD01067
tool.
2) Loosen idler yoke mounting bolts (IO) gradu-

ally in turn on diagonally opposite sides.
~TO prevent danger, never stand in front
of the idler yoke assembly or behind the
recoil cylinder assembly.
AThe recoil spring inside the recoil spring
case is applying a pushing force of 363
Plated bushing
kN (37 tons) on the yoke, so be careful
not to loosen the mounting bolts sud-
denly. Loosen the mounting bolts gradu-
ally until clearance a between the flange
of the recoil cylinder and idler yoke as- DLD02848
sembly is 8 - 12 mm.
3) When the bolts are loosened, the torque will
suddenly drop. Check that the spring is not
a
applying any pushing force on the mount-
ing bolts, then remove all bolts.
* If the torque increases (the pushing force
of the spring is applied) during the loos-
ening operation, stop the loosening op-
eration and disassemble as follows.
CLD01069
glf the torque does not drop during Steps 2) and

3) described above, and the torque when the
bolts are loosened remains large, there is prob-
ably damage to recoil spring set bolt (19), or nut
(20) at the tip of the shaft has fallen off, so there
is danger that the yoke assembly may fly off to
the front. For this reason, disassemble as fol-
lows.
30-150
0
a When disconnecting the yoke assembly and re-
coil cylinder assembly, do not stand in front of
the yoke assembly or behind the recoil cylinder
assembly until safety has been confirmed and
the recoil spring assembly has been removed.
i) Prepare the following parts.

Bolt @ (x6): 791-730-I 110
Nut @ (x6): 01580-12722
Washer @ (x6): 01643-32780 (use again)
ii) Remove 6 bolts marked %, then install bolts CKD01063

0, nuts 0, and washers @ listed in Step i).
* Check that dimension L is less than 361
mm.
* Screw in bolts (I) until they contact the
bottom of the yoke thread.
iii) Remove remaining 12 bolts (those not
marked a).
iv) Hold bolts 0 with a wrench to prevent them

from turning, then loosen 2 nuts @ simulta-
neously on opposite sides.
* Be careful not to let the load bear on
only one bolt.
DKD0.2847
J
v) When recoil spring is fully extended and

torque has completely dropped in loosening
direction of nut 0, remove bolt 0.
* When clearance b is approx. 165 mm,
the spring is fully extended.
CLD01071
9. Remove ring (11).
CLD01072
10. Remove adjustment cylinder (12).
* Pump in grease from lubricator (141, and
push out piston assembly (13).
CLD01073
CKD01074
. Disassembly of piston assembly a

i) Remove wear ring (15) from piston assem- 15 17 16
bly, then remove snap ring (16), and remove
packing (17).
13
CLD01075
11. Remove recoil spring assembly (18).
&I kg Recoil spring assembly : 400 Kg
30-150-2
0
INSTALLATION OF RECOIL
SPRING ASSEMBLY

removal.
Spring chamber: Approx. 7%

When using waster oil, use oil that does not
include mercury, alkali or any other danger-
ous substance.
When installing the pin, align the center of

the idler and recoil spring cylinder with a
bar, and install.
& Mounting bolt (IO):

Therad tightener (LT-2)
w Tightening torqe of bolt (IO):
. Top mounting bolt (IO bolts):
1324 +_ 147 Nm (135 +_ 15 kgm)
. Bottom mounting bolt with plate
(8 bolts)”
1564 + 172 Nm (159.5 f 17.5 kgm)
* If the recoil spring holding nut has fallen off,
see ASSEMBLY OF RECOIL SPRING for as-
sembling.
* Pump in grease as follows to prevent air

from collecting inside the cylinder.
1) Fill inside of cylinder with approx. 75cc
of grease (each side).
2) Set cylinder drain hole facing up, then
loosen lubricator (14).
3) Tighten lubricator (14) to specified
torque.
m Lubricator: 73.5 f 14.7 Nm
(7.5 f 1.5 kgm)
30-150-3
0
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Set recoil spring assembly (I) in tool 0.
a The spring is under high installed load,
so be careful to set it correctly.
* Installed load of spring: 388.3 kN (36.9 tons)
CLD01077
2. Apply hydraulic pressure slowly to compress

spring, then remove
nut (3).
lock plate (2) and remove
0 0
3. Release hydraulic pressure gradually and relieve 2
tension of spring.
4. Remove rear pilot (5), spacer (61, bolt (7), and

pilot (8) from spring (4). 3
CL001078
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
1. Assemble pilot (8), bolt (7), spacer (61, and rear
pilot (5) to spring (4), then set in tool 0.
a The spring is under high installed
be careful to set all parts correctly.
load, so
2. Apply hydraulic pressure slowly to compress

spring, and set so that installed length of spring
~!$$dl~r$~.a : 1078 mm CL001079
/
L a
-1
I CKD01080
30-150-4
5
3. Fit nut (3), then install lock plate (2).
Sr When securing the recoil spring mounting TClearance O-1. Omm
nut, make a clearance of 0 - 1.0 mm be-

tween lock plate (2) and nut (31, then bring
lock plate (2) and bolt (7) into tight contact,
and secure in position.
* Purpose of making clearance
I) If the nut is screwed in a small amount
and nut (3) protrudes beyond bolt (71,
lock plate (2) may bend and lock bolt (8)
may fall off.
7
2) If the nut is screwed in too far, the load DKD02849
of the spring will always be applied to
the set bolt, and the set bolt will break.
4. Gradually release hydraulic pressure to com-

pletely relieve tension of spring, then remove
recoil spring assembly (1) from tool 0.
30-151
0
REMOVAL OF IDLER
ASSEMBLY
1. For details, see REMOVAL OF TRACK SHOE

ASSEMBLY.
2. Remove inside and outside covers (I) and (2)
(2 each). a
ATo prevent danger, never stand in front of the
idler yoke assembly.
3. Sling the idler assembly (31, and remove cap

(4), then remove the idler assembly (2).
Idler assembly: 350 kg /GJ 17MF02630
INSTALLATION OF IDLER
ASSEMBLY
‘02631
removal.
w Mounting bolt of front cover (I):

549.1 = 58.8 Nm I56 + 6 kgm)
* Tighten the idler cap mounting bolts in the or-

der @+@I+@
Ir After tightening, check that clearance a at the
bottom of the cap is 0 mm.
& Cap mounting bolt:
Q~EI Cap mounting bolt:
1,324 f 147 Nm (135 t 15 kgm}
30-152
@
DISASSEMBLY OF IDLER ASSEMBLY
1. Remove plug and drain oil.

:
u Idler: Approx. 1.5 P
2. Set idler assembly (1) on block 0.
3. Remove mounting bolts, then using forcing

screws 0, remove retainer (3) together with
seal guide (2).
4. Turn over idler assembly (4), remove mount-

ing bolts, then using eyebolts 0, remove
shaft (4) together with retainer.
5. Using puller 0, remove seal guide (5)

together with retainer (6) from shaft.
6. Remove seal guides (2) and (5) from retainers

(3) and (6).
2-5
\ 17MF02635 17MF02636
I
I 17MF02639
7. Remove floating seals (7) and (8) from seal

2.5’
guides (2) and (5), and retainers (3) and (6).
* Keep the floating seals in a safe place to
17MF02637 17MF02638
protect them from damage.
8. Remove bushing (9) from idler (10).
17MF02640
ASSEMBLY OF IDLER ASSEMBLY

1. Set tool J, to idler (IO), and press fit bushing

(3).
A When press fitting the bushing, center it
with a plastic hammer, then press fit with
a puller.
* Press fit the bushing so that the distance
from the end face of the idler to the top
face of the bushng is 15 f Imm.
2. Using tool J,, install floating seal (8) to retai-

ners (3) and (6).
3. Fit O-ring, install retainer (3), then tighten

4. Using eyebolts 0, set idler (IO) on shaft (4).

j, Set a block (approx. 140mm) under the
idler.
5. Turn over idler assembly.

j, Tie the shaft with wire to prevent it from
falling out.
6. Fit O-ring, install retainer (6), then tighten

17MF02644 17MF02&
7. Using tool J,, install floating seal (7) to seal

guides (2) and (5).
8. Fit O-ring to seal guide.
J3
17MF02646
30-154
0
9. Set tool J, to idler, and press fit seal guide
J2
(2). /
* Press fit the seal guide so that distance “a”
from the end face of the shaft to the top
face of the seal guide is 96 f 0.2mm.
j, Turn over the idler assembly, and repeat
the same procedure to press fit seal guide
(5).
10. Add gear oil through oil filler to the specified

level.
I& Idler: Approx. 1.5 Q
z
m Plug: 21 f 5 kgm
5
z
30-155
0
REMOVAL OF TRACK
1. For details, see REMOVAL OF TRACT SHOE

ASSEMBLY.
2. Remove retainer (1). m
3. Remove track roller guard (1).
52 kg Track roller guard inside: 85 kg
kg Track roller guard outside: 90 kg

* If the mounting bolts cannot be removed,
use a power wrench to remove them.
i 17MF02649
4. Start the engine, then operate the blade and
ripper levers, and raise the machine.
A After raising the machine, set the block on

the track shoe, and lock the work equipment
layer and brake pedal.
5. Remove track roller assembly (2). 1131

* Set tool K under the track roller assembly,
then remove the track roller assembly.
Track roller assembly: 120 kg

I3 kg
ROLLER ASSEMBLY
removal.
& Retainer mounting bolt:

m Retainer mounting bolt: 56 f 6 kgm
1121
* Assemble the guard tension bolt with the
head on the inside.
& Guard tension bolt:

a Guard mounting bolt:

N Guard tension bolt: 94.5 * 10.5 kgm
B Guard mounting bolt:
94.5 f 10.5 kgm
m
* Assemble so that the oil plug is on the
outside of the machine.
* Install the dowel pin only on the oil plug
side.
& Roller mounting bolt:
N Roller mounting bolt:
94.5 k 10.5 kgm
30-156
n
DISASSEMBLY OF TRACK ROLLER ASSEMBLY
1. Remove plug, and drain oil.

:
u Track roller assembly: Approx. 14 P
2. Set track roller assembly (1) on block 0.

screws 0, remove seal guide (2) together
with retainer (3) from shaft.
4. Turn over track roller asembly, and remove

mounting bolts, then using eyebolts 0,
remove shaft (4) together with retainer.
5. Using press, remove seal guide (5) together

with retainer (6) from shaft.
6. Remove seal guides (2) and (5) from retainers

(3) and (6).
g 17MF02654 17MF02639
3
z
7. Remove floating seals (7) and (8) from seal
guides (2) and (5) and retainers (3) and (6).
* Be careful not to damage the floating
seals, and keep in a safe place.
17MF02656 jj 17MF02657
8. Remove bushing (9) from roller (10).

ASSEMBLY OF TRACK ROLLER ASSEMBLY

1. Set roller (IO) in press, then use tool L, to

press fit bushing (9).
* When press fitting the bushing, center
it with a plastic hammer, then press fit
with a press.
* Press fit the bushing so that the distance
from the end face of the roller to the top
face of the bushing is 15 * Imm.
17MF02659 1j 17MF02660
2. Set shaft (4) to roller.
3. Using tool L,, install floating seal (8) to retai-

ners (3) and (6).
4. Fit O-rings, install retainers (3) and (6), then

I 17MF02661 17MF02662
5. Using tool L,, install floating seal (7) to seal

guides (2) and (5).
6. Fit O-ring to seal guide.
7. Using tool L,, press fit seal guide (2).

face of the seal guide is 69 k 0.2mm.
* Turn over the track roller assembly, and
repeat the same procedure to press fit
seal guide (5).
8. Add gear oil through oil filler to the specified

level.
Q Track roller: Approx. 1.4 P

1 a 17MF02665
w Plug: 21 f 5 kgm
30-158
0
REMOVAL OF CARRIER ROLLER ASSEMBLY
1. Track tension
Loosen track tension.
* For details, see REMOVAL OF TRACK
SHOE ASSEMBLY.
2. Carrier roller assembly (1) m

A Using a jack, raise the track shoe so that
the carrier roller assembly can be removed.
INSTALLATION OF CARRIER
ROLLER ASSEMBLY

removal.
When installing the carrier roller to the

support, leave a clearance as shown in the
diagram.
&I& Support mounting bolt:

30-l 59
0
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY
1. Remove plug and drain oil.

:
u Carrier roller assembly: Approx. 0 7e
2. Set carrier roller assembly on block 0.
3. Remove mounting bolts, then remove cover

(2).
4. Remove ring (3).
a
17MF02667 17MF02666
5. Using tool M,, remove nut (4).
6. Using puller 0, remove press-fitting portion

of seal guide, then use eyebolts to remove
bearing (5) together with roller (6).
I 17MF02669 17MF02670
7. Remove outer races (7) from roller.
6. Using puller 0, remove seal guide (8) toge-

ther with bearing (9) from shaft.
9. Remove floating seal (IO) from seal guide (8).
I-L---J
1 17MF02671 17MF02672
17MF02675
10. Using push tool 0, remove seal guide (11).
11. Remove floating seal (12) from seal guide

(11).
17MF02613 17MFO2614
30-l 60
0
ASSEMBLY OF CARRIER ROLLER ASSEMBLY

1. Using push tool 0, press fit bearing (9).
2. Using push tool 0, press fit outer race (7).
3. Set roller (6) and bearing (5) on shaft.
4. Using push tool 0, press fit bearing (5) on

shaft.
* Rotate the roller when press fitting the
bearing. Press fit the bearing until the rota-
tion of the bearing becomes slightly heavy.
.
17MF02678 17MF02679
Using tool M,, tighten nut (4) at IO kgm.

* After tightening the nut, if the nut hole and
the shaft hole are not aligned, align in the
direction of loosening the nut.
6. Install ring (3).
17MF02669 i/ 17MF02668
7. Fit O-ring, install cover (2), then tighten with

mounting bolts.
17MF02680
30-l 61
0
8. Using tool M,, install floating seal (10) to seal
guide (8).
9. Fit O-ring, then align with dowel pin and in-

stall seal guide (8).
17MF02681 17MF02682
r
10. Using tool M,, install floating seal (12) to seal
guide (11).
11. Using tool M,, press fit seal guide (11).

face of the seal guide is 159.75 f 0.2mm.
si$&&
,I
’
I_
,
‘11
17MF02683
17MF02685
12. Add gear oil through oil filler (1) to the speci-
fied level.
* Rotate the roller when adding the oil.
Q Carrier roller: Approx. 0.7 e
m Plug: 21 f 5 kgm
30-162
0
CHECKING BEFORE REMOVAL
OF TRACK SHOE ASSEMBLY
aln some cases, it may be extremely dangerous
to remove the track shoe assembly. To prevent
danger, carry out the following checks before
removing the track shoe assembly.
. Checks before starting
I) Loosen the lubricator at the adjustment cyl-
inder, release the grease, then move the
machine backward and forward a short dis-
tance, and check that the track tension is
relieved. If the track tension is not relieved
and the track shoe assembly remains tense,
there may be an abnormality inside the track
frame (the recoil spring case is broken, the
recoil spring set bolt is broken, or the nut at
the end of shaft has fallen off).
g Never loosen the lubricator more than
one turn.
REMOVAL OF TRACK SHOE

ASSEMBLY (NORMAL)
CA
; * If CHECKING BEFORE REMOVAL OF TRACK

SHOE ASSEMBLY shows that there is no abnor-
z mality, do as follows.
1. Set master link in position.
+ Set a block (height: approx. 400 mm) so that
the master link is approx. 600 mm from the
ground at the front.
2. Relieve track shoe tension. m
a Never loosen lubricator (I) more than one
turn.
* If the track is not relieved by loosening the
lubricator, move the machine backwards and
forwards.
3. Remove mounting bolts of track shoe (2) and

master link (3). a
4. Raise tip of master link, move machine towards
rear slowly, and lay out track shoe assembly (4).
CLD01083 CLD01084
30-163
z
REMOVAL OF TRACK SHOE
ASSEMBLY
(WHEN THERE IS ABNORMALITY INSIDE
TRACK FRAME)
* When CHECKING BEFORE REMOVAL OF TRACK

SHOE ASSEMBLY shows any abnormality, do
as follows.
a If there is any abnormality inside the track frame,
there is danger that the track shoe assembly
may spring back when it is removed or that the
idler may spring out when the track shoe as-
sembly is removed. This may lead to serious
injury, so remove the track shoe assembly as
follows.
a If there is any interference or abnormal catching
around the idler assembly, examine carefully
and remove the problem before starting.
1. Remove work equipment assembly.
For details, see REMOVAL OF WORK EQUIP-
MENT ASSEMBLY.
2. Loosen lubricator (I) of adjustment cylinder, then
move machine backwards and forwards to re-
lease grease. m
a Never loosen the lubricator more than one
turn.
* Check that all the grease has been removed.
3. Drive slowly forward to put track shoe at idler

end in contact with large block @ or a wall (if
another large bulldozer of the same capacity as
the machine being repaired is available, put in
contact with the blade). Stop machine when
recoil spring bends and slack is formed in track
shoe assembly, then apply brake. When doing
this, set so that master link is between idler and
front carrier roller. For safety reasons, fit a le-
ver block between carrier roller support and link.
4. Remove shoe (4), then disconnect master link
(5). 11
CLD01085
ABe extremely careful to ensure safety when
disconnecting the track shoe.
5. Move machine towards rear slowly and lay out
track shoe assembly.
30-l 63-1
&
SHOE ASSEMBLY
removal.
* When adjusting the track shoe tension, set

dimension a to 25 + 5 mm.
m___
t Tighten the shoe bolts in the order shown in
the diagram.
6 Mounting bolt : ------GO1048
m Mounting bolt (master bolt)
Initial torque : 490.3 + 49.0 Nm
(50 ? 5 kgm)
Tightening angle : 180 k 10”
I DKD00282
30-163-2
5,
A This section describes only for the lubricated
track link.
Shoe (master link portion)

Set the track assembly on a flat floor with the
shoe facing up, then remove the shoe bolt at
the master link, and remove the shoe.
A Do not use an impact wrench when
x
loosening the master link bolt.
F6164026
Disassembly into l/4 parts

Because of the weight of the track assembly,
if the l/2 assembly is too large and there are
problems with disassembly and assembly
work, divide into l/4 assemblies.
Shoe (regular link portion)
Raise the track assembly and set it on the
floor with the shoe facing up, then use a shoe
bolt impact wrench to remove the shoes.
* When moving the track assembly, be care-
ful not to damage the master link portion.
* If a gas cutter has to be used to remove
the shoe nut, to prevent deterioration of
the seal due to the heat, keep the
temperature of the seal portion below
80°C. and take action to prevent welding
spatter from entering the gap between the Burrs Chamfer
links.
Draining oil
Before disassembling the link assembly, drain
the oil from inside the pin and take precau-
tions so that the link press does not become
dirty with oil.
* Before disassembling, if it is judged that it
is necessary to rebuild the track as a dry F 19802241
type track, the following work need not be
carried out.
1) Set the link assembly on a flat floor with
the large plug side facing up, then cham-
fer the burrs on the end face of the pin
with a grinder.
* If the track is disassembled with burrs
still at the end face of the pin, the pin
press fitting hole of the link will be
scratched, and this will cause leakage
from the pin press-fitting portion after
rebuilding.
2) Using a drill (elOmm), make a hole in the
large plug, then remove the large plug.
* If any dirt or deteriorated oil is stuck to
the pin hole, drill through with a longer
drill to remove it. When doing this, be
careful not to damage the oil hole.
30-164
0
3) After removing the large plug, use a baby
grinder (angle of grinder tip: 45” - 60’7,
and chamfer the pin hole so that the plug
is not damaged when the plug is knocked
in.
4) Turn over the link assembly so that the

small plug side is facing up, remove the
burrs at the end face of the pin with a
grinder, then use tool W to knock the
small plug to the inside.
j, If the small plug hole is blocked with
burrs, grind with a grinder until the
hole can be seen completely.
5) Using a drill (olOmm), chamfer the small

plug hole.
6) Blow with comressed air to remove the

metal particles when draining the oil
inside the pin or removing the burrs, then
wash the link assembly with high-pressure
water or steam.
0
5. Dissasembly of link F 19802245
1) Set the link assembly on a link press, then
hit with a hammer so that the bushing and
jaw are in tioht contact.
* If the linktread and outside diameter of
the bushing are worn, adjust the height
of the shoe or guide plate, and center
the disassembly jig with the pin and
bushing center to prevent damage to
the link hole when disassembling.
* If the centering is not carried out
properly, the link hole may
damaged, the pin may break, or the
be
Left disassembly jig Jaw Right disassembly jig
bushing may crack during disassembly.
2) Operate the left cylinder and remove the

left link and pin and bushing press-fitting
portion at the same time.
* Check the removal force of the pin and
bushing, and use this value as
reference to judge if it is possible to
obtain the necessary pin and bushing
press-fitting force when turning and
reassembling.
* Do not push the disassembly jig inside
more than is necessary as the spacer
may break. 9802248
30-165
a
3) Return the left cylinder, then operate the
right cylinder and remove the right link
and pin and bushing press-fitting portion
at the same time.
4) Return the right cylinder, remove the left

and right links, pins, bushings, and spacers,
then feed the following set for one link
assembly into the jaw.
To decide if the seal can be used again,
carry out inspection when the seal is
still installed to the link, so do not
Fl 980224
remove the seal from the link.
If oil is remaining, this can be used as
a guide line for reuse of the seal, so
F19802248
mark such links or seals.
If the end face of the bushing and seal
surface are damaged, it will cause oil
leakage, so be extremely careful when
handling.
6. Inspection
Check the following items to determine if the
part can be reused as a lubricated track or as
a grease-filled track. Carry out a comprehen-
sive check to determine if the link assembly
can be rebuilt as a lubricated track or as a
grease-filled track.
A When making judgements about reuse

of parts, see Shop manual “Guidance for
Reusable Parts”.
Check the pins, bushing, links and spacers

visually for damage, and carry out a color
check or use a flaw detector to check
parts that are suspected of being
damaged. Any part that is cracked must
not be used again, so scrap it.
Check the external appearance of the seal

and the end face of the bushing visually
to determine if they can be used again.
* If only the bushing is replaced with a
new part, the worn or damaged part of
the seal lip contacts the end face of the
bushing directly, so it may not be able
to carry out its sealing function. For this
reason, always replace the seal
together with the bushing, or rebuild as
a grease-filled track.
30-166
a
3) Using calipers, measure spacer thickness
a and overall length b of the sliding
portion of the bushing and spacer. Check
if it is possible to obtain the specified seal
0
mounting dimension when reassembling.
j, If the amount of wear of the spacer and
bushing is greater than the specified
ll
amount, the assembly precision of the
seal portion cannot be guaranteed, so
replace with new parts, or rebuild as a
a
grease-filled track.
4) Using a micrometer, cylinder gauge, and 1 F19802249
calipers, measure the outside diameter of

the pin and the inside diameter of the
bushing at the worn portion, and judge if
the parts can be used again.
j, If the amount of wear is greater than
the specified amount, there will be play
during travel, and it will also cause the
oil to become dirty, so replace with
new parts or rebuild as a grease-filled
track.
* For details of the dimensions when
making judgement, see MAINTENANCE
STANDARDS.
Fl9802250
5) Using a micrometer and cylinder gauge,
measure the outside diameter of the pin
and bushing press-fitting portion, and the
inside diameter of the pin and bushing
press-fitting portion of the link to deter-
mine if the permitted interference can be
obtained. However, when rebuilding as a
lubricated track, check the standard inter-
ference for the pinand link.
* If the permitted interference can not be
obtained, replace with new parts or
replace with an oversize part.
* For details of the dimensions when
making judgement, see MAINTENANCE
STANDARDS.
h A198022521
30-167
0
I I
F 19802253
A PRECAUTIONS FOR STORAGE
To prevent rust of the counterbore portion

of the link, leave the seal installed to
the link and be careful not to damage the
seal lip during storage.
Coat the pin and bushing press-fitting
portion, shoe mating surface, and master
link mating surface of the link with rust
prevention oil to prevent rust.
Coat the whole circumference of the pins,
bushings, and spacers with rust preven-
tion oil to prevent rust, and be particularly
careful not to damage the end face of the
bushing during storage.
30-168
0
1. WHEN REBUILDING AS LUBRICATED TRACK
1. Preparatory work
1) Washing seal assembly
l Machines equipped with F3 type seals Load ring Seal ring
Remove the seal assembly from the
link, then separate into the seal ring
and load ring, and clean the parts.
* The seal ring and load ring deterior-
ate easily when brought into contact
with cleaning agent (trichlene, etc.),
so wash the parts quickly.
After cleaning, wipe the parts with a
clean cloth to remove all the clean-
ing agent.
F 19802254
l Machines eqipped with W7 type seals
For seals that are to be reused, leave
the seal installed to the link, and do not
wash it.
2) When reusing the pin, chamfer the corner

of the end face smooth with a grinder.
Remove any protruding parts stuck to the
press-fitting portion with a grinder.
* If the corner of the end face has
become sharp due to wear, there will
be scuffing when press fitting and this
will cause oil leakage.
3) Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin Make a mark to show
when assembling.
* When rebuilding the pin, assemble in
the same direction as when the part is
new (side hole on the link tread side).
30-169
a
4) If the link, pin, bushing, or spacer are dirty,
wash them. Remove any protruding parts
stuck to the link and bushing with grinder.
* These parts easily rust, so wash them
immediately before assembly.
* Use tool X to wash the pin hole.
A Do not polish or carry out any other
treatment of the end face of the bush-
ing as this causes the oil leakage.
5) Use tool Y to knock the large plug into the

pin.
9 Insert plug into hole in guide through
plug insertion window. (Coat the plug
with oil.)
ii) Push bar by hand and insert the plug
as far as it will go.
iii) Push plug with bar, and push guide
itself against pin.
iv) Hit in bar with a hammer.
* Dimension “a” to knock in the plug

from end face of pin: 11 k 2 mm
A If there is no more place to chamfer at

the pin hole because of wear, use a
baby grinder (angle of grinder tip: 45
- 60”) to carry out chamfering. 17MF02805
* Coat the outside circumference of the
plug with G0140B and knock in the
smaller diameter part first.
6) Installation of seal assembly

l Machines equipped with F3 type seal
Remove all oil and grease
fro
Y
Clean the link counterbore, then use
tool KA to push the seal in fully to the Direction to push in
bottom. 1
A If there is oil stuck to the link

counterbore and seal assembly,
the seal will rotate and its sealing
performance will drop, so do not
coat with oil. In addition, be care-
I F19802259A
ful not to let oil get into the
counterbore portion of the seal
when pushing in.
l Machines equipped with W7 type seal Remove all oil and grease
When reusing the link and replacing from shaded area 5%
u
the seal with a new part, clean the link
counterbore, then push the seal in fully
to the bottom.
A If there is oil stuck to the link

counterbore and seal assembly,
the seal will rotate and its sealing
coat with oil. In addition, be care- F 19802260
ful not to let oil get into the
counterbore portion of the seal
when pushing in.
30-170
0
7) In order to keep the protrusion of the pin
and bushing constant and the installation
dimensions of the steel within the speci-
fied value during assembly, adjust the
press-fitting jig dimensions of the link
press
For details of the standard dimensions,
see PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS.
F19802261
To leave a small space for the pin

when assembling, ensure that the
dimension (dimension a’) is greater
than dimension “a” at the pin pushing
portion of the left press-fitting jig.
When assembling in order @ left link
press fitting, @ right link press fitting,
provide the extra space.for the pin on
the right press-fitting jig.
F 19802262
If the end face of the pin (portion P) or

the end face of the link (portion 0, R)
are worn, add the amount of wear to
the standard dimension when adjusting
the dimension of the press-fitting jig so
that the amount of protrusion of the
left and right pin and bushing is
uniform.
8) Adjust the relief pressure of the link press

to make sure that the pushing force of the
press does not exceed the specified value.
* If the pushing force is too strong,
excessive force will be brought to bear I- F19802263
on the spacer, and it will be pushed

against the bushing. This will cause the
spacer to break or will cause abnormal
wear between the spacer and bushing
end face.
* If the interference at the press-fitting
portion is different from when the part
is new, as when reusing a pin or bush-
ing, measure several of the press-fitting
portions, and use the value below to
determine the set pushing force
according to the average interference.
* Set pushing force of pin and bushing:
150 ton
Set pushing force k 1.8 X average
pushing force
(Adjust the relief pressure of link press
to fix the set pushing force)
30-171
0
2. Assembly of link
1) Use a clean brush to coat the area
between the pin and bushing with oil
(G0140B), set in position, then set in front
of the jaw of the link press.
* When reusing (turning) the bushing, set
the worn surface on the outside
circumference of the bushing facing
the shoe mounting surface of the link
(facing up on the link press).
2) Set the left and right bushing end master

link with the shoe mounting surface facing
up, then press fit to the bushing.
* When doing this, use the pin end
master link as a support.
* Bushing press fitting force: 10 - 35 ton
3) Using a shoe bolt hole pitch gauge, press

fit until the distance between the shoe bolt
holes of the left and right link is the speci-
fied value.
* Use compressed air to remove all
metal particles from burrs while press
fitting the bushing.
4) Turn over the master link, and check that

the left and right master links have been
press fitted in parallel.
30-172
0
5) Measure the amount of protrusion of the
left and right bushings with a depth
gauge.
* Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
6) Feed the master link portion, then set the

pin and bushing in position.
* When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing
the specified direction, the strength
may drop, so mark the direction of the
side hole clearly on the end face to
prevent any mistake during assembly.
* Align the large plugs so that they are
on the left side facing the link press
when assembling.
7) To prevent oil from leaking out from scuff

marks on the pin press-fitting portion, coat
the pin press-fitting hole in the link and the
outside diameter of the pin press-fitting
portion with gasket sealant (198-32-l 9890).
Coat whole circumference / /

’ F19802299
8) Set the right link in position and install the

spacer to the pin.
* Check that there is no dirt or dust stuck
\\ ’
to the seal surface and bushing end : i
face, then use a clean cloth or brush to

coat with oil (G0140B). ~
j, Wipe the spacer with a clean cloth,
then install it.
1 ,
” j
~
\
I=19802270
30-173
0
9) Using the right jig as the receiving end
and the left jig as the pushing end, press
fit the pin and bushing at the same time.
j, When press fitting, the seal may come
off the link due to the play, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit
the seal correctly on the link, then start
the press-fitting operation again.
* Pin and bushing press fitting force:
65-105ton
10) Using a fine adjustment spacer, press fit

so that the end face of the pin is in tight
contact with the bottom of the receiving
jig.
* Adjust the depth of lthe hole in the
receiving jig so that the protrusion of
the left and right pins is uniform.
r
11) Set the left link in position and install the
spacer to the pin.
* Coat with oil in the same way as when
installing the right link.
I I
F 19802273
12) Using the left jig as the receiving end and

the right jig as the pushing end, press fit
the left link.
* When press fitting, be careful that the
left and right seal and spacer do not
come out of position.
j, Provide enough space on the left jig so
that the end face of the pin does not
contact the bottom of the jig.
* Link press fitting force: 65 - 105 ton
30-174
0
13) Press fit the link, spacer, and bushing so
that they are each in tight contact.
* It is impossible to check from outside if
they are in tight contact, so control the
hydraulic force of the link press and set
the relief pressure to a constant value.
Then apply hydraulic force and push in
until this pressure is reached.
For details of the setting for the relief
pressure, see “Preparatory work”.
* Check that neighboring links rotate
together.
F19802275
14) After assembling each link, use a dial

gauge and pinch bar to measure the end
play from the link previously assembled,
to check that the link is assembled within
the specified value.
* If the end play does not come within
0 - 0.13mm even when applying the
pushing force until the relief valve is
actuated, raise the relief pressure
setting gradually to adjust.
* Adjust the relief pressure setting care-
fully and be sure not to raise the push-
ing force of the link press higher than
necessary.
Using a shoe bolt hole pitch gauge, check

that the distance between the shoe bolt
holes is within the standard value.
* If the distance between the shoe bolt
holes is greater than the specified
value, disassemble and check for any
abnormality, then press fit again.
* If the distance between the shoe bolt
holes is smaller than the specified
value, and the shoe cannot be installed,
the wear of the spacer or bushing end
face is probably greater than the repair
limit, so disassemble and replace with
a new part.
* If the end play is too large, the sealing
performance will drop, so set the end
play to a small value.
16) After assembling each link, use tool KB to

remove the air from inside the pin, and
check the sealing performance.
* Hold the space inside the pin at a
vacuum of 650 - 700 mmHg for 5
seconds and check that there is no
change in pressure.
If the pressure changes, disassemble
and check the seal for any abnormality,
then assemble again.
30-175
0
17) Assemble the pin end master link as the
final link.
* Check that the left and right master
links are press fitted in parallel.
3. Filling with oil

After completion of assembly of the link
assembly, fill the pin hole with oil.
1) Using tool KC, remove the air inside the
pin from the small plug hole, set to a
vacuum of 650 - 700 mmHg, then fill with
oil (G0140B) until the pressure is 2 - 3
kg/cm*.
* In cold or extremely cold areas, instead
of G01408, fill with Komatsu genuine
oil (150-09-19270) which has excellent
low temperature qualities.
j, Be careful not to raise the oil pressure
too high as this will have an adverse
effect on the seal.
* To determine the oil amount, set the
small plug end at the top (stand the link
assembly on its side), leave for 30
minutes, then charge with oil so that
depth L of the space at the pin hole is
within the specified value below. G0140B
Specified value of L: 50 - 80 mm
901 FOOl
2) After completion of filling with oil, use tool

2 to knock in the small plug to the speci-
fied position.
j, Coat the outside circumference of the
small plug with G0140B.
* Knock in the plug to the depth given
below.
Depth to drive from end face:
7.5 f 1 mm
30-176
Co
4. Shoe (regular link portion)
Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench
to install the shoe.
m Shoe bolt (regular link):
Initial tightening torque: 80 + 8 kgm
Tightening angle: 120 f 10
5. Connecting to make l/2 assembly

Set two completely assembled portions of
track on a flat surface in a straight line with
the shoes facing up. Pull master link (1) at the
pin end to master link (2) at the bushing end,
and set at the mating surfaces. Then put shoe
(3) on top, ,check that shoe bolt (4) goes in
easily by hand, and connect the two parts.
&III& Mounting bolt:
m Shoe bolt (master link):
Initial tightening torque: 50 rir:5 kgm
Tightening angle: 180 + 10
* When tightening, tighten in order 0 - 0.

* Do not use an impact wrench for the
master link mounting bolt.
x F6164026
F19802282
30-l 77
@
4) Use tools Y and 2 to knock the large and
small plug into the pin.
i) Insert plug into hole in guide through
plug insertion window. (Coat the plug
with oil.)
ii) Push bar by hand and insert the plug
as far as it will go.
iii) Push plug with bar, and push guide
itself against pin.
iv) Hit in bar with a hammer.
* Dimension “a” to knock in the plug from
end face of pin: Small plug: 7.5 If: 1 mm
17MF02805
Large plug: 11 f 2 mm
* If the plug is not removed from the pin

during disassemlby, it can be used as it is.
5) Clean any part where outside diameter of

Rem
the pin, front face of the spacer, end face
from
or inside diameter of the bushing are dirty.
6) Coat the outside diameter of the pin and Direction to push in
the front face of the spacer with grease.
I
7) Installation of seal assembly
l Machines equipped with F3 type seal
Clean the link counterbore, then use
tool KA to push the seal in fully to the
bottom.
F 19602259A
* If there is grease stuck to the link
counterbore and seal assembly, the
seal will rotate and its sealing
coat with grease. Remove all oil and grease
from the shaded area
l Machines equipped with W7 type seal
When reusing the link and replacing
the seal with a new part, clean the link
counterbore, then push the seal in fully
to the bottom.
* If there is grease stuck to the link
counterbore and seal assembly, the
seal will rotate and its sealing
performance wil drop, so do not
F19602260
coat with grease.
8) In order to keep the protrusion of the pin

and bushing constant and the installation
dimensions of the steel within the speci-
fied value during assembly, adjust the
press-fitting jig dimensions of the link
press.
* For details of the standard dimensions, a
see PRESS-FITTING JIG DIMENSION
b
TABLE FOR LINK PRESS.
* If the end face of the pin (portion P) or
the end face of the link (portions Q, R)
are worn, add the amount of wear to
the standard dimension when adjusting
F19602261
the dimension of the press-fitting jig so
that the amount of protrusion of the
left and right pin and bushing is
uniform.
30-l 79
Co
2. Assembly of link
1) Coat the area between the pin and bush-
ing with lithium grease (G2-LI), set in posi-
tion, then set in front of the jaw of the link
press.
* When reusing (turning) the bushing,
set the worn surface on the outside
circumference of the bushing facing
the shoe mounting surface of the link
(facing up on the link prss).
IF1 9902264
2) Set the left and right bushing end master

link with the shoe mounting surface facing
up, then press fit to the bushing.
* When doing this, use the pin end
master link as a support.
* Bushing press fitting force: IO - 35 ton
3) Using a shoe bolt hole pitch gauge, press

fit until the distance between the shoe bolt
holes of the left and right link is the speci-
fied value.
* Use compressed air to remove all
metal particles from burrs while press
fitting the bushing.
4) Turn over the master link, and check that

the left and right master links have been
press fitted in parallel.
5) Measure the amount of protrusion of the

left and right bushings with a depth
gauge.
jr Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
30-180
0
I
6) Feed the master link portion, then set the
pin and bushing in position.
* When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing
the specified direction, the strength
may drop, so mark the direction of the
side hole clearly on the end face to
prevent any mistake during assembly.
* If the outside diameter of the pin is
worn, assemble so that the face that is I
F19802284
not worn is on the pulling side.
However, in this case, also assemble so
that the side hole faces the tread
surface of the link.
7) Set the left and right links in position, then

operate the left and right pushing jigs to
press fit the pin and bushing at the same
time.
* When press fitting, the seal may come
off the link due to the play, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit
the seal correctly on the link, then start
the press-fitting operation again.
9802285
* Set pushing force of pin and bushing:
150 ton
Set pushing force k 1.8 X average
pushing force
(Adjust the relief pressure of link press
to fix the set pushing force)
8) Using a shoe bolt hole pitch gauge, check

that the distance between the shoe bolt
holes is within the standard value.
9) Assemble the pin end master link as the

final link.
* Check that the left and right master
links are press fitted in parallel.
3. Shoe (regular link portion)

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench
to install the shoe.
QE Shoe bolt (regular link):
Initial tightening torque: 80 f 8 kgm
Tightening angle: 120 f 10
F 19802240
30-181
0
4. Connecting to make l/2 assembly
track on a flat surface in a straight line with
the shoes facing up. Pull master link (1) at the
pin end to master link (2) at the bushing end,
and set at the mating surfaces. Then put shoe
(3) on top, check that shoe bolt (4) goes in
easily by hand, and connect the two parts.
NC& Mounting bolt:

m Shoe bolt (master link):

Initial tightening torque: 50 f 5 kgm
Tightening angle: 180 1- 10
j, When tightening, tighten in order 0 - 0.

* Do not use an impact wrench for the
master link mounting bolt.
x ~6164026
F19802282
30-182
0
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
a-
6-b
Unit: mm
Jig dimension
a b C
4.525 k 2 2.00 Y!Y0.28 53.6
30-l 84
0
FIELD DISASSEMBLY OF ONE LINK
A This section gives only the procedure for

using the tools. For details of the procedure
for disassembly or assembly, see OVERALL
DISASSEMBLY (or ASSEMBLY) OF TRACK
SHOE.
1. Using two bolts (2), install tool KD-1 (adapter,

guide, bolt) to link (1).
* It is also possible to use two track bolts for
bolt (2).
2. Assemble tool KD-2 (pump, cylinder 150t)

and toll KD-3 (frame, rod, adapter, bolt X 1,
eyebolt), then raise the assembly and set on
the track.
KD-2 KDi3 I-
Insert the rod of tool KD-4 from the cylinder

end, and install with two nuts.
4. Set tool KD-5 (adapter, guide, pusher) in posi-

tion, then apply hydraulic pressure and
remove pin (3).
When the cylinder reaches the end of its
stroke, insert extension KD-5 between the
adapter and guide, and repeat the operation.
L _J
F19802291 A
30-l 85
0
5. Set tool KD-6 (30t puller) and spacer 0 to the
center of the roller tread of the link to be
disassembled, then apply hydraulic pressure
to the puller, open the link 5 - 6 mm and
disconnect the link.
F19802292A
30-186
0
FIELD ASSEMBLY OF ONE LINK
Press (or remover)

1. Assemble the link sub-assembly.
1) Set tool KE-1 to the end face of the link,
then press fit bushing (1).
* Bushing press fitting force: 10 - 35 ton
2) Set tool KE-1 to the end face of the link

(pin end), then press fit pin (2). Press (or remover) I
j, Set side hole of pin to the link tread Side hole +
side.
* Pin press fitting force: 55 - 70 ton
KE-1
side
I I
z
z
,
F15421167 I
I-
FS
2. Set link sub-assembly (3) on the link to be
connected.
F19802294
3. Set link (4) on the opposite side, and support

KE-2
with tool KE-2 (guide).
- /J t”o\ F19802295A
30-187
0
4. Set tools KE-3 and KE-4 in the same way as
for the operation to remove the pin, then use
tool KE-3 (adapter, extension, guide, adapter,
I KE-4
bolt) for press fitting the pin, and tool KE-4

(extension, guide, adapter, bolt) for press
fitting the bushing, and press fit in turn.
A Bushing press fitting force: 10 - 35 ton
I KE13 ” \A F19802296A
5. Use tool KE-7 (30t puller) in the same way as

when disassembling, and push open link (5)
at the bushing end.
KE-7
F 19802297A
6. Set link (6) at the pin end to link (5) at the

bushing end, connect with tool KE-5 (guide),
then remove tool KE-7 (puller).
F19802298A
7. Set tool KE-3 at pin (7) end, then use tool KE-6
(adapter, bolt and guide) to press fit (7).
AL, Pin press fitting hole in link:

Gasket sealant (198-32-l 9890) :ylin
A Set side hole of pin to the link tread side.

F19802299A
30-188
0
DISASSEMBLY OF MASTER LINK
1. Removal of track assembly

Remove the track assembly from the chassis.
2. Separation of track
Disconnect all master portions, and divide
into four parts.
3. Removal of master link

l Master pin type
1) Gas cutting of regular link
Gas cut the portion marked WV , and
remove @ZB .
Special tool to use:
Manual gas cutting torches
Bus
32FO21
2) Removal of regular link

Press pin (1) in the direction of the
arrow with a press, remove from link
(2), then remove pin (1) and link (3) at
the same time from bushing (4).
* E 32F022A
l Master link type

1) Gas cutting, removal of master link at
bushing end gas cut the portion
marked WV , remove EBj, then
move master links (5) and (6) up or
down to remove them. Push pins (8)
and (9) press fitted to regular link (7)
with a press in the direction of the
arrows to remove them.
1. Manual gas cutting torches
2. Tool KF
30-l 89
0
2) Removal of master link at pin end
Gas cut the portion marked WV ,
remove m , push pin (10) with a
press in the direction of the arrow and
remove from link (1I), then remove pin
(IO) and link (12) at the same time from
bushing (13).
1. Manual gas cutting torches
2. Tool KF
32F024A
30-190
a
ASSEMBLY OF MASTER LINK
1. Assembly of link at bushing end

1) Using a press, press fit master link (1) at
the bushing end to bushing (2).
A When press fitting the left and right
master links, be extremely careful to
keep them parallel.
* Be careful not to scratch or damage the
mating surface of the master link and
the end face of the bushing.
D2
F19802300
Unit: mm
b 184.15 k 0.7
2. Assembly of link at bushing end

1) Push open the central part of the link tread
with tool KE-7 as shown in the diagram. mm
(Open approx. 10 mm at the tip of the

link.)
-7
mm
I 17MF02806
2) Set spacer (3) and seal assembly (4) at the

counterbore of the link at the connection.
I/
32F014A
30-191
0
3) Align the pin hole and bushing hole, and
connect with guide pin 0.
32FO15A
i
4) Remove puller KE-7, press fit pin (5) with

tool KF, and install master link (1) at the
bushing end.
/r;\- Pin press-fitting hole in link:
Gasket sealant (198-32-l 9890)
* Set side hole of pin to the link tread
side.
5/ ’
Press fit 32F016A
5) Install the shoe to the link at the connec-

tion.
6) After knocking in large plug (6) with tool Y,

fill with oil using tool KC, then knock in
small plug (7) with tool 2.
* When-press fitting the left and right
master links, be extremely careful to
keep the left and right links parallel.
(bushing end and pin end)
* Be careful not to scratch or damage the
mating surface of the master link and 6
32FO18A
the end face of the bushing.
* End play at connection (play in thrust
direction of links in front of and behind
pin): 0 - 0.13 mm
* Be extremely careful not to get mud or
dust on the tap hole mating face of the
master link, bushing end face, spacer,
or seal.
30-192
0
3. Assemblv of link at Din end
1) Set spacer (3) and’ seal assembly (4) in the
Link
counterbore of the master link. r 3
p,f
4
\. Bushing I
32F014A
2) Pass pin (9) through bushing (8), set pin

end master link (10) from the left and
right, then press fit with tool KF.
3) After knocking in large plug (11) with tool

Y, fill with oil using tool KC, then knock in
small plug (12) with tool 2.
9’i-1 Fl gBO2301
8
H
12
5;
4) Connecting master link portion
track on a flat surface in a straight line
with the shoe facing up. Pull master link
(13) at the pin end to master link (14) at
the bushing end, and set at the mating
surfaces. Then put the shoe on top, and
check that the shoe bolt goes in easily by
hand.
Mounting bolt:
Anti-friction compound (LM-P) U U 32FOZOA
Shoe bolt (master link):
Initial tightening torque: 50 + 5 kgm
Tightening angle: 180 + 10
30-193
0
REMOVAL OF PIVOT SHAFT TWISTING SEAL
1. For details, see REMOVAL OF TRACK FRAME

ASSEMBLY.
2. Remove twisting seal assembly (I). m
1’ i_Lf 17MF0269C
INSTALLATION OF PIVOT
SHAFT TWISTING SEAL

removal.
m
* Using tool N, press fit twisting seal assem-
bly (1).
* Press-fitting force:
17.6 - 31.4 kN Il.8 - 3.2 ton1
* Set the distance from the end face of the
shaft to the end face of the metal fitting on
the inside of the seal ring to the dimension
below.
Dimension a: 493 * 1.0 mm
* Remove all oil and grease from the oil seal
press-fitting surface.
.- .
& Press fitting surface Of seat:
I u 09002981
30- 194
@
1. For details, see REMOVAL OF TRACK FRAME
ASSEMBLY.
2. Remove twisting seal assembly.

For details, see REMOVAL OF PIVOT SHAFT
TWISTING SEAL.
3. Sling pivot shaft assembly (1).

screws 0 and guide bolts 0, pull out pivot
shaft assembly.
& Pivot shaft assembly: 160 kg
INSTALLATION OF PIVOT
SHAFT ASSEMBLY
removal.
j, Set with the match marks at the top when

assembling.
&, Pivot shaft:
* Press-fitting force: 0.1 - 2.0 ton
mu Pivot shaft mounting bolt:

w Pivot shaft mounting bolt:
159.5 k 17.5 kgm
30-l 95
0
REMOVAL OF EQUALIZER BAR ASSEMBLY
1. Using transmission jack, remove underguard

(1) under engine and under power train.
2. Disconnect greases hoses (2) (front: 2, rear:

2).
3. Remove stopper plate, and pull out pins (3),

then remove rods (4) (front: 1, rear: 1). lfll
4. Remove mounting bolts of left twisting seal

(5).
5. Remove mounting bolts of right twisting seal 17MF02695

(6).
6. Remove right side pivot shaft covers (7) and

(8). m
7. Remove holder (9), and disconnect blade tilt

hose (IO).
8. Remove plates (11) and (12).

A The oil inside the pivot chamber will leak
out, so put a container under it to catch
the oil.
:
u Pivot chamber: 12 e
30-196
0
9. Remove left and right pin covers (13) and
(14).
10. Remove lock plate, then remove left and right

shafts (15). m
11. Sling equalizer bar assembly (16) with crane

and chain block.
12. Support bottom frame of machine with hy-

draulic jack (30 ton).
13. Remove lock plate, then set tool 0 in position, 17MF02701 II 17MF02702
pull out center shaft (17). m
A When operating the hydraulic system,

do not operate it in front of or under the
puller. Operate it from as far away as
possible.
Center shaft: 25 kg
PI kg
14. Raise machine approx. 200 mm more with

hydraulic jack.
15. Operate chain block while operating crane to

remove equalizer bar assembly (16).
.A\
m equalizer bar assembly: 300 kg
A After removing the equalizer bar assem-

bly, do not lower the machine.
Hydraulic jack 17MF02704
Front side
I 17MF02705
30-l 97
0
INSTALLATION OF EQUALIZER BAR ASSEMLY
Oil quantity of pivot shaft
Oil level
removal.
-1
& Mounting bolt:
112]
w Mounting bolt:
277.0 + 31.9 Nm I28.25 d 3.25 kgm)
* The stopper plate and pin stopper are in
tight contact.
& Cover mounting bolt: I
a
T
-
Sr Add oil to replace the oil that leaked out

from the pivot shaft chamber. (For the
oil level, see the diagram on the right.)
a
Serial No. : 10001 - 10127
& Outside surface of pin:
Greese (G2-LI)
Before installing the side shaft, align
the position of flanged bushing (18)
and the track frame slit, and drive in
so that bushing (18) is in tight con-
tact with faces b and c.
17MF02708
Slit aiea ’ frame
Track
t Clearance d between the equalizer bar
and the track frame is the same (15 5 2
mm) at the front and rear. (When check-
ing this, check that surfaces a, b and c
are in tight contact.)
k Measure stepped difference A between
surface e and surface f with a depth
gauge, and adjust with shims so that it
is 0.2 - 0.3 mm.
Ir When tightening the mounting bolts of
the lock plate at the rear of the machine
to the specified torque 549.2 + 8.8 Nm
(56 f 6 kgm), if the flanged bushing (18) a
rotates, tighten mounting bolts (19) of
cover (14) first to a maximum of 147
Nm (15 kgm1, then tighten the lock plate
to the specified torque, and tighten
mounting bolt (19) again to the speci-
fied torque.
QEI Mounting bolt of lock plate at rear of
machine:
549.2 z 58.8 Nm {56 2 6 kgm}
& Outside surface of center shaft:

Grease (G2-LI)
I 17MF02710
30-198
r
& Outside surface of pin :
Grease (G2-LI)
Before installing the side shaft, align
flanged bushing (18) and position of
slit in track frame, then drive in bush-
ing (18) until it is in tight contact with
surfaces b and c.
* Clearance d between the equalizer bar
and the track frame must be the same
(15 2 2 mm) at the front and rear. (When
measuring, check that surfaces a, b, and a C b DBD02982
c are in tight contact.)
* When tightening the lock plate mount-
ing bolts to the specified tightening
torque (549.2 r 58.8 Nm {56 f 6 kgm)), if
flanged bushing (18) rotates, tighten
mounting bolts (19) of cover (14) to a
maximum of 147 Nm (15 kgm), then
tighten the lock plate mounting bolts,
and finally tighten mounting bolts (19)
to the specified tightening torque.
m Lock plate mounting bolt:
549.2 + 58.8 Nm (56 + 6 kgm}
m
& Center shaft outside surface :
Grease (G2-LI)
30-198-l
@
REMOVAL OF EQUALIZER BAR SIDE BUSHING
1. For details, see

BAR ASSEMBLY.
2. Remove seal (1).

REMOVAL OF EQUALIZER
r
3. Remove Ring (2).
17MF02711
4. Using tool P, pull out spherical bushing (3).
i
17MF02712
30- 199
0
INSTALLATION OF EQUALIZER BAR SIDE BUSHING
1. install ring (2) on one side.
2. Using tool P, press fit spherical bushing (3).

* Direction of assembly for spherical bush-
ing
I) The split face of the outside ring should
be horizontal as shown in the diagram.
2) The grease hole in the outer ring
should be at the top and facing the
inside as shown in the diagram.
& Outside surface of spherical bushing: 17MF02713

* Press-fitting force:
68.6 - 133.4 kN I7 - 13.6 tons}
Grease hole Split face
3. Install ring on poopsite side.
Serial No. : 10001 - 10127

4. Using push tool, press fit seals (I) on both
side.
& Inside, outside circumference of seal:


5. Remove equalizer bar assembly.
For details, see REMOVAL OF EQUALIZER I, - /’
BAR ASSEMBLY.
30-200
@
REMOVAL OF SUSPENSION CUSHION ASSEMBLY
1. Remove equalizer bar assembly.

For details, see REMOVAL OF EQUALIZER
BAR ASSEMBLY.
2. Set transmission jack under machine, and

remove mounting bolts, then remove cap (1)
and cushion (2). m
3. Operate transmission jack slowly, and remove

bolster assembly (3).
4. Remove cushion (4). m 02716
INSTALLATION OF SUSPEN-
SION CUSHION ASSEMBLY
z I
zb 1jMFO2717
TT l Carry out installation in the reverse order to

removal.
a Mounting bolt:
w Mounting belt: 135 + 15 kgm
m
* The distance between the end face of the

circular portion and the machined surface
shall be dimension a.
The installation dimensions shall be the
same on both the left and right sides.
a=30flmm
Machined surface
17MF02719
30-201
0
REMOVAL OF SEGMENT TOOTH
1. Stop machine at position where tooth can be

removed (between shoe and track frame).
2. Remove 2 covers (1).
3. Remove mounting bolts, then remove tooth

(2). m -
IN STALLATION OF SEGMENT
TC 1OTH

removal.
m
m Tooth mounting nut: 120 + 10 kgm
30-202
0
REMOVAL OF HYDRAULIC PUMP ASSEMBLY
Lower the work equipment to the ground

and stop the engine. Operate the control
levers several times to release the remaining
pressure in the hydraulic piping. Then
loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
1. Drain oil
:
u Hydraulic tank oil: Approx 95n
2. Remove floor frame assembly.

For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
3. Disconnect hydraulic oil temperature wiring

connector (1).
4. Disconnect suction tube (2) and 3 delivery

hoses (3).
5. Remove mounting bolts, and lift off hydraulic

pump assembly (4).
& Hydraulic pump assembly: 35 kg
0”
2 INSTALLATION OF HYDRAULIC
z PUMP ASSEMBLY

removal.
Add engine oil inside the hydraulic tank to the
specified level, and run the engine to circu-
late the oil through the system. Then check
the oil level again.
30-203
0
REMOVAL OF BLADE LIFT VALVE ASSEMBLY
A Lower the work equipment to the ground

1. Drain oil.
/ci7+ Hydraulic tank: Approx 95 e
2. Remove side cover of hydraulic tank.
3. Remove rod (1).
4. Disconnect pilot hose (2).
5. Disconnect tube (3).
7. Remove blade lift valve assembly (5).

* Sling the lift valve assembly, and remove
the mounting bolts.
/L
m Blade lift valve assembly: 60 kg
INSTALLATION OF BLADE
LIFT VALVE ASSEMBLY

removal.
. Refilling with oil
Add engine oil to the hydraulic tank to the
specified level, and run the engine to circu-
late the oil through the system. Then check
the oil level again.
30-204
0
DISASSEMBLY OF BLADE LIFT VALVE ASSEMBLY
1. Disassembly of main spool assembly

Remove lever case assembly (1).
Remove case (2). then remove retainer (3),
plug (4) and collar (5) from case.
Remove plug (6), then remove spring (7),
spacer (8) and ball (9).
Remove spring (IO), then remove retainer
(11) and spool (12).
* If there is any abnormality in the spool
or body, replace the spool and body as
an assembly.
2. Disassembly of demand valve assembly

1) Remove case (13), then remove spring
(14).
2) Remove plate (15), then remove spool (16)
and seal (17).
3. Disassembly of main relief, shuttle valve

assembly
1) Remove main relief valve assembly (18).
* If the adjusting screw nut is loosened
and the screw turned, the set pressure
will change, so do not disassemble.
2) Remove plug (19), then remove piston
(20), shuttle valve spool (21) and spring
(22).
3) Remove valve body (23).
4. Disassembly of suction valve assembly

Remove plug (24), then remove spring (25)
and valve (26).
5. Disassembly of check valve assembly

Remove plug (27), then remove spring (28)
and valve (29).
6. Disassembly of shuttle valve assembly

Remove plug (30). then remove ball (31).
30-206
0
30-207
a
ASSEMBLY OF BLADE LIFT VALVE ASSEMBLY
* Clean all parts, and check for dirt or damage. 5. Assembly of demand valve assemblv
Coat the- sliding surfaces of all parts with 1) Assemble seal (17) and spool (16), then fit
engine oil before installing. O-ring and install case (15).
w Case mounting bolt: 19 I!I 1 kgm

1. Assembly of shuttle valve assembly
Assemble ball (31), then fit O-ring and install
2) Assemble spring (14) and install (13).
plug (30).
m Mounting bolt: 19fl kgm
Q!Z Plug: 3.5 f0.5 kgm
6. Assembly of main spool assembly
2. Assembly of valve assembly I\ Fit O-ring and install lever case assembly
‘I
Assemble valve (29), spring (28), fit O-ring
(1).
and install plug (27).
2) Set spool (12), retainer (11) and spring (10)
m Plug: 37.5 +2.5 kgm in position.
3) Assemble ball (9), spacer (8) and spring (7)
3. Assembly of suction valve assembly in case (2), then fit O-ring and install plug
Assemble valve (26), spring (25), fit O-ring (6).
and install plug (24). QE Plug: 3.5 f0.5 kgm
w Plug: 52.5 +2.5 kgm
4) Set collar (5), plug (4) and retainer (3) in
4. Assembly of main relief, shuttle valve as- case (2), then fit O-ring and install case (2).
sembly
1) Fit O-ring and install valve body (23).
m Mounting bolt:
The first time 3.5 f 0.5 kgm
The second time 6.75 f 0.75 kgm
*Tighten the mounting bolts in order

shown.
2) Assemble spring (22). shuttle valve spool
(21) and piston (20), then fit O-ring and
install plug (19).
m Plug: 7fl kgm
3) Install main relief valve assembly (18).

m Relief valve assembly: 8.5 f 1.5 kgm
* It the valve assembly has been disassem-

bled, insall the main control valve aseem-
bly on the machine, then turn the adjust-
ment screw to adjust the set pressure to
210 kg/cm*.
30-208
0
1
10
I
197F371
30-209
a
REMOVAL OF BLADE TILT, RIPPER LOW VALVE ASSEMBLY

1. Drain oil.
:
u Hydraulic tank: Approx 95 II
2. Remove side cover of hydraulic tank.
1 - 17MF02724 1) 17MF02725
3. Remove hydraulic tank support bracket (1).
4. Disconnect blade lift control rod (2).
5. Remove control rods (3), (4) and (5) of work

equipment.
* Before removing the rods, mark the posi-
tion of installation.
6. Disconnect tube (6) between blade tilt-ripper

low valve and blade lift valve at blade lift
valve end.
7. Di$;,nrct hoses (71, (81, (91, (IO), (1 I), (121,

1’1 to \9 17MF02726
* Before disconnecting the hoses, mark the
position of installation.
8. Sling the valve (14) assembly, then remove

the mounting bolts.
& Blade tilt, ripper low valve assembly:

54 kg
TILT, RIPPER LOW VALVE

removal.
* Add engine oil to the hydraulic tank to the
specified level, and run the engine to
circulate the oil through the system. Then
30-210
0
DISASSEMBLY OF BLADE TILT, RIPPER LOW VALVE ASSEMBLY
1. Disassembly of spool assembly

1) Remove case assembly (I), then remove
collar (2) from case assembly.
2) Remove joint (3).
* Always loosen the joint with the spool
assembled in the body.
3) Remove case (4).
4) Remove bolts (5), then remove washer (6),
retainer (7), spring (8), collar (9) and
retainer (IO).
* Always loosen the bolts with the spool
assembled in the body.
5) Pull out spool (11) from body (12).
* If there is any abnormality in the spool
or body, replace the spool and body as
an assembly.
Main relief valve assembly

Remove main relief valve assembly (13).
* If the cover is removed and the adjust-
ment screw turned, the set pressure will
change, so do not disassemble unless
necessary.
3. Disassembly of check valve assembly

Remove mounting bolts (14). then remove
bar (15), seat (16), spring (17) and valve (18).
4. Disassembly of shuttle valve assembly

Remove plug (19), then remove seat (20) and
ball (21).
30-212
a
1'4
17MF02728
30-2 13
0
ASSEMBLY OF BLADE TILT, RIPPER LOW VALVE ASSEMBLY

1. Assembly of shuttle valve assembly

1) Assemble ball (21) in plug (19), fit O-ring,
then assemble seat (20).
2) Fit O-ring and install plug assembly.
m Plug: 3.5+_0.5 kgm
2. Assembly of check valve assembly

1) Assemble valve (18) and spring (17).
2) Fit O-ring and assemble seat (16), then
install bar (15) and tighten bolts (14).
Main relief valve assembly

Fit O-ring and install main relief valve assem-
bly (13).
QE Main relief valve assembly:
8.5 f 1.5 kgm
* If the valve assembly has been disassem-

bled, install the main control valve assem-
bly on the machine, then turn the adjust-
ment screw to adjust the set pressure to
210 kg/cm’.
4. Assembly of spool assembly

1) Assemble spool (11) in body (12).
2) Set retainer (IO), collar (9), spring (8).
retainer (7) and washer (6) in position,
then tighten bolts (5).
* Always tighten the bolts with the spool
assembled inside the body.
m Bolt: 3.5 f 0.5 kgm
3) Fit O-ring and install case (4).

4) Install joint (3).
* Always tighten the bolts with the spool
assembled inside the body.
w Joint: 6.75 f 0.75 kgm
5) Assemble collar (2) in case assembly, then

fit O-ring and install case assembly (1).
w Mounting bolt: 3.15 f 0.35 kgm
30-214
0
17MF02728
30-215
0
REMOVAL OF RIPPER HIGH VALVE

1. Drain oil
:
u Hydraulic tank: Approx 95 P
2. Disconnect bracket of fuel drain hose (1) from

valve.
3. Disconnect 14 pipes (2), (3), and (4).
4. Remove valve assembly (5).
INSTALLATION OF RIPPER
HIGH VALVE ASSEMBLY

removal.
17MF02730
* Add engine oil to the hydraulic tank to the 2
specified level, and run the engine to
circulate the oil through the system. Then
Q Hydraulic tank: Approx 95 P
30-216
a
DISASSEMBLY OF RIPPER HIGH VALVE ASSEMBLY
1. Disassembly of valve assembly

1) Remove blocks (1) and (2).
2) Remove plug (3), then remove ball (4).
3) Disassembly of fixed differential pressure
valve assembly.
i) Remove plug (5), then remove retainer
(6), spring (7) and retainer (8).
ii) Pull out spool (9).
* Always loosen the plug with the
spool assembled inside the valve.
4) Disassembly of ripper lift high valve assem-
bly.
i) Remove plug (IO), then remove spring
(11) and retainer (12).
ii) Remove plug (13), then remove spring
(14) and retainer (15).
iii) Pull out spool (16).
* Always loosen the plug with the
spool assembled inside the valve.
5) Disassembly of ripper tilt high valve assem-
bly.
Repeat the procedure for disassembling
the ripper lift high valve and disassemble
the ripper tilt high valve.
6) Remove plug (17), then remove spring (18)
and check valve (19).
7) Remove plug (20), then remove seat (21),
spring (22) and valve (23).
30-218
0
i7
3
197F373
30-2 19
0
ASSEMBLY OF RIPPER HIGH VALVE ASSEMBLY
j, Clean all parts, and check for dirt or damage.

1. Assembly of valve assembly

1) Assemble valve (23), spring (22) and seal
(21), then fit O-ring and install plug (20).
m Plug: 52.5 + 2.5 kgm
2) Assemble check valve (19) and spring (18),

then fit O-ring and install plug (17).
m Plug: 13 f 2 kgm
31 Assembly of ripper lift high valve assem-

bly:
i) Assemble spoool (16).
ii) Set retainer (15) and spring (14) on
spool, then fit PO-ring and install plug
(13).
m Plug: 6.75 f 0.75 kgm
iii) Set retainer (12) and spring (11) on

spool, then fit O-ring and install plug
(IO).
m Plug: 6.75 f 0.75 kgm
* Always tighten the plug with the spool

assembled inside the valve.
4) Assembly of ripper tilt high valve assem-

bly.
Repeat the procedure for assembling the
ripper lift high valve and assemble the
ripper tilt high valve.
5) Assembly of fixed differential pressure

valve assembly.
i) Assemble spool (9).
ii) Set retainer (8), spring (7) and retainer
(6) on spool, and install plug (5).
* Always tighten the plug with the spool
assembled inside the valve.
6) Assemble ball (4). then fit O-ring and

install plug (3).
m Plug: 3.5 + 0.5 kgm
7) Fit O-ring and install blocks (2) and (1).
30-220
0
197F373
30-221
0
REMOVAL OF BLADE LIFT CYLINDER ASSEMBLY

ground.
completely to the
1. Sling head end of lift cylinder assembly, and

remove cap (1). m
, Start engine, retract piston rod fully, tie the

A rod with wire to prevent it from coming out,
then stop engine.
After stopping the engine, operate the F19802231

* control lever several times to release the
remaining pressure in the hydraulic
piping. Then loosen the oil filler cap
slowly to release the pressure inside the
hydraulic tank.

* Fit a blind plug to prevent dirt or dust from
entering the piping.
3. Sling cylinder assembly (3), then remove cap

(4), then remove cylinder assembly. m
f+l Blade lift cvlinder assembly: 210 kg

I
LIFT CYLINDER ASSEMBLY

removal.
j, Standard shim thickness: 4 mm
a Yoke: Grease (G2-LI)
l Bleeding air
Bleed the air from cylinder.
30-222
0
REMOVAL OF BLADE TILT CYLINDER ASSEMBLY

ground.
completely to the
1. Sling tilt cylinder assembly (I), and remove

lock plate, then pull out pin (2). m
A Start engine,
stop engine.
retract piston rod fully, then
After stopping the engine, operate the

+ control lever several times to release the
L
hydraulic tank.
2. Disconnect 2 hoses (3).

3. Remove lock plate, and pull out pin (4), then

remove tilt cylinder assembly. m
* When slinging, be careful not to damage
the hose with the bottom end.
Blade tilt cylinder assembly: 225 kg
& kg
TILT CYLINDER ASSEMBLY

removal.
a Pin: Grease (G2-LI)
l Bleeding air
30-223
0
REMOVAL OF RIPPER LIFT CYLINDER ASSEMBLY

ground.
completely to the
1. Sling lift cylinder assembly (I), remove lock

plate, then pull out pin (2) at head end. m
A Start the engine and retract the piston rod

fully.
Stop the engine and operate the control

lever several times to release the
hydraulic tank.

entering the piping. [121
3. Remove lock plate, then pull out pin (4) at

bottom end and lift off cylinder assembly (1).
f=h Ripper lift cylinder assembly: 205 kg
LIFT CYLINDER ASSEMBLY
0 Carry out installation in the reverse order to

removal.
& Pin: Grease (G2-LI)
l Bleeding air
30-224
0
REMOVAL OF RIPPER TILT CYLINDER ASSEMBLY

ground.
completely to the
1. Sling tilt cylinder assembly (I), remove lock

plate, then pull out pin (2) at head end. m
A Start the engine and retract the piston rod

fully.
Stop the engine and operate the control

lever several times to release the
slowly to release the pressure inside the I-
hydraulic tank.

3. Remove lock plate, and pull out pin. m
& kg Ripper tilt cylinder assembly: 190 kg
8
z
0
TILT CYLINDER ASSEMBLY
0 Carry out installation in the reverse order to

removal.
& Pin: Grease (GZ-LI)
RZZ+ Pin: Grease (GZ-LI)
l Bleeding air
30-225
0
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
(BLADE LIFT, BLADE TILT, RIPPER LIFT, RIPPER r

TILT CYLINDER)
1. Cylinder tube
Remove cylinder tube.
2. Quick drop valve (blade lift cylinder)

Remove block (I), then pull out spring (2),
spacer (3), valves (4) and (5), and collar (6).
3. Piston rod assembly

0 Blade lift cylinder
1) Set cylinder assembly (7) to tool Q,.
2) Using hydraulic pump or power wrench,
disconnect head assembly (8) with tool Q,.
3) Pull out piston rod assembly (9).
* Put an oil pan or container under the
cylinder to catch the oil.
1 l1h.iF02737
Blade tilt, Ripper lift, Ripper tilt cylinder
y, Remove mounting bolts, and disconnect
head assembly (10).
2) Pull out piston rod assembly (11).
* Put an oil pan or container under the
cylinder to catch the oil.
- 17MF0273P
4. Piston assemblv
Blade lift cyli;der
;I Remove mounting bolts, then remove
spacer (12), and pull out valve (13).
2) Remove piston assembly (14).
3) Remove backup rings (15), and O-ring (16).
4) Remove retainer (17).
17MF02739
30-226
0
5) Disassemble the piston assembly as fol-
lows.
i) Remove wear ring (18).
ii) Remove piston ring (19).
iii) Pull out seat (20), and valve (21).
I I.8 I95FO5365
J
. Blade tilt, ripper lift, ripper tilt cylinder I 22
spacer (22).
2) Pull out piston assembly (23).
3) Remove backup ring (24) and O-ring (25).
4) Disassembly of piston assembly
i) Remove wear ring (26).
23
ii) Remove piston ring (27).
24
r 17MF02740
il
L I95FO5364
Blade tilt
5. Head assembly
1) Remove head assembly (8) or (IO). 17MF02741
2) Disassemble the head assembly as follows.
i) Remove O-ring (28). (only for blade
cylinder) Blade lift
ii) Remove O-ring (29) and backup ring
(36).
iii) Remove packing (31).
iv) Remove snap ring (32), then remove
dust seal (33).
Blade tilt
v) Remove bushing (34).
Ripper lift
Ripper tilt
30-227
0
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
(BLADE LIFT, BLADE TILT, RIPPER LIFT, RIPPER

TILT CYLINDER)

engine oil before installing. Be careful not to
Blade tilt
damage the packings, dust seals, and O-rings Ripper lift
when assembling. Ripper tilt
1. Head assembly
1) Assemble head as follows.
i) Press fit bushing (34).
ii) Assemble dust seal (33), and secure
with snap ring (32).
iii) Assemble packing (31).
iv) Assemble backup ring (30) and O-ring
(29). Blade lift
* Do not try to force the backup ring
into piston. Warm it in warm water
(50 - 60°C) before fitting it.
v) Assemble O-ring (28). (blade lift cylin-
der only)
Blade tilt
2) Assemble head assembly (8) or (10) to Ripper lift
piston rod. Ripper tilt
17MF02741
2. Piston assembly
l Blade lift cylinder
1) Assemble the piston as follows.
i) Assemble valve (21) and seat (20).
ii) Using tool Q,, expand piston ring (19).
j, Set the piston ring on tool Qs and
turn the handle 8 - 10 times to
expand the ring.
iii) Remove piston ring (19) from tool 4,
then install it to piston.
iv) Using tool Q,, compress piston ring
(19).
17MF02743
v) Assemble wear ring (18).
J18 17MF02744 2:2FO5487 / I 97F3779
30-228
0
2) Install retainer (17).
3) Install O-ring (16) and backup rings (15).
* Do not try to force the backup ring into
the piston. Warm it in warm water
(50 - 60°C) before fitting it.
* Coat the O-ring and the backup rings
with grease, then secure the backup
rings so that they do not open.
4) Install piston assembly (14).
5) Assemble valve (13) to spacer (12), then fit
spacer and tighten with mounting bolts.
/‘r\- Mounting bolt: w 17MF02739
w Mounting bolt: 11.25 Z!I 1.25 kgm
@Y
c3
2
. Blade tilt, ripper lift, ripper tilt cylinder
1) Using tool Q, in the same way as for Step
2-l) -ii) - iv), assemble piston ring (27),
9
2’7
26
I95FO5364
z then assemble wear ring (26).

z
2) In the same way as for Step 2-3) - 4),
assemble O-ring (25), backup ring (24),
and piston assembly (23).
3) Fix spacer (22) in position, then tighten
&, Mounting bolt:

m Mounting bolt: 11.25 k 1.25 kgm
17MF02740
3. Piston rod assembly

l Blade lift cylinder
1) Set cylinder (35) in tool 0,.
2) Assemble piston rod assembly (9) to cylin-
der.
Z-EL Seal portion: Grease (G2-LI)
* Push the piston rod in the end of its

stroke.
3) Using tool Q,, tighten head assembly (8).
w Head assembly: 105 _+ 10.5 kgm
, 1 1 :dFO2737
30-229
0
Blade tilt, ripper lift, ripper tilt cylinder
;, Assemble piston rod assembly (11) to
cylinder (36).
H-E>= Seal portion: Grease (G2-LI)

* Push the piston rod in to the end of its
stroke.
2) Tighten head assembly (10) with mounting
bolts.
m Mounting bolt:
17MF02745
Quick drop valve (blade lift cylinder only)

Assemble collar (6), valves (5) and (4), spacer
(3), and spring (2), then fit O-ring and install
block (1).
Tube
Fit O-ring and install tube.
I l98FO2792
30-230
0
REMOVAL OF WORK EQUIPMENT ASSEMBLY
Stop the machine on a firm, level place, and

A lower the work equipment to the ground.
Then put blocks 0 securely under the
straight frame on the left and right.
1. Remove cap (1). m

j, Check the number and thickness of the
shims (2), and keep in a safe place.
2. Sling blade lift cylinder (3), start engine and

retract piston rod fully, then fit cylinder lock
plate to secure to guard.
A Tie the rod with wire to prevent it from 175FO2577
coming out.
* Repeat Steps 1 to 2 to disconnect the
cylinder on the other side from the blade.
Stop the engine and operate the con-
trol lever several times to release the
hydraulic tank.
2
17MF02746 17MF02747
3. Remove right cover (4).

A Make match marks before disconnecting
the hose.
5. Remove left and right trunnion caps (6).
6. Remove work equipment assembly (7). IfEt21

A Start engine and drive machine slowly in
reverse to disconnect blade assembly
from trunnion on track frame.
I98FO2808
30-231
0
INSTALLATION OF WORK EQUIPMENT ASSEMBLY

removal.
Adjust so that play C of the spherical

portion in the axial direction is within 0.5
mm, but can still rotate smoothly.
Standard shim thickness: 4 mm
Adjust with a block @ so that the height

and width of the left and right straight
frames are dimensions A and B as shown
below.
Dimensions A: Approx. 2876 mm

Dimensions B: Approx. 559 mm
198F1423
30-232
0
DISASSEMBLY OF WORK EQUIPMENT ASSEMBLY
A Insert 5 blocks 0 under the left and right

straioht frames, the bottom of the blade, and
the left and right arm mounts to set the
dozer assembly securely in the position.
1. Sling tilt brace (I), and remove lock plate,

then pull out pin (2).
* If the pin is stiff, rotate brace (1) with lever
(3) to adjust.
2. Remove lock plate, then pull out pin (4) and

remove tilt brace (1).
I 17MF02749
& Tilt brace: 150 kg
3. Raise right center brace (5) and left center

brace (6), remove pins (7) and (8) and
connection with straight frame, then remove.
m
A Always
prevent
put block @ under
arm (9) from falling.
the arm to
* There are shims at the spherical connec-

tion at the straight frame end, so check
the number and thickness of the shims,
and keep in a safe place.
& Center brace: 130 kg
8 4 17MF02749
z
4. Sling straight frame (IO), then remove
lz
connecting pin (11) and lift off.
& Straight frame: 900 kg
* Check the condition of the block and be

careful to prevent the blade from falling
over during the operation.
6 \
5 17MF02750
I
._
\11
10 17MF02751
30-233
0
5. Raise blade (12) and tip blade over.
6. Raise right arm (13), remove connection of

blade (12) and left arm (14), then remove.
Raise left arm (14). then remove from blade
(12).
PI kg Blade: 3550 kg
6 kg Arm: 175 kg
A There are shims at both ends and at the
center spherical connection, so check the
number and thickness of the shims, and
keep in a safe place.
I li
17MF02752
17MF02753 8
z
z
30-234
0
ASSEMBLY OF WORK EQUIPMENT ASSEMBLY
* There are shims at all connections, so

assemble the same number and thickness of
shims as was disassembled, and adjust all
dimensions.
* Coat the connecting pins with grease when
installing.
. Carry out assembly in the reverse order to
disassembly.
m
* Adjust the shim at the spherical joint so
that play of the spherical portion in the
axial direction is within 1 mm, but can still
rotate smoothly.
* Standard shim thickness: 4 mm
* If the arm does not match when connect-
ing, shake the straight frame on the left or
right to align.
1121
. Adjusting dimension C
* Adjust so that the play of the spherical
portion in the axial direction is within
1 mm, but can still rotate smoothly.
* Standard shim thickness: 4 mm
C C
F15A01185
30-235
0
DISASSEMBLY OF RIPPER ASSEMBLY
1. Set block 0, raise machine, and lower blade

assembly to ground.
A Lock brake pedal securely.
2. Sling shank (1) temporarily, operate pin-puller

cylinder and pull out pin. (For giant ripper)
3. Start engine, raise ripper fully, then lower

shank (1) gradually, and remove.
Shank: 350 kg
& kg
4. Set block 0 under arm and beam to support

ripper assembly.
5. Sling lift cylinder assembly (2) temporarily,

remove pin (3).
* Start engine, retract piston rod fully, and
lower to arm.
6. Sling tilt cylinder assembly (4) temporarily,

remove pin (3).
* Start engine, retract piston rod fully, and
lower to arm.
Operate the control levers several

* times to release the remaining pres-
sure in the hydraulic piping. 2755
7. Sling beam (6), then using forcing screws 0,

remove left and right pins (7) and remove
beam (6).
& Beam: 1750 kg
8. Disconnect hoses (8) and (9).

remove pin (10) and lift off.
el kg Tilt cylinder assembly: 190 kg
IO. Sling lift cylinder assembly (2) temporarily,

remove pin (11) and lift off.
Lift cylinder assembly: 205 kg
& kg
11. Sling arm, then using forcing screws Q,

remove left and right pins (12), and remove
arm (13).
Arm: 700 kg
& kg
30-236
0
ASSEMBLY OF RIPPER ASSEMBLY
_
1. Insert block under the arm, and set arm (13)
in mounting position, install left and right
pins (12) and lock with lock plate.
2. Set lift cylinder assembly (2) in mounting

position, then install pin (11) and lock with
lock plate.
3. Set tilt cylinder assembly (4) in mounting

position, then install pin (10) and lock with
lock plate.
4. Connect hoses (9) and (8).
5. Insert block 0 under the beam, and set beam

(6) in mounting position, install left and right
pins (7) and lock with lock plate.

start engine, extend piston rod and align pin
hole, then install pin (5) and lock with lock
plate.
7. Sling lift cylinder assembly (2) temporarily,

start engine, extend piston rod and align pin
hole, then install pin (3) and lock with lock
plate.
8
Is ‘/ 2 - 17MF02759
8. Set block 0, raise machine, and lower blade

z
assemly to ground.
A Lock brake pedal securely.
9. Start engine, raise ripper assembly, and

insert wire in hole of shank holder hook, then
raise shank (1) gradually, align pin hole and
install.
10. Raise blade, lower machine from block 0.
11. Bleed the air from hydraulic cylinder.
. Bleeding air
For details, see TESTING AND DADJUSTING.
* Refill each connect pin with grease.
30-237
0
REMOVAL OF ROPS GUARD
1. Sling ROPS gvard (I), and remove mounting

bolts, then remove ROPS guard. )#II
& ROPS guard: 550 kg
INSTALLATION OF ROPS
GUARD
l Carry out installation in the reverse order to 762

removal.
m
m Guard mounting bolt: 135 f 15 kgm
30-238
0
REMOVAL OF OPERATOR’S CAB ASSEMBLY
A Disconnect the cable from the negative

(-)
1. Remove ROPS guard.

For details, see REMOVAL OF ROPS GUARD.
2. Remove left and right covers (I), then remove

rubber mat (2).
3. Remove left, right, and rear panel covers (3).
4. Disconnect central wiring connectors (4).

* After disconnecting the connectors, fit
caps to prevent dirt or dust from getting
in.
5. Disconnect cable (5), then remove heater

panel (6).
6. Disconnect 4 wiper hoses (vinyl hoses) (7).

j, When disconnecting the hoses, mark them
with tags to indicate the position where
they are connected. m
7. Remove 14 cab mounting bolts, raise slowly,

then remove operator’s cab assembly (8). m
el
kg Operator’s cab assembly: 500 kg
17MF02767
30-239
0
I
removal.
* They vinyl hoses can be distinguished by

their color, so connect the hose with the
same color as the joint.
* Install the cab assembly as follows.

1) Set mounting dimension a of adjusting
joints installed at points A - G in the
17MFO2769
diagram to 10 - 12 mm.
2) Set cab assembly on floor frame, screw
bolts 3 - 4 threads into points A - N
in the diagram to check that the bolts
can be tightened.
3) Tighten bolts H - N in the diagram.
* When tightening the bolts, check
that adjusting joints A - G in the
diagram are not in contact with the
surface of the floor frame.
4) Screw in adjusting joints A - G in the
diagram until they contact the surface
of the floor frame, then tighten the
mounting bolts.
17MF02770
After installing the ROPS cab, check that the
instruments and other equipment work
normally.
30-240
0
REMOVAL OF FLOOR FRAME ASSEMBLY
1. Remove operator’s cab assembly.

For details, see REMOVAL OF OPERATOR’S
CAB ASSEMBLY.
2. Remove covers (I), (2), and (3), floor plate (4)

and step cover (5).
4 \ 17MF02
3. Remove wiring clamp, and disconnect wiring

connectors (6), (7), (8), (9), (IO), (11) and (12).
* After disconnecting the connectors, fit
caps to prevent water, dirt or dust from
getting in.
4. Disconnect ground connection (13).
8 17MF02772
E
‘0
6. Loosen top and bottom locknuts, rotate joint,

and disconnect 4 transmission and steering
control rods (15). 1111
7. Remove 2 mounting bolts (16) of control

cable lock bracket.
17MF02774 17MF02775
8. Disconnect heater hoses (17).

* After disconnecting the hoses, fit caps to
prevent dirt or dust from getting in.
9. Disconnect cooler hose (18).

* When disconnecting the hoses, mark them
with tags to indicate the position where
they are connected.
10. Disconnect fuel control rod (19). m

* After disconnecting the rod, tie it with wire
to the floor to hold it in position.
30-241
0
11. Disconnect brake rod (20). m
12. Disconnect control rod (21) of work equip-

ment. m
* After disconnecting the rod, tie it with wire
to the floor to hold it in position.
17MF02777
13. Remove 4 front and rear mounting bolts, then

raise floor frame assembly (22) slowly and
remove.
j, Be careful not to damage the control
cables, rods, and wiring when removing
the assembly.
PI kg Floor frame assembly: 650 kg
17iFOi779
INSTALLATION OF FLOOR
FRAME ASSEMBLY
l Carry out installation in the reverse order to * After connecting the rod, adjust it correctly.
removal. For details, see TESTING AND ADJUST-
ING, Adjusting brake pedal linkage.
w Locknut: 0.8 + 0.2 kgm m

* Insert the stopper for the yoke connecting
* After connecting the cables, adjust them pin securely.
correctly. * After connecting the rod, adjust it correctly.
For details, see TESTING AND ADJUST- For details, see TESTING AND ADJUST-
ING, Adjusting speed lever linkage, and ING, Adjusting ripper, blade control link-
Adjusting steering clutch linkage. age.
m
* Insert the stopper for the yoke connecting
w Floor frame mounting bolt:
pin securely.
135 f 15 kgm
* After connecting the rod, adjust it correctly.
ING, Adjusting fuel control linkage.
m
Bend the cotter securely.
30-242
0
40 MAINTENANCE STANDARD
Engine mount .......................... 40- 2

Power train mount ...................... 40- 4
Damper and universal joint .............. 40- 6
Torque converter ....................... 40- 8
Torque converter valve .................. 40-I 0
Transmission ........................... 40-I 2
Transmission control valve ............... 40-14
Power train and lubricating pump ......... 40-16
Transfer and bevel pinion ................ 40-17
Bevel gear shaft, steering clutch
and steering brake ..................... 40-18
Steering control valve ................... 40-20
Final drive ............................. 40-22
Main frame ............................ 40-24
Track frame ............................ 40-26
Recoil spring ........................... 40-28
Idler .................................. 40-30
Track roller ............................ 40-32
Carrier roller ........................... 40-34
Track ................................. 40-36
Suspension ............................ 40-38
Hydraulic pump ........................ 40-43
Blade lift control valve ................... 40-44
l Main relief valve and shuttle valve ..... 40-45
Blade tilt control and ripper low valve ..... 40-46
Ripper high valve ....................... 40-47
Hydraulic cylinder ...................... 40-48
l Blade lift cylinder .................... 40-48
l Blade tilt cylinder .................... 40-48
l Ripper lift cylinder ................... 40-48
l Ripper tilt cylinder ................... 40-49
l Dual tilt cylinder ..................... 40-50
l Pin puller cylinder .................... 40-50
Quick drop valve ....................... 40-51
Cylinder stay ........................... 40-52
Semi U-dozer .......................... 40-54
l Cutting edge and end bit .............. 40-56
Ripper ................................. 40-58
l Variable multiple shank ripper ......... 40-58
l Variable giant ripper .................. 40-60
40-l
0
ENGINE MOUNT
94.5 + 10.5 kgm
94.5 f 10.5 kgm
B-B
17MF02101
A-A
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
size clearance limit
I Clearance between bracket and cushion Shaft Hole
f0.018 +0.046 -0.018 -

70 0.1 Replace
-0.012 0 0.058
Standard size Repair limit

2 Free height of mounting rubber
108 106
40-2 D275A-2
m 94.5/fl0.5 kgm 94.5f10.5 kgm
j 3 2.
1
, P
i!
u J
A-A
17MF02102
40-4 D275A-2
DAMPER AND UNIVERSAL JOINT
28.5 f 3 km
17MF02103
Unit: mm
Tolerance
1
I Clearance between
and cover
flywheel housing size
Shaft Hole
clearance limit
-
647.7 -0.024 +0.080 0.024 0.2
-0.105 0 0.185
-
2 Clearance between flywheel and damper 546 -0.022 f0.110 0.022 0.25
-0.092 0 0.202
I
Outside diameter of oil seal contact surface
3
of coupling 0
109.9
’ “-0.087
Outside diameter of oil seal contact surface 0

4 109.9
of output shaft l lo-0.035
-
5 Dimension between bearing and holder 46 + 0.1 47.7

-
40-6
w 11.25fl.25kgm w 11.25~1.25kgm 7 w 5.5f0.5kgm
8
6.75 f 0.75 kgm
11.25+ 1.25 kgm
11.25+1.25kgm 6.75fl25kgm 1 .I5 f 0.15 kgm 6.75 f 0.75 kgm
-5
17MF02104
40-8 D275A-2
Unit: mm
NO Check item Criteria Remedy
Standard size Tolerance Repair limit High chrome

Outside diameter of oil seal contact surface I
1 painting repair
of coupling 0
120 119.8 or replace
I -0.100 I
inside diameter of seal ring contact surface +0.040

2 170 170.5
of retainer II 0 I
,
Inside diameter of seal ring contact surface +0.035

3 110 0
110.5
of sleeve
I I
Standard clearance Clearance limit

Backlash between PTO drive gear and
4
driven gear
0.250 - 0.420 -
Backlash between PTO drive gear and 0.204 - 0.516 -

5
driven gear
-

6 Wear of seal ring of stator shaft
Width: 4.45 Width: 4.00
Height: 6.00 Height: 5.40
-
5.0 4.5
7 5.0
I 4.5 Replace
Overall thickness 15.0 13.8

I
Thickness of disc 5.0 4.5
I
8 Stator clutch Thickness of plate 5.0 4.5
I
Overall thickness 15.0 13.9
I
I
Free Installation Installation Free Installation
9 Stator clutch spring
length length load length load
35 27 8.7 kg 32.8 7.4 kg
D275A-2 40-9
TORQUE CONVERTER VALVE
__-__
17MF02105
D275A-2
40-10
Unit: mm
I I 1 I r
Tolerance
Clearance between main relief valve size clearance limit
1 Shaft Hole
and valve body I I
I I I I
-
40 -0.035 f0.016 0.035 0.08
-0.045 0 0.061
Clearance between torque converter -0.035 f0.016 0.035 -

2 relief valve and valve body 40 -0.045 0 0.061 0.08
Clearance between stator clutch -0.035 f0.013 0.035 -

3 modulating valve and valve body 25 -0.045 0 0.058 0.08
Clearance between lock-up clutch -0.035 f0.013 0.035 -

4 modulating valve and valve body 25 -0.045 0 0.058 0.08
Clearance between lock-up selector valve -0.035 f0.016 0.035 -

5 and valve body 40 -0.045 0 0.061 0.08
Standard size Repair limit Replace

6 Main relief valve spring
120.3 102.0 144.57 kg 116.7 137.3 kg
7 Torque converter relief valve spring 116.92 90.8 56.16 kg I 13.41 53.35 kg
8 Stator clutch modulating valve spring 103.5 92.7 20.10 kg 100.4 19.10 kg
g Lock-up clutch modulating valve spring

141.4 88.7 16.18 kg 137.16 15.37 kg
I (outer)
1o Lock-up clutch modulating valve spring -

80.5 80.5 78.09 -
(inner)
II Lock-up selector valve spring I 10.07 100.0 3.0 kg 106.8 2.85 kg
40-11
TRANSMISSION
17MF02106
40-12 D275A-2
Unit: mm
I No. I clutch spring (12 PCS.)
2 No. 2 clutch spring (12 PCS.) 60.3 22.3 kg 65.8 19.0 kg
3 No. 3 and 4 clutch spring (I 2 PCS.) 1 91.0 1 71.9 1 16.6 kg 1 85.5 1 14.1 kg
4 No. 5 clutch spring (5 PCS.) 7.75 7.40 137.2 kg - 116.6 kg
Standard size Tolerance Repair limit

5 Overall thickness of No. 1 clutch
45.5 * 0.3 42.9
6 Overall thickness of No. 2 clutch 41.2 * 0.3 38.6

-
7 Overall thickness of No. 3 clutch 23 * 0.2 21.4
-
8 Overall thickness of No. 4 clutch 27.3 f 0.2 25.7

-
9 Overall thickness of No. 5 clutch 41 * 0.3 38.4

-
10 Thickness of discs of No. I - 4 clutches 4.8 * 0.1 4.3 Replace

-
II Thickness of discs of No. 5 clutch 5.0 * 0.1 4.5
-
12 Thickness of plates of No. I - 4 clutches 4.3 + 0.1 3.9

-
13 Thickness of plates of No. 5 clutch 4.0 f 0.1 3.6

I I I
Width: 3.0 Width: -0.01 Width: 2.7
14 Wear of seal ring of input shaft -0.03
Thickness: 3.1 Thickness: f 0.10 Thickness: 2.9
Width: 4.5 Width: -0.01

Width: 4.1
I5 Wear of seal ring of output shaft -0.03
Thickness: 5.8 Thickness: + 0:15 Thickness: 5.6
Width: 5.0 Width: -0.01 Width: 4.5

16 Wear of seal ring of No. 5 clutch -0.03
Thickness: 6.0 Thickness: * 0.15 Thickness: 5.8

Backlash between No. I and 2 sun gears
17
and planetary gears
0.13 - 0.40 -
I I
Backlash between No. 1 planetary gear -

18 0.13 - 0.40
and rina__
aear
-
Backlash between No. 2,3 and 4 planetary 0.14 - 0.40 -
19
gears and ring gear
-
Backlash between No. 3 and 4 sun gears and -
20 olanetarv aears 0.13 - 0.37
40-13
TRANSMISSION CONTROL VALVE
17MF02107
D275A-2
Unit: mm
Clearance between modulating valve
10 Reducing valve spring 68.0 55.5 26.7 kg 66.0 25.37 kg
D275A-2 40-15
POWER TRAIN AND LUBRICATING PUMP
BAL100+140
11.5f 1.0 kgm_

11.5f 1.0 kgm
BALI00 BALI 40
I97F2008
Unit: mm
Model Standard Clearance Clearance limit
1 Side clearance BALl 00 0.04 - 0.10 0.13
BAL 140 0.07 - 0.12 0.15

-
BAL 100
Clearance between inside diameter of plain
2 bearing and outside diameter of gear shaft 0.060 - 0.145 0.20 Replace
BAL 140
-
Model Standard size Tolerance Repair limit
3 Pin insertion depth BAL 100

14 0 -
-0.5
BAL 140
4 Rotation torque of spline shaft 0.6 kgm
Standard Repair limit

Revolution Pressure
Model discharge discharge
@pm) (kg/cm’)
(a/min) (a/min)
Discharge
Oil: Class-CD SAE 1OW BAL 100 2200 30 200 185

Temperature: 45 - 50°C
BAL 140 2200 30 280 258
40-16 D275A-2
TRANSFER AND BEVEL PINION
.25 f 3.25 kgm
f 0.75 kgm
/ I \
m 18+2kgm m 18*2kgm m 18f2kgm
17MF02108
Unit: mm
No. I Check item

I Criteria
I
Remedy

Adjustment
Backlash of transfer gears or replace
0.22 - 0.61 0.75

Thickness of collar between transfer gear
2 Replace
and bearing
15 14.6
3 Standard shim thickness of bearing cage 2.0 Adjustment

I
D275A-2 40-17
@
BEVEL GEAR SHAFT, STEERING CLUTCH AND STEERING BRAKE
___-_------
----___ ----
j--v
/-t
Ir-4d
__
I V
m 1;.5+1 kgm m 25+15kgm w 18+2kgm
17MF02109
40-18 D275A-2
Unit: mm
No Check item Criteria Remedy

Thickness of brake and clutch plate - Replace
2.9 2.6
1
Tolerance Repair limit Correct

Strain of brake and clutch plate or replace
within 0.3 0.4

Thickness of brake and clutch disc Replace
4.5 4.2
2
Tolerance Repair limit Correct
Strain of brake and clutch disc or replace
within 0.3 0.4
-
Overall thickness of brake plates
3
and discs
56.3 53.8
Overall thickness of clutch plates

4 59.2 57.7 Replace
and discs

Backlash between brake and clutch discs,
5
and brake hub
0.4 - 0.7 1.0
Backlash between bevel gear and Adjustment

6 0.3 - 0.4 0.75
- bevel pinion I or replace
Clearance between seal ring groove
7 0.5 - 0.8 0.8
- of piston and seal ring
Clearance between seal ring groove
8 0.5 -0.8 0.8
of cage and seal ring
I I I
Tolerance
Inside diameter of seal ring contact size clearance limit
9 Shaft Hole
surface of cage
275 - 0.110 + 0.081 0.110 -
- 0.191 0 0.272
Inside diameter of seal ring contact - 0.100 + 0.072 0.100 -
10
surface of brake piston 230 - 0.172 0 0.244
Inside diameter of seal ring contact - 0.100 + 0.072 0.100 -
11
- surface of clutch piston 220 - 0.172 0 0.244 Replace

12 Brake belleville spring
16.5 10.4 3.530 kg 15.9 3.550 kg

-
13 Clutch belleville spring 16.5 10.6 3.500 kg 15.9 3.330 kg
Tolerance
Standard Standard Interference
Interference between bevel gear and size interference limit
14 Shaft Hole
reamer bolt
- -
14 + 0.019 + 0.027 0.026 0.02
+ 0.001 0 0.019
15 Face runout of back of bevel gear Repair limit: 0.05 (measure after installing to bevel gear shaft) ~~~~c&e
Preload of tapered roller bearing Standard rotating torque: 0.4 - 0.5 kgm (2.2 - 2.8 kg at tip of Adjustment
16
- of lever gear shaft bevel gear teeth with bevel pinion and bevel gear not meshed)
17 Standard shim thickness of bearing cage 2.0 Adjust shim
D275A-2 40-19
STEERING CONTROL VALVE
197F161
40-20
D275A-2
Unit: mm
Tolerance
Standard _ Standard Clearance
Clearance between brake and clutch size clearance limit
1 Shaft Hole
valves, and valve body
-0.020 +0.013 0.020 -
24.0 0.06
-0.030 0 0.043
-
Clearance between clutch shaft and -0.020 +0.013 0.020 -
2 valve body I 24.0 -0.030 0 0.043 0.06
-
3 Clearance between brake shaft and guide I 22.0 -0.034
-0.043
+0.013
0
0.034
0.056
0.08
-
4 Clearance between brake shaft and guide I 20.5 -0.034
-0.043
f0.013
0
0.034
0.056
0.08
Clearance between brake and clutch valve, I -0.030 f0.015 0.030 -

5 and piston 9.0 -0.040 0 0.055 0.08
Clearance between check valve and -0.020 f0.052 0.020 -

6 valve body I 20.0 -0.041 0 0.093 0.11
Replace
I Standard size
I
Repair limit

7 Clutch modulating spring
76.0 49.0 14.7 kg 72.0 14.0 kg
8 Clutch valve return spring 41.9 32.0 7.3 kg 40.0 6.9 kg

-
9 Clutch shaft return spring 15.5 15.5 - 14.0 -
-
10 Brake modulating spring 50.0 42.0 6.5 kg 47.5 6.2 kg

-
11 Brake valve return spring 50.2 37.0 18.0 kg 47.5 17.1 kg
-
12 Check valve spring 38.5 30.0 0.34 kg 34.5 0.3 kg
40-21
N
80flOkgm
w
28.5 f 3 kgm
135?15kgm
8/
,_.l~YmYrjI
bm
120?10kgm
w
56+6 kgm
w
28.5 do3 kgm
cgx53
15.5 * 2.5 kgm
17MF02110
40-22 D275A-2
Unit: mm

Backlash between No. 1 pinion and I I
No. 1 gear
0.28 - 0.93 1.5
I I
Backlash between sun gear and
2 0.22 - 0.81 1.5
planetarv aear
Backlash between planetary gear and

3 0.25 - 0.90 1.5
ring gear

Outside diameter of oil seal contact
4 Replace
surface of No. 1 pinion
95.0 94.9
-
5 Height of cover and ball 16.5 15.0
Tolerance
Clearance between pinion shaft and size clearance limit
6 Shaft Hole
carrier
-
85 -0.036 -0.024 -0.023 0.1
-0.058 -0.059 0.034
Clearance in axial direction of No. 1

7 0 - 0.1 (Standard shim thickness: 2)
pinion bearing I
8 Press-fitting force of rubber bushing Max. 13.5 ton Adjustment
9 Press-fitting force of sun gear Max. 10 ton
40-23
MAIN FRAME
A-A
D-D
17MF02111
40-24 D275A-2
Unit: mm
Tolerance
’ Clearance between radiator guard size clearance limit
Shaft Hole
mounting pin and bushing
-
80 -0.030 f0.479 0.410 1.0
-0.076 f0.380 0.555
Clearance between radiator guard -0.030 f0.329 0.343 - Replace
mounting pin and bushing 80 -0.076 f0.313 0.405 1.5
Press-fitting force of ripper beam -0.036 +0.164 0.098 -

mount bushing 110 -0.090 +0.062 0.254 1.5
Clearance between ripper cylinder -0.036 +0.170 0.109-

mounting pin and bushing 90 -0.090 f0.073 0.260 1.5
Press-fitting force of radiator guard

mount bushing 6.2 - 14.1 ton
Press-fitting force of radiator guard

mount bushing 10.2 - 23.2 ton
Adjustment
Clearance between ripper beam mounting
pin and bushina 7.1 - 14.0 ton
I I
Press-fitting force of ripper cylinder

8 5.9 - 11.7 ton
mount bushina
D275A-2 40-25
TRACK FRAME
_--.------ -
_-- -%-
m 15.5 f 2.5 kgm
A-A
i. -.-.-.--_.e
B-B
17MF02112A
40-26
0
Unit: mm

1 Clearance between idler yoke and guide Adjustment
0 - 0.5 3
40-27
7 6 2 1
56f6kgm
m 135f15kgm
25 f 3.25 kgm
159.5 & 17.5 kgm
B-B
A-A
F17MO2006
40-28 D275A-2
Unit: mm
-
-
1 Recoil spring
Tolerance
Standard Standard Clearance Replace
Clearance between outside end and inside size clearance limit
2 Shaft Hole
end of outside cylinder bushing
-
340 -0.055 f0.317 0.115 0.8
-0.228 f0.060 0.545
Clearance between adjustment cylinder and 110 -0.100 f0.054 0.100 -

3
bushing -0.350 0 0.404
Clearance between inside cylinder and -

4 50 -0.15 f0.1 0.15 2.0
adjustment cylinder -0.35 0 0.45
Item Repair limit

I
Bend 7 (in length of 3000 mm)
Deformation of track frame Correct
5
(outside cylinder) or replace
Torsion 3 (in length of 300 mm)
Dents (bent plate) 10

-
Press-fitting force of outside cylinder
6 4.3 - 9.8 ton
bushing
-
Press-fitting force of inside cylinder
7 4.5 - 23.3 ton Adjustment
bushing
8 Dimension between front pilot and nut 4.0
40-29
IDLER
3 21 zt 5 kgm
9’
L- - -- ___._-I
17MF02114
40-30 D275A-2
Unit: mm

Outside diameter of idler protrusion
section
872 -
2 Outside diameter of idler tread face 830 805
Rebuild
3 Width of idler protrusion section 124 107
or replace
4 Width of idler tread face 71 79.5
5 Overall width of idler 266 -
6 Width of collar of shaft 242 -
Clearance
limit Replace
7 Clearance between shaft and bushing
bushing
155 -0.350 +0.220 0.230 -

1.5
-0.413 -0.120 0.633
-
1 I
Tolerance
Standard Standard IInterference
size interference limit
8 Interference between shaft and seal guard Shaft Hole
95 +0.046 -0.150 0.150 -

Replace
0 -0.200 0.246
-
I
9 Free play of shaft in the axial direction
0.47 - 0.83 1.5
D275A-2 40-31
TRACK ROLLER
k
4
8,_ 6 ,9 5 ,7 11 12
/ /
w 21 f5 kgm
17MF02115
40-32 D275A-2
Unit: mm

1 Outside diameter of flange (outside)
291 -
2 1 Outside diameter of flange (inside)

II 284
I -
I 1
3 Outside diameter of track roller

255 219
tread face
4 1 Overall width of track roller

I 327
1 -
5 Width track roller tread face Rebuild
(single flange) 74 83
or replace
6 Width of track roller tread face

(double flange) 74 93
7 Width of flange (single flange) 27.5 18.5

I I
8 Width of flange (double flange outside) I 27.5 I 18.5
9 Width of flange (double flange inside) 24 14

I I
10 Width of collar of shaft 276 -
I I
Standard
)
size ki :ta::;; Cly$ce
Replace
11 Clearance between shaft and bushing
bushing
-
130 -0.350 10.260 0.360 1.5
-0.413 +0.010 0.673
Tolerance
Interference between shaft and size interference limit
12 Shaft Hole
seal guard
-
Replace
70 -0.150
-0.200 f0.046
0 0.150
0.246 -

13 Free play of shaft in the axial direction
0.49 - 0.86 1.5
I
40-33
CARRIER ROLLER
4 3
6
i--
i
-
-li__li-
-
_
3 _-
--
-1
I
- -21
/
*5kgm
‘\“\
I
17MF02116
40-34 D275A-2
Unit: mm

I I
1 Outside diameter of flange
242 I - I
Outside diameter of carrier roller Rebuild
2 210 185
tread face or replace
3 Width of carrier roller tread face 68 79

I I
4 Width of flange 23 12
I I
Tolerance
size clearance limit Replace
5 Clearance between shaft and support Shaft Hole
bushing
0 f0.350 o-
86
-0.2 0 0.550 I
Standard
size ~~.::tar:de lnteyferynce
Interference between shaft and
6
seal guard
+0.245 f0.035 0.150 -

90 Replace
+0.185 0 0.245 -

I I
7 Free play of roller in the axial direction
0.01 - 0.22 0.3
I I
D275A-2 40-35
TRACK (LUBRICATED TRACK LINK)
1 I
6 5
m 1st tightening: 80 * 8 kgm w 1st tightening: 50 5 5 kgm

2nd tightening: 120’ f IO” 2nd tightening: 180” f IO”
197F169
40-36 D275A-2
0
Unit: mm
NC Check item Criteria Remedy

I

Turn
1 Link pitch or replace
260.6
-
Lug weld, repair
2 Height of grouser 88 30 by build-up weld-
ing, or replace
Repair by
3 Link height 161 143 build-up welding
or replace
-
84 (Normal loading) Turn
4 Outside diameter of bushing 92.5
86.5 (Hard loading) or replace
- I I
I
Standard
size
5 Interference between link and bushing
92
-
+0.30 -0.21 0.41 -
6 Interference between link and pin 57 0.25
+0.20 -0.28 0.58
I
7 Clearance between links ri Replace
D275A-2 40-37
0
SUSPENSION (l/3)
Serial No.: 10001 -10127
,2---\
___.._---------- “1
_..e
[Pivot shaft L.H. side] [Pivot shaft R.H. side]
17MF02117
40-38 D275A-2
@
c-c
SBDO1524
Unit: mm
No. Check item Criteria I Remedy
1 Tolerance
Interference between thrust washer size interference limit
1 Shaft Hole
and seal 1 I
f0213 -0.180
210
f0.098 -0.226
-
Interference between thrust washer -to.1 40 -0.061
2 140
-
and seal +0.100 I -0.124
Interference between pivot shaft f0.096 -0.115

3 194
and seal +0.050 -0.187
-
Interference between side pin bushing +0.035 -0.104
4 100
and seal I 0 I -0.171
Interference between side pin boss 0.130- _

5
and seal
Replace
Interference between side pin boss
6
and bushing
7 Clearance between pivot shaft and bushing
0.229 -
8 Clearance between pivot shaft and bushing 1 .o
0.386 I
Clearance between center shaft and
9
Clearance between bolster bushing and

10
-
11 Press-fitting force of equalizer bar bushing 32.4 - 225.6 kN I3.3 - 23 ton}

-
12 Press-fitting force of bolster bushing 19.6 - 127.5 kN I2 - 13 ton1

Adjustment
13 Press-fitting force of side pin bushing 68.6 - 133.4 kN I7 - 13.6 ton}
Standard shim thickness between lock

14 2
plate and side pin
-
D275A-2 40-39
0
:: .-
--Tim- __;@I_
’ __
-..
it
[Pivot shaft L.H. side] [Pivot shaft R.H. side]
17MF02117
40-39- 1 D275A-2
0
13
0-B SBDOI 524
Unit: mm
-
No.
-
Interference between thrust washer

1
and seal
5
-
6
7 Clearance between pivot shaft and bushing
8
-
10
11
-
12 19.6 - 127.5 kN {2 - 13 ton)
13
-
D275A-2 40-39-2
a
SUSPENSION (Z/3)
E-E
F-F
3/
17MF02119
Unit: mm
C
Tolerance
Standard Standard IInterferencf
size interference limit
1 Interference between rod and rod bushing Shaft Hole
90 0 -0.024 0.009 - -
-0.015 -0.059 0.059
Tolerance
Clearance between rod pin and bolster size clearance limit
2 Shaft Hole
hole and crossbar hole
60 -0.030 +0.146 0.130 -

0.5
-0.060 +0.100 0.206
-
60 -0.030 +0.046 0.030 -
3 Clearance between rod and rod bushing 0.5
-0.060 0 0.106
4 Clearance at spherical face of rod pin p30 I -I- 0.08 -

0.15
0.5
5 Press-fitting force of rod bushing 6.9 - 43.2 kN IO.7 - 4.4 ton}

-
40-40 D275A-2
0
SUSPENSION (313)
Small cushion
Small cushion Large cushion Large cushion
/ \
\
17MF02120
+ ---_
-
I
Under cover
Z-Z
(When chassis is contacting ground)

_
z-z
(When chassis is floating)

_
+
I
t3-l
e
B’
z-z
f
(When chassis is floating)
17MF02121
Unit: mm
-
Standard value Repair limit

Total of stepped difference at bottom face Replace
of equalizer bar and bottom face of under-bar cushion
2.0 f 2.0 8.0
Procedure for measurement

Measure the stepped difference at two places (e and f) in front of and behind the center (portion P) of the equalizer bar
center pin.
When the chassis is floating, operate the blade tilt to make the equalizer bar horizontal.
With the chassis in contact with the ground, raise the blade and ripper, and measure stepped difference A at the bottom
face of the equalizer bar and the bottom face of the under-bar. (At points e and f)
With the chassis floating (the chassis lifted off the ground by using the blade and ripper), measure stepped difference 6
or B’ at the bottom face of the equalizer bar and the bottom face of the under-bar. (At points e and f)
* For machines not equipped with blade and ripper, jack up the chassis at the front and rear.
Calculate the movement of the equalizer bar as follows:
l With the chassis floating, when the bottom face of the equalizer bar is in the +direction from the bottom face of the
under-bar:A -6
l With the chassis floating, when the bottom face of the equalizer bar is in the -direction from the bottom face of the
under-bar:A +B
* If the movement of the equalizer bar is more than 8.0 mm, check for damage to the cushion (large), (small), and re-
place the cushion. (The same applies if the value is more than 8.0 mm at either point e or point f.)
D275A-2 40-41
HYDRAULIC PUMP
SAR (3) 100 + SAR (2) 50
/
m 28.5 f 3.5 kgm m 28.5 f 3.5 kgm
. I=
SAR (3) 100 SAR (2) 50
17MF02122
Unit: mm

I
Model Standard clearance Clearance limit

I
1 Side clearance SAR (3) 100 0.13 - 0.18 0.22
I I
SAR (2) 50 0.10 - 0.15 0.19 Replace

I I
SAR (3) 100 0.06 - 0.149 0.20

Clearance between inside diameter of plain I
2
bearing and outside diameter of gear shaft
SAR (2) 50 0.06 - 0.149 0.20
I
Model Standard size Tolerance Repair limit
I
0 -
3 Pin insertion depth SAR (3) 100 14
I - 0.5 I
0 -
SAR (2) 50 14
- 0.5
4 Rotation torque of spline shaft 1.4 - 2.4 kgm
Standard Repair limit

Revolution Pressure
Model discharge discharge
(rpm) (kg/cmz)
(n/min) (n/mm)
SAR (3) 100 2500 210 231 214 -

Oil: Class-CD SAE 1OW I
Temperature: 45 - 55°C
SAR (2) 50 2500 210 112 102
I
40-43
Q
BLADE LIFT CONTROL VALVE
m 19fl kgm
B-B
A-A
m 3.5 _+0.5 kgm
D-D
E-E F-F
197FO2120
40-44 D275A-2
MAIN RELIEF VALVE AND SHUTTLE VALVE
k 1 .O kgm
7.0 f
197Fl74
/
m 7.0 f 1 .O kgm
Unit: mm

1 Spool return spring
size length load length load
55.6 38.0 6.0 kg 52.1 4.8 kg
2 Detent spring 20.5 17.0 3.7 kg 19.8 2.96 kg
3 Check valve spring 75.7 43.5 1.0 kg 69.3 0.8 kg
4 Check valve spring 32.7 24.5 4.5 kg 31 .o 3.6 kg Replace
5 Suction valve spring 75.9 38.5 1.16 kg 69.4 0.93 kg
6 Demand spool spring 121.4 99.0 36.0 kg 114.7 28.8 kg
7 Main relief valve spring 41 .I 32.6 26.4 kg 39.4 21.1 kg
8 Shuttle valve spring 42.7 22.0 0.83 kg 38.6 0.66 kg
Height of main relief pressure adjustment 8 (one turn of the screw will charge the pressure by:
screw 24.9 kg/cm’)
‘.
D275A-2 40-45
BLADE TILT CONTROL AND RIPPER LOW VALVE
m 3.5 f 0.5 kgm
197F175
0.5 kgm
Unit: mm
No. Check item Criteria

I Remedy
Standard size
Spool return spring
40-46 D275A-2
RIPPER HIGH VALVE
135
1 3.5 + 0.5
52.5 * 2.5 kgm
,3
197FI 76
Unit: : mm
Standard size
Spool return spring
Replace
BLADE LIFT CYLINDER
\
w 11.25+1.25kgm
17MF02123
BLADE TILT CYLINDER
w 50;5kgm m 11.;5f 1.25 kgm

17MF02124
RIPPER LIFT CYLINDER
w 11.25kl.25 kgm
17MF02125
40-48 D275A-2
17MF02126
Unit: mm
Clearance between piston rod

1
and bushing
Blade
tilt
70
f0.200
0
1.o
I
Clearance between piston rod Ripper +0.207
3 90 1 .o
connecting pin and bushing lift +0.120
Ripper +0.207
90 1 .o
tilt f0.120
Clearance between trunnion Blade -0.170

4 95 1 .o
bushing and cylinder stay lift -0.250
Blade +0.174
tilt 70 +0.100 2.0
Clearance between cylinder bottom Ripper +0.207

5 90 1 .o
connecting pin and bushing lift f0.120
-
Ripper
tilt II
90
I I
f0.207
f0.120
I I
1 .o
I
I
Standard shim thickness between Blade

6 4.0 Adjustment
too of oiston rod and cao lift
DUAL TILT CYLINDER
m 50+-5kgm 11.25f1.25 kgm

17MF02127
PIN PULLER CYLINDER
m 45 f 4.5 kgm
\
17MF02128
Unit: mm
No. Check item Criteria
Clearance between piston rod Dual

1
and bushing tilt
Pin
puller
-
Clearance between piston rod
2
connecting pin and bushing
Clearance between pin and

3
spherical face of piston rod
Clearance between cylinder bottom

4
connecting pin and bushing
Clearance between cylinder bottom

5
support shaft and boss
40-50 D275A-2
QUICK DROP VALVE
17MF02129
Unit: mm
Tolerance
Clearance between plunger and size clearance limit
1 Shaft Hole
valve body
38.0 -0.011 +0.010 0.011 -

-0.016 0 0.026
Replace

2 Valve spring
75.2 55.9 13.9 kg 67.7 12.5 kg
D275A-2 40-5 1
CYLINDER STAY
2 1 3
17MF02130
Unit: mm
Tolerance
Clearance between cylinder yoke size clearance limit
1 Shaft Hole
and bushing
-
140 -0.085 f0.063 0.085 0.5 Replace
-0.148 0 0.211
2 Clearance between cylinder yoke 105 -0.072 +0.054 0.072 -

and bushing -0.126 0 0.5
0.180
3 Clearance between lift cylinder trunnion 95 -0.120 +0.035 0.120 -

and bushing -0.207 0 0.5
0.242
40-52 D275A-2
SEMI U-DOZER
li' B-B
‘7
c-c
A-A
14
\
E-E F-F G-G
J-J K-K
H-H 17MF02131
40-54 D275A-2
17MF02132
Unit: mm
ce between joint and bracket
D275A-2 40-55
CUlTING EDGE AND END BIT
w 152.5 + 16.5 kgm
m 152.5 + 16.5 kgm
_-------------------------------
i 1 197Fl8l-I
Unit: mm

1 Height of end bit outside
415 300
Replace
2 Width of end bit 662 500
3 Height of end bit inside 330 260
260 Replace
4 Height of cutting edge 330
(215 after turned) or turn
D275A-2
---
A-A B-B
C-C D-D
40-58
0
Unit: mm
Tolerance
Clearance between bracket and arm pin, size clearance limit
1 Shaft Hole
and bushing
..n -0.036 +0456 0.405 - ~c

1 I” -0.090 f0.369 0.546 “=
Clearance between beam and arm pin, -0.036 +0.456 0.405 -

2 1.5
and bushing 110 -0.090 +0.369 0.546
Clearance between cylinder connecting -0.036 f0.207 0.156 -

3 pin and bushing 90 -0.090 f0.120 0.207 1.5
Replace
Standard size Tolerance Repair limit
4 Dimension of shank mounting pin
80 * 0.3

5 Wear of point
6 Wear of protector I 131 I 106 I
D275A-2
VARIABLE GIANT RIPPER
-..- -.-
”
A-A B-B
P-
tL_l
c-c D-D
-..-
il Detail P
40-60
0
Unit: mm
Tolerance
Clearance between bracket and arm pin, size clearance limit
1 Shaft Hole
and bushing
- -
110 0.036 + 0456 0.405 1.5
- 0.090 + 0.369 0.546
Clearance between beam and arm pin, - 0.036 + 0.456 0.405 -

2 110 - 0.090 1.5
and bushing + 0.369 0.546
3 Clearance between cylinder connecting 90 - 0.036 + 0.207 0.156 -

- 0.090 + 0.120 0.207 1.5
pin and bushing
I I Reolace
Repair limit
I
Standard size Tolerance
4 Dimension of shank mounting pin I I
80 f 0.3
I I I
I I Standard size I Repair limit I
5 1 Wear of point
6 Wear of protector 131 106
40-61
0
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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SEBM000207

November 2000 Copyright 2000 Komatsu

01 GENERAL ,............,,.....,.........,,,.................................~........... 01-l

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-I

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-l

40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . ..*........................... 40-l

0 Page to be newly added Add

0 Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are not revised atthistime.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

0 oo- 1 @ IO-IO IO-52 IO- 93 IO-127

20- 4 @ 20- 53 20-108 0 20-140-15 @ 30- 13 @

30- 64 30-122 @ 30-170 @ 30-230 @ 40- 46

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Example 1 (Chassis volume):

Special technical precautions

Example 2 (Engine volume):

Places that require special at-

. If a part cannot be smoothly removed from

A Slinging with one rope may cause

Wire ropes 4) Do not sling a heavy load with ropes form-

* The allowable load value is estimated to

2) Sling wire ropes from the middle portion

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

. Used to prevent rubber gaskets, rubber

. Used in places requiring an immediately

. Features: Resistance to heat and chemi-

. Quick hardening type adhesive

. Quick hardening type adhesive

. Features: Resistance to heat, chemicals

. Used as adhesive or sealant for gaskets

. Used as sealant for various threads, pipe

Three bond l Used as heat-resisting sealant for repairing

l Used as lubricant for sliding portion (to pre-

SYG2-4OOLI l General purpose type

l Used for normal temperature, light load

l Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

Thread diameter Width

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat T Tightenin! j torque

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)