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SEBM04250107

KOMATSU

WA5004
MACHINE

WA5004

MODEL

SERIAL

10001

No.

and up

This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
WA500-1 mount the S6D140-1 engine;
For details of the engine, see the 6D140-1

Series Engine Shop Manual.

00-l
05-91(02)03261

CONTENTS
10 ENGINE
11
- 12

No. of page

STRUCTURE
TESTING

AND FUNCTION

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

AND ADJUSTING

13

DISASSEMBLY

...........................................
AND ASSEMBLY
......................................

14

MAINTENANCE

STANDARD

20

POWER

21

STRUCTURE
TESTING

23

DISASSEMBLY

24

MAINTENANCE

AND

FUNCTION

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

AND ADJUSTING

...........................................
AND ASSEMBLY
......................................
STANDARD ...........................................

STEERING

SYSTEM
AND FUNCTION

41

STRUCTURE

42

TESTING

43

DISASSEMBLY

44

MAINTENANCE

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

AND ADJUSTING

...........................................
AND ASSEMBLY
......................................
STANDARD ...........................................

50 BRAKE AND
51

STRUCTURE

52

TESTING

53

DISASSEMBLY

54

MAINTENANCE

60 WORK

AND FUNCTION

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

...........................................
AND ASSEMBLY
......................................
STANDARD ...........................................

EQUIPMENT

61

STRUCTURE
TESTING

AND

FUNCTION

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

63

DISASSEMBLY

...........................................
AND ASSEMBLY
......................................

64

MAINTENANCE

STANDARD

81

STRUCTURE

82

TESTING

83

DISASSEMBLY

22-1
23-l
24-1

41-1
42-l
43-1
44-l

AND

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

ELECTRONIC

AND FUNCTION

51-l
52-1
53-l
54-l

SYSTEM

AND ADJUSTING

ELECTRIC

21-1

AIR SYSTEM

AND ADJUSTING

62

80

14-1

13-l

TRAIN

22

40

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

11-l

12-1

61-l
62-l
64-l

63-1

SYSTEM

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

AND ADJUSTING

...........................................
AND ASSEMBLY
......................................

81-1
82-l
83-1

90 OTHERS
91
93
97

OTHERS..

............................................................
DISASSEMBLY AND ASSEMBLY
......................................
GEAR PUMP ........................................................

Ok2

91-1
93-1
97-101

WA500-

01 GENERAL

(THIS SECTION IS NOT USED IN THIS MANUAL)


m

10 ENGINE

20 POWER TRAIN

40 STEERING

SYSTEM

50 BRAKE AND AIR SYSTEM

60 WORK EQUIPMENT

80 ELECTRICAL

90 OTHERS

SYSTEM

AND ELECTRONIC

SYSTEM

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WA5bO- 1

IMPORTANT

Proper service and repair is extremely


The

service

and repair techniques

manual are both effective

important

injury to workers,

cautions

in this manual.

followed

carefully.

If any dangerous

safety, and take the necessary

by Komatsu

of operation.

of your machine.

and described

in this

Some of these operations

re-

by Komatsu for the purpose.

the symbols

The cautions

NOTICE

for the safe operation

recommended

and safe methods

quire the use of tools specially designed


To prevent

SAFETY

iY

and

accompanying

situation

are used to mark safety pre*


these symbols should always be

arises or may possibly arise, first consider

actions to deal with the situation.

A SAFETY
GENERAL

6. Decide

PRECAUTIONS

a place

in the repair

keep tools and removed


Mistakes
Read

in operation

the

carefully

are extremely

Operation

dangerous.

and Maintenance

BEFORE operating

Manual

the tools
Always

and parts in their correct

read

all

the

precautions

or repairs,

given

places.

sure that there is no dirt or oil on the floor.

the machine.

out any greasing

to
keep

keep the work area clean and make

Smoke
1. Before carrying

workshop

parts. Always

on

only

smoking.

in

the

areas

provided

for

Never smoke while working.

the

decals which are fixed to the machine.


2.When

carrying

out

any operation,

always

wear safety shoes and helmet.

Do not wear

loose work clothes,


missing.

with buttons

Always

or clothes

wear safety

Always

glasses when

hitting

trained,
work.

wear

safety

glasses

when

experienced

always wear welding


cap

and

welder

carrying

other

out

carry

out the

welding

work,

gloves, apron, glasses,

clothes

suited

for

welding

work.
4.When

carrying

inform

out any operation

work,

always

procedure
your fellow

any step

agree

before

UNDER

workers
REPAIR

controls in the operators


5. Keep all tools

in good

with two
on the op-

starting.

of the operation.

hang

oil or making

any

repairs,

on hard, level ground, and

the wheels

8. Before

starting

or tracks

to prevent

the

before
Before

to the

If this

equipment
to

lock

warning

is not

possible,

insert

the

port

the

In addition,

control

levers

be sure

and

hang

signs on them.
disassembling

the

machine

or assembling,
with

blocks,

sup-

jacks

or

stands before starting work.

starting
starting

machine.

and learn

lower

from falling.
all

other

on the

work,

safety pin or use blocks to prevent the work

10. Remove

compartment.

the correct way to use them.

ripper,

Always

signs

condition

blade,

or any other work equipment

ground.

9. When

or more workers,
erating

block

bucket

repairs are needed, always have a

When

adding

machine from moving.

grinding parts with a grinder, etc.


3. If welding

7. Before

FOR WORK

park the machine

parts with a hammer.


l

PREPARATIONS

or

steps

machine.
If

it

all mud and oil from

places

used

Always

to get

the steps or

on and off

use the handrails,

when

getting

on

or

the

ladders
off

the

Never jump on or off the machine.

is impossible

to

use

the

handrails,

ladders or steps, use a stand to provide safe


footing.

00-3

PRECAUTIONS
1 1. When
or

DURING

removing

the oil filler

hydraulic

loosen

pressure

them

spurting

slowly

19 Be sure to assemble

WORK
cap, drain

measuring

to prevent

plug

places.

Replace

any damaged

plugs,

of the

remove

oil,

the

or removing

water

pressure

compo-

or air circuits,
completely

from

the

20 . When

the

engine

when

oil

in the

circuits

is stopped,

are

hot

so be careful

that

rying

out

any

work

to cool before

on

the

oil

car-

or

water

starting

battery.

14 When

work,

remove

Always

the negative

(-1

remove

terminal

raising

Check

that

heavy

the

parts

lead

from

high

first.

rope,

are free from

damage.

use

lifting

ample

capacity.

Install

the

places.

use

equipment

a hoist

other

covers

ternal

pressure

or

spring,

always

sides. Slowly
loosen

bolts

components,

removing

the floor,
on the

any

in-

from

a
on

the pressure,

the

piping,

be careful
wiring.

not

Damaged

fires.
stop

the fuel

or oil

out. If any fuel or oil drips on to

wipe

floor

with

the bolts to remove.

or damage

spilling

hit-

in position

release

it up immediately.

can cause

you

Fuel or oil

to slip, or can

even start fires.


18. As

a general

wash.parts.
mum
parts.

00-4

of

rule,

do

In particular,
gasoline

when

not

use gasoline

to

use -only the miniwashing

not

which
speed,

hoses,

twisted.

make

Damaged

so be extremely

check

for

that

high

care-

pressure

connecting

or installing
tightening

protective

parts

two

fingers

caught

always
When

violently

be particularly

or hand.

parts,
torques.

parts such as guards,

vibrate

aligning

or

rotate

careful

or
at

to check

correctly.
holes,

never

Be careful

insert

your

not to get your

in a hole.

electrical

measuring
the

24. Take

hydraulic

measuring

bled before

from

are under

pressure

may cause electrical

17 When
from

under

leave two

removing

wiring

operate

which

the ma-

installed.

fingers

that

by the hoist or crane.

removing

break

correct

and

Do not work

when

has

at the

the component

15 When

opposite

which

or crane

part.

part still raised

then slowly

and hooks

equipment

to prevent
any

chains

be
by

pressure

that they are installed

23. When

lifting

Use

slowly

to

Also,

the leads from

components,

wires,

be damaged

parts

tubes

assembling

22. When

the wire

Always

16 When

are

installing

are correctly

installing

hoist or crane.

ting

high

use the specified

13 Before

not

other

they

ful when

21 When

circuits.

the

will

are dangerous,

circuits.

not to get burned.


Wait for the oil and water

with

installing

sure
and

they

new parts.

and

chine is being operated.

tubes
water

hoses

in their

first

circuit.
12 The

that

again

parts with

installing

contact

disconnecting

nents

When
sure

the oil from

out.

Before

all parts

original

care

taking
when

tracks

of track-type
removing

either

pressure,

check

is correctly

assem-

any measurements.
removing

When

rates suddenly,

tool

or installing

the

machines.
the

track,

so never

end of the track.

the

track

let anyone

sepa-

stand

at

FOREWORD

This shop
serviceman

manual

has been prepared

an accurate

understanding

repairs and make judgements.

as an aid to improve

of the product

the quality

and by showing

Make sure you understand

of repairs

by giving the

him the correct way to perform

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

components;

of

understanding,

these chapters

STRUCTURE

AND

This

section

adjustments

This

section

assembling
MAINTENANCE

into

chapters

for

each

main

group

of

sections.

the structure

of the structure,

and function

of each component.

but also serves as reference

It serves not only to give

material for troubleshooting.

ADJUSTING
explains

checks

to be made

to be made at completion

Troubleshooting
DISASSEMBLY

is divided

FUNCTION

an understanding
AND

manual

are further divided into the following

This section explains

TESTING

the

charts correlating

AND

before

and after

performing

repairs,

as well

as

of the checks and repairs.

Problems

to Causes

are also included in this section.

ASSEMBLY

explains

the order to be followed

each component,

when

as well as precautions

removing,

installing,

disassembling

or

to be taken for these operations.

STANDARD

This section gives the judgement

standards

when inspecting

disassembled

parts.

NOTICE
The

specifications

contained

in this

shop

time

and without

any advance

notice.

Contact

latest

manual
your

are

subject

KOMATSU

to change

at any

distributor

for the

information.

00-5

HOW

TO READ THE SHOP

MANUAL

HOW

TO READ THE SHOP

MANUAL

Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When a manual is revised, an edition mark is


recorded on the bottom outside corner of the
pages.

volume:

Engine volume:

Issued for every machine


model
Issued for each engine series

Electrical volume
Attachments
volume

:
:

Each issued as
one volume to
cover all models

These various volumes are designed to avoid


duplicating the same information.
Therefore to
deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready.
DISTRIBUTION

MARK

-... )

REVISED

Chassis

EDITION

(a@@

VOLUMES

AND

UPDATING

Any
changes
Get the
you start

amendments
or other
additions,
will be sent to KOMATSU
distributers.
most up-to-date
information
before
any work.

FILING

METHOD

REVISIONS
Revised pages are shown at the LIST OF
REVISED PAGES on the between the title page
and SAFETY page.

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

Symbol

1. See the page number on the bottom of the


page. File the pages in correct order.
2. Following examples shows how to read the
page number.
Example 1 (Chassis volume):

1 Item

Remarks
Special safety precautions
are
necessary
when performing
the
work.

A
Safety

Extra special safety precautions


are necessary
when performing
the work because it is under
internal pressure.

YY
9

IO-3

17_

Item number (I 0. Structure


and Function)
Consecutive page number for
each item.

Special technical precautions


other precautions
for
preserving
standards
are
necessary when performing
work.

Caution

Example 2 (Engine volume):

Weight

3. Additional
pages: Additional
pages are indicated by a hyphen (-1 and number after the
page number. File as in the example.
Example:

4
4

1 o-4

12-203

1 o-5

12-204

00-6

Places that require special


attention
for the tightening
torque during assembly.
Places to be coated with
adhesives
and lubricants

Oil, water

Drain

the

Weight of parts or systems.


Caution necessary when
selecting hoisting wire, or when
working
posture is important,
etc.

12-410
Unit number (I. Engine)
Item number (2. Testing and
Adjusting)
Group No. (4. Fuel system)
Consecutive page No. (Page
10 of Group 4)

or

etc.

Places where oil, water or fuel


must be added, and the
capacity.
Places where oil or water must
be drained, and quantity
to be
drained.

HOISTING

INSTRUCTIONS

HOISTING

INSTRUCTIONS

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

1. If a part cannot be smoothly removed from


the
machine
by hoisting,
the following
checks should be made:
. Check for removal of all bolts fastening
the part to the relative parts.
. Check
for existence
of another
part
causing interference
with the part to be
removed.

2. Wire ropes
1) Use adequate
ropes depending
on the
weight of parts to be hoisted, referring to
the table below:

Wire ropes
(Standard Z or S twist ropes
without galvanizing)
Rope diameter

(mm)

Allowable

load (tons)

10

1 .o

11.2

1.4

12.5

1.6

14

2.2

16

2.8

18

3.6

20

4.4

22.4

5.6
10.0

30
40

18.0

50

28.0

60

40.0

Slinging near the edge of the hook may


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

100%

as%

79%

71%

41%
FSO064

3) Do not sling a heavy load with one rope


alone, but sling with two or more ropes
symmetrically wound on to the load.
Slinging with one rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping of
the rope from its original winding
position on the load, which can result
in a dangerous accident.

4) Do not sling a heavy load with ropes


forming a wide hanging angle from the
hook.
When hoisting a load with two or more
ropes, the force subjected to each rope
will increase with the hanging angles. The
table
below
shows
the variation
of
allowable load (kg) when hoisting is made
with two ropes, each of which is allowed
to sling up to 1000 kg vertically, at various
hanging angles.
When two ropes sling a load vertically, up
to 2000
kg of total weight
can be
suspended. This weight becomes 1000 kg
when two ropes make a 120 hanging
angle. On the other hand, two ropes are
subjected to an excessive force as large as
4000 kg if they sling a 2000 kg load at a
lifting angle of 150.
A

The allowable
load value is estimated
to
be one-sixth
or one-seventh
of the
breaking strength of the rope used.
2) Sling wire ropes
of the hook.

from

the middle

portion
Lifting

angle

: a
FSO065

00-7

STANDARD

TIGHTENING

TORQUE

STANDARD
1. STANDARD

TIGHTENING

TIGHTENING

TORQUE

OF BOLTS

The following charts give the standard tightening


sections of Disassembly
and Assembly.

Thread diameter
of bolt
(mm)

AND
torques

TORQUE
NUTS
of bolts and nuts. Exceptions

are given in

Width
across flat
(mm)

kgm

Nm

10

1.35kO.15

13

3.2kO.3

31.4t2.9

10

17

6.7f0.7

65.7k6.8

12

19

11.5+1.0

112k9.8

14

22

18.0~2.0

177r19

16

24

28.5t3

279+29

18

27

39I+4

20

30

56+6

13.22

383t39
549k58

22

32

76-t8

745r+78

24

36

94.5*10

927*98

27

41

30

46

33

50

36

55

39

60

1.4

This torque table does not apply to the bolts with which nylon packings or other nonferrous metal washers are to be used, or which require tightening
to otherwise
specified
torque.
*

Nm (newton

2. TIGHTENING

meter):

TORQUE

INm

& 0.1 kgm

OF SPLIT

FLANGE

BOLTS

Use these torques for split flange bolts.

Threa$

00-8

gtlyeter

Tightening

torque

(mm)

Width
across flats
(mm)

10

14

12

17

11.5&l

112k9.8

16

22

28.5+3

279229

kgm
6.71~0.7

Nm
65.7k6.8

STANDARD

TIGHTENING

TORQUE

Sealing surface

3.TlGHTENlNG
Use these

TORQUE
torques

FOR

NUTS

OF

FLARED

for nut part of flared.

Tightening

Thread diameter
of nut part
(mm)

Width across flats


of nut part
(mm)

14

19

2.520.5

18

24

5k-2

Nm

kgm

24.5 24.9
49k19.6

22

27

8k2

24

32

14k3

137.3k29.4

30

36

1823

176.5 k29.4

33

41

2OC5

196.1

36

46

25+5

245.2*49

42

55

3OA5

294.2249

COATING
The recommended

coating

Nomenclature

materials

Grease
(Lithium grease)

249

MATERIALS
in Komatsu

Shop

Manuals

are listed

below.

Applications

LT-1A

Used to apply rubber pads, rubber gaskets, and cork plugs.

LT-IB

Used to apply resin, rubber, metallic and


non-metallic parts when a fast, strong seal is needed.

LT-2

Preventing

LT-3

Provides an airtight, electrically


Used for aluminum surfaces.

LT-4

Used to coat plugs (plate shaped, bowl shaped) and holes, and
mating portion of shaft.

LG-1

Used with gaskets and packings to increase sealing effect.

LG-3

Heat-resistant gasket for precombustion


and exhaust piping.

LG-4

Used b itself on mounting surfaces on the%al drive and transmission


cases. YThrckness after tightening:
0.07 - 0.08 mm)

LG-5

Used by itself to seal grease fittings, tapered screw fittings and tapered
screw fittinas in hvdraulic circuits of less than 50 mm in diameter.

Sealant gasket

Antifriction compound
(Lubricant including
molvbdenum disulfide)

prescribed

78.5 f 19.6

Komatsu code

Adhesives

Vaseline

torque

LG-6

bolts, nuts and plugs from loosening and leaking oil.


insulating seal.

1 Srlrcon
.
base type used in combination

chambers
-

with LG-1 and LG-4.

LG-7

Has a shorter curing time than LG-6, and is easier


to peel off.

LM-P

Applied to bearings and taper shafts to facilitate


prevent sticking, burning or rusting.

G2-LI

Applied to bearings, sliding parts and oil seals for lubrication,


prevention and facilitation of assembling work.

Used for protecting

battery electrode

press-fitting

and to

rust

terminals from corrosion.

LT-2 is also called LOCTITE in the shop manuals

00-9

ELECTRIC WIRE

CODE

ELECTRIC
In the wiring

diagrams,

various

colors

and symbols

This wire code table will help you understand


Example:

5WB

indicates

CLASSIFICATION

a cable

having

a nominal

Number

Dia. Tp$nds

to indicate

the thickness

of wires.

DIAGRAMS.

number

5 and white

coating

with

black stripe.

Cross section

Cable O.D.

Current rating

(mm)

(A)

2.4

12

Applicable

circuit

(mm*)

11

0.85

CODE

BY THICKNESS

strands
0.32

0.88

Starting,

lighting, signal etc.

26

0.32

2.09

3.1

20

Lighting,

signal etc.

65

0.32

5.23

4.6

37

Charging

and signal

15

84

0.45

13.36

7.0

59

Starting

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

217

0.80

230

Starting

100

CLASSIFICATION

are employed

WIRING

Copper wire

Nominal
number

Prioritv

WIRE

I\

BY COLOR

109.1

AND

CODE

Charging

Starting

Ground

Lighting

I tPri-

Circuits

Classk
fication

marY

17.6

(Glow plug)

Code
Red

Color

RW
White&

Red

WB
White & Black

Black&White
BY
Black &Yellow

Red & White


RB
Red & Black
RY

YB

GR

Yellow & Black 1 Green & Red


YG

GY

LR

Blue & Red

LY

Red & Yellow


RG

00-l 0

Red & Green

Yellow & Blue

RL

YW

(GL)

Red & Blue

Yellow & White

(Green & Blue)

WEIGHT

TABLE

This weight table is a guide for use when transporting

or handling components.
Unit.

Machine Model

WA500- 1

Machine Model

Serial Number

10001 -

Serial Number
pump

WA500-1
10001 -

Engine assembly

1453

Hydraulic

Radiator

assembly

285

Steering and POC pumps

Torque converter assembly

193

Switch pump

13

Transmission assembly

980

POC valve

Damper

91

Machine control valve

Upper drive shaft

18

Lift cylinder

Center drive shaft

33

Dump cylinder

Front drive shaft

44

Engine hood

Rear drive shaft

42

Front frame

Front axle assembly

2028

Rear axle assembly

1776

Front differential

288

Rear differential

assembly
assembly

282

Planetary carrier assembly (1 piece)

80

Planetary hub assembly (1 piece)

102

Axle pivot (Rear axle)

(1 piece)

Lift arm (with bushing)

20

90
279
283
43

1996

931119

Tire (1 piece)

421

Battery (1 piece)

Steering valve

55

Cab assembly

47

Air conditioner

Brake (1 piece)

170

Hydraulic

156

WA500-1

13

2486

Fuel tank

tank

240

(1 piece)

Wheel (1 piece)

Steering cylinder

kg

328
53
305

unit

115

Operators seat

40

Floor plate

131

02

TABLE OF OIL AND

QUANTITIES

AMBIENT

KIND OF
.FLUID

RESERVOIR

COOLANT

_22
-30

-1014

-240

320

CAPACITY

TEMPERATURE
50
10

68
20

Engine oil pan

Specified

$E

Refill

I !
32

~~~,~~~~~~~,~~
!...
,.,,I,,,..,.....,.:_.,.,.,,,.,
., .(.,,,.,..,....
-l-

IQ)

28.5

Engine oil

Brake

Transmission case

Hydraulic system
Axle
(Front and rear)

See NOTE

each 75

(4)

each 75

Fuel tank

Water

Cooling system

Add antifreeze

ASTM:

American

SAE:

Society of Automative

API:

American

Society of Testing and Material


Petroleum

Specified capacity:
Refill capacity:

80

Engineers
Institute

Total amount of oil including oil for components and oil in piping.

Amount

of oil needed to refill system during normal inspection and maintenance.

NOTE:
(I)

When
change

fuel

sulphur

oil in the

content

nance hours described


Change

oil according

sulphur content

is less

oil pan every

than

periodic

0.5%,

to 10C
(3)

Above 1 .O%

the engine

(4)
l/2 of regular interval

l/4 of regular interval

SAElOW-30

and

an atmospheric

Use API classification

SAE15W-40,

temperature

goes up

CD as engine

CC, reduce

the

oil and if API

engine

oil change

to half.

For axle oil, use only recommended


SHELL:

DONAX

CALTEX:

RPM TRACTOR
TRACTOR

TEXACO:

TDH OIL

MOBIL:

MOBILAND

* It is possible

oil as follows.

TT or TD

CHEVRON:

SAE30

HYDRAULIC

HYDRAULIC

to substitute

SUPER

FLUID

FLUID

UNIVERSAL

engine

oil CLASS-CD

for axle oil.

If noise comes

from the brake,

it is no problem

durability.

0i2

tem-

more or less in the day time.

classification
interval

in an atmospheric

of lower than OC, be sure to use engine

even though

if fuel

Change interval of oil


in engine oil pan

starting

oil of SAElOW,
table

is above 0.5%.

Fuel sulphur content

When

perature

in this manual.
to the following

0.5 to 1.0%

(2)

mainte-

WA500-

of

PRECAUTIONS

4. Bearing

FOR

DISASSEMBLY

AND

ASSEMBLY

separator

5. Hook wrench
A hook wrench

has a claw which

turning

of round nuts. The wrench

defined

sockets
by the

turned.

The

wrench

designed

different

outer

diameter

accompanying

of the

figure

for use with

hooks

into the
size is

round

shows

nut

a hook

round nuts of two

sizes.

FSOOl4

FSOO 13

:
FSOO15

Removal

and Installation

of the Sprocket

Wheel

02P-023

FSOO16

00-l 3

PRECAUTIONS

FOR

S.CLEARANCE
Store

DISASSEMBLY

AND

ASSEMBLY

12. CENTERING

ADJUSTMENTS

each set of shims or washers

can be installed

in their

original

so that they

condition

at the

time of reassembly.

Centering
power

is very important

train

for example,

and

the

transmission

bevel

gear

shaft

centering
deviation

parts,

between
and

the stresses

so always

is within the specified

in the

the engine

between

and the final drives.

only increases

the turning

for interfaces

make

the

Incorrect
acting

on

sure that the

limits.

Engine

10. LINK

RODS

1) If it is necessary

to change

the length

of the

link rod in order to remove

it, first record

original

rod can

length

reassembled
2) Remove

so that

the

in its original condition.

the link rod at the pins.

Rod

r-l----

Correct

o]

Transmission

the

be easily

Yoke

Pin
FSOOI

Transmission

11 .SHIMS
1) Shims
adjust

AND

WASHERS

are

used

the action

very carefully
2) Record

the

adjustment

center

of the

the

bevel

engine
gears.

as they get deformed


numbers

and

Handle

Correct

easily.

and positions

to speed

after reinstallation.

3) Do not reuse
deteriorated,

to

any shims
damaged,

or washers

that

are

bent or deformed.

4) Insert thin shims between

thicker ones.

FSOO18

00-14

MEASURING

INSTRUCTIONS

MEASURING
PREPARATIONS
1. Cleaning
Wash

BEFORE

INSTRUCTIONS

CHECKING

BLOCK

To bring two blocks into contact,

of parts

parts to be checked.

Special

paid to thoroughly

remove

surfaces

measurements

on which

care should be

dust and dirt from

the

are to be made

repair

Remove

of part surfaces

scratches,

be checked.
ments

and rust from

If the surface

will

surface,

dents

be careful

parts to

When

smoothing

not to use an oilstone

paper coarser than the finished

benzene

wipe

with

to remove

a clean cotton

the other,

causing

wash each block

rust-preventing

oil and

cloth. Put one block on

a sliding or twisting

movement

the two.

If the

contact

apply

a fine-grade

their edges.

between

two

oilstone

blocks
to the

feels

rough,

blocks

(Do not try to rub thecontact

along
surface

of the blocks.)

are rough, the measure-

be inaccurate.

with

between

so that possible errors can be eliminated.


2. Minor

GAUGES

any

or sand

Do not leave the blocks in contact


Long-time
separate

surface.

contact

for a long time.

will make the blocks difficult

to

or cause black rust to appear on the con-

tact surfaces.
3. Preparation
Clean

the tools

dirt from
the

of measuring

and thoroughly

the surfaces

tools

for

adjustment.

When

tools

which

proper

Remedy

remove

contact

function

dust and

parts. Check

and

storing

Handle

of measuring

all tools

subject

them

which

with

to

can affect

odically

check

necessary,

sufficient

their delicate
the

tools

calibrate

them.

their cases and return


locations

whenever

care

and do not

force

or shocks

construction.

for

accuracy

by force

them.

or strike

gauge,
coat

wipe

with

off

moisture,

a rust-preventing

such as Vaseline, and put the gauge back

Periand,

if

them

to their fixed

VERNIER

CALIPERS

At the start

storage

not in use. It is recommended

of measuring

slide or twist

apart,

Put the tools back into

to assign a person to be responsible


storage

blocks,

in its case.

tools

unreasonable

a block

dirt and fingerprints,

any abnormality.

lubricant
4. Maintenance

two

them with a mallet.


When

zero-point

separating

Do not try to pull them

for the proper

is no clearance

tween

and that

the jaws

graduation

tools.

of measurement,

check that there

is in exact

close the jaws

and

(due to wear)

be-

the zero

alignment

with

point of the
the zero

point of the vernier scale.

MEASURING
Repeat

TOOLS

each

eliminate

measurement

possible

necessary,

Measuring

if

two

or three

errors. Further

there

is a

large

times

an outer

diameter

to

repetition

will be

variation

in the

readings.
When

measuring

a cylindrical
measuring
angles

the inside or outside

object,
device

take
put

two

in two

to each other. Repeat

diameter

readings

with

directions

of
the

at right

this at several

points

along the overall length of the object.


Along
may

eye-measurement
be used for

two approximately
racy

of

such

considered
At

the

for judging
allowable

below

the unit of a scale

a comparison

equal measurements,

eye-measurements

between
the accu-

should

not

be
a

as reliable.

start

measuring

making

of

device
whether
limit.

each

measurement,

select

having

an accuracy

appropriate

the measurement

reaches

Correct

its
FSOO 19

00-l 5

MEASURING

INSTRUCTIONS

Measuring

DIAL

an inner diameter

GAUGES

Carefully
to

be

put the gauge contact-point

measured

to

protect

the

on a surface
delicate

gauge

against shock.
Set the zero-point

@
Correct

the

movement

of the gauge
of

the

with care to keep

contact-point

within

its

stroke during measurement.


Careless

setting

spindle

to

making

The

Correct

Measuring

measurement

minute

by

extend

pointer

of
of

errors)

through

the
the

are

protrusions,

probe

does

thus

gauge

are

errors

because

mechanism

dial
using

can not

unit on the scale.

depressions

so that vertical

not exceed

(and

by the

of eye measurements

Measuring

zero-point

the

limit,

contact-point

below the minimum

the

dial

indicated

be assured

Set the

its

large

an expanding

gears. The reliability

may cause

to

impossible.

relatively

variations

accompanying

a depth

or

measurements

accompanied
FSOOZO

of the zero-point

retract

or steps
movement

its stroke

limits,

of
and

slide the base of the gauge on a fiat surface.

Correct

Wrong

FSOO21

MICROMETERS
Put the anvil onto an object
turn in the spindle
the object.
two

or

Rotate
three

at a right angle

until it comes
the ratchet
idle

into contact

stop until there

rotations,

then

and
with

read

are
the

FSO023

measurement.
When

reading a measurement,

right angle to the graduation


To turn back the spindle,

keep your eyes at a

Measuring

bending

on the sleeve.
rotate

the thimble

with

your fingers.

Wrong

Correct

FSO022

Read

the

moving
When

storing

ance between

a micrometer,

leave

a slight

the anvil and the spindle.

clear-

Indicator

object

Turn

the

the

difference

minimum

00-l 6

Total

the

object

back

Reading
and

forth

one complete
between

indications

the

(T.I.R.)

while

or vertically.

rotation

and read

maximum

of the gauge pointer.

and

MEASURING

Measuring

INSTRUCTIONS

end play,

looseness

or deviation

Measuring

gear backlash

Lever and fulcr

dial gauge

FSO025

Read the T.I.R. while

moving

the object

1) Fully mesh one of two gears and place the dial

back and

gauge

forth or vertically.
Measuring

face runout

or radial

runout

contact-point

on a tooth

of the

other

gear. Swing

the free gear within the limits of its

play in the

rotational

directions,

and read the

T.I.R.
2) Use of the lever and fulcrum
recommended
point

type dial gauge

for this purpose

placed

is

as the contact-

on the gear is moved

tangentially

to the gear pitch circle.


3) The lever and fulcrum
for

use

measurement

Radial runout

type dial gauge is suitable

in a narrow

space

which

contact-point

or for

requires

on an object

a special

placing

at an angle

the
to the

spindle of the gauge.


Since
FSOO26
1) Read runout

complete

at six or more positions

rotation

point at the middle


the spindle

during one

fully checked

movement.

Be careful

range

for contact

of gauge
(usually

should

be care-

with the object during

of

not to con-

fuse positive and negative readings of runout.

CYLINDER
l

GAUGES

Install

a contact-point

mately

equal to the cylinder

on the cylinder
test indicator
cylinder

gauge.

having

a length

Set the zero-point

to the bore diameter

measured

with

approxi-

bore to the measured

a reference

of the

of the standard
ring gauge

or

a micrometer.

When the pointer is


to the left of 0

3) When

range

measurement.

set the zero-

of the assumable

of this type

measuring

mm or less), the contact-point

of the object.

2) At the start of each measurement,

the contact-point

has a very narrow

measuring

contact-point

face

runout,

place

the

on the object along a circle 2 or 3

mm smaller in diameter
ter of the object.

than the outside diameContact-point

Measuring

point

FSO028

00-17

PARTS

CHECKING

INSTRUCTIONS

Insert the gauge into the bore to be measured


read the minimum
while

giving swings

the detachable
l

indication

When

the

and

of the test indicator

to the gauge

about

the tip of

rod used as the fulcrum.

minimum

reading

right side of the zero

is obtained

on the

point of the test indicator,

and the reading to the standard

value to which the

zero point is set.


When

the minimum

reading

side of the zero point,


the standard

is obtained

subtract

Check

from

value.

PARTS
l

on the left

the reading

disassembled

CHECKING

parts to see if they are reusa-

INSTRUCTIONS
3. PITTING

ble or need repair. If the part failed due to an external

source,

before

determine

the

cause

and

correct

1) Pitting

by cavitation

In most

assembly.

cases,

chemical

scale, carefully
1. GENERAL

PRECAUTIONS

When

Visually

inspect

rosion,

scoring,

inspection,

every

parts

for

cracks,

ridging

etc.

part

should

To
be

pitting,

cor-

ensure

proper

clean

before

If the cause of the defect


great

help to analyze

the defect

can be found,

it will be a

whether

the part condition;

will progress

Knowing

the cause of the defect,

can give good advice

the service

to the customer

man

to prevent

him from having the same trouble again.


l

Visual

inspection

damage.

Other

can

not find

methods

of

minute

or hidden

inspection

are

as

follows;
a)

Water-pressure

b)

Color check or magnetic

or air-pressure
damage

test
test

2. CRACKS
l

If

the

part

inspection,
l

is found

to

be

it should be replaced

cracked

If the length or depth of crack exceeds


thickness

by

visual

or repaired.
113 of the

of the part, it should be replaced

instead

of repaired.
l

A part having an internal crack should be replaced.

00-l 8

removing

rust

by
or

within the

limit, replace the part.


is not deep,

removing

the rust and scale.

due to removal

resurface

the part after

of surface

If ball bearing is pitted, replace it.


If more

than

l/3

of the contact

face

is pitted,

the part should be replaced.

or not, and the possibility

of future trouble.

is accompanied

inspect the depth of pitting.

If pitting

2) Pitting

inspection.
l

After

the pitting can not be repaired

allowable
l

cavitation

corrosion.

If pitting is not serious, resurface

the part.

PARTS

HANDLING

PARTS

HANDLING

1. OIL SEALS
3) Use a suitable

in the

proper

direction,

as shown

in the

press to press fit the oil seal into

the housing.

1. Direction
Be careful to install the oil seal with its lips facing

When

installing

the

oil seal flush

with

the

housing surface..

figure

below.
Oil seal nominal outside

Oil

pressure

side

Main lip

&.t

lip

FSO031
FSO029

2. Inspection prior to installation


1) Keep the oil seals free from

dust,

rust

and

scratches.
Take

special

care to prevent

on the lips.
slide

a wire

across

its

surface.

gently

If the

replace the oil seal with a new one.

sure that

the wire

the

oil

seal

inside

the

outside diameter
l.O)mm

outside diameter
l.O)mm

wire

catches,
Make

installing

housing..
Oil seal nominal
Oil seal nominal outside diameter
+ (0.5 I
- (0.5 - l.O)mm
Oil seal nominal
- (0.5 t-L-7

rust or scratches

2) To check the oil seal lip for smoothness,

When

used for this test

does not scratch the lip surface.


3) Do

not

would

use the

come

oil seal

into contact

on a shaft

where

it
FSO032

with rust or scratches

FSO033

on the shaft surface.


4) When

removing

damage
3. Installing
1) Coat

the

oil seal, take

not to

4) After

press-fitting

the oil seal, check that it has

not been installed at an angle to the housing.

the oil seal


the surface

to which

applied with a lubricant


+

care

the housing or shaft surfaces.

If the lip should double


being
proper

fitted
place

over
by

the oil seal is to be

or grease.

the

over as the oil seal is


shaft,

rotating

return
the

it to its

shaft

and

pulling the oil seal slightly backwards.


2) When
with

installing
a

keyway,

an oil seal on a shaft


splines,

suitable jig to protect

or

machined

threads,

use

Max. permissible oil seal slant


(H, -

the lip.

HI)/2 S l/400
FSO034

Lip protectton jig

FSOO30

00-l 9.

PARTS

HANDLING

4. Applying grease to the lips


Before installing an oil seal, coat it with grease
according to the following procedure to prevent
friction from burning the seal surfaces while the
machine is being started.
1) Single-lip oil seal
Place a flat, uniform coating of grease on the
surface away from the sealing surface.

Grease
FSO035

2) Double-lip oil seal


Coat the entire surface between the two lips
with grease in the manner shown in the accompanying figures.

Grease

2. FLOATING

SEALS

1. Handling floating seals


1) Keep each pair of floating seals bundled
together with tape to avoid mix-ups when they
are reinstalled.
2) Discard the old O-rings. Always use new ones
when installing the floating seals.
3) Replace a floating seal if its contact surface is
rusted.

2. Installing floating seals


1) Remove all rust and dust from the mounting
surfaces of the seal. Use sandpaper to remove
any rust that might come into contact with the
O-ring.
2) When installing the floating seal, coat the
mounting surfaces with oil. Then install the
O-ring, taking care not to twist it.
* Do not coat the O-ring with oil.
* The floating seal has been correctly installed
if the seal ring rotates.
3) After installing the O-ring and seal rings in both
housings, mate the two together.

Grease

FSO036

Housing

Seal ring
FSO037

5. Applying adhesives
Take special care when applying adhesives. to the
outer surface of oil seals. Adhesive on the surface
of the lip or shaft leads to oil leakage.
* Since any adhesives on the surface of the press
jig will soon transfer to the oil seal lips, clean
the jig before use.

4) An installer is recommended for inserting the


O-rings.
t Using a screwdriver or other pointed object
risks scarring the O-ring.
5) Attempting to mate the two housings together
without the O-rings and seal rings in place can
damage the O-rings and lead to oil leakage.

O-ring

Housing

Seal ring
FSO038

00-20

PARTS

HANDLING

4. GASKETS

3. O-RINGS

1. Handling

1. Handling
1) Discard

any O-ring

that has been in storage

too

2) Use only the O-rings


for

rings

used

parts, where

materials

prescribed

for the part in

BOOK. This is especially

those

engine

with

important

USE

NEW

2) Make

packings,

gaskets

and copper

with new ones.

sure that there

on the contact

are no scratches

surfaces

or burrs

of the gasket.

high-temperature

heat-resistant

and durable

2. Installing

gaskets

I) Make

such as silicon are required.

3) ALWAYS

replace

packings

long or has hardened.


the PARTS

gaskets

I) Always

sure that

the holes in the gasket

those in the mating

O-RINGS.

2) Apply

gasket

match

part.

sealant

to the joints so specified

in the SHOP MANUAL.


2. O-ring

types

KOMATSU
as shown

O-rings

are marked

in the accompanying

with colored

dots

3. Precautions
gasket
2) Coat

Material

Part Number

Marking

Application

One blue spot

07000-0

..... Nitrile rubber

For
low-pressure

Two blue spots

07000-1

..... Nitrile rubber

For
high-pressure

One green spot

07000-3

..... Fluorine rubbel

For
low-pressure

07000-2

Fluorine rubbel

07000-4

One red spot

..... Nitrile rubber

For
high-pressure
For
low-pressure
in cold weather

all scratches,

the specified

07000-5

Two red spots

,..., Nitrile rubber

applying

a new coat.

area evenly

and let dry for

several minutes.
3) Assemble
sealant

the

mating

parts

when

the

gasket

is stickly to the touch.

5. BEARINGS

1) Shield

bearings
the

bearings

from

dust

and dirt;

the tiniest speck rapidly accelerates


+

Leave

the

packaging

bearings
until just

in

their

before

even

wear.
protective

they

are to be

installed.
2) Protect

For
high-pressure
in cold weather

dirt, paint, grease and old

sealant before

1. Handling
Two green spots

for using liquid gasket

1) Remove

chart.

a bearing

from

excessive

force

and

compressed

air

shocks.
*

Never

dry

a bearing

with

after cleaning.
07000-6

Orange spot

..... Silicon rubber

For
low-pressure
in hot weather

2. Installing

bearings

I) Never drive a bearing onto a shaft by pounding


on

the

outer

pounding
produces
3. Inserting
After

O-rings

coating

so as not

the O-ring

to damage

2) When
with

oil, insert

it. Silicon

rubber

carefully
O-rings

race

on the

into

an

race.

Such

opening

by

pounding

dents in the tracks in the races.

a bearing

with some

or

inner
must

interference,

with the jig shown

be fitted
press-fit

onto

a shaft

the inner race

in the accompanying

figure.

require special care since they tear easily.


Jig

Press fit

FSO039

00-2 1

PARTS

HANDLING

6. PRESS

3) If the shaft
ference,
*

of opening

has considerable

heat the bearing before

with

a non-separable
interference

the jig shown

BUSHINGS

Do not drive in a bushing

installing.

Use a press so that

Do not heat above 120C.

4) When

FITTING

inter-

bearing

must

for both races,

be fitted

press-fit

in the accompanying

with

1) If no press is available,
a

distributed

with a hammer.

is uniform

over the

entire circumference.
using

figure.

directly

pressure

driving

tool

hammer
so

that

in the bushing
the

force

is

evenly.

Jig
I

Press fit

FSOO40

5) Thoroughly

coat

the

bearing

with

oil before

installing.
6) Install

the

chamfered

bearing,
surface

spacer

or washer

with

its

facing the step on the shaft.

2) If the bushing

has an oil hole, bring the hole into

exact alignment

with the oil hole in the housing.

Rear face of

To injection

FSO043

3) When

Correct

burrs
FSO041

a bushing
and

has been removed,

foreign

matter

from

the

remove

all

mounting

hole, and then clean.

7. REMOVING
I) Use snap

SNAP

RINGS

ring pliers to remove

rings. Do not overexpand

or install snap

them-especially

the

smaller ones.
2) After

installing,

check

to make

sure that

snap ring is firmly in place within its groove.

00-22

the

PARTS

HANDLING

8. HYDRAULIC

2. Installing

PIPING

the hydraulic

I) Thoroughly
B

Precautions
ment

for

hydraulic

I) Lower

servicing

the

work

equip-

equipment

to the ground

and

the oil filler cap to relieve

the hydraulic
3) Operate
eliminate

pressure

in

to

control

levers

hydraulic

pressure

or

times

remaining

in the

the

work

equipment

prevent

it

removed

and the hydraulic

1. Removing

from

falling

the hydraulic

1) Disconnect
tubes

by

male

side

loosening

hydraulic
holding

remove

all

with compressed

air.

when

the

pressure

and

4) Install

the

piping

so that

piping!

alt the identification

tags match.
a pipe

must

be joined

at

both

ends,

to

tightening

only one end at a time may make

is

too short.

First fit both ends by hand and then

piping

is released.

it

tighten the ends by turns. (See figure.)

piping
nut on the

joint)

one

on a stand

a
oil,

tubes from hoses or other

the

of the
the

and

with

light

dents are too large, replace.

5) When

piping to be disassembled.
4) Support

trichloroethane)

traces of detergent

of piping

example,

3) Do not use gasket sealant for hydraulic

oil tank.

the

piece

(for

2) Repair the sealing faces or, if the scratches

turn off the engine.


2) Loosen

piping

each

detergent

kerosene,

system

the work

suitable

clean

with

on the

spigot

a wrench

socket

(the

(the
while

female

side).

Tighten gradually and alternately


the both ends.
FSO045

6) To ensure tight-fitting
80%

then tighten
FSO044

7) After
engine

2) Seal

the ends

hoses

and

equipment
matter.

oil

ports

For the same

reason,

the

tubes

and

hydraulic

neath to catch

Then

idling

levers
check

90,

and

of

all
speed
the

connections,
and

operate

run

the

hydraulic

all the

attachments.

the oil level in the hydraulic

tank

and add oil as necessary.

tape.

containers

the hydraulic

control

the nuts to

loosen

to the full torque.

completing
at

torque,

seal the ports of

tank with adhesive

appropriately-sized

out when

to

with blind plugs to keep out foreign

the hydraulic
3) Have

of the disconnected

the

seals, tighten

of the specified

under-

fluid that will flow

the piping is disconnected.

Clean

up

all spills immediately.


4) When

working

yourself
5) Tag

under

the

machine,

position

out of the way of the oil shower.

the ends of all piping

removed

as well as

the ports to which they were attached.

00-23

PARTS

HANDLING

3. Handling

high-pressure

hoses

I) Do not try to shorten


the accompanying

Shorting

under

the hose. A hose shorter

than the specified

length is subject

to the defects

shown

in

figures.

pressure

increases

the tension.

Too

sharp

a bend

damages

FSO046

2) Make sure the hose is not twisted


The

FSO047

after it is installed.

letters

printed

on the

hose

soon

reveal

any twists.

FSO048

3)

Similarly,

the hose must not twist as it moves.

FSO049
Improper
the pipe

connection

causes

the

hose

to twist

as

moves.
FSOO50

4) The last figures on this page are examples

of poor connections.

e must

have

it to contract

FSO05

Rubbing

FSO053

00-24

sufficient
under

play
pressure

FSOO52

PARTS

HANDLING

4. Handling

hoses with

self-seal

1) Do

attempt

to connect

not

coupling

without

hydraulic

pressure.

The gushing

first

use

relieving

hydraulic

also damage

or disconnect
the

or

internal

fluid will not only soil

but the high flow rate may

the O-ring

a hammer

halves

tighten

them

tightly

together,

distance

the surroundings,
2) Never

2) Press the two

couplings

they

equivalent

the fastening
pathway

completely

uniformly.

If they
will

to the

together

and

are

held

separate

clearance

bolts and their

not

by

between

holes, forming

for oil leakage.

of the coupling.

to tighten

or loosen

coupling.
*

Such

sharp

leading

to

blows
oil

can deform

leakage

the coupling,

or cracking

of

the

coupling.
3) Protect

the

intrusion

disconnected

of

dust

disconnected

for

necting

to another

and

dirt

some
coupling

piping

from

the

! If it is to remain
time,

seal

by

or by fitting

cona dust
FSO057

cap or a blind plug to each end.


6. Using sealing
1) To

tape

prevent

around

oil

leakage,

the tapered

thread

wind

sealing

before

inserting

tape
the

plug into the plug hole.


2) Wrap
then

all but the first 1.5 threads


force

fingernail.
I.4

During

FSOO54

1) Follow

Wind

tape

into

the

at the tip and

threads

with

the tape in the same direction

as the threads.

storage

FSO055

5. Handling

the

ave 1.5 threads

FSO058

split flanges
the

bolt

bare.

tightening

sequence

given

in

the figure.

FSO056

00-25

PARTS

HANDLING

9. SPRING
Judging

ll.PUMP

WASHERS

I) After

suitability

I) Discard

the spring

washer

if the overlapping

assembly

pump

with

and before

oil

through

installation,
the

intake

fill the
port

to

provide initial lubrication.

portion is worn or damaged.

2) Before

installing

shaft

by

hand

smoothly

the
to

without

pump,

make

turn

sure

the

that

drive

it turns

any catching.

*
Inlet
-

If

FSO059

2) Discard if the distance P is more than 2t/3.

FSO062

3) Test

run the

installed

pump

and

check

for

unusual noises and leakage.

12. SEAL
I) Seal
FSOO60

RINGS
rings

are very

delicate,

so handle

and

store carefully.

2) Do not reuse rubber seal rings.


3) Avoid excessive stretching when fitting a seal
10. SPRING

(ROLL)

ring

PINS

over

a shaft;

it decreases

the

rings

fitting

a seal

performance.
Handling

spring

4) Remove

pins

all sharp

edges

before

ring into a slot on an abutment.


1)

A spring

pin performs

the split is placed

facing

somewhat

better

the load instead

when
of at a

right angle to the load.

Check for sharp edges and scratches

FSOO61

Seal ring

00-26

HOISTING

INSTRUCTIONS

HOISTING

INSTRUCTIONS
Slinging

near the edge of the hook may cause

Heavy parts (25 kg or more) must be lifted

the

with

a hoist etc. In the Disassembly

and As-

and a serious

25 kg or

maximum

strength

100%

88%

sembly

section,

every

more is indicated

1. If a part

cannot

machine

part weighing

clearly with the symbol

be smoothly

by hoisting,

removed

the following

Check

Check

for

removal

from

checks

of all bolts

to slip off the


accident

hook

during

hoisting,

can result. Hooks

the

should

fastening

the

79%

71%

41%
FSOO64

part to the relative parts.


for

interference

existence

of another

part

causing

with the part to be removed.

3) Do not sling a heavy load with one rope alone,


but sling with two or more ropes symmetrically
wound

2. Wire

ropes

I) Use adequate
of

parts

ropes

depending

to be hoisted,

referring

on to the load.
Slinging

with one rope may cause turning

of the load during

hoisting,

the rope, or slipping

on the weight

original

to the table

winding

untwisting

of

of the rope from

its

position

on

which can result in a dangerous

below:

When

galvanizing)

hoisting

the force
Rope diameter

(mm)

load,

Allowable

load (tons)

with

a load with two

subjected

the

hanging

shows the variation


hoisting

1 .o

10

angles.

to sling up to 1000

1.4

various hanging angles.

12.5

1.6

When

2.2

16

2.8

18

3.6

two

becomes

make a 120
ropes

as large

4.4

20

ropes

ropes,

table

below

load (kg) when


kg vertically,

sling a load vertically,

kg of total weight

weight
two

The

of allowable

11.2

2000

or more

to each rope will increase

is made with two ropes, each of which

is allowed

14

wide hanging angle from the hook.

Z or S twist ropes

without

the

accident.

4) Do not sling a heavy load with ropes forming

Wire ropes
(Standard

have

at the middle portion.

&

be made:
l

rope

1000

at

up to

can be suspended.This
kg when

two

ropes

hanging angle. On the other hand,

are subjected

as 4000

to an excessive

kg if they

force

sling a 2000

kg

load at a lifting angle of 150.


5.6

22.4

10.0

30

The

40

18.0

50

28.0

60

40.0

allowable

one-sixth
strength

or

load

value

one-seventh

is estimated
of

the

to be
breaking

of the rope used.


30"

2) Sling wire ropes from the middle


hook.

portion

of the

60"

Lifting angle

SO'

120"

1500

: cy
FSO065

00-27

HOISTING

INSTRUCTIONS

Approximate

reduction

of

allowable

load

for

3. Hanging

bolts

wire ropes at various hanging angles.

Hanging

91

angle

Reduction

120

50%

in %

02P-02
Hanging angles should not exceed

150.

5) When
hoisting
several
parts as a unit, be
careful not to allow any part of the unit to fall.
Use a suitable container when hoisting many
small parts at a time.
6) Select
the most suitable
hoisting a specially-shaped

sling device
object.

when

Part Number

04530-0815

Cylinder
head

7) When using a hoist to turn over a heavy part,


observe the following instructions:
l Clear as much
of the area surrounding
the
part as possible.
.

When

the ropes from slackening

changes.
Gradually

slacken
sure

that

the
the

wire
part

ropes

after

is completely

Slackening

the

ropes

before

complete

of the part may cause the part to fall

back to its original position.

80

018

10

1.5

18

150

04530-l

222

12

1.75

22

220

04530-l

628

16

2.0

28

450

04530-2030

20

2.5

30

630

04530-2438

24

3.0

38

950

04530-3045

30

3.0

45

1500

04530-3655

36

3.0

55

2300

04530-4625

46

3.0

25

3400

04530-487C

48

3.0

70

4500

* The

allowable

load

maximum

static

withstand.

The

in the

table

these

values

should

safety

in the

load

table

which

actual

hoisting

in the

table

factors

reduced,

means

the

bolt

can

load given
taking

the

into consideration,

as

operation.

are applicable

from a hoist.

the

of allowable
be

bolts will be subjected

vertically

00-28

15

04530-l

necessary

turned over.
turning

1.25

Allowable
load (kg)

and the

part from slipping when the center of gravity

making

turning the part over, take special care

to prevent

Pitch

to shocks

The

allowable

to the

bolts

during
loads
slung

STANDARD

TIGHTENING

TORQUE

STANDARD
1. STANDARD

TIGHTENING

The following
Disassembly

TIGHTENING

TORQUE

charts give the standard

OF

BOLTS

tightening

AND

torques

TORQUE

ml4

NUTS

of bolts and nuts. Exceptions

are given in sections

and Assembly.

Thread diameter
of bolt
(mm)

Width
across flat
(mm)

07

z
Nm

kgm
6

10

13

10

17

12

19

1 1.5 f

14

22

18.Ok2.0

16

24

28.523

279*29

18

27

39*4

383239

20

30

56?6

549t58

22

32

76a8

745278

24

36

94.5&10

927+98

27

41

135+15

1320&140

30

46

175220

1720&l

33

50

225&25

22102240

36

55

280*30

2750+290

39

60

335235

3280?340

1.35*0.15

This torque table does not apply to the bolts with which
to be used, or which
*

of

Nm (newton

2.TlGHTENlNG

require tightening

meter):

TORQUE

1 Nm f

OF

to otherwise

13.2+

3.2 a0.3

31.422.9

6.7 20.7

65.7t6.8

1 .o

112k9.8
177*19

nylon packings

specified

1.4

or other non-ferrous

90

metal washers

are

torque.

0.1 kgm

SPLIT

FLANGE

BOLTS

Use these torques for split flange bolts.

Threatf difi;eter

Tightening

torque

(mm)

Width
across flats
(mm)

10

14

12

17

11.5*1

11229.8

16

22

28.523

279+29

kgm
6.7kO.7

Nm
65.7k6.8

00-29

STANDARD

TIGHTENING

3. TIGHTENING

TORQUE

TORQUE

Use these torques

FOR

NUTS

OF

Sealing surface

FLARED

for nut part of flared.

FSOO68

Thread diameter
of nut part
(mm)

Width across flats


of nut part
(mm)

14

19

Tightening

torque
Nm

kgm
2.5 F0.5

24.5 t4.9

18

24

522

22

27

812

24

32

1423

137.3t29.4

30

36

1823

176.5t29.4

49tlS.6
78.5 k 19.6

33

41

2Ok5

196.1

36

46

2525

245.2*49

42

55

3oi5

294.2a49

COATING
The recommended

coating

Nomenclature

materials

prescribed

r+49

MATERIALS

in Komatsu

Shop

Manuals

Komatsu code

are listed

below.

Applications

LT-1A

Used to apply rubber pads, rubber gaskets, and cork plugs.

LT-1B

Used to apply resin, rubber, metallic and


non-metallic parts when a fast, strong seal is needed.

LT-2

Preventing

LT-3

Provides an airtight, electrically


Used for aluminum surfaces.

LG-1

Used with gaskets and packings to increase sealing effect.

LG-3

Hea;t-resistant

Adhesives

bolts, nuts and plugs from loosening


insulating

gasket for precombustion

and leaking oil.

seal.

chambers

and exhaust piping

Liquid gasket

LG-4

Used by itself on mounting surfaces on the final drive and transmission


(Thickness after tightening:
0.07 - 0.08 mm)

cases

LG-5

Used by itself to seal grease fittings, tapered screw fittings and tapered screw
fittings in hydraulic circuits of less than 50 mm in diameter.

Antifriction compound
(Lubricant including
molybdenum disulfide)

LM-P

Applied to bearings and taper shafts to facilitate


prevent sticking, burning or rusting.

Grease
(Lithium grease)

G2-LI

Applied to bearings, sliding parts and oil seals for lubrication,


prevention and facilitation of assembling work.

Vaseline

LT-2

00-30

Used for protecting

is also called

LOCTITE

battery electrode

in the shoo manuals

press-fitting

terminals from corrosion.

and to

rust

ELECTRIC WIRE

CODE

ELECTRIC
In the wiring

diagrams,

various

colors

and symbols

This wire code table will help you understand


Example:

05WB

indicates

CLASSIFICATION

a cable having

WIRE
are employed

WIRING
a nominal

the thickness

of wires.

number

05 and white

coating

with

black stripe.

BY THICKNESS

Number
strands

Dia. of strands
(mm)

Cable O.D.
(mm)

Cross section
(mm?

Current rating
(A)

Applicable circuit

01

11

0.32

0.88

2.4

12

Starting, lighting, signal etc

02

26

0.32

2.09

3.1

20

Lighting, signal etc.

05

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

j7a

Starting

100

217

0.80

17.6

230

Starting

CLASSIFICATION

to indicate

DIAGRAMS.

Copper wire
Nominal
number

CODE

BY

COLOR

109.1

AND

CODE

Instrument

Other

Code

Color

Black

White

Red

Green

Yellow

Blue

YR

LW

Yellow & Red

Blue & White

GR

YB

LR

Green & Red

Yellow & Black

Blue & Red

GY

YG

LY

Yellow & Green

Blue &Yellow

Primary

BW
2

WR

Black & White

RW

White & Red

Red &White

Green &White

3
Auxiliary
4
Black & Red

1 White

&Blue

1 Red &Yellow

Green &Yellow

Code

WY

RG

GB

YL

LB

Color

White &Yellow

Red & Green

Green & Black

Yellow & Blue

Blue &Black

Code

WG

RL

GL

YW

Color

White &Green

Red & Blue

Green &Blue

Yellow &White

00-3 1

WEIGHT

TABLE

This weight table is a guide for use when transporting or handling components.

(Unit: kg)
Engine assembly

1453

Radiator assembly
Torque converter assembly
Transmission assembly

I
I

Steering cylinder (I piece)

285

Brake (1 piece)

193

Hydraulic tank

980

Main control valve

47
170

90

Damper

91

Lift cylinder (I piece)

279

Center drive shaft

33

Dump cylinder

283

44

Engine hood

42

Front frame

2486
2012

Front drive shaft

Rear drive shaft

Front axle assembly

2028

Rear frame

Rear axle assembly

1776

Bucket link (with bushing)

Front differential assembly

43

94

288

Tilt lever (with bushing)

1::

Lift arm (with bushing)

1996

Planetary carrrer assembly (I prece)

Bucket with teeth

2351

Planetary hub assembly (I piece)

Counterweight

Rear different:

assembly

I
1

Axle pivot (Rear axle)


Wheel (I piece)
Tire (1 piece)
Steering valve

WA500-

92 (I 19)

Fuel tank

240

Battery (I piece)

421

Operators seat

55

Floor plate

457

880

I
I

328
53
40
131

0if3

TABLE OF OIL AND

RESERVOIR

KIND OF
FLUID

COOLANT

QUANTITIES

CAPACITY (PI

AMBIENT TEMPERATURE
-22
-30

-2

-1014

320

50
10

;:

::

g$E

Specified

Refill

,,,,.,.
,,,, :.:.:.:.:.:.:c:<.:;:.:.:.
,, ,.,,,,,......,,
~~~~~~~~~ii.i~~~~~~~~~
.:<.:.:.y..:.:.:<.:.:<.>,,,&
..,,._
(1.
*, ,n ,.,,,,.
.,.:,,.,............
Engine oil pan

28.5

Engine oil

Brake

2.4

62

Transmission case

150

Hydraulic system
AMa
(Front and rear)

Fuel tank

SW NOTE (4)

Diesel fuel

ASTM:
SAE:

each 75

435

Add antifreeze

Water

Cooling system

each 75

80

American Society of Testing and Material


Society of Automative Engineers

Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity:

Amount

of oil needed to refill system during normal inspection and maintenance.

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

Fuel sulphur content

0.5 to 1.O%

Above 1.O%

I
I

l/2 of regular interval

l/4 of regular interval

(2) When starting the engine in an atmospheric temperature of lower than OC, be sure to use engine
oil of SAEl OW, even though an atmospheric temperature goes up to 10C more or less in the day
time.
(3) Use API classification CD as engine oil and if API
classification CC, reduce-the engine oil change interval to half.
(4) For axle oil, use only recommended oil as follows.
DONAX TT or TD
SHELL:
RPM TRACTOR HYDRAULIC FLUID
CALTEX:
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO:
TDH OIL
MOBILAND SUPER UNIVERSAL
MOBIL:
* It is possible to substitute engine oil CLASS-CD
SAE30 for axle oil.
If noise comes from the brake, it is no problem of
durability.

o634

WA500- 1

10 ENGINE

VHEEL n4DER

ENGINE
11 STRUCTURE

AND

FUNCTION

Engine mount .............................


Radiator ..................................
Fuel tank and piping ........................
Engine control .............................

WA500-

11-2
11-3
11-4
11-5

11-l

ENGINE MOUNT

Section A - A

Section B - B

425FOO7

The engine is mounted

separately from the torque

converter and transmission.

Both front and rear have rubber mounts.

1. Rear mount
2.

11-2

Front

mount

WA500-

RADIATOR

Section A - A

1.

Radiator

2.

Coolant level sensor

3.

Fan guard

425FOO8

Specifications
Core type:
Total

Cross-sectional
4.

G7 type

heat dissipating

area:

area of water

89.9

cm2

tubes:

193.8

cm2

Torque converter oil cooler

5.

Hydraulic oil cooler

A.

Coolant inlet port

B. Coolant outlet port


C. Wind

WA500-

11-3

FUEL TANK

AND

PIPING

The fuel level sensor is installed in the fuel tank.

11-4

1.

Fuel level sensor

2.

Drain valve

3.

Injection pump

WA500-

ENGINE

CONTROL

F42101002

WA500-

1.

Accelerator pedal

2.

Accelerator cable

3.

Injection pump

1 l-5

ENGINE

12 TESTING

AND

ADJUSTING
...................
...........
Adjusting valve clearance ................
Measuring compression pressure ...........
.........
Testing and adjusting fuel injection
Measuring blow-by pressure ..............
Testing and adjusting belt tension ..........
Measuring exhaust gas color ..............
Standard value table

Tool list for testing and adjusting

Measuring engine oil pressure and temperature


Adjusting fuel cut solenoid

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

12- 2
12- 3
12- 4
12- 5
12- 6
12- 8
12- 9
12-10

. . 12-l 1
12-12

Measuring accelerator pedal operating force

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

and operatin angle

The following

precautions

12-13

are necessary when using the Standard Value Tables to make judgement

during trouble-

shooting or during testing and adjusting.


1.

The values in these tables are based on the values for new machines leaving the plant, so they should be used
as target values when repairing or when estimating wear after a period of use.

2.

The standard

values in these tables for judgement

when troubleshooting

are estimated

values based on the

standard values for the machine when shipped from the plant, and on the results of various tests.
Therefore,

they should be used as reference in combination

with repair and operating

records when making

judgements.
3.

These

standard

these values

WA500-

value

alone

tables

to make

must
simple

not be used for standard values

when

judging

claims.

In addition,

do not use

judgements.

12-1
0

STANDARD

VALUE TABLE
Engine

Cate-

KOMATSU
Condition

Item

S6D140-1

Unit

Standard value

Permissible value

rpm

2250 - 2350

slow

High idling speed

I-----

Engine speed

:
E
b
=
a

. Necessary

660 - 720

starting speed

Intake resistance

z
>
0l

Exhaust temperature

5
2
!z
0
:

Exhaust gas color

Oil pressure
(entine water tempwrature
green range

E
r
t

All speed (intake air temp. 2OC

OC

Oil temperature

1 Oil consumption ratio

Bosch index

Max. 4.0

5.0

At high idling

Bosch index

Max. 1 .O

2.0

Intake valve

mm

0.43

Exhaust valve

mm

0.80

Oil temperature 40 - 60C


(engine speed: 160 - 200 rpm)

kg/cm

Min. 32

22

At high idling

mmH,O

Max. 100

200

kg/cm

3.5 - 5.5

2.0

Min. 1.0

0.7

Min. 1 .O

0.7

At high idling
At low idling

SAE30

Coolant temperature

kg/cm

Whole speed range


(inside oil pan)

OC

At continuous rated horesepower


(proportion

rg

110

120

Max. 0.5

1 .o

80-

to fuel consumption)

Nozzle tester

kg/cm2

Before top dead center

degree

27

27 * 1

70 - 95

100

74.5 - 78.5

74.5 - 78.5

Whole speed range


(at engine outlet)

250*

E
t;
?;

10

250 c 10

90

90

Thermostat function

.-r
5
s

Max. 650

At abrupt acceleration

SAEIOW

.-5

Max. 650

9.5 Fan belt tension


(Tension pulley-

9.5 -

10.5

6
I

kg

8-9

Max. 13.5

I
i

z
&
z
s

Operatinganglea

Stopper height L,

o1 45 os 30

15-25

14-24

136 -

12-2
0

10.5

146

WA500-1

TOOL LIST FOR TESTING


NO

Testing and measuring

item

AND

Tool Name

Battery

specific gravity

Coolant

freezing temperature

Water temperature,
oil temperature, intake temperature

Battery

Exhaust temperature

Lubricating

Fuel pressure

Intake pressure,
exhaust pressure

Blow-by

coolant

Thermistor
temperature

Part No.

Remarks

xx

Digital display 60-19999

Tachometer

Engine speed

ADJUSTING

tester

rpm

gauge
799-l 01-6000

0 -

oil pressure

Engine pressure
measuring kit

799-203-2002

10 kg/cm

2
0 - 1000 mmH,O

pressure

10
11

Compression

12

Blow-by

13

Valve clearance

Feeler gauge

795-l 25-1210

0.43, 0.80 mm

14

Exhaust gas color

Handy smoker checker

799-2 1O-9000

Discoloration
(Discoloration

15

Fuel on water mixed in oil

Engine oil checker

799-201-6000

Water content 0.1%. 0.2%


in standard sample

16

Coolant

Water quality

799-202-7001

PH. nitrous

17

Leakage from cooling

Cap tester

799-202-9001

0 - 2 kg/cm

18

Fuel injection pressure


Nozzle injection condition

Nozzle tester

Commercially
available

0 - 300 kg/cm

19

Electrical

Tester

Commercially
available

Current,

20

Accelerator

Push-pull scale

79A-262-0020

Commercially

Compression

pressure

Blow-by

pressure

quality

circuit

pedal force

system

gauge

checker

tester

0 to 70% standard color


%x l/10 = Bosch index)

acid ion concentration

voltage, resistance

available 0 - 25 kg

n!

When carrying out testing, adjusting or troubleshooting,

Qf

When working in groups, use agreed signals and do not allow unauthorized

n!

When checking the water level in the radiator wait for the water to cool.

Qt

Be careful not to get caught in rotating parts.

stop the machine on level ground, insert the safety pins

and block the tires.

the water is hot.

WA500- 1

persons near the machine.


Do not remove the radiator cap while

Boiling water may spurt out.

12-3
0

ADJUSTING
*

Condition:

Adjust

VALVE CLEARANCE

Engine is cold.

clearance

between

crosshead

and rocker

lever

as follows.
Unit:

mm

Intake valve

Exhaust valve

0.43

0.80

Cold

Special tool
Part No.
A

Part Name
Feeler gauge

795-l 25-1210

Remove cylinder
Rotate

the

align

pointer

(2) with

shaft

pulley.

When

1.6 TOP

head cover (1).

crankshaft

of the valves.

Qty

in the

normal

rotating,

to

on crank-

check the movement

When the pointer

mark,

direction

the 1.6 TOP mark

is in line with

No. 1 cylinder

should

the

be at com-

pression top dead center.


When

No.

1 cylinder

is at compression

center, adjust the valve marked


When

No.

6 cylinder

is at compression

center, adjust the valves marked


Cylinder No.

I,

I-

Intake valve

To

adjust,

insert

and crosshead
until

I,

Exhaust valve

4.

2
l

tool

is a sliding

nut (6) to hold adjustment


m
5.

Lock nut:

Next,

rotate

crankshaft

and adjust

maining

valves marked

After

adjusting

top dead center,


shaft

120

ance

of

Then

rocker

adjustment
fit.

I II

lever

(3)

screw

(5)

tighten

lock

screw in position.

one turn

the

valve

in the normal

clearance

of the

dire-

0.

No.

1 cylinder

at compression

it is also possible to turn crank-

each time and adjust

each

dead

6.0 ? 0.6 kgm

rection
*

top

II

A between

(4) and turn

clearance

deal

0.
3

I,

top

0.

cylinder

the valve clear-

according

to the

firing

order.

- Firing order:
*

After

tightening

l-5-3-6-2-4
the

lock

nut,

check

the clear-

ance again.

615OF201

12-4
0

WA500-

MEASURING
*

Measurement

COMPRESSION

PRESSURE

condition

* Coolant temperature:
Inside operating range.
* Engine valve clearance: Standard value.
* Engine speed: 160 to 200 rpm
Unit:
Item

kg/cm*

Standard value

Permissible value

Min. 32

22

Compression
pressure

Special tools
Part No.

Compression gauge

510

/
1

Adapter

520

Plate

Tachometer

795-502-I

204

795-502-I

A,

1
I

795-502-I

8
*

799-203-8000 1

If performance
the piston,

tests

piston

or troubleshooting

ring or cylinder

When

1.

measuring

the

compression

pressure,

be

the

manifold

or

not

muffler,

or to get caugh t in rotating

Adjust

touch

exhaust

careful

to

shows that

liner may be worn,

pressure.

measure the compression

I Otv

Part Name

parts.

valve clearance.

For

details,

see ADJUSTING

VALVE

CLEAR-

ANCE.
2.

Warm up engine (oil temperature

3.

Remove nozzle holder


*

40 to 6OC).

assembly.

For details, see REMOVAL

OF NOZZLE

HOLD-

ER ASSEMBLY.
4.

Install

tool A, AI

assembly,

and Az in mount

and connect

5.

Set engine tachometer

6.

Disconnect

B in position.

fuel CUT-OFF

Crank engine with

of nozzle holder

pressure gauge.
solenoid

valve connector.

motor

and measure com-

starting

pression pressure.
*

Measure
where

the
the

compression
pressure

pressure

gauge

at the point

indicator

remains

steady.
*

When

measuring

measure
within
*

Installing

the

the specified
the

nozzle

ing the compression


For

the

engine

details,

see

compression

speed to confirm

pressure,
that

it is

range.
holder

assembly

after measur-

pressure.
INSTALLATION

HOLDER

ASSEMBLY.

WA500-

OF

NOZZLE

TESTING
*

AND

ADJUSTING

FUEL INJECTION

TIMING

Measurement condition

- Coolant temperature:

Inside operating range.


Unit:

Fuel injection
timing

TESTING

B.T.D.C.

FUEL

1.

Disconnect

2.

Remove
delivery

Permissible value

Standard value

Item

degree

27

27 + 1

INJECTION

TIMING

fuel injection pipe (1) of No. 1 cylinder.

delivery

valve

holder

(2),

then

remove

valve (3) and spring (4). and install deliv-

ery valve holder (2) again.


3.
4.

Place accelerator pedal at FULL


Operate
slowly

priming
in normal

pump

position.

and

direction.

rotate
Check

crankshaft
point

where

fuel stops flowing from delivery valve holder (2).


5.

Check that 27 I.J. line on damper (5) and pointer


(6) are aligned at point where fuel stops flowing.
*

BEYOND

injection timing line:

Timing
*

BEFORE

RETARDED

injection timing line:

Timing ADVANCED
*

If the test shows that the fuel injection

timing

is

incorrect, adjust as follows.

12-6
0

WA500- 1

ADJUSTING
FUEL INJECTION
BY DELIVERY
CHECK
6.

Turn

crankshaft

TIMING

back 30 to 40

from

top

dead

center.
7.

Rotate

crankshaft

to align 27

I.J. line on crank-

shaft pulley and pointer correctly.


8.

Loosen nut

(7) on the

injection

flange

and

the

bolt,

rotate

side little

by little

(8)

no fuel

until

pump mounting

flange

on the

pump

by operating the priming pump


flows

out of the

delivery

valve

holder.
9.

Tighten

nut (7) in oblong hole of mounting

flange

of fuel injection pump.


*

After

tightening

the nut, check again that the

fuel stops flowing


at the point

from the delivery valve holder

where

the pointer

the line on the crankshaft


IO.

Remove

delivery

ery valve (3)

is aligned with

pulley.

valve holder

(2), assembly deliv-

and spring (41, then install delivery

valve holder (2) again.


w
11.

Delivery holder:

3.3 f 0.2 kgm

Connect fuel injection pipe (1).


w

Sleeve nut:

WA500- 1

2.4 i 0.1 kgm

12-7
0

MEASURING
*

BLOW-BY

PRESSURE

Measurement condition

- Coolant tempe*ure:
Inside operating range.
* Engine valve clearance: Standard value.
* Engine oil temperature: Min. 60C
Unit:

Permissible value

Standard value

Item

Blow-by
pressure

Max. 100

mmH,O

Max.200

Special tool
Part Name

Part No.

Q
f

799-201-l

Blow-by checker

503

When taking measurements,


the exhaust

Oty

manifold

be careful not to touch

or muffler,

or to get caught

When measuring the blow-by,

warm the engine

in rotating parts.
1.

Measuring blow-by
up thoroughly.
Stop

engine

and

install

adapter

of

blow-by

checker on engine breather hose (1).


Connect

adapter

mmH,O)

to hose.

and

blow-by

(0 to

500

Run the engine at high idling and measure the


blow-by pressure.
2.

Precautions when measuring blow-by


*

The

blow-by

should

be

measured

with

the

engine running at rated output.

- When measuring in the field, a similar value


can be obtained at stall speed.

- If it is impossible to check at rated output


or stall speed, measure at high idling.
In this case, the blow-by value will be about
80% of the value at rated output.
*

Blow-by

may

vary

greatly

according

to

the

condition

of the engine, so if there is any ab-

normality

in the reading,

lem

related

cessive

to

oil

gas color,

defective

consumption,
or

early

check for
blow-by,

defective

deterioration

any prob-

such as exexhaust

or contami-

nation of the oil.

12-8
0

WA500-

TESTING
TESTING
TENSION

AND
AND

ADJUSTING

ADJUSTING

BELT TENSION

FUN

BELT
Approx. 6 mm

Unit:

Standard
value

Item

mm

Permissible
value

I
Deflection of belt

Testing fun belt tension


Check the amount the fan belt deflects when pushed with a force of approx.

6 kg at a point mid-way

between the fun pulley and tension pulley.


Use a scale to measure the amount the V-belt deflection.

Adjusting fun belt tension


1)

Loosen lock nut (I) of tension pulley.

2)

Adjust

the belt tension

of adjusting bolt

(2),

tighten lock nut of tension pulley.

TESTING
AND ADJUSTING
BELT TENSION

ALTERNATOR
Approx.

Unit: mm
Standard
value

Item
Deflection of belt

15 mm

Alternator pulley

Permissible
value
-

15

Approx. 6 kg
Testing alternator

belt tension

Check the amount the alternator


pushed with
mid-way

a force

between

of approx.

the alternator

belt deflects when


6 kg at a point
pulley

and water

pump pulley.

Water pump pulley


425F202

Use a scale to measure the amount the V-belt deflection.


Adjusting alternator
1)

belt tension

Loosen alternator

mount bolt, nut (I) and bolt

(2) of adjusting plate.


2)

Use a bar, rise alternator


tension
adjusting

of

belt

(3),

plate

as

assembly and adjust

and tighten
first,

tighten

bolt

(2)

of

alternator

mount bolt, nut (1).

WA500- 1

12-9
0

MEASURING
*
.
.

Measurement

EXHAUST

GAS COLOR

condition

Coolant temperature:
Valve clearance:

inside operating range.

Standard value.
Unit:
Standard
value

Permissible
value

Acceleration

Max. 4.0

5.0

High idling

Max. 1 .o

2.0

Part Name

Oty

Smoke meter

Item

Exhaust
color

Bosch index

Special tool

Part No.
Commercially
available

Q
f

When measuring the exhaust color,

be careful

not to touch the exhaust pipe.

When measuring the exhaust color, warm the engine


up thoroughly

(oil temperature

6OC).

1.

Insert probe A rn outlet of exhaust pipe (I)


0
secure to exhaust pipe with clip.

2.

Connect

probe hose, connector

switch and air hose


*

and

hose of accelerator

to smoke meter A.

8
The pressure of the air supply should be under
15 kg/cm2.

3.

Connect power cord to socket.


t

Check

that

the power

switch

is OFF

before

connecting the cord.


4.

Loosen cap nut of suction

pump and insert filter

paper.
5.

Turn power switch ON.

6.

Accelerate

engine suddenly.

press accelerator

At the same time, de-

switch of smoke meter, operate re-

lief valve and catch exhaust gas color on filter paper.


7.

Lay filter
top

of

paper used to catch exhaust gas color on

unused

filter

papers (IO

sheets or more)

inside filter paper holder, and read indicated value,

12-10
0

WA500-

MEASEURING

ENGINE

MEASURING

ENGINE

*
.

condition

Measurement
Coolant

OIL

temperature:

OIL PRESSURE

TEMPERATURE

PRESSURE

Inside operating

range.
Unit:

Item

AND

Standard value

kq/cm*

Permissible value

Oil pressure
High idling

Low idling

Min. 1 .O

0.7

Special tool

Part No.

Part Name

Engine pressure
measuring kit

799-203-2002

n
n !

When measuring,
rotating

Oty

be careful

not to get caught in

parts.

Install

and

remove

the

plug

and oil

pressure

gauge with the engine stopped.


*

1.

Measure

the engine

perature

is at the specified

Disconnect
plug

2.

oil pressure when

connector

of

the oil tem-

temperature.
wiring

(I),

then

remove

(2).

Install oil pressure gauge A (20 kg/cm2).


*

Install

the oil pressure gauge so that it is affect-

ed as little as possible by the engine vibration.


3.

Start engine and measure oil pressure.

MEASURING

OIL

TEMPERATURE

Measurement

condition

Coolant

temperature:

Item

Inside operating

Standard value

Oil temperature

range

Permissible value

80-llOC

120c

Special tool

A
Al
1.
2.

I
I

Part No.

Part Name

799-l016000

Thermister temp. gauge

799-l 01-6140

sensor

Qty

Remove dipstick

(1).

Insert sensor A,

of thermistor

temperature

gauge in

sensor to thermistor

temperature

gauge A

dipstick
Connect

guide.

and measure temperature

WA500- 1

of oil in oil pan.

12-11
0

ADJUSTING

1.

FUEL CUT SOLENOID

Adjust rod 15) while pulling rod (5) in the running direction so that there is clearance of 0.4 kO.1 mm between
stop lever (4) and stopper (7).

2.

Turn

on the engine starting

solenoid

key and confirm

that the

has a stroke of 12 mm and clearance of 0.4 *

0.1 mm.
3.

After

turning

reconfirm

on and off the key two or three times,

that solenoid works smoothly and engine runs

v;

or stops completely.
*

If the solenoid does not work


coil

burns

flywheel

in the

horsepower

cause of

smoothly,

solenoid

excessive current

or

downs in the cause of dropp-

ing fuel injection volume.

is

_1

IL
-.

621OFlll

12-12
0

WA500-

MEASURING
ACCELERATOR
AND OPERATING ANGLE
*

PEDAL OPERATING

FORCE

Measurement condition

- Coolant temperature:

Inside operating range.

Unit:
Item

Permissible value

Standard value

Operation force of
accelerator pedal

kg

13.5

8-9

Special tool
Part No.

Part Name

aty
423F304

OPERATING
1.

Push-pull scale

79A-262-0020

FORCE

Measuring procedure
1)

Put push-pull
celerator

scale A in contact

pedal at point

150

with the ac-

mm from

pedal

fulcrum a.
*

The

center

contact

of

push-pull

with a point

scale A must be in

150 mm from

the pedal

fulcrum.
2)

Start
tion

the engine, push the pedal in the direcof operation

and measure the maximum

value when pushing from

idling to the end of

the pedal travel (high idling).


Testing and adjusting
1)
2)

Stop the engine.


Disconnect

the cable (1) at the bottom

accelerator

pedal,

of the

and check that the linkage

(2) and ball joint (3) at the bottom of the pedal


move smoothly.
3)

Connect
then

the cable at the bottom

disconnect

injection

pump,

at

the

of the pedal,

connection

for

the

and check that the cable (4)

moves smoothly.
*

When

carrying

out

this

inspection,

or replace parts as necessary.


operating

force

adjust

Measure the

again and check that

it is

within the standard value.

WA500-

12-13
0

OPERATING

ANGLE

OF ACCELERATOR

PEDAL

423F305C

1.

Measuring procedure
1)
2)

Stop the engine.


Measure the operating
pedal

it is operated

a2, put the

angle q,

angle gauge A in contact

with

from

the accelerator

low-idling

and high

idling.
3)
2.

Measure installed

length X of rod (1).

Adjusting procedure

1)
2)

Remove cover under cab.


Loosen

nut

X of the
3)

Loosen

4)

L1

of

Loosen

nut (3) and adjust


L2

Adjust

the

injection

length
pump

high idling
(high

idling)

stopper

value.

pedal

stopper

is

bolt so that installed

accelerator

the standard

length

value.

height

of

installed

the standard

bolt so that installed

accelerator

the standard

within
5)

so that

(1) is within

nut (2) and adjust

height
within

and adjust

rod

pedal

stopper

is

value.
of the
governor

rod

(4) so that

lever

contacts

the
the

when the pedal is depressed

and still

tighten

stopper

bolt

(3)

half turn.

12-14
0

WA500- 1

ENGINE
13

STARTING

DISASSEMBLY

AND

TURBOCHARGER

MOTOR

.. ..
. ...... ..
Installation
. .. .........

Removal

. .

13-2

Removal

. .

13-2

Installation

. .

13- 3

Removal

. .

13- 3

Installation

AIR

ALTERNATOR

...... .
.... ..
Installation
.. .......... ...

Removal

OIL

..............,..
Installation
....., ........
INJECTION

Removal

. .

13-4

Installation

. .

13- 5

...
...

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

13- 9

_. . . . . . . .
.... ...

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

13-10

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

...........

13-21

...........

13-23

........._
........

...........

13-25

...........

13-31

..........
_. . . . . . .

...........

13-37

...........

13-38

.....
....

13- 9

13-15

Removal

. . 13- 5

Installation
ENGINE

....
... .

Installation

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

. .

13- 6

Removal

. .

13- 6

Installation

. .

13-7

Removal

. .

13-7

Installation

FUEL

HOLDER

.......
Installation
.
..
Removal

Take

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

the

cylinders
1.
2.

following

for

air bleeding

cylinders,

TANK

when

you

start

to operate

hydraulic

pumps and pipings.

Start engine, keep idling.


Operate

hydraulic

cylinder

4 -

5 cycles,

but do not exceed beyond

100 mm or

end.

3.

Continue

4.

After
NOTE:

method

after reassembling

stroke

WA500-

13- 8

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

RADIATOR

PUMP

Removal

NOZZLE

13- 8

...........

HEAD

. . 13-4

PUMP

...... ..........
Installation
. ............

Removal

WATER

...........

..

COMPRESSOR

CYLINDER

COOLER
Removal

FULE

ASSEMBLY

to operate

finishing
After

cylinder

3 - 4 cycles until

above steps, keep normal

stroke

end.

engine speed.

long storage, same procedure

is required.

13-1
0

REMOVAL

n!
1.

OF STARTING

MOTOR

ASSEMBLY

Disconnect the cable from the negative (-) terminal


of the battery.

Remove catch, open side cover, then

remove two side

covers.
2.

Disconnect connector (1).

3.

Disconnect wire (2).

4.

Remove

ground

connection

(3). then

remove starting

motor assembly (4).

INSTALLATION
OF STARTING
MOTOR ASSEMBLY
1.

Fit gasket and install starting motor assembly (4), then


tighten together with ground connection

(3).

2.

Connect wire (2).

3.

Connect connector

4.

Install cover, close two side covers, then lock with catch.

5.

Connect cable to negative (-)

13-2
0

(1).

terminal

of battery.

WA500-

REMOVAL

Disconnect the cable from the negative (-) terminal


of the battery.

1.

Remove catch, then open side cover.

2.

Disconnect wires (l),

3.

ASSEMBLY

OF ALTERNATOR

Remove

bolt

(4)

(2) and (3).


of

adjustment

plate,

then

loosen

mounting bolt and nut (5).


4.
5.

Remove adjustment
Move alternator

plate (6).

assembly towards lower to loosen belt

tension, then remove belt (7).


6.

Remove mounting

bolt and nut, then remove alternator

assembly (8).

INSTALLATION
OF
ALTERNATOR ASSEMBLY
Install

alternator

assembly

(8), then

partially

tighten

mounting bolt and nut (5).


2.

Fit belt (7) in pulley groove and install,

3.

Install adjustment

4.

Partially tighten bolt (4) of adjustment

5.

plate (6).

Insert a bar between


block,

raise alternator

alternator

plate.

assembly and cylinder

assembly and adjust tension of

belt.
+

The belt should deflect

about

15 mm when pushed

with a finger pressure of 6 kg at a point midway


tween the alternator
Tighten

bolt

be-

and the fan pulley.

of adjustment

plate,

mounting

bolt

and

nut.
Connect wires (3), (2) and (1).
Close cover, then lock with catch.
Connect cable to negative (-)

WA500- 1

terminal

of battery.

13-3
0

REMOVAL
1.
2.

OF OIL COOLER ASSEMBLY

Remove catch, then open engine left side cover.


Loosen drain valves (I),
t

If the coolant

(2) and drain cooling

contains

antifreeze,

water.

dispose of it cor-

rectly.
3.

Remove

connector

(3) between

oil

cooler

and water

pump.
4.

Remove muffler

5.

Disconnect

6.

Remove
sembly

drain tube (4).

turbocharger

mounting

drain tube

bolts

(6), then

(5).
remove

oil cooler

as-

(7).

INSTALLATION
OF OIL
COOLER ASSEMBLY
1.

Fit

gasket and set oil cooler

block

side, then tighten

2.

Fit gasket and connect

3.

Install muffler

4.

assembly

mounting
turbocharger

drain tube

Fit gasket and install

bolts

(7) on cylinder
(6).

drain tube

(5).

(4).

connector

(3) between

oil cooler

and water pump.


5.

Tighten

drain

valve

(I)

and

water filler to the specified


*

Run

the

system.
6.

engine

to

(2) and add water

circulate

the water

through

the

Then check the water level again.

Close engine left side cover and lock with

13-4
0

through

level.

catch.

WA500-

REMOVAL

OF FUEL INJECTION

1.

Remove three side covers of engine right hand.

2.

Disconnect

control

3.

Disconnect

fuel hoses (3). (4) and (5).

4.

Disconnect

fuel feed hose (6).

5.

Remove lubrification

6.

Disconnect

7.

Remove flange lock bolt

8.

rods (1) and (2).

tubes (7) and (8).

6 fuel injection

Remove 4 mounting
tion
*

PUMP

pump assembly
When removing

tubes (9).
(IO) of fuel injection

bolts

(11). then

pump.

pull out fuel injec-

(12).
fuel injection

pump

assembly

do not

lose the key.

INSTALLATION
OF FUEL
INJECTION
PUMP ASSEMBLY
1.

Set fuel
tighten
+

injection

pump

4 mounting

When

assembly

(12) in position,

and

bolts (11).

installing

fuel

injection

pump,

insert

key se-

curely.
2.

Tighten

lock bolts

(IO) of coupling.

3.

Connect

6 fuel injection

Sleeve nut:

tubes (9).

2.4 + 0.1 kgm

4.

Fit gaskets and install lubrication

5.

Fit gaskets and connect

fuel feed hose (6).

6.

Fit gaskets and connect

fuel hoses (5), (4) and (3).

7.

Connect
*
*

control

8.

rods (2) and (I).

To adjust

fuel cut solenoid,

JUSTING

FUEL

To adjust

fuel

ADJUSTING

tubes (8) and (7).

see TESTING

injection
FUEL

timing,

INJECTION

see TESTING
TIMING.

Install cover, close cover, then lock with

WA500-

AND

AD-

CUT SOLENOID.

catch.

AND

ASSEMBLY

REMOVAL
1.

OF WATER

PUMP

ASSEMBLY

Remove catch, then open side cover of engine left side.


Loosen drain valve (1). (2) and drain cooling water.

2.

If the coolant

contains antifreeze,

dispose of it cor-

rectly.
3.

Remove

alternator

ALTERNATOR

assembly

is see

REMOVAL

4.

Remove connector

5.

Disconnect connector

6.

Remove spring (5) and push up tube (6) with bar.

7.

Remove bolt (7) and remove pulley (8).

8.

OF

ASSEMBLY.
(3) between water pump and cooler.

Remove 4 mounting

(4) of water pump outlet tube.

bolts (9) and remove water pump

assembly (10).

INSTALLATION
OF WATER
PUMP ASSEMBLY
1.

Fit O-ring and install water

pump assembly

(lo),

then

tighten 4 bolts (9).


2.

Connect pulley (8) and tighten bolt (7).

3.

Push down tube (6) and install spring (5).

4.

Fit gasket and connect water pump outlet connector

5.

Fit

gasket

on

both

sides and connect

connector

(4).
(3)

between water pump and cooler.


6.

To install alternator
ALTERNATOR

7.

Tighten

assembly, see INSTALLATION

OF

ASSEMBLY.

drain valve (2). and (1) and add water through

water filler to the specified level.


*

Run the
system.

8.

engine to circulate

the water through

the

Then check the water level again.

Close side cover and lock with catch.

13-6
0

WASOO-

REMOVAL
Preparatory

OF NOZZLE

HOLDER

work

Remove side cover, exhaust pipe and hood.


*

Remove

cylinder

sembly,

muffler

head assembly,
assembly intake

cleaner assembly, then disconnect

nozzle

holder

connector

as-

and air

all nozzle holders

No. 1 to No. 6.
1.

Remove mounting

bolt (I) head cover, and remove head

cover.
2.

Disconnect fuel injection tube (3).

3.

Remove lock nut (4) and disconnect connection

4.

Disconnect bolt (6) and remove nozzle holder.

5.

Screw in forcing bolt @


1.5 mm)

to

nozzle

(Thread dia. 10 mm,

holder

and remove

nozzle

(5).

Pitch =
holder

assembly (8).
t

When removing the nozzle holder,

clean around the

nozzle holder and prevent dust or dirt from entering.


*

Checking gasket on the tip of nozzle holder fitting.

INSTALLATION
OF NOZZLE
HOLDER ASSEMBLY
*

Check that dirt and foreign matter are not in the sleeve
of nozzle holder.

Check that there is a gasket on the tip of nozzle holder


fitting.

*
1.

Check that there is no damage to O-ring.


Fit O-ring and install nozzle holder assembly (8). and fit
holder (7), then tighten bolt (6).
w

2.

Bolt:

6.75 +_0.75 kgm

Insert connection

(5) and tighten lock nut (4).

Connection:

Lock nut:

3.8 f 0.3 kgm


6.5 f 0.3 kgm

3.

Connect fuel injection tube (3).

4.

Fit gasket, install head cover (2) and tighten bolt (I).
m

5.

Bolt:

0.4 f 0.1 kgm

Install hood, exhaust muffler and side cover.

WA500-

ASSEMBLY

REMOVAL
Preparatory

OF TURBOCHARGER

work

Remove side cover, exhaust


*

ASSEMBLY

Remove

exhaust

assembly,

muffler

muffler

and hood.

assembly

see REMOVAL

OF

and air cleaner

CYLINDER

HEAD

ASSEMBLY.
1.

Disconnect

clamp

(I)

and disconnect

inlet

connector

(2).
2.
3.

Disconnect
Remove

supply

hose (3) and drain pipe (4).

mounting

turbocharger

bolt

assembly

(5) of turbocharger,

and remove

(6).

INSTALLATION
OF
TURBOCHARGER
ASSEMBLY
1.

Fit

gasket

tighten
*

3.

install

Mount

bolt:

Fit gasket, connect


Fit

turbocharger

mounting

Fit the gasket with

m
2.

and

turbocharger

O-ring

UP

bolt

assembly

(6), then

(5).

mark facing up.

6.75 f 0.75 kgm

drain pipe (4) and supply

and gasket,

install

inlet

hose (3).

connector

(2) and

clamp (I).
*

Install exhaust
For

details,

HEAD
4.

muffler
see

OF

CYLINDER

ASSEMBLY.

Install hood, exhaust

13-8
0

assembly.

INSTALLATION

pipe and side cover,

WA500-

REMOVAL

OF AIR COMPRESSOR

1.

of

Remove

catch

engine right side cover, then

ASSEMBLY

open

cover.
2.

Disconnect air tubes (I),

3.

Disconnect water tube (4).

4.

Remove lubrication

5.

Remove mounting

(2) and (3).

tubes (5) and (6).


bolts (7), then remove air compressor

assembly (8).

INSTALLATION
COMPRESSOR
1.

OF AIR
ASSEMBLY

Fit O-ring and install air compressor assembly (81, then


tighten mounting bolts (7).

2.

Fit gasket and install lubrication

3.

Fit gaskets and install water tubes (4).

4.

Fit gaskets and install air tubes (31, (2) and (I 1.

5.

tubes (6) and (5).

Close cover of engine right side cover, then lock with


catch.

WA500-

13-9
0

REMOVAL
1.

OF CYLINDER

HEAD

ASSEMBLY

Hood, side cover


1) Remove

exhaust

pipe

(I),

sling hood

(2), then

lift

off.
2) Remove left and right hand engine side cover.

2.

Draining

water

Loosen drain valve (3) and drain coolant.


*

If

the

coolant

contains

antifreeze,

dispose

of

it

correctly.

3.

Bracket
Disconnect

4.

cable bracket

(4).

Tube
Disconnect

5.

fuel control

muffler

Piping, corrosion
1) Disconnect

drain tube

(5).

resistor
piping

(6), then

remove

piping

(7) and

(8).
2) Remove corrosion

13-10
0

resistor assembly

(9).

WA500-

6.

Muffler

assembly

1) Disconnect komaclone

pipe at flange (10) end.

2) Remove bracket mounting bolts (11).


3) Remove elbow (12) mounting bolts.
4) Remove

muffler

assembly

(13),

then sling muffler,

bracket and connector as one unit.

el

Muffler assembly:

kg

7.

50 kg

Switch, hose
1) Disconnect

wire

(15).

then

remove

electrical

air

intake heater switch assembly (14).


2) Disconnect komaclone

8.

intermediate

hose (16).

Compressor tube
Remove tube (17) between air cleaner and compressor.
*

9.

Remove two clamps.

Connector assembly
1) Remove clamp (18).
2) Remove

mounting

connector

bolts

(19)

then

remove

(20).

3) Remove electrical air intake heater (21).

WA500-

intake

,,,

10. Air cleaner assembly


1) Remove air cleaner mounting band.
2) Remove

intake

connector

bracket

mounting

bolts

(22).
3) Remove

air cleaner

cleaner and intake


m

11.

assembly

(231, then

sling air

connector as one unit.

Air cleaner assembly:

35 kg

,, ,,,,,

Intake manifold
Remove

mounting

bolts

(24),

then

remove

intake

manifold assembly (25).

12.

Fuel injection tube, fuel spill tube


1) Remove 6 fuel injection tubes (26).
2) Remove spill tubes (27).

13.

Turbocharger
Disconnect

piping
turbocharger

oil

supply

hose

(28)

and

drain pipe (29).

13-12
0

WA500-

14, Turbocharger,
1) Remove

exhaust manifold
mounting

assembly

bolts of exhaust

manifold

(30)

and remove remaining bolts.

Then

with 2 - 3 bolts remaining.


2) Sling turbocharger

remove turbocharger

and exhaust manifold

assembly

(31) as one unit.


Turbocharger,

6 kg

exhaust manifold

assembly:
40 kg

15. Overflow

tube

Remove overflow tube (32).


16. Head cover
Remove

mounting

bolts

(33) then remove head cover

(34).

17.

Rocker arm assembly


Remove

mounting

bolts (35) then remove rocker arm

assembly (36).
*

When install rocker arm, turn the adjustment

screw

back 2 - 3 times to prevent strain on the push rod.

18.

Retainer
Remove mounting bolts (37), then remove retainer (38).

19. Connection
Loosen lock nut (39), then remove connection
pull out.

WA500-

(40) and

20.

Nozzle holder
Using bolt @

(Thread dia. = 10 mm,

Pitch = 1.5 mm),

remove nozzle holder (41).


*

Check that there

is a gasket fitted to the tip of the

nozzle holder.
21.

Push rod
Remove push rod (42).

22.

Rocker arm housing


Remove

mounting

bolts (43) then remove rocker arm

housing (44).
23.

Crosshead
Remove crosshead (45).

24.

Cylinder head assembly


1) Remove

mounting

bolts

(46) then remove cylinder

head assembly (47).


2) Remove gasket (48).

WA500-

INSTALLATION

OF CYLINDER

HEAD

ASSEMBLY

Special tool

I
I

A
1.

Part No.

Part name

795-125-1210

Oty

Feeler gauge

Cylinder head assembly


1) Make sure the mounting

surface of cylinder head and

the inside of cylinders are free from dust and foreign


matter,

and place cylinder

head gasket (48) in posi-

tion.
*

Check that there

is no dirt or foreign

matter on

the surface of cylinder.


*

When installing the gasket, make sure the grommet


is not loose.

Fit the gasket with TOP

2) Install

cylinder

head

mark facing up.

assembly

(47)

and

tighten

mounting bolt (46).


&

Coat the threads and lower side of the bolt


head before

tightening

with lubricant
*

First screw in the


revolutions

by

the mounting

bolts

(LM-P).
mounting

hand,

then

bolts two or three


tighten

the

bolts as

follows.
*

Tighten the bolts in the order shown.

Cylinder head mountint

bolts.
Unit:

Bolt
No.

Order

Target

1st step

15

2nd step

22

Range
14-16
21.5 - 22.5

Mark the bolts and the cylinder

head with a felt-tip


3rd step

1 4th steo

7
2.

kgm

pen, and turn

the bolts with following

90

6.75

degrees.

75O -

105O

6.0-7.5

Crosshead
Install crosshead (45).
*

Adjust crosshead according to following

steps:

i) Loosen lock nut and tighten adjusting screw.


ii)

Hold upper face of crosshead lightly and screw in


adjusting screw.

iii)

After

adjusting

screw comes into contact

valve stem, screw in an additional


iv)

Tighten lock nut at this position.


w

WA500-

Lock nut:

6 ? 0.6 kgm

20.

with

425F253

3.

Rocker arm housing


Fit

gasket

and install

rocker

arm housing

(44).

then

tighten mounting bolts (43).


w
*

Mounting bolt:

IO + 0.5 kgm

Loosen lock nuts of adjustment


each adjustment

screw 2 -

screws, then loosen

3 turns to avoid excessive

pressure being brought to bear on the push rods when


installing the rocker arm.

4.

Push rod
Install push rods (42).
*

Check that the push rod is properly fitted in the cam


follower.

5.

Nozzle holder
*

Check that there is no dirt or foreign matter

inside

nozzle holder sleeve.


*

Check that there

is a gasket fitted to the tip of the

nozzle holder.
Align

mounting

hole of nozzle holder connection

and

insert nozzle holder (41).

6.

Connection
Tighten connection
w

Connection:

Lock nut:

13i6

(40) then lock with lock nut (39).


3.8 + 0.3 kgm
6.5 ?r 0.5 kgm

WA500-

7.

Holder
Fit holder

(38).

then

fit

spherical

washer to mounting

bolts (37) and tighten.


*

Set one side of holder

on head of mounting

bolt

of

rocker arm housing and tighten.

8.

Rocker

lever assembly

Assemble

rocker

lever assembly

(36) and tighten

mount-

ing bolts (35).


*

Check

that

completely

9.

Adjustment
Using tool

round

part

inserted

the

adjusting

screw

is

of valve clearance
A, adjust valve clearance.

For details, see ADJUSTING

10.

of

into the push rod socket.

VALVE

CLEARANCE.

Head cover
Fit O-ring and install
mounting
m

WA500-

head cover

(34) then tighten

bolts (33).
Mounting.

bolt:

0.5 + 0.1 kgm

with

11. Overflow tube


Fit gasket and install overflow tube (32).
m

Joint bolt:

12. Turbocharger,
Fit

gasket

6.75 f 0.75 kgm

exhaust manifold assembly


and

assembly (31)

sling turbocharger,

(30).
* Fit the gasket with the OUT
*

The tightening
tighten

exhaust

as one unit, then tighten

procedure

mounting

manifold

mounting

bolts

mark facing out side.

of exhaust

bolts from

manifold

is to

inner to outer,

alter-

nately and evenly.


m

Mounting bolt:

13. Turbocharger

6.75 f 0.75 kgm

piping

Fit O-ring and connect drain pipe (29) and supply hose
(28).

14.

Fuel spill tube, fuel spill pipe


1) Fit gasket, and install fuel spill tube (27).
w

Joint bolt:

1.15 f 0.15 kgm

2) Install 6 fuel injection tubes (26).


w

15.

Sleeve nut:

2.4*

0.1 kgm

Intake manifold
Fit gaskets.and set intake manifold

assembly (25), then

tighten mounting bolt (24).


*

The tightening
tighten

procedure

mounting

of exhaust manifold

bolts from

inner to outer,

is to
alter-

nately and evenly.


m

Mounting bolt:

13d8

6.75 + 0.75 kgm

WA500-

16. Air cleaner assembly


1) Sling air cleaner

and intake

connector

as one unit,

then install air cleaner assembly (23).


2) Tighten

intake

connector

bracket

(22).
3) Secure air cleaner mounting

17. Connector

mounting

bolts

band.

assembly

1) Fit gaskets and install electrical air intake heater (21).


2) Fit gaskets and O-ring then install intake connector
(20) and tighten mounting bolts (19).
3) Install clamp (18).

18. Compressor tube


Fit

gaskets and install

between

air cleaner

and com-

pressor tube (17).

Install clmaps at 2 points.

19. Hose, switch


1) Connect komaclone
2) Connect

wire

(Is),

intermediate
then

heater switch assembly (14).

WA500-

hose (16).

install electrical

air intake

20.

Muffler
1) Sling

assembly
muffler,

bracket

and connector

as one unit,

then install muffler assembly (13).


2) Tighten elbow mounting bolts (12).
3) Tighten bracket mounting bolts (11).
4) Connect komaclone

21.

pipe at flange (IO) end.

Corrosion resistor, piping


1) Install corrosion resistor assembly (8).
2) Fit gaskets and connect pipes (8), (7) and (6).

22. Tube
Connect muffler drain tube (5).
23.

Bracket
Connect fuel control cable bracket (4).

24.

Refilling with water


Tighten

radiator

drain valve (3) and add water through

water filler to the specified level.


+

Run the engine to circulate


system.

25.

the water

through

the

Then check the water level again.

Side cover, hood


1) Install engine left and right side cover.
2) Install hood (2) and exhaust pipe (I ).

3620

WA500-

REMOVAL
Stop

OF RADIATOR

the

machine

on level ground

safety bar on the frame.

ground and stop the engine.


brake

and put blocks

and install the

Lower the bucket

to the

Then apply the parking

under the wheels to prevent

the machine from moving.

Q!

Loosen the oil filler


sure inside the
control

cap slowly to release the pres-

hydraulic

pressure in the hydraulic


*

tank.

Then

operate

the

levers several times to release the remaining


piping.

Loosen plugs (1) and (2) at the top of the hydraulic tank
filter,

and

plugs (3) and (4) of the

pump

piping to

prevent the oil inside the tank from flowing out.


1.

Draining water
Loosen drain valve (5) and drain coolant.
*

If

the

coolant

contains

antifreeze,

dispose

of

it

correctly.
- :

2.

Coolant:

80 Q

Cover
Remove engine hood (6), side hood (7) and grille.
& kg

Engine hood:
Side hood:

3.

60 kg

42 kg

Radiator guard
Remove radiator guard (8), then lift it off.
*

Be careful

not to hit the radiator

when

lifting

off

the radiator guard.


*

Disconnect wiring from connector.


Radiator guard

WA500-

: 84 kg

13-21
0

4.

Fan guard, support


1) Remove radiator support (9).
2) Remove fan guard (10) from the radiator.
+

5.

Remove the clamp of hose (11).

Radiator hose
Disconnect

radiator

hoses (12) and (13) at the engine

end.
*

Loosen radiator and clamp at engine end, and remove


tube (14) when removing radiator.

6.

Cooler piping
1) Disconnect

hydraulic

oil cooler hoses (15) and (16)

from the radiator.


2) Disconnect

torque

converter

hoses (17)

and

(18)

from the radiator.

7.

Radiator
Sling radiator

(19), remove mounting

bolts, then lift off

radiator.
*

Disconnect

coolant

level sensor

wiring

from

con-

nector.
*

Sling

radiator

and lift off while moving the radiator

to the rear.
*

Be careful so that fan does not interfere with radiator


core.
Radiator:

285 kgm

WA500-

INSTALLATION
1.

OF RADIATOR

Radiator
Raise radiator

(19), set in mounting

position and install

mounting bolts.
+

Tighten

the

mounting

bolts partially,

then

tighten

them fully after installing the support.


8

Connect coolant level sensor wiring to connector.

Mounting bolts:

56 + 6 kgm
(width across flats:

30 mm)

425P275

2.

Cooler piping
1) Connect

torque

converter

cooler

pipings

(17)

and

(18) to radiator.
m

Cooler hose: 20 + 5 kgm


(Width across flats:

2) Connect hydraulic

41 mm)

oil cooler pipings (15) and (16) to

radiator.
N

Cooler hose: 20 * 5 kgm


(Width across flats:

3.

41 mm)

Radiator hose
Connect radiator hoses (12) and (13) to engine.

4.

Install the clmap properly.

Set the tube (14) in position, then tighten clamp.

Fan guard, support


1) Install fan guard (IO) to radiator.
*

Install

so that

the

clearances

between

the

fan

and fan guard at the left and right, and top and
bottom are the same.
*

Install clamp of hose (1 1).

2) Install radiator support (9) to radiator.


*

Tighten the radiator mounting bolt.

WA500- 1

&!
I
*i:
g;.

5.

Radiator guard

II

.Qrt radiator guard (8) in mounting

position and tighten

mounting bolts.
*

Connect wiring to connector.

Install the radiator guard without


Install

so that

interference.

the clearances between

the radiator

guard and radiator at the left and right are the same.

4 .25P269

6.

Hood
Install engine hood (6), side hood (7) and grille.

7.

Refilling with oil, water


1) Tighten drain valve and add water through water filler
to the specified level.
-

Coolant:

2) Tighten

80 !J

plug at the top of hydraulic

tank filter and

plug of pump piping, then add hydraulic

oil through

oil filler to the specified level.


m

Plug at the top of hydraulic tank filter:


1.2 kO.1 kg

3) Add transmission oil through oil filler to the specified


level.

Run

the

engine

to

circulate

the oil and water

through the system.


Then, check the oil and water levels again.

13Gf4

WA500-

REMOVAL

OF ENGINE

Stop the

machine

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
*&

Loosen the oil filler cap slowly to release the pres-

sure inside the hydraulic


control

pressure in the hydraulic


*

tank.

Then operate

the

levers several times to release the remaining


piping.

Loosen plugs (I) and (2) at the top of the hydraulic tank
filter,

and the plugs (3) and (4) of the pump piping to

prevent the oil inside the tank from flowing out.


*

Disconnect

the cable from the negative (-)

terminal

of the battery.
1.

Draining water
Loosen drain valve (5) and drain coolant.
*

If

the

coolant

contains

antifreeze,

dispose

of

it

correctly.
- :

2.

Coolant:

80 !2

Hood
1) Remove side panel (61, (7) and (8) and grille.
*

Remove left and right hand side panel.

2) Raise engine hood (IO) side hood (9), then lift it off.
FYIkg

Engine hood:
Side hood:

WA500-

60 kg

42 kg

13-25
a

3.

I 1

Radiator guard
Raise radiator

guard (1 I), then lift it off.

not to hit the radiator

Be careful
radiator

when lifting

off the

guard.

Disconnect

electric

Radiator

wiring

guard:

from

connector.

85 kg

425P280

4.

Fan guard, support


1) Remove radiator

support

(12).

2) Remove fan guard (13) from the radiator.


*

5.

Remove clamp of hose (14).

Radiator

hose

Disconnect

radiator

hoses (15) and

(16) at the engine

end.
*

Loosen clamps of hose (15) at the radiator

Loosen

clamp

when removing

6.

Cooler

at engine

end, and remove

end.
tube

(17)

radiator.

piping

1) Disconnect

hydraulic

oil cooler

hoses (18) and (19)

from the radiator.


2) Disconnect

torque

converter

hoses

(20)

and

(21)

from the radiator.

13-26
0

WA500-

7.

Radiator
Sling radiator
radiator
+

(22), remove mounting

bolts, then lift off

(22).

Disconnect

coolant

level

sensor wiring

from

the

connector.
*

Sling radiator

and lift off while moving the radiator

to the rear.
*

Be careful so that fan does not interfere

with radia-

tor core.
Radiator:

8.

285 kg

Wiring

I) Disconnect starting motor wiring (23).


2) Disconnect main breaker wiring (24).
3) Disconnect wiring of engine (25).
4) Disconnect ground connector
*

After

removing

the

(26) and (27).

wirings,

mark

with

tags to

distinguish when installing.

9.

Fuel hose
Disconnect fuel hoses (28),

(29) and (30) from the fuel

tank.

10.

Fuel control cable


Disconnect fuel control

cable (31) from the bracket and

lever.
*

After disconnecting,

WA500-

move cable to front.

13-27
0

2) Sling air cleaner (39), remove it.


*

An O-ring is inserted at the connecting


the

air cleaner

and turbocharger

portion of

so be careful

when removing.
Air cleaner:

&I kg

15.

32 kg

Brake chamber
1) Disconnect air piping (41), oil piping (42) and electrical wiring (43) from chamber.

2) Remove brake chamber (44).

16. Engine
1) Disconnect
end.

WA500-

greasing hose (45) for damper at damper

2) Disconnect
*

Make

drive shaft (46) from


match

marks

before

engine.

disconnecting

the cou-

pling.

3) Temporarily

sling engine,

then

ing bolts and rear mounting


+

Remove

the bracket

from

side and loosen mounting

remove

front

mount-

bolts.
the engine on the front
bolts of bracket.

4) Sling engine (47) and remove it.


Engine:

13-30
0

1,450 kg

WA500-

INSTALLATION
1.

OF ENGINE

Engine
1) Sling engine (47), and set in mounting position.
*

When installing rubber, coat with water or rubber


grease, then install.

Do not use other than specifi-

ed coating.
2) Tighten front and rear mounting bolts.
*

Install front bracket of engine then tighten bracket


mounting

bolts.

Rear mounting

bolt:

95 f 10 kgm

(Width across flats:


Front bracket mounting
Front mounting bolt:
*

Tighten
between

the mounting
the

engine

bolt:

36 mm)

28.5 * 3 kgm

39 + 3.5 kgm

bolts so that clearance


damper

and the

trunnion

support is the standard value.


Clearance a: 3 - 7 mm

,a

ilil425FO1012

3) Align match marks and install drive shaft to engine.


w
*

Mounting

When connecting

bolt:

11.5 + 1 kgm

the drive shaft, clean the contact

surfaces of the spider and coupling.

4) Connect greasing hose for damper (45) to damper.


*

Connect the hose without

WA500-1

twisting.

2.

Brake chamber

I) Set brake chamber (44) and install mounting

2) Connect
wiring

3.

air piping

(41), oil piping

position.

(42) and electrical

(43) to chamber.

Air cleaner
1) Sling air cleaner
then tighten
*

Be careful

2) Connect

(39),

mounting

and set in mounting

not to damage O-ring

air intake

position,

bolt.

port

(38),

then

(40).

install

tube

(36)

and hose (37).

13-32
0

WA500- 1

4.

Muffler
Sling muffler

(35),

and set in mounting

position, then

tighten mounting bolt.

5.

Drain valve
Connect engine oil drain valve (34) to fuel tank.

6.

Air piping
Connect air pipings (32) and (33).
*

7.

Check the air leakage from connection

of piping.

Fuel control cable


Connect fuel control cable (31) to the lever and bracket.
*

For adjustment
ING

WA500-

AND

of length of cable, refer to 12 TEST-

ADJUSTING.

13-33
0

8.

Fuel hoses
Connect fuel hoses (28), (29) and (30) to the fuel tank.

9.

Wiring
1) Connect ground connection

(26) and (27).

2) Connect wiring of engine (25).


3) Connect main breaker wiring (24).
4) Connect starting motor wiring (23).
*

IO.

Install clamps of wiring.

Radiator
Set radiator

(22)

in mounting

position,

then tighten

bolts partially,

then tighten

mounting bolts.
*

Tighten

the mounting

them fully after installing the support.


*

Connect wiring of coolant level sensor to connector.

Mounting bolts:

56 + 6

kgm

(Width across flats:

30 mm)

11. Cooler piping


1) Connect

torque

converter

hoses (20)

and

(21)

to

radiator.
m

Cooler hose nut:

20 + 5 kgm
(Width across flats:

2) Connect

hydraulic

41 mm)

oil cooler hoses (18) and (19) to

radiator.
m

Cooler hose nut:

20 * 5 kgm
(Width across flats:

13-34
0

41 mm)

WA500-

12. Radiator

hose

Connect radiator hoses (15) and (16) to engine.

13.

Tighten clamps securely.

Set the tube (17) in position, then tighten clamp.

Fan guard, support


1) Install fan guard (13) to radiator.
*

Install

so that

the clearances between

and fan at the circumference


*

fan guard

are the same.

Install clamp of hose (14).

2) Install radiator support (12).


*

14.

Tighten radiator mounting bolts.

Radiator guard
Set radiator guard (11) in mounting position, then tighten mounting bolts.
*
*

Connect wiring to connector.


Install so that clearances between radiator

guard and

radiator at the left and right are the same.

425P280

15.

Hood
1) Set engine hood (10) and side hood (9) in mounting
position, then tighten mounting bolts.

WASOO-

2) Install side panel (6). (7) and (8) and grille.

16.

Refilling with oil, water


1) Tighten

the

drain

valve and

add

coolant

through

water filler to the specified level.

G
2) Tighten

Coolant:

80 II

plug and add engine oil through the oil filler

to the specified level.


N

Plug at the top of filter:

1.2 f 0.1 kgm

3) Add transmission oil through oil filler to the specified


level.
*

Run

the

engine

to

circulate

the

oil and water

through the system.


Then check the oil and water levels again.
4) Bleeding air from brakes.
*

For details of bleeding air, see 52 TESTING

AND

ADJUSTING.

WA500-

REMOVAL

OF FUEL TANK

Stop the

machine

on level ground and install the

safety bar on the frame.


ground and stop the engine.

Lower the bucket to the


Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.

1.

Draining fuel
Loosen drain valve (1) and drain fuel.
b

&

2.

Fuel:

4359

Drain valve
Remove engine oil drain valve (2) from the fuel tank.

3.

Fuel hose, wiring

1) Disconnect fuel hoses (3). (4) and (5) from the fuel
tank.
t

Remove remote grease clamps from the fuel tank.

2) Disconnect wiring (6) of fuel unit from theconnector.


*

4.

Remove hoses (7) and (8) from clamps.

Fuel tank

1) Sling fuel tank (9), remove mounting bolts, then lift


off fuel tank.
*

Lay a pallet below the fuel tank,

keep the tank

balanced and lower slowly.


Fuel tank:

kg
C?z

330 kg

2) Remove breather tube (IO), and pull the fuel tank


out from under machine.
*

There

is a limitation

on height so be careful that

fuel tank does not interfere with frame.

WA500-

INSTALLATION
1.

OF FUEL TANK

Fuel tank
1) Set fuel tank on pallet, then push into lower mounting position and install breather tube (IO).

2) Raise fuel tank

(9), set in mounting

position, then

tighten mounting bolts.


*

When raising the tank,

keep it horizontal

and set

in the mounting position.


*

Tighten the mounting bolts in the following

order:

Left + rear + right.


w

Mounting bolt:

95 + 10 kgm
(Width across flats:

2.

36 mm)

Fuel tubes, wiring, clamp


1) Connect wiring (6) for fuel unit to connector.
*

Install hoses (7) and (8) to fuel tank.

2) Connect fuel hoses (3), (4) and (5) to fuel tank.


*

3.

Install remote grease clamp to fuel tank.

Drain valve
Install engine oil drain valve (2) to the fuel tank.

4.

Refilling with fuel


Tighten

the drain valve fuel tank and add fuel through

fuel filler.

Ii8

Fuel:

435 R

425P832
---,

13Z8

WA500-

14

ENGINE
MAINTENANCE

STANDARD

Engine mount .

WA500-

.... ....

. . . . . . . . . . . . 14-2

14-1

ENGINE

MOUNT

Section A - A

Section B - B

425F131

Unit:

Remedy

Criteria

Check item

No.

Clearance between engine damper


and trunnion support

Tightening torque of bolt

94.5 * 10.5 kgm

Tighrening torque of bolt

39.25 i 4.25 kgm

3.0 - 7.0

Adjust

Retighten

14-2

WA500-

mm

20

POWER TRAIN

POWER TRAIN
21 STRUCTURE

AND

FUNCTION

General ................................
.
. Hydraulic circuit for power train ........
.
- Hydraulic circuit diagram for power train
Damper ................................
.
Torque converter and transmission piping . .
Torque converter charging pump .........
.
Torque converter oil cooler. ..............
.
Torque converter oil filter ................
Torque converter .......................
Transmission mount .......
.,............
Torque converter relief valve .............
Transmission ...........................
Transmission control valve ..............
.
Upper valve ........................
..
Lower valve ........................
.
Transmission solenoid valve ..........
.
Emergency manual spool ............
.
Priority valve ........................
..
Modulating valve and quick return valve . .
Accumulator valve ..................
..
Pilot reducing valve ..................
.
. Main relief valve .....................
Reducing valve. .....................
.
Lubrication bypass valve .............
.
Pilot oil filter. . . . .
Transfer . . . .
. ..
. .
Drive shaft
.. . .
.. .
.. .. ..
Center support . . . . . .
Axle mount
...
..
.. .. .
Axle and differential
.
.. .. .
.. .
Final drive . . . . . .
..
Tire and wheel.
_
.
.

WA500-

21- 2
21- 4
21- 5
21- 6
21- 8
21- 9
21-10
21-11
21-12
21-14
21-15
21-16
21-24
21-26
21-27
21-28
21-2s
21-32
21-33
21-36
21-38
21-39
21-40
21-41
21-42
21-43
21-44
21-45
21-46
21-48
21-53
21-54

21-1

GENERAL

16

24

421FOO3

OUTLINE
.

The power from engine (1) is transmitted


flywheel
damper

to damper

alleviates the torsional

the variation

vibration

The

caused by

of the engine torque and transmits the

power to torque
(24).

from the

(2) through the ring gear.

converter

The torque

converter

(6) through

drive shaft

converts the delivered

torque according to the variation

in load on the oil

The output

shaft of transmission

power to the output


the gears.
transfer

(7) transmits the

shaft of transfer

(8) through

The power from the output shaft of the

is transmitted

to both the

front axle and

the rear axle.


The power transmitted

to front axle and rear axle is

reduced through pinion and ring gears in differential

used as the medium, and transmits the power to the

(13) and (19), and is transmitted

input shaft of transmission

The power from the axle shafts is reduced through

(7).

Then, the engine

to the axle shafts.

power is transmitted

to POC pump (3) and steering

final

pump

pump

(12) and (21) through the planetary carrier.

(4), hydraulic

and torque

converter

the

driving

pump

(5). switch pump (22),

charging pump

gear in torque

drive

(10)

and (18) and transmitted

to tires

(23) through
converter

(6),

thereby driving the pumps.

In transmission

(7), the six hydraulically-operated

clutches are operated


and the

valves, which
valves.
ed from

by the forward-reverse

spool

speed change spools in the transmission


are themselves activated

by solenoid

Thus, the desired travel speed can be selectamoung the 4 forward

and 4 reverse gear

speeds.

21-2

WA500-

425FOO6

WA500- 1

1.

Engine (S6D140)

2.

Damper

9.

Parking brake

17.

Rear drive shaft

IO.

Front final drive

18.

Rear final drive

1 I.

Front brake

19.

Rear differential
Rear brake

3.

POCpump

4.

Steering pump

12.

Front wheel

20.

5.

Hydraulic pump

13.

Front differential

21.

Rear wheel

6.

Torque converter

14.

Front drive shaft

22.

Switch pump

7.

Transmission

15.

Center support

23.

Torque converter charging Pump

8.

Transfer

16.

Center drive shaft

24.

Upper drive shaft

21-3

HYDRAULIC

Engine

running,

CIRCUIT

gear shift

* Serial No. 10001


* Serial No. 10001

FOR POWER TRAIN

levers at Neutral.

10186

(Except

D spec.)

and up (D spec.)

27

28

29

31

32

30

c
c

c--

r=
425F503

WA500-1

.
*

HYDRAULIC
Serial

No.

CIRCUIT

10081

* Serial No. 10001

10186

DIAGRAM

(Except

FOR POWER TRAIN

D spec.)

and up (D spec.)

;
5!.!_?_
4

__J

!O kg/cm

M
m

F425CO1003A
1. Transmission case

12.

Oil cooler

23.

I St spool

2.

Strainer

13.

Transmission lubrication relief valve

24.

Emergency manual spool

3.

Torque converter charging pump

14.

Transmission lubrication

25.

Solenoid valve

4.

Oil filter

I 5.

Main relief valve

26.

Accumulator

5.

Priority valve

16.

Lubrication bypass valve

27.

Reverse clutch

6.

Modulating valve

17.

Reducing valve

28.

Forward clutch

7.

Quick return valve

18.

Reverse spool

29.

4th clutch

8.

Pilot oil filter

19.

Forward spool

30.

3rd clutch

9.

Pilot reducing valve

20.

4th spool

31.

2nd clutch

I 0.

Torque converter relief valve

21.

3rd spool

32.

I st clutch

II.

Torque converter

22.

2nd spool

WA500- 1

valve

2&5

Engine running

gear shift levers at Neutral

* Serial No. 10187 and up (Except

D spec.)

F42501006

22-1

WA500- 1

- Serial No. 10187 and up (Except

Dspec.)

27kg,cm2i----_________~
022,3kg/cm2

Min.
_----_

_N i

j 1 0.8kg/cm2

L_____l

7
M

A
-2

1
1. Transmission

case

F425M 1004

12.

Torque converter

23.

2nd spool

2.

Strainer

13.

Oil cooler (water cooled type)

24.

1st spool

3.

Torque converter charging pump

14.

Oil cooler (air cooled type)

25.

Emergency manual spool

4.

Oil filter

15.

Transmission lubrication relief valve

26.

Solenoid valve

5.

Priority valve

16.

Transmission lubrication

27.

REVERSE

6.

Modulating valve

17.

Lubrication bypass valve

28.

FORWARD

7.

Quick return valve

18.

Reducing valve

29.

4th clutch

8.

Pilot oil filter

19.

REVERSE

9.

Pilot reducing valve

20.

FORWARD

10.

Main relief valve

21.

11.

1 orque converter relief valve

22.

spool

clutch

30.

3rd clutch

31.

2nd clutch

4th spool

32.

1st clutch

3rd spool

33.

Accumulator

spool

clutch

valve

Czoo-1
2z2

DAMPER
-

Serial No. 10001 -

10809

Section A - A

425FOll

21-6
0

FUNCTION

1.

Coupling

2.

Output shaft

3.

Cover

4.

Bearing

to protect

5.

Bearing

twisting and vibration.

6.

Outer body

7.

Rubber cushion

8.

Inner body

The

damper

reduces

the

caused by the variations


the

twisting

and

in engine torque,

engine and other

vibration
and acts

parts from

WA500- 1

such

.A..

Serial

No.

10810

and up

AI

i
Section

A - A
425FO1103

1. Coupling
2. Output

shaft

3.

cover

4.

Bearing

5.

Bearing

Outer body

7.

Rubber cushion

8.

Inner body

WA500-1

2&7

OPERATION

-l

No load applied

Engine torque

Path of power transmission

Engine torque applied


421 FOlO

The

engine power

is transmitted

to the flywheel

and outer body (6) and rubber cushion (7) absorbs


the twisint

and vibration

of the enigne.

The engine

power is then transmitted

through inner body (8) to

output

here, the engine power is

shaft (2).

transmitted

From

through

the

coupling

to

the

torque

converter and drive shaft.

2ic-1

WA500-1

TORQUE
*

Serial

No.

CONVERTER

10001

- Serial No. 10001

10186

(Except

AND

TRANSMISSION

PIPING

D spec.)

and up (D spec.)

425FOlO

21-8
8

1.

Transmission

5.

Torque converter charging pump

2.

Lubrication bypass valve

6.

Radiator

3.

Transmission control valve

7.

Oil cooler

4.

Torque converter

8.

Torque converter oil filter

WA500-

Serial

No.

10187

and up (Except

D spec.)

F42501007

1.

Transmission

2.

Lubrication bypass valve

3.

Transmission control valve

4.

Torque converter

5.

Torque converter charging pump

6.

Radiator

7.

Torque converter oil cooler (Air-cooled type)

8.

Torque converter oil cooler (Water-cooled

9.

Torque converter oil filter

WA500-1

type)

2iY

TORQUE

CONVERTER

The torque

converter

CHARGING

charging pump is installed to

PUMP

The torque
the

converter
bottom

charging

pump

the torque converter case. It is driven by the motive

from

of the transfer

force from the engine and supplies oil to the torque

strainer and sends oil to the oil filter.

sucks in oil

case through

converter and transmission system.

Section A - A
425FO12

1.

Drive gear (Teeth 12)

2.

Front cover

3.

Gear case

4.

Rear cover

5.

Driven gear (Teeth 12)

WA500-

Specifications:
Model

Theoretical

SAR(3)-080
discharge:

80 cc/rev

Max. pressure:

210 kg/cm2

Max. pump speed:

2,500 rpm

21-9

TORQUE
*

CONVERTER

Serial No. 10001 -

10186

OIL COOLER

(Except D spec.)

- Serial No. 10001 and up (D spec.)


OUTLINE
The oii which comes out from the torque converter
outlet

port is at a high temperature

Energy used in transmitting


torque

converter

D and enters the oil cooler.


port

This

oil passes through oil cooler port

engine cooling water.


oil outlet

because of the

the motive force.

Here it is cooled by the

The oil then flows out from

C, lubricates

the transmission

and

returns to the transmission case.

/p/y- ---I\,
A

1
C

425FO45

1.

Radiator

A.

Hydraulic oil outlet port

2.

Torque converter oil cooler

6.

Hydraulic oil inlet port

3.

Hydraulic oil cooler

C.

Torque converter oil outlet port

D. Torque converter oil inlet port

WA500-1

Serial No. 10187 and up (Except

D spec.)

OUTLINE
.

The

oil leaving

perature.

This

the torque
oil enters

converter

is at high tem-

pot-t D of the water-cooled

oil cooler and is cooled by the engine cooling water.


It is then discharged from port C, and enters port E
of the air-cooled

oil cooler.

cates the transmission

From port F, it lubri-

and returns to the transmis-

sion case.

View Z

F42501008

F42501009

1.

Radiator

2.

Torque converter

3.

Hydraulic

4.

Torque converter

oil cooler (Water-cooled

oil cooler (Water-cooled

WA500-1

type)

type)

oil cooler (Air-cooled

type)

A.

Hydraulic

oil outlet port

B.

Hydraulic

oil inlet port

C.

Torque converter oil outlet port

D. Torque converter oil inlet port


E.

Torque converter oil inlet port

F.

Torque converter oil outlet port

21
-GO-

TORQUE

CONVERTER

OIL FILTER

Relief valve
Element
Center bolt
Drain plug

Filtration

area:

8,900 cm2

Relief pressure: 3.25 kg/cm2

L-...

__

SectionA-A

-J

425FO13

View 2

&&

To transmission
control valve

OPERATION
.

The

oil from the torque

converter

charging pump

(5) enters the filter inlet port A and passes from the
outside of element

(2) to the inside.

It then flows

to the outlet port B.

423FOlO

To transmission
control valve

If the element
temperature

(2) is clogged with

dirt,

or the oil

is low, the pressure at the inlet port A

rises. When this happens, the oil from the inlet port
A opens relief valve (I)
outlet

and flows directly

to the

port B. This prevents damage to the pump or

element (2).

423FOll

WA500- 1

21-11

TORQUE

CONVERTER

.2

1-

425FO14

-A
1. Mount of switch pump

/*

_.--9

2.

Mount of POC and steering pump

3.

Mount of torque converter charging pump

4.

Mount of hydraulic pump

5.

Drive case

6.

Turbine

7.

Housing

6.

Pump

9.

Stator

10.

Transmission input shaft

11.

PTO gear (drive)

A.

Inlet port

B.

Outlet port

Specifications
Model:

TCA40-1 A

Type:

3-element,

Stall torque ratio:

single stage, single phase


3.22

425FO15-1
Section

2122

X-X

WA500-

Flow of motive force

The

torque

damper

converter

is installed

and transmission.

between

the

The motive force from

the damper passes through the drive shaft and enters


drive case (5).
gear (drive)

Drive case (51, pump (8) and PTO

(11)

are fixed

with

bolts.

They

are

rotated directly by the rotation of the engine.


The

motive

turbine

froce

(6).

of pump

(8) uses oil to rotate

This transmits

motive force to trans-

mission input shaft (10).

The motive force of drive case (5) passes through


PTO gear (drive) (11) and is also used as the motive
rransmission

force to drive the gear pump.

425FO16
Flow of oil

The oil pressure is adjusted by the torque converter


relief

valve and then

enters inlet

port

A,

passes

through the oil passage in housing (7) and flows to


pump (8).

In pump (8) centrifugal

The oil enters turbine


is transmitted
Turbine

force is applied.

(6) and the energy of the oil

to the turbine.

(6) is fixed to transmission input shaft (IO),

so the motive force is transmitted

to the transmis-

sion input shaft (10).


The oil from

turbine

again enters the


passes from

(6) is sent to stator

pump.

However,

the stator through

(9) and

part of the oil

outlet

port B and

is sent to the cooler.

425FO17

WA500-

21-13

TRANSMISSION

MOUNT

Section A - A

Section B - B

425FOO9

View 2

1.

Torque converter

2.

Transmission

3.

Transmission mount

OUTLINE
.

The transmission

is mounted

separately

from the

engine.

To

position

the

transmission

on the engine, the

front mount can be adjusted with shims.

Both front

and rear have rubber mounts.

21-14

WA500- 1

TORQUE

CONVERTER

RELIEF VALVE

FUNCTION
.

The torque

converter

relief valve acts to maintain

the pressure of the oil entering the torque converter


at a constant

pressure.

To each

transmissionspool

It drains the oil if it goes

above the specified pressure.

OPERATION
.

The oil from the pump passes through main relief


It then enters port A and flows to the

valve (1).

torque converter.

lubrication

425FO42

If the oil at oort A Qoes above the specified pres.


sure, it passes through
verter

relief

orifice

a of torque

valve (2) and enters port

moves torque

converter

B.

To each

relief valve (2) to the left.

As a result, the oil from port A is drained,


oil flowing

con-

It then

to the torque

converter

and the

is maintained

at the specified pressure.

425 F043

WA500-

21-15

I-D
f

View Z

Section C - C

Section D - D

Section E - E
425FO18-1
1. Oil filler

21-16
0

2.

Transmission input shaft

3.

Transmission

4.

Transfer

5.

Transfer output coupling

6.

Transmission control valve

7.

Lubrication bypass valve

8.

Strainer

WA500- 1

9.

No. 1 sun gear (Teeth 30)

10.

No. 1 planetary

11.

No. 1 clutch

gear (Teeth 28)

12.

No. 1 ring gear (Teeth 70)

13.

No. 1 idle gear (Teeth 86)

14.

No. 2 sun gear (Teeth 42)

15.

No. 2 clutch

16.

No. 2 ring gear (Teeth 90)

17.

No. 2 planetan/

gear (Teeth

18.

No. 3 planetary

gear (Teeth 24)

19.

No. 3 clutch

20.

No. 3 sun gear (Teeth 42)

21.

No. 3 ring gear (Teeth 90)

22.

No. 4 clutch

23.

No. 4 hub

24.

No. 5 clutch

25.

No. 5 ring gear (Teeth 90)

26.

No. 5 planetan/

27.

No. 5 sun gear (Teeth 50)

28.

No. 6 clutch

29.

No. 6 ring gear (Teeth 90)

gear (Teeth 21)

30.

No. 6 planetary

31.

No. 6 sun gear (Teeth 50)

32.

Output

33.

No. 1 carrier

24)

gear (Teeth 20)

shaft

34.

No. 2,3

35.

No. 5 carrier

carrier

36.

No. 6 carrier

Section A - A
425FO19-1

WASOO-1

21-17
0

OUTLINE
The transmission
REVERSE

consists of a 4-FORWARD,

4-

Speed range

Clutch combination

Fl

No. 2, No. 6

F2

No. 2, No. 4

speed planetary gear transmission, trans-

fer, and transmission control valve.


In the transmission, the motive force of the input
shaft is changed by the combination

of No. 1 or

No. 2 clutch with No. 3, 4, 5 or 6 clutch to give


FORWARD

1 - 4

or

REVERSE

F3

hlo.2,

No.5

R4

No.1,

No.3

1 - 4 speed, and

is transmitted to the output shaft.

OPERATION

The

OF CLUTCH

oil sent from the transmission

control

valve

passes through the oil passage inside the transmission.

When it reaches the rear of piston (2).

it

moves the piston (2).


When the piston (2) moves, disc (4) and plate (5)
are pressed together.

Ring gear (6) is meshed with

disc (4), so the rotation is topped.

423FO18

cl

Disengages
When the supply of oii from the transmission control valve is shut off, the pressure of the oil acting
on the rear of piston (2) is reduced.

Thepiston

is

then pushed back to the right by return spring (3).


and disc (4) and plate (5) are separated.
(6)

then

rotates

freely,

and no motive

Ring gear
force

is

transmitted.

423FO19

21-18

WA500- 1

FORWARD

1ST

In 1st FORWARD,
clutch

(28)

No.

2 clutch

are engaged.

(15) and No. 6

The motive force trans-

mitted

mitted from the torque converter by input shaft (2)


is transmitted
.

No.

2 clutch

is actuated

pressure applied to the clutch


ring gear (16)
actuated

in position.

by the hydraulic

The rotation

of the

to planetary gear (17)

through sun gear (14).


by

the hydraulic

piston, and it locks


No.

to the input shaft (2).

input shaft (2) is transmitted

to output shaft (32).


(15)

The motive force from the torque converter is trans-

6 clutch

(28)

is

pressure applied to the

clutch piston and holds gear (29) in position.

Ring gear (16) is held in position by No. 2 clutch so


the rotation

of planetary

gear (17)

rotates carries

(34), which is on the inside of ring gear (16).


carrier

is connected

to No. 5 carrier

This

(33) through

No. 4 ring gear (24), so when No. 6 clutch is actuated, the rotation

of carrier

(33)

is transmitted

to

gear (30) and rotate output shaft (32).

WA500- 1

21-19

FORWARD

2ND

425FO21

In 2nd FORWARD,
clutch

(22)

No. 2 clutch

are engaged.

(15) and No. 4

input

mitted from the torque converter by input shaft (2)


is transmitted
.

to output shaft (32).

ton.

pressure applied to the clutch pis-

No. 2 clutch

hold ring gear (21)

to the input shaft (2).


shaft

is transmitted

The rotation

to planetary

and No. 4

Ring gear (16) is held in position by No. 2 clutch, so


the rotation

of planetary

gear (17)

rotates carrier

(34), which is on the inside of ring gear (16).

clutch hold hub (23).

21-20

of the

gear (17)

through sun gear (14).

No. 2 clutch (15) and No. 4 clutch (22) are actuated


by the hydraulic

The motive froce from the torque converter is transmitted

The motive force trans-

WA500- 1

FORWARD

3RD

425FO22

In 3rd
clutch

FORWARD,
(24)

No. 2 clutch

are engaged.

(15) and No. 5

The motive force trans-

mitted from the torque converter by input shaft (2)


is transmitted

is held in position by No. 2 clutch

so the rotation

of planetary

gear (17) rotates

carrier (34), which is on the inside of ring gear (16).

to output shaft (32).

Ring gear (16)


(15),

Ring gear (21)

is held in position by spline to car-

No. 2 clutch (15) and No. 5 clutch (24) are actuated

rier (35),

by the hydraulic

mitted to output shaft (32) through sun gear (27).

pressure applied to the clutch pis-

so the rotation

of ring gear (21) is trans-

ton, and they hold ring gears (16) and (25) in position.
The motive force from the torque converter is transmitted
input

to the input shaft (2).


shaft

is transmitted

The rotation

to planetary

of the

gear (17)

through sun gear (14).

WA500-

21-21

FORWARD

4TH

14

15

16

17

19

18

21

No.4

__

20

2nd

No.5
3rd

I_
1

NO.6
1st
425FO23

In 4th
clutch

FORWARD,
(19)

No. 2 clutch

are engaged.

(15) and No. 3

The motive force trans-

Ring gear (16)


(15).

is held in position by No. 2 clutch

so the rotation

of planetary

gear (17) rotates

mitted from the torque converter by input shaft (2)

carrier (34), which is on the inside of ring gear (16).

is transmitted

Ring gear (21)

to output shaft (32).

is held in position by No. 3 clutch

No. 2 clutch and No. 3 clutch are actuated by the

(19), so the rotation of carrier (35) is transmitted

hydraulic

planetary

pressure applied to the clutch piston, and

gear (26).

The planetary

they hold ring gears (16) and (21) in position.

the inside of ring gear (21).

The motive force from the torque converter is trans-

(27), which forms one unit with output shaft (32).

mitted
input

to the input shaft (2).


shaft

is transmitted

to

The rotation
planetary

and rotates sun gear

of the

gear (17)

through sun gear (14).

21-22

to

gear rotates on

WA500- 1

REVERSE

IST

Reverse Forward

4th

2nd

3rd

1st

425FO24

In

1st

REVERSE,

No.

1 clutch

clutch

(28)

are engaged.

mitted

from

the torque

is transmitted

to output

No.

is actuated

1 clutch

applied

to the clutch

in position.
hydraulic

(11)

The motive

converter
shaft

pressure applied

by input

No.

trans-

shaft (2)

input
through

pressure

and it locks carrier


(28)

is actuated

to the clutch

The motive
mitted

(32).

by the hydraulic

piston,

No. 6 clutch

and
force

(33)

by the

piston

and

force from the torque

to the
shaft

input

shaft

(2).

is transmitted

to

converter

is trans-

The rotation
planetary

of the

gear (IO)

sun gear (9).

Carrier

(33) is held in position

so the

rotation

ring gear (12).


site direction

of planetary

by No. 1 clutch
gear (IO)

Ring gear (13) rotates

from the input

rotates

(11).
the

in the oppo-

shaft (2).

holds ring gear (29) in position.

WA500- 1

21-23

TRANSMISSION

CONTROL

VALVE

425FO25

1. Lower valve

21-24

7.

Priority pressure pick-up

2.

Pilot reducing pick-up

8.

Modulating pressure pick-up

3.

Upper valve

9.

Accumulator

4.

Main relief valve

10.

Transmission solenoid valve

5.

Transmission lubricating pressure pick-up

11.

Emergency manual spool

6.

Torque converter relief pressure pick-up

12.

Connector

pressure pick-up

WA500-

Reverse
Forw;3rd
4th
3rd
2nd

Saction A-A

13.

17.

1st solenoid valve

FORWARD

14.

2nd solenoid valve

18.

REVERSE

15.

3rd solenoid valve

19.

Body

16.

4th solenoid valve

solenoid valve
solenoid valve

Actuation

table

423F026A

for solenoid valve

and clutch

STRUCTURE
.

The transmission
transmission

solenoid valve is installed to the

together

When the directional


operated,

with

the transmission

valve.

lever or speed control lever are

the solenoid valve is actuated and moves

the spool inside the transmission valve.

WA500- 1

21-25
0

UPPER VALVE

1
Lower
valve

425FO26

Upper
valve

Section C - C
425FO27

OUTLINE
-

The oil from the torque converter charging pump


enters port A, and passes through the priority valve
(7) via by main relief valve (3). It is then divided
into three lines; there are; to the clutch pistons, to
the pilot reducing valve(l4) and main relief valve.
The priority valve (7) acts to control the three lines
so that the pilot reducing valve (4) is the priority
circuit.
The oil flowing to the pilot reducing valve (4) controls the pilot pressure used to actuate the directional and speed spools. The oil regulated by the
pilot reducing valve (4) presses through the orifice
in each spool and fills the spool.

21-26

The other oil line flows to the modulating valve (6)


and quick return valve (5). The action of the modulating valve (6) and quick return valve (5) raises the
clutch pressure smoothly.
This reduces the shock
when actuating the FORWARD,
REVERSE and Ist,
2nd, 3rd, and 4th speed clutches to change gear.
The accumulator valve (11) controls the oil flow at
the 2nd clutch and reduces the filling time when
shifting from 2nd to 1st or 3rd gear.
The lubrication valve (15) controls the lubrication
oil inside the transmission.

WA500- 1

LOWER

VALVE

425FO28

Section B -

1.

Piston

7.

Priority valve

13.

FORWARD

2.

Torque converter relief valve

8.

Housing

14.

Pilot reducing valve

3.

Main relief valve

9.

1 St spool

15.

Lubrication valve

4.

Reducing valve

10.

2nd spool

5.

Quick return valve

11.

Accumulator

6.

Modulating valve

12.

Pilot filter

WA500- 1

(for 2nd)

16.

REVERSE

17.

4th spool

18.

3rd wool

spool

spool

21-27
0

TRANSMISSION

SOLENOID

VALVE

Function
.

There is one solenoid valve installed for each directional and speed spool in the transmission valve.
When the directional
in the

operators

solenoid

lever and speed control

compartment

valve is actuated,

actuate the directional

levers

are operated,

the

and oil is drained

to

and speed spools.

Operation
1)

Solenoid valve OFF


The oil of spool (1) enters port A.
(2) shuts off the oil, so directional

However,

valve

and speed spool

(1) does not move.

reducing valve

2)

423FO31

Solenoid valve ON
When the directional

and gear shift lever are operat-

ed, the solenoid valve is pulled up.


The oil from directional

and speed spool (1) enters

port A and flows from port B to the drain circuit.


Therefore,

port A becomes the low pressure circuit,

and directional

and speed spool (I) is actuated.

2
/
From quick return valve
/

From pilot
&
reducing valve

21-28

423FO32

WA500-

EMERGENCY

MANUAL

SPOOL

Function

If there

is any failure

transmission

does not work,


This spool
spool

in the electrical

control

system,

the emergency

is attached

of the
valve

manual spool is used.

to each directional

and is used to operate

mechanically.

circuit

and the solenoid

and speed

the transmission

valve

(It is used to drive the machine

place where it can be repaired.)


*
Particular
attention
must

be paid

for

to a
when

using this spool.

Operation
1.

When solenoid valve is normal:


(Emergency
When the

manual spool is at normal position)


solenoid

spool is maintained
Oil from

valve

is working

normally,

the

in this position.

directional

and speed spool (1) enters port

A, but it is shut off by solenoid

valve (2).

423FO44

2.

When solenoid valve is abnormal:


a.

Clutch in disengaged position


(Emergency

manual spool is pushed to the left)

Emergency

manual

left,

spool

and the oil at port

of the

action

cannot

flow

of
to

(3) is pushed

A is shut off regardless

solenoid
port

From quick
return valve

to the

valve

B, so the

(2).

The oil

clutch

is not

actuated.

b.

423FO45

Clutch in engaged position


(Emergency

manual spool is pulled to the right)

When emergency manual spool (3) is pulled to


the right,
regardless
(2).

the oil at port


of the

A is drained

operation

As a result, the clutch

to port

of solenoid

From quick
return valve

valve

is actuated.

From
reducing valve
423FO46

WA500- 1

21-29
Cc

FORWARD

IST
Forward

1 St

425F501

1.

Solenoid valve

2.

Solenoid valve

3.

Oil filter

4.

Priority valve

5.

1st spool

6.

FORWARD

7.

Spring

8.

Spring

9.

Piston

spool

There are two oil coolers on Serial No. 10187 and up

IO.

Quick return valve

(except D specification).

11.

Pilot reducing valve

12.

Piston

13.

Main relief valve

21-30
@

WA500-

Operation
When

the

directional

moved to FORWARD

and speed control

levers are

Ist, solenoid valves (1) and (2)

The

other

oil

line flows from

quick return valve (10).

priority

valve (4) to

It then flows through orifice

are opened.

a, and directional

The oil from the pump is divided into three lines, but

flows to the FORWARD

when the gears are being changed, the oil flows main-

it starts to flow to the clutch, it passes through orifice

ly to each clutch.
In one of the three
relief
then

valve (13)
lubricates

lines, the oil passes from

through

the torque

the transmission

converter.

main
It

and returns to the

and speed spools (5) and (61, and


clutch and 1st clutch.

a andcreates

a difference

C and port D.

Quick return valve (IO)

right,

and the oil at the

in pressure between port

is filled

port C and port D disappears.

the orifice

of FORWARD

of each speed spool to the

However, solenoid valves (1) and (2)


spool (6) and 1st spool (5) are open,

so the oil passing through


drain circuit.
created

the orifice

As a result, a difference

between

the clutch is then connected.

back

with

to the

oil, the difference


left

in pressure between
The valve is pushed

by the difference

in area of the

valves, and drain circuit Eis closed.


At this point, each clutch is filled with oil, but the oil

flows to the

has not reached the specified

pressure.

in pressure is

port

D flows

back

of

port A and port B, and this over-

comes the force of springs (7) and (8).

The port to

valve

piston (9) flows to drain circuit E. When each clutch

One of the two oil lines flows from the pilot reducing
valve through

moves to the

rear of modulating

transfer case.

solenoid valve.

When

through

modulating

orifice
piston

(9).

The oil at

and reaches the


The piston

(12)

moves to the right and the clutch pressure rises slowly. When the modulating

piston reaches the end of its

stroke, the clutch pressure reaches the specified level,


and the clutch is completely

WA500-

engaged.

21-31

PRIORITY

VALVE

Function

The priority

valve (1) controls the minimum

sure of the pilot reducing valve (2).


priority

valve (I)

gives the oil flow

reducing valve (2) priority

pres-

In addition, the
to the

pilot

over the other circuit.

Operation
.

The oil from the pump flows to port A of priority


valve (1) and port B of pilot reducing valve (2).

To modulating valve

!$

To each transmission spool

To main relief valve

425FO35

The oil entering


priority

port A flows from

orifice

valve (I) to port D. The hydraulic

a of
pressure

and force of poppet spring (3) push back spring (4)


and move priority

valve (1) to the right.

When this happens, port A and port C are connected, and the oil flows from

port

C to the clutch

spool.
To modulating valve

To each transmission wool

To main relief valve

425FO36

21-32

WA500- 1

MODULATING

VALVE

AND

QUICK

RETURN

Function
.

VALVE

k/cm*)

The

modulating

together

to

slowly.

valve

raise the

transmission

In this way,

shifting

gear, and

torque

in the

fatigue

is reduced,

comfort

and quick
they

reduce

prevent

power

the

train.

return
clutch

valve

the shock when

generation

of peak

As a result,

operator
operator

of the power

C
Shifting gear

pressure

and at the same time,

and the durability

40

act

train

are

increased.

30!?
$
h
5

20_

10 -

Time

(Set)
425F175

1)

Immediately

after shifting gear (Point A on Fig. 425F175)

valve

425FO37

Operation

The

oil

sent

from

valve (I) through

the

valve

(21, and enters

(3).

The oil

return
which

valve

port

WA500-

orifice

flows

from

B of quick

passes through
(3)

and flows

orifice
to the

priority

modulating
return
a

valve

of quick

clutch

piston,

when

it passes

it creates a difference

in pres-

has been actuated.

through

pump

port A, passes through

However

sure between

port

B and port

valve moves to the right


(5).

In addition,

to the right,
surized

when quick

drain

oil at the

port

C.

The quick

return

and the oil flows to clutch


return

valve (3) moves

D is opened,

rear of piston

and the pres-

(4) flows to the

drain circuit.

21-33

2)

Clutch pressure rising (Point B on Fig. 425F175)

valve

425FO38

Operation

As the pressure at the clutch piston rises, the pres-

At the same time, pressurized oil also passes thorugh

sure at port C also rises. Quick return valve (3) is

the

pushed back to the left and drain port D is closed.

valve (2).

The oil from

the pump flows from

port C to the

and some of the oil at port A flows to port G.

clutch

and at the same time

it flows from

orifice

piston
b

through

quick

return

valve

(3)

orifice

and

enters poppet

It moves modulating

(7) of modulating
valve (2) to the left

and

enters port E.
The oil at port E acts on the modulating
It

pushes back

spring

(6)

piston (4).

and moves piston

(4)

to the right.

21-34

WA500-

3)

Completion

of rise in clutch pressure (Point C on Fig. 425F1751

To solenoid valve

To pilot reducing

425FO39

Operation

The oil entering

port

When the piston

to push piston

(4).

reaches the end of its stroke,

the

rise in pressure stops.


sure

reaches

valve.

the

In addition,

by piston

(4).

WA500-

set

E continues

When this happens, the prespressure


port

of

the

F and port

modulating
G are closed

ACCUMULATOR

VALVE

Function

The accumulator
when
clutch

shifting

valve acts to reduce the filling time

gear by allowing

the oil at the 2nd

piston to escape slowly when shifting from

2nd to 1st.

This allows the clutch to be engaged

smoothly when shifting from 2nd to 1st.

1.

Shifting to 2nd

* When shifting to 2nd gear, the oil from the pump


passes through the reducing valve and enters port
A of the 2nd spool (5).

When the 2nd spool

moves, port A and port B are connected and the


oil flows to port C.
The oil at port C flows from check valve (2) and
orifice a to port D.

From reducing valve


R

---I

From pilot reducing valve


423FO39

21-36

WA500- 1

As the pressure of the oil entering port D rises,


the oil continues to push piston (3) to the left
until stops.
At the same time, oil is sent to the clutch piston
and actuates 2nd clutch (4).
From reducing valve

423FO40

2.

Shifting from 2nd to 1st

- The oil from the clutch piston of 2nd clutch (4)


enters port D and acts on the rear of the check
valve (2).
orifice

The oil from


and flows

this way the


reduced.

port D passes through

to the drain circuit.

shock when shifting

In

gears can be
From reducing valve

423FO41

WA500-

21-37

PILOT

REDUCING

VALVE

Function

The pilot reducing valve acts to control the

Pressure

needed to actuate the transmission spools.


Operation

The
filter
The

oil from

the pump

passes through

the

pilot

and enters port A of pilot reducing valve (1).


oil passes through

port B and enters through

the orifice of transmission spool (2) to fill the inside


of port C.

&B To main relief valve

425FO33

When the

pressure inside port C rises, pressurized

oil flows from orifice a of pilot reducing valve (I)


and goes to port D.
As a result, pilot

reducing valve (I)

moves to the

right, and port A and B are shut off, so the pressurized

oil

at

port

C is maintained

at the same

pressure.

@&To

main relief valve

425FO34

21-38

WA500-

MAIN

RELIEF

VALVE

Function

Clutch

The main relief valve acts to supply the necessary oil


to the clutch when shifting
are not being shifted,

gear.

When the gears

it sends all of the oil directly

to the torque converter.

425FO30

Operation
.
The oil from the pump passes through the oil filter
and enters port A of main relief valve (I).

Until the specified pressure is reached, the oil flows


to the priority

valve.

425FO31
.

When the pressure goes above the specified level, oil


passes through the orifice in relief valve (I), pushes
poppet

(21, and moves relief valve (1) to the left.

The oil is relieved to the torque

converter,

converter

so the

specified pressure is maintained.


*

Specified pressure: 27 kg/cm2

425FO32

WA500- 1

21-39

REDUCING

VALVE

Function

The

reducing

valve is in the circuit

quick return valve and the 2nd spool.

between

the

It reduces the

pressure applied to the 2nd clutch, and in this way


acts to protect the 2nd clutch.
The maximum

pressure in the main circuit is kept to

the specified level by the main relief pressure.

Operation
.
The oil from the quick

return

valve enters port A

and then flows from port B to 2nd spool (2).

When the circuit to the 2nd clutch is filled with oil


and the hydraulic
which

flows

poppet (3).

pressure rises, the oil from port B

through

orifice

a to port

C pushes

The reaction to this compresses spring

reducing valve

(4) and moves reducing spool (I) to the left.

425FO40

As a result, port A and port B are closed, and the oil


stops flowing.
The hydraulic

pressure at this point is 20 kg/cm2.

From pilot
reducing valve
425FO41

21-40
-FL

WA500- 1

LUBRICATION

BYPASS

VALVE

Function

When

traveling

are rotating
churning

in 4th

at high

resistance

oil increases.

gear, the transmission


speed.

of the transmission

the

lubrication

To reduce this power loss,only

oil to lubricate

gears

Because of this,

enough

the gears at 4th speed is kept.

the rest of the oil is bypassed

All

to the transmission

case.

Operation

4th clutch

not being operated

When the 4th clutch


no hydraulic

is not being operated,

pressure

at port

a of spool

there
(1).

is

As a

result, spool (I) is pushed to the left by the spring.


The
spool

oil

from

(I),

the

torque

so all the oil

converter

is stopped

is used for lubricating

by
the

transmission.

425F176

4th clutch

being operated

When oil flows


from

4th

spool

to the 4th clutch,


(2) to port

pressure oil enters port


and moves spool
torque

converter

(2).

to the

From quick return valve 2

When

a, it pushed back the spring

(2) to the right.


flows

pressure oil flows

a of spool

j,,,,,,
,,,,,
,*Y~~
,n\*\b*:y,*~~
$?e&@
\ I,
J ~~%e&t&~@>*~i

The oil from the


transmission

lubri-

cation system and drain port b.

lission
ltion

From
reduc

425Fl77

WA500- 1

21-41

PILOT OIL FILTER

IN

OUT

Section A - A

1. Oil filter head


2. Element
3. Case

Specification:
Filtration

21-42

area: 370 cm2

WA500-

OUTLINE
.

Transfer

The transfer

is installed at the power output end of

the transmission

and is secured to the transmission

case by bolts.

TRANSMlSSlON
.

Output

PATH

shaft (I)

of the transmission

transfer input gear (2) by a spline.


is transmitted

is coupled to

The motive force

to output gear (4) through

idler gear
1.

Transmission output shaft

2.

Transfer input gear (teeth 48)

the center

3.

Transfer idler gear (teeth 45)

The rest of the

4.

Output gear (teeth 43)

5.

Output shaft

6.

Rear coupling

(3) and output shaft (5).


Part of the power transmitted
transmitted

to the front

to the output shaft is

axle through

drive shaft and front

drive shaft.

power

to the rear axle through

is transmitted

the

rear drive shaft.

7.

Front coupling

8.

Rotating pick-up sensor

\
To

front a

425FO48

WA500- 1

To
rear axle

425FC49

21-43

DRIVE

SHAfT

OUTLINE
.

The

motive

the damper,

force

from the engine passes through

upper drive shaft (5). torque converter,

transmission and transfer.


passes through

Part of this motive force

rear drive shaft (4) and goes to the

rear axle; the rest of the motive force passes through


center drive shaft (3), center support

(2) and front

When the body is articulated,


from

the

road

or when there is shock

surface during

traveling,

there is shock during operations,


and

behind

the

engine

or when

the axle in front

and transmission

change

position.
To allow the motive force to be transmitted

without

drive shaft (1) and is sent to the front axle. In addition to transmitting
the motive force, the drive

damage to parts of the machine when there is shock

shafts have the following

shafts have a universal

purposes.

or when the components


This allows them

move position,
joint

to handle

the drive

and a sliding joint.


changes in angle and

length.

425FO50

21-44

1.

Front drive shaft

4.

Rear drive shaft

2.

Center support

5.

Upper drive shaft

3.

Center drive shaft

WA500- 1

CENTER

SUPPORT

425FO51

1.

Front coupling

2.

Case

Function

The center support


between

3.

Grease nipple

4.

Rear coupling

is installed to the front

frame

the center drive shaft and the front drive

shaft.
.

With the articulating


twisting

from

frame,

this part is constantly

side to side, so there is liable to be

large stress on the drive shaft.


support is used to transmit

Therefore,

the center

the power smoothly,

to

reduce the stress on the drive shafts, and in this way


improve the durability

WA500-

of the drive shafts.

21-45

AXLE MOUNT

Seotion A - A

21-46

\L

/-

SectionB

425FO58

WA500- 1

-._-J

-..1

View Z
425FO59

1.

Front axle

Front axle

2.

Rear axle

3.

The front axle (1) receives the force directly during


operations,

Front frame

so it is fixed directly

to the front frame

(3) by axle mounting bolts (5).


4.

Rear frame

5.

Axle mounting bolt

Rear axle

The rear axle (2) has a structure which allows the


center of the rear axle to float, so that all tires can
be in contact

with the ground when traveling over

soft ground.

WA500-

21-47

AXLE
.

The

AND
motive

the damper,

DIFFERENTIAL

force

from the engine passes through

torque

converter,

transmission,

trans-

Inside the axles, the motive

force passes from the

bevel pinion to the bevel gear and is sent at right

fer, and drive shafts, and is then sent to the front

angles.

and rear axles.

passes through the front differential


shaft.

At the same time, the speed is reduced and


(1) to the axle

The motive force of the axle shaft is further

reduced by a planetary-gear-type

final drive (4) and

is sent to the wheels.

FRONT

1.

Front differential

2.

Front axle

3.

Brake (See page 51-I 8)

4.

Final drive (See page 21-53)

5.

Parking brake

6.

Drain Plug

\li
21-48

View 2

425FO52

WA500- 1

10

Section A - A

11

425 F053

7.

Side gear (Differential)

8.

Bevel gear (Teeth 37)

9.

Shaft

(Teeth 18)

10.

Pinion (Differential)
(Teeth 10)

11. Bevel pinion (Teeth 9)

WA500- 1

21-49

REAR

View

5
425FO54

21-50

1.

Rear

differential

4.

Final

drive

2.

Rear

axle

5.

Drain

plug

3.

Brake

(See page

51-I

(See page

21-53)

8)

WA500- 1

I I Section

A - A

425FO55

6.

Bevel gear (Teeth 37)

7.

Bevel pinion (Teeth 9)

8.

Shaft

9.

10.

WA500-

Pinion (Differential)
(Teeth 10)
Side gear (Differential)
(Teeth 18)

21-51

OUTLINE

The motive force from the drive shaft passesthrough


bevel pinion
(5).

The

(1) and is transmitted

to the bevel gear

bevel gear changes the direction

of the

motive force by 90, and at the same time reduces


the

It then

speed.

transmits

through the differential

the

motive

force

(4) to the sun gear shaft (2).

423FO59

When driving straight forward

When the
rotating

machine

is driven straight forward,

speed of the

the

left and right wheels is the

same, so the pinion gear (4) inside the differential


assembly (6) is sent through the pinion gear (4) and
the side gear (3) and is transmitted

equally to the

left and right sun gear shafts (2).

423FO60

When turning

When turning,

the

rotating

right wheels is different,

speed of the left and

so the pinion gear (4) and

side gear (3) inside the differential


in

accordance

rotating

with

speed of the

the

difference

assembly rotate
between

left and right wheels.

motive force of the carrier

the
The

(6) is then transmitted

to the sun gear shafts (2).

423FO61

21-52

WA500-

FINAL

DRIVE

To gain a large drive force, the final


planetary

drive uses a

gear system to reduce the speed and send

drive force to the tires.

The motive force transmitted


through

from the differential

axle shaft (1) to sun gear (5) is transmitted

to planetary

gear (2).

The planetary

gear rotates

around the inside of a fixed ring gear (3) and in this


way

transmits

planetary

rotation

carrier

(4).

at a reduced speed to the


This motive force is then sent

to the wheels (6) which

are installed to the plane-

tary carriers (4).

425F057A

WA500-

1.

Axle shaft

2.

Planetary

3.

Ring gear (Teeth 78)

gear (Teeth 29)

4.

Planetary

5.

Sun gear (Teeth 18)

carrier

6.

Wheel

21-53
0

TIRE AND

WHEEL

The tire acts to absorb the shock from the ground

SPECIFICATIONS

surface to the machine, and at the same time they

must rotate in contact with the ground to gain the

TRA code:

*
.

Nominal size of wheel:

power which drives the machine.

Various
pose.

types of tires are available to suit the purTherefore

correct

tires

for

it is very important
the

type

of work

to select the
and

Tire type:

26.5 x 25 - 20PR
L3

Normal in flation

22.00 x 25WTB

pressure: 3.5 kg/cm2

bucket

capacity.

33
--

---\

O;\,

0 1
o\
0)

01

Of

0 //

OO,

--____-x

o,,-

425 FO60

1.

21-54
0

Tire

2.

Rim

3.

Air valve

4.

Lock ring

5.

Side ring

WA500-

POWER TRAIN
22

TESTING

AND

ADJUSTING
...................
...........
Measuring engine stall speed ..............

Standard
Tool

value table

list for testing and adjusting

Measuring
converter

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

and transmission
shift lever

for operation

The following
shooting
1.
2.

precautions

or during testing

are necessary when using the Standard

spool

Value Tables to make judgements

during

leaving the plant, so they should

or when estimating

values in these tables

values for the machine


they

22-

22-

trouble-

and adjusting.
of use.

Therefore,

22-

22-11

as target values when repairing


The standard

22-10

The values in these tables are based on the values for new machines

standard

22.

of emergency

......................
Tire and wheel .......................
Troubleshooting
......................
manual

2
3

oil pressure of torque

Measuring
Method

2222-

should

for

judgement

when shipped

be used as reference

wear after a period


when

troubleshooting

are estimated

values based on the

from the plant,

and on the results of various test.

in combination

with

repair and operating

be used

records when

making

judgements.
3,

These standard value tables must not be used for standard values when judging claims.
these values alone to make simple judgements.

WA500-

In addition,

do not use

STANDARD

VALUE TABLE

Measurement condition

Testing and measuring item

Standard value

Permissible value

. Torque converter oil


temperature:
60-80C

Shift lever operating force and stroke

* Directional

Unit

lever operating force

0.3 - 0.9

Max. ? .4

0.3 - 0.9

Wlax. 1.4

0.3 - 0.9

Max. 1.4

2nd - 3rd

0.3 - 0.9

Max. 1 4

3rd - 4th

0.3 - 0.9

Max. 1.4

N-F

* Engin speed:

Low idling

kg

N-R
Speed lever operating force

kg

lst-2nd

* Directional

lever travel
32 - 42

27 - 47

32 - 42

27 - 47

mm

32 - 42

27 - 47

rm

660 - 720

mm

N-F
N-R

* Speed

lever
1st - 2nd - 3rd - 4th

* Coolant temperature:
Inside operating range

Engine stall speed

* Low idling
* High idling
- Torque converter
* Hydraulic stall
- Full stall

* Torque

converter temperature:
60 -80C

stall

2250 - 2350
2085 - 2185

+ Hydraulic temperature:
45-WC

Oil pressure of torque converter and


transmission

* Torque converter oil


temperature: 60 - SO C

- Pilot reducing pressure


* Modulating pressure (except

* Engine

speed: High idling

.g/cm'

F,, R,)

* Reducing valve pressure (for F,,

R, )

- Torque
- Torque

converter inlet pressure

(A)

Tire inflation pressure:


Specified pressure

(B)

- Clearance

of wheel lock ring

1665

mm

Tire

9.8 - 11.8

27 - 30

27 - 30

19 -22

19-22
2-4

10.5

O-ring

9.5 - 10.5
3-5

Max. 2.5
Max. 4.0
2-10

(ct

F4.2301008

423F30W

2%2

1865

9.8 - 11.8

3-5

converter outlet pressure

of wheel lock ring

1265-

9.5 -

Tire and wheel

* Fitting

1950 - 2350

1465 -

2-4

. Lubrication oil pressure

1935 - 2335

2100 - 2200

WA500-1

TOOL LIST FOR TESTING


No.

Testing and measuring item

AND

ADJUSTING

Tool Name

Engine speed

Tachometer

Oil temperature

Thermistor

Oil pressure

Hydraulic

Part No.

Remarks

799-203-8000

Digital display 60 -

kit

799-l 01-6000

0 -

tester

799-l 01-5000

Q1

Pedal and lever


operating force
Measuring clearance

Push-pull gauge

Feeler gauge

79A-262-0020

Commercially

When carrying out testing, adjusting or troubleshotting,

rpm

loooc

0 - 25 kg/cm2
0 -

19999

50 kg/cm2

0 - 25 kg

available

0.1 - 3.0 mm

stop the machine on level ground, install the safety bar

on the frame, lower the bucket to the ground, and stop the engine.
Then apply the parking brake and block the tires.

Do not allow unauthorized

When measuring the engine speed, one worker should measure the engine speed while the other sits in the op-

persons near the machine.

erators seat to operate the controls.

Always check that the operation

is safe, and use agreed signals.

Be careful not to get caught in rotating parts.

WA500-

22-3
0

MEASURING
*

Measurement

ENGINE

STALL SPEED

condition

- Coolant temperature:
Inside operating range.
* Hydraulic temperature:
45 - 55C
- Torque converter oil temperature:
60 - 80C
Unit:
Standard

Item

rpm

Permissible
value

value

Low idling

660

High idling

2250

- 2350

2085

- 2185

1935

- 2335

2100

- 2200

1950

- 2350

1665

1265

Torque

converter

Hydraulic

stall

stall

Full stall

- 720

1465-

1865

Special tools

Check

that

the low idling

the standard
Before

and high idling

speeds are

value.

measuring

on

the

Set

tachometer

the

outer
A

rpm

at each stall,

circumference
and

adapter

of
@

put

the

on

mark

damper.

top

of the

engine mount.
Check
If

that the engine speeds are the standard

any

item

is outside

the

permitted

value.

range,

check

for any looseness for play in the linkage.

Block the tires

1.

Measuring

torque

converter

stall

1)

Start engine and run at low idling.

2)

Put

the

REVERSE,

directional
and

lever

speed

in

FORWARD

control

lever

in

or
the

highest speed range.


3)

Using the brake, stop the machine

and measure

the engine speed when the engine reaches accelerator

pedal depress fullv.


the
transmission

* Turn

switch

(Check that the pilot

Do not

cut-off

lamp is OFF).

run at stall speed for more than 20

seconds, and do not let the torque


oil temperature

22-4
0

selector

(1) to OFF, and use the left brake.

converter

rise above 120C.

WA500-

2.

Measuring hydraulic stall


1)

Start engine and run at high idling.

2)

Operate

the dump

the cylinder

or lift control

the relief valve of the main control


3)

move

and actuate
valve.

Measure the engine speed at this point.


*

Do

not

more
control
3.

lever to

to the end of its stroke

run

than

the
20

engine
seconds,

at stall
and

speed

operate

for
the

lever quickly.

Measuring full stall


Measure
stall

the

engine

and hydraulic

time.

WA500-

speed
stall

when

torque

are reached

converter

at the

same

MEASURING
OIL PRESSURE
TRANSMISSION
* Measurement conditions

OF TORQUE

CONVERTER

AND

- Coolant temperature:
Inside operating range.
- Torque converter oil temperature:
60 to 80C
* Engine speed: High idling
Unit:

kg/cm

Standard value

Permissible value

Pilot reducing
pressure

10.8 + 1.0

10.8 i: 1 .O

Modulating
pressure
(Except F,,

28.5 + 1.5

28.5 f 1.5

item

R, )

Torque converter relief


pressure

8*1

8 +l

Special tool

I
A

Part No.

the parking

Oty
1

Hydraulic tester

799-l 01-5000

Apply

Part Name

brake and block the tires.

Measuring procedure
*

The following
measuring

preparatory

work

is necessary

before

any oil pressure.

* Remove covers (2) on left side under the cab.


- Turn the transmission cut-off selector switch
to

OFF

pilot

and use the left

brake.

(Check

that

pull

the

lamp is OFF.)

* Remove the plug from the measuring port of the


transmission

Install

(1)

hydraulic
the

tester

gauge

to

the

A to the measuring
operators

port,

compartment,

then start the engine and measure the pressure.


*

Check that there

is no leakage of oil from

any joints.

valve.

I
/

P!

22-6
0

Pl

P3

425F203

WA500-

1.

Measuring pilot reducing pressure


1)

Measuring

2)

Put the directional


the

port

pressure

(P5).
lever in neutral,

when

the

speed

and measure

control

lever

is

operated.
2.

Measuring modulating
1)
2)

Measuring

port

pressure

(PI).

Put the directional


the

pressure

lever in neutral,

when

the

speed

and measure

control

lever

is

operated.
3.

C38

Torque converter inlet port oil pressure

I)

Measuring port (P8).

2)

Start

the engine and measure the pressure at

high idling.
4.

Measuring lubrication

valve pressure

1)

Measuring port (P9).

2)

Start

the engine and measure the pressure at

high idling.
5.

Measuring reducing valve pressure

1)

Measuring port (P3).

2)

Start

the engine and measure the pressure at

high idling and low idling.

6.

Measuring torque converter outlet port pressure


1) Measurement

port (3) (PT1/8)

2) Measure

pressure with

the

the engine

at high

idling.

425FOlOlO

WA500-

22-7
@

MEASURING

SHIFT

LEVER

Measuring conditions

- Torque converter
- Engine stopped.

60 - 80C

oil temperature:

Unit:

kg

Standard
value

Permissible
value

0.3 - 0.9

Max. 1.4

Neutral + Reverse

0.3 - 0.9

Max. 1.4

1st - 2nd

0.3 - 0.9

Max. 1.4

2nd - 3rd

0.3 - 0.9

Max. I .4

3rd - 4th

0.3 - 0.9

Max. 1.4

Neutral -+ Forward

32 - 42 mm

27 -47

Neutral + Reverse

32 - 42 mm

27 - 47 mm

In each range
from 1st three
4th speeds

32 - 42 mm

27 - 47 mm

\leutral

+ Forward

1Directional

mm

Directional
lever

3
!z
+

Speed
lever

Special tool
425PO29

-Part

No.

A /

79A-262-0020

A Be
1.

Part Name

Qty

Push-pull scale

sure to set chocks

firmly

against

the tires.

Measuring the lever operating effort


1)

Stop

2)

Attach

the engine.
push-pull

to the
the

lever

The

scale

knob

operating

operating

(I)

A or a spring

at the center

effort

required

to

balancer

and measure
pull

it in the

direction.
measurement

speed
2.

should

be made

in each

range.

425PO30

Measuring the lever travel


1)

Stop the engine.

2)

Put

mark

knob
moved

22-8
@

and

on

the

measure

center
the

in the operating

on the
travel

when

control
the

lever
lever

is

direction.

WA500-

METHOD
SPOOL

OF EMERGENCY

FOR OPERATION

MANUAL

OUTLINE
.

The

transmission

Therefore,

valve

is controlled

electrically.

the emergency manual spool is installed

to enable the machine to be moved if there is any


failure

in the electrical

system, or in the solenoid

valve and spool.

The

emergency

manual spool is for use when

failure in the transmission control


machine

from

being

prevents the
It

moved.

allows

the

machine to be moved from a dangerous place to


a place where repairs can be carried out safety.
The

emergency

manual

spool must never be

used except when the transmission control

has

broken down.
When

operating

follow

the emergency

the correct

manual spool,

order of operation

and pay full attention

exactly,

to safety when moving

the machine.

To prevent the machine from moving, lower the


bucket to the ground, apply the parking brake,
and block the wheels.
inside the air tank

Check that the pressure

is above the specified pres-

sure.
1.

Remove R.H. machine panel.


*

If an air conditioner

is installed, push condenser

(1) over to the front.


Always

stop the engine before

operating

the

spool.

2.

Remove

lock plate

(2)

of the emergency

manual

Y!

spool of the transmission valve.


*

Simply

loosen the mounting

bolts to remove

the lock plate.

Rev&

Forward

spool

spool

spool

3rd

2nd

1st

spool

spool

SPOOl

425F204

3.

Decide the direction

to move the machine (forward

or in reverse),

move the emergency

then

manual

spool to the operating position.


FORWARD:

Rotate

FORWARD

clutch spool and

1st spool counterclockwise,


out approx.

and pull

position.
REVERSE:

Rotate

REVERSE

clutch spool and

1st spool counterclockwise,


out approx.

and pull

10 mm to the operating

Approx.

position.
~pprox.

WA500- 1

I===
I=
00

10 mm to the operating

10 mm

00

421 F203

22-9
0

4.

Check

that

the area around

the machine

is safe,

remove the blocks from under the wheels.


5.

Sit in the operators

seat, and depress the left brake

pedal fully.
6.

Start the engine, release the parking brake, then release the brake pedal gradually to start the machine.
When the engine is started, the transmission

is

engaged and the machine will start. Therefore,


before

starting

the direction

the engine, always check that

of travel is safe, and always keep

the brake pedal depressed.


If the

machine

does not start,

turn

the 2nd

spool, 3rd spool, and 4th spool clockwise,


screw in approx.

7.

After

and

10 mm to the OFF position.

moving the machine,

stop the engine, apply

the parking brake, and block the wheels.


8.

Return

the emergency manual spool to the neutral

position, and install the lock plate.

TIRE AND

WHEEL
Tire
Unit:

Item

No.

Standard value

Max. 2.5

Max. 4.0

kg/cm2

Permissible
value

Fitting of wheel
lock ring

Clearance of
wheel lock ring

2-10

F42301008

Measuring procedure
1.

Fitting of wheel lock ring


Measure distances A and B at four places around
the circumference.

2.

Clearance of wheel lock ring


Measure dimension C.

423F309

22&l
O

WA500-

TROUBLESHOOTING
Precautions
Method

Preventing
Method

recurrence

of locating

troubleshooting

2.
3.

Machine

Torque
too high

WA500-

transmission
table

. .

points when
system

. .

does not move

Excessive timing
machine

4.

of trouble

main problem

. 22-12
....
..
. 22-14
. . . . . . . . . 22-16
table

..

. 22-17

. 22-18
. . . . . . . . . 22-18
Machine lacks power or speed . . . . .
. 22-20

Troubleshooting
1.

..

when troubleshooting

of reading troubleshooting

. .

..

lag when starting

or shifting
converter

. . . . . .

gear

. . . . . . . . . . . 22-21

oil temperature

..........

. . . . . . . . . . . 22-22

22-11
0

PRECAUTIONS
1.

WHEN

TROUBLESHOOTING

SAFETY
* Stop the machine on level ground, and check that the safety pins and parking brake are correctly applied,
p\.
and that the tires are blocked.

- When working in groups, use agreed signals and do not allow unauthorized persons near the machine.
-

Be careful not to get burned by hot parts or to get caught in rotating parts.

* Always disconnect the cable from the negative (-1 terminals of the battery before disconnecting any wiring.

- Always release the pressure before removing the plugs or caps of any place under hydraulic or air pressure,
and connect all measuring tools correctly.

2.

METHODS
FOR TROUBLESHOOTING
* Just because a failure occurs, do not immediately

start to disassemble the machine.

If the machine is disassembled before making the proper checks.

* The machine may be disassembled in such a way that the problem cannot be located, so the cause of the
problem will be unknown.
As a result,

* The customer and operator will lose confidence in you.


- Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.
To avoid these problems,use the following
1.

2.

questions about

the breakdown.

a.

Have there been any other problems apart from the one reported?

b.

Was there anything usual before the machine broke down?

c.

Did the breakdown

d.

What was the machine doing when the breakdown

e.

Had the machine been repaired before the breakdown?

f.

Had the same kind of failure occurred before?

Check the following


a.

3.

procedure when troubleshooting.

Ask the customer and operator the following

occur suddenly, or had there been signs of trouble before?


occurred?
If so, who carried out the repair, and when?

items which can be checked simply by visual checks, etc.

Check oil level.

b.

Check for leakage of oil from piping or hydraulic equipment.

c.

Check travel of control levers.

d.

Check stroke of spool in control valves.

Reenact the failure


a.

and check the condition

Ask the user or operator

if

the machine

(particular

conditions

at the time of failure).

if the decision about the failure was made based on measured values, or by com-

parison, or by feeling.
b.

Compare extent of failure with standard values.

- Check safety before carrying out any check.


- Did not make any check or measurement that will make the conditon worse.
4.

Try to locate the possible causes for the failure.


The transmission

system consists of the transmission

itself, the transmission control

valve, and the transmis-

sion electric control.


In particular,

when trouble

occurs in the transmission

system, the probable

location

of the failure can be

divided as follows.

- Transmission itself, or transmission control valve.


- Transmission electric control.
To decide which of the two is the location of the failure, go to page 22-17.

22-12
0

WA500-

5.

Carry out troubleshooting


There are the following
1.

2.

using the troubleshooting

two types of troubleshooting

TROUBLESHOOTING

The troubleshooting

FLOW

charts.

. . . . . . . . . . . . 22

TABLE

TROUBLESHOOTING

charts.

CHART.

_.

POWER TRAIN,

42

STEERING

52

BRAKE

62

WORK

. . . . 82

SYSTEM,

AND Al R SYSTEM,
EQUIPMENT

ELECTRIC

AND

SYSTEM

ELECTRONIC

SYSTEM

charts consist of:

1)

Items which can be checked easily.

2)

Items which are likely to be the cause of such failures.

Follow these charts to carry out troubleshooting.


At the same time, do not forget the following

points.

- Check related items.


- Check that there are no other failures or breakdowns.
*

For details of troubleshooting

6.

Investigate causes of breakdown

Even if the breakdown

tables, see page 22-14.

is repaired, if the original cause of the problem is not removed, the same breakdown

will occur again. To investigate and remove the original cause, see Actions to take to prevent failures from
occurring again.

3.

PRECAUTIONS
WHEN REMOVING,
INSTALLING,
DISASSEMBLING
OR ASSEMBLING
PARTS DURING TROUBLESHOOTING
- If it is necessary to remove, install, disassemble or assemble parts for troubleshooting, remember the following
points.

- Carry out the various testing and adjusting while observing the items on quality control given in Testing and
Adjusting.

+ When removing parts, check their condition of mounting, and distinguish between front and rear, left and right,
and top and bottom.

* Check the match marks, or make match marks to prevent mistakes when installing.
- If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it.

Check the part to see if there is any problem

with it, and remove the problem

before trying to dis-

assemble the part.

- When installing or assembling, clean off all dust and dirt and repair any scratches or dents.
Remove all grease or oil before coating with gasket sealant.

WA500- 1

22-13
0

METHOD

OF READING

DESCRIPTION

OF SYMBOLS

The

following

column

USED

are used

symbols

to indicate

the method

TROUBLESHOOTING
IN TROUBLESHOOTING

TABLE
TABLE

in the Remedy
of eliminating

the

cause of a fault.
X:

Replace;

A:

Repair;

A:

Adjusting;

C:

Clean

METHOD OF READING
ING TABLE

TROUBLESHOOT-

The symbol 0 in the table is inserted only for causes


which can be diagnosed.
nosed, the corresponding

If a cause cannot be diagbox is left blank.


:

If the result of problems 1 using the troubleshooting


table shown at right
trouble

is abnormal,

the cause of the

can be assumed to lie between a and d.

Because it is not possible to make a problems regardinge,

it is necessary to perform

the next problems

(owing to the possibility of a multiple fault).


If the result of problems 1 is normal, the cause of the
fault

does not lie between

case, before

a and d.

In such a

diagnosing the cause as e, however,

carry out a check by means of problems 2 or 5.


If now the result of problems

1 is abnormal

and the

result or problems 2 normal, the cause is one of a,


b or d.
abnormal,

In addition,

if the result of problems 3 is

the cause will be narrowed down to one of

b or d.

To determine

actual cause, perform

which of b or d is the

problems 4.

If the result of problems is abnormal,


corresponding

blacken out the

in the table and then perform

the

Not necessen/
problems

next problems on these causes in order to narrow the


likely causes.

Example 1 :
Problem 1 + Abnormal

From the table of ex-

Problem 2 + Normal

ample 1, the cause of

Problem 3 + Abnormal
Problem 4 + Normal

ti

the fault is b.

Example 2:

Not

From the table of exProblem 1 + Normal


Problem 2 -+ Abnormal
*

ample 2, the cause of


the fault is ,,e,,.

In example 2, it is evident that the cause is e


without
blem

carrying out problems 2, however pro2 is performed

by way of an additional

check.

22-14
0

WA500- 1

Example 3:
Problem 1 + Abnormal

From the table of ex-

Problem 2 -+ Normal

ample 3, the cause is

Problem 3 + Normal

one of a, c and
e.

Continue problems

-i

From the table of ex-

Problem 4 + Normal

ample 3-1, the cause is

Problem 5 + Normal

C.

x c
1

Example 4:

\
lrlrlrlrl

From the table of ex-

Problem 1 + Abnormal

ample 4, the cause is

Problem 2 + Noraml

one of a, b or d.

Continue problems

Problem 3 + Abnormal

From the table of ex-

Problem 4 -+ Abnormal

ample 4-1, the cause is

Problem 5 + Normal

a or Id.

As can be seen from the above examples, it is not necessary to perform all of the problems.
Also, looking at a particular cause, no matter how many
0 marks there are in the column corresponding

to that

cause, it will cease to be an actual cause if there is even


one 0 mark is the same column.

WA500-

22-15
0

PREVENTING
*

RECURRENCE

The troubleshooting
ment.

OF TROUBLE

table is used to establish the direct cause of damage or breakdown

of a part or piece of equip

It is not able to establish the root cause of the damage or failure, however.

- Also, this table only describes the action to be taken with the particular part or piece of equipment.

It does not

mention what action should be taken to prevent a recurrence of the root cause.

In order to remove the root cause of a fault so as to prevent a recurrence, carefully


referring to the following

investigate the real cause while

items.

Regarding the method of checking and adjusting each part or piece of equipment,

refer to Testing and adjusting in

the Shop Manual.

HYDRAULIC
1.
.

EQUIPMENT

Oil checks

3)

The fundamental
ing in hydraulic

equipment

wash the oil using an oil refresher or replace it.

Accordingly,

the

action.

for

water

2.

Check for ingress of other foreign matter


the drain plug and filter,

by water,

matter

then check

has collected

Check the degree of contamination

to

there.

by means

checker.

Cleaning fragments of damaged parts


If

a part

becomes damaged,

In addition,
valves and
metal
helping

disassemble

fragments

fragments

may

and

to prevent

and wash such parts as

which
other

are liable
foreign

a recurrence

becoming

to

of faults

or not the

oil is satisfactory.
2)

Check of ingress point


If, as a result of the above checks, it is discovered that the oil is contaminated
or other foreign

matter,

by water

it is necessary to find

out where the contamination

is occurring and

also the take steps to prevent it.


Water:

Oil storage tank, breather, etc.

Stand:

Oil replenishing

or replacing meth-

od, etc.
Rubber: Cylinder packing, etc.
Metal:

Wear

or

equipment
motor,

as

damage

to

such

as

well

as

hydraulic
pump

and

transmission

and torque converter, etc.

22k6

thus

due to

lodged in various parts

of the oil using a viscowhether

collect

matter,

of the engine or hydraulic equipment.

meter in order to confirm

pass

It is thus necessary to wash the oil.

cylinders

such fragments

Viscosity check
Check the viscosity

it is

When washing the oil, also wash or replace

into the oil line.

of the tank and also the filter

of a contamination

If the oil is contaminated

ingress by

plate.

see if any foreign

in the oil, either

the strainer and replace the filter.

possible

means of a diesel engine oil checker or a hot

Remove

is discovered

of an oil refresher.
*

oil

matter

not possible to remove the water by means

Check for water ingress

the bottom

or

Oil checks
Check

of metal particles or other

in the oil.

any of the above substances, and

then take appropriate

If a large amount
foreign

it is necessary to check the oil to see whether

1)

Oil cleaning and replacement

is the inclusion of water,

air or other foreign matter


not it contains

cause of almost all faults occurr-

WA500-1

METHOD OF LOCATING MAIN PROBLEM POINTS


TROUBLESHOOTING
TRANSMISSION
SYSTEM
The problem

points

in the transmission

system can be broadly

1.

Transmission

itself and transmission

2.

Transmission

electric

control.

Use the following

method

to decide which

Problem:

control

divided

into the following

WHEN

two areas.

valve.

of the two areas has the problems.

Machine

will not start.

Machine

will only travel in one direction.

(FORWARD

or REVERSE)

Cause
2
Does machine move
if screw of
emergency
spool
forForRandlstis
pushed in?

l-l

Is voltage and
resistance of F or R
solenoid correct?

YES
c

Replace transmission
valve

Go to Troubleshooting
transmission
LSee page 22-18
-

Remedy
control

I I
NO

for
22-22)

1 I Voltage 20 - 3ov.
2) G&yance
approx.

L
NC

Machine will not move in certain

Problem:

Go to Troubleshooting
electrical system of
transmission
(See page 82-38 -

for

82-43)

speed ranges

Replace transmission
control valve

solenoid for problem


speed range correct?
1) Voltage

20 -

Go to Troubleshooting
transmission
(See page 22-l 8 -

for
22-22)

30V.

Go to Troubleshooting
electrical system of
transmission
(See page 82-38
-

WA500- 1

for

82-43)

TROUBLESHOOTING
1.

TABLE

Machine does not move.


Ask the operator the following

points.

- Did the machine suddenly stop moving?


Yes = Component

Was

there

any

chine stopped

seized or damaged.
abnormal

noise

when

the

ma-

moving?

Yes = Comoonentbroken.
Checks before troubleshooting
*

Is oil level in transmission

case correct?

* Is monitor display normal?


* Is drive shaft broken?

Problems
1

Abnormal noise between pump and filter.

Machine does not move in any speed range.


(Item 1 normal)

Machine moves normally in certain speed ranges.

Machine will not move when T/C oil temperature

0
0000

rises.

I
Low at every speed range.
Transmission
modulating
pressure
too low.

0
0

Pilot pressure defective

Note 1:

If

the

Low at certain speed ranges.

Indicator fluctuates violently.

solenoid

are normal,

valve

the I

and

hydraulic

pressure

in the Causes column

in-

dicates that the valve spool does not work.


Note 2:

If

the

but
table,

transmission

the

cause cannot

a possible

clutch

pressure

be found

cause is cracks

is

low,

in the above
in the

valve

or transmission.

2268

WA500- 1

The following symbols are used to indicate the action


to be taken when a cause of failure is located.

WA500-

22-19
0

2.

Machine lacks power or speed


Checks before troubleshooting

* Is oil level in transmission case correct?


- Is there any leakage of oil from joints of piping
or valves?

- Is parking brake or brake locked?


- Is operation of electric circuit correct?
Checking for abnormalities

- Engine high idling speed


* Torque converter stall speed
-

Machine

Transmission

Pressure at outlet

Pilot reducing

Tire

NO.

travel

inflation

speed
clutch

pressure

port of pump

pressure
pressure

Problems

I Abnormal

noise from between pump and filter.

Torque converter stall speed too high.

Torque converter stall speed too low

45

modulating
Transmission
too
low
pressure

--I

IOIO

(Item 2 abnormal)
Indicator
Low at every
fluctuates
speed range
violently.

I
I

I
I

Pilot reducing pressure too low (Items 4 and 5 normal)


Relief pressure at torque converter inlet port too low

Iron or aluminium particles stuck to strainer of

Modulating pressure drops when oil temperature

rises.

loI

The following symbols are used to indicate the action


to be taken when a cause of failure is located.

22ifo

WA500-1

3.

Excessive time

lag when starting machine

or shift-

ing gear
Checks before troubleshooting

- Is oil level in transmission case correct?


- Is there any leakage of oil from joints of piping
or valves?

Is operation

of control

valve normal?

Checking for abnormalities

Check

STANDARD

VALUE

that time lag is actually


*

Standard

TABLE

to confirm

excessive.

time lag.

Engine high idling:

Max. 0.8 sec.

No.
Problems
1

Abnormal noise between pump and filter

Excessive time lag in every speed range

Machine moves normally in certain speed ranges.

Transmission modulating pressure too low


in every speed range

As in Item 4; indicator fluctuates violently

Torque converter oil temperature


range.

I Ol

ollolol

I
0

I4

I
0

I
0

is above operating

The following symbols are used to indicate the action


to be taken when a cause of failure is located.
X : Repalce
A: Repair
A : Adjust
C : Clean

WA500-

22-21
0

4.

Torque converter oil temperature


Ask the operator the following

- Does not torque


torque

the torque

converter

Yes = Normal

points.

converter

up during

too high

oil

converter

temperature

go

stall, and down when

is not stalled?

(Incorrect

selection

of gear speed)

Checking before troubleshooting

Is oil

level

in

transmission

and

steering

case

correct?

* Is filter clogged?
Checking for abnormalities

- Check STANDARD
that torque

VALUE

converter

TABLE

oil temperature

to confirm
is actually

high.
*

If the

oil temperature

temperature

gauge

is normal

is outside

range, the oil temperature

the

but the oil


operating

gauge is defective.

Problems
1

Pump makes abnormal noise when oil temperature

is low.

High idling and low idling speeds are too low.

Hydraulic pressure at inlet port of torque converter too low

Transmission modulating pressure too low

0
0
0
0

The following symbols are used to indicate the action


to be taken when a cause of failure is located.

22622

WA500-

POWER TRAIN
23 DISASSEMBLY

AND

REAR

DAMPER
Removal .........................
Installation
.......................
Disassembly .......................
Assembly
........................

23- 2
23- 6
23-10
23-12

TORQUE
CONVERTER
CHARGING
Removal .........................
Installation
.......................

23-14
23-14

FRONT

23-l 5
23-22

REAR

Disassembly. ......................
Assembly
........................

23-39
23-49

23-68
23-70
23-72

FINAL
Removal .........................
Installation
.......................

Take

the following

method

.
.
.
......

23-98
23-100

..
_.
..
..

.
.
.
.

..
..
_.
..

..
._
_.
..

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

23-l 10
23-111
23-112
23-114

. .
..

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

23-116
23-118

. _.
. .

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

.........

SHAFT

..... .
. .. ..

23-119-1
23-119-3

DRIVE

Disassembly
Assembly
.

23-76
23-79

23-88
23-92

. . . . . _ . . . . . . . . . . . . . . . . 23-102
. . . _ . _ . . . _ . _ . . . . . _ . . . 23-106

Disassembly
Assembly

DIFFERENTIAL

..........

. . . _ . . . _ . . _ _ _ ..........
. . . . . . . . . . . . .........

(Serial No. 10001-l


0222)
Disassembly .
..
Assembly
. ... ..
(Serial No. 10223 and up)

VALVE

Removal .........................
Installation
.......................
Disassembly and assembly .............

..........

AXLE

Assembly

23-61
23-64

............
. . . . . . . . __ . .

CENTER SUPPORT
Removal . . . . _ .
Installation
....
Disassembly . . _ .

DRIVE

TRANSFER
Disassembly .......................
Assembly
........................

23-82
23-85

AXLE

Removal .
Installation
23-29
23-33

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

GEAR

Removal .
Installation

TRANSMISSION

FRONT

. __ . _ . __ . _ . .
............

DIFFERENTIAL

PUMP

TORQUECONVERTER
Disassembly. ......................
Assembly
........................

CONTROL

DIFFERENTIAL

Removal .
Installation

Disassembly
Assembly
.

TORQUE
CONVERTER
AND TRANSMISSION
Removal .........................
Installation
.......................

TRANSMISSION

ASSEMBLY

....
. ..

......
. . . .

for air bleeding when you start to operate

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

23-120
23-123

hydraulic

cylinders after reassembling cylinders, pump and pipings.


1.
2.

Start engine, keep idling.


Operate hydraulic

cylinder

4 -

5 cycles, but do not exceed beyond 100 mm of

stroke end.
3.

Continue to operate cylinder 3 - 4 cycles until stroke end,

4.

After finishing above steps, keep normal


NOTE:

WASOO-

engine speed.

After long storage, same procedure

is required.

23-1
a

REMOVAL

OF DAMPER

Stop the

Q1

machine

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
Loosen the oil filler cap slowly to release the pres-

Q
!

sure inside the hydraulic


control

pressure in the hydraulic

Loosen plugs (1) and


tank filter,

tank.

Then operate the

levers several times to release the remaining


piping.

(2) at the top of the hydraulic

and plugs (3) and (4) of the pump piping to

prevent the oil inside the tank from flowing out.


1.

Cover
1) Remove hydraulic

tank cover (5), side panel (6) and

(7).

2) Sling engine hood (8) and side hood (9), then remove.
& kg

Engine hood:
Side hood:

60 kg

42 kg

425P306

2.

Brake, air piping


1) Remove air pipes (10) and (11) from chamber.
2) Remove brake pipes (12) and (13) from chamber.
+

Disconnect air pipe (11) under the hydraulic tank.

Remove each piping clamp to bulkhead.

2%2

WA500-

2.

POC piping

* Disconnect hose (14) between POC pump and strainer at tube of strainer side.

* Disconnect hose (15) between main control valve and


manifold at manifold
*

end.

Remove clamp.

* Disconnect hose (16) between POC valve and manifold at manifold end.
*

Remove clamp.

Disconnect

hose (17)

between

POC relief valve and

POC valve at POC relief valve end.


*

3.

After disconnecting,

Hydraulic
-

pull out of bulkhead.

piping

Loosen clamp of hose (18)

between

hydraulic

tank

and switch and hydraulic pump.

* Loosen clamp of hose (19) between hydraulic tank


and steering pump.

- Disconnect hose (20) between hydraulic tank and oil


cooler at tube end.

Disconnect
hydraulic
mission.

WA500-

hose (21) between main control valve and


tank

at connection

at left side of trans-

4.

Bulkhead
1) Disconnect bulkhead wiring (22) at connector end.
2) Disconnect

hose (231, then disconnect air intake port

(24).

3) Sling bulkhead

(251, remvoe mounting bolts, then lift

off.
*

Be careful not to hit the glass of cab when lifting


off the bulkhead.
Bulkhead:

5.

Hydraulic
1) Remove

500 kg

pump
tubes

(26)

and

(27)

then

remove

switch

pump (28).
2) Remove hose (29) then steering and POC pump (30).

3) Remove tubes (31) and (32),then


pump (33).
* Remove manifold

remove hydraulic

(34).

4) Remove hose (35) and tube (361, then remove torque


converter charging pump (37).
*

Remove contact faces of O-ring of each pump.

2&4

WA500-

6.

Drive shaft
Make match marks then remove drive shaft (38).

7.

Damper
1) Disconnect

greasing hose (39) for damper at damper

end.
*

Remove coupling (40).

2) Temporarily

sling cover (41) and remove mounting

bolts, then using forcing screws lift off.

Cover:

kg

3) Temporarily

32 kg

sling damper

(42),

with

eye bolts then

remove mounting bolts and lift off damper.

4kg

WA500-

Damper:

60 kg

INSTALLATION
1.

OF DAMPER

Damper
1) Sling damper

(421, set in mounting

position,

then

tighten mounting bolts.


Mounting bolt: 11.25 + 1.25 kgm

2) Sling

cover

(41),

set in mounting

position,

then

tighten mounting bolts.


6

Cover contact surface:

Metal sealant (LG-4)

3) Connect damper greasing hose (39) to damper.


*

2.

Installed coupling (40).

Drive shaft
Align match marks and install drive shaft (38).
m

23-6
a

Mounting bolt:

11.5 f 1 kgm

WA500-

3.

Hydraulic

pump

1) Set torque converter charging pump (37) in mounting


position then connect hose (35) and tube (36).
2) Set hydraulic

pump in mounting

position

and con-

nect tubes (31) and (32).


*

Before

installing

hydraulic

pump

(33),

set mani-

fold (34).

3) Set steering and POC pump (30) in mounting position


then connect hose (29).
4) Set switch pump (28) in mounting position then connect tubes (26) and (27).

4.

Bulkhead
1) Sling

bulkhead

(25)

and set in mounting

position

then tighten mounting bolts.


*

Be careful of glass of cab and install.

Insert suction hose in tube at pump end.

2) Set air intake

port

(24) to air cleaner and connect

hose (23).
3) Connect bulkhead wiring (22) to connector.

WA500- 1

23-7
0

5.

Hydraulic
*

piping

Connect
hydraulic

hose (21)
tank

between

main control

at transmission

valve and

left side connection

end.

Connect

hose (20)

between

hydraulic

tank and oil

cooler at tube end.

* Tighten clamp of hose (19) between hydraulic tank


and steering pump.
*

Tighten

clamp of hose (18)

and switch and hydraulic

6.

between hydraulic

tank

pump.

POC piping
l

Connect hose (17) between POC relief valve and POC


valve at POC relief valve end.

Connect

hose (16) between

POC valve and manifold

at manifold end.
*

Connect clamp.

- Connect hose (15) between main control valve and


manifold at manifold end.
*

Connect clamp.

* Connect hose (14) between POC pump and strainer


at tube of strainer side.

232

WA500-

7.

Brake, air piping


1) Connect brake piping (12) and (13) to chamber.
*

Connect air pipe (11) under the hydraulic tank.

Install each piping clamp to bulkhead.

2) Connect air pipes (IO) and (11) to chamber.

8.

Cover
1) Sling engine hood (8) and side hood (9), then install.

2) Install

hydraulic

tank

cover (5), side panel (6) and

(7).

9.

Refilling with oil


Tighten
pump

plug at top of hydraulic


piping,

then add hydraulic

tank filter, and plug of


oil through

oil filler

to the specified level.


m
10.

plug at top of filter:

1.2 f 0.1 kgm

Bleeding air
Bleed air from brakes.
*

For details

of bleeding

air, see 52 TESTING

AND

ADJUSTING.

WA500-1

23-9
0

DISASSEMBLY
1.

OF DAMPER

Cover
1) Remove mounting

bolt, then remove cover (1).

2) Remove oil seal (2) and O-ring (3) of cover (1).

3) Pull out shaft

(5).

4) Remove snap ring (4) and bearing

(8) from shaft

(5).

425F256

5) Remove

snap

rings

(6).

(6A)

and oil seal (9) from

cover (7).

23do

WA500- 1

2.

Damper
1) Using forcing screws, remove flange (10).
*

Tighten the two forcing screw evenly.

It

Do not remove spacer (18) unless necessary.

18

425F258

2) Remove inner body (11) and rubber (12).

3) Remove

snap ring (13)

and oil seal (14) from the

inner body.

4) Remove flange (16) from outer body (15).


t

Screw

in the

mounting

bolts,

then tap with

hammer to remove.

WA500- 1
236

ASSEMBLY
1.

OF DAMPER

Damper
1) Install flange (16) at bottom of outer body (15).
a

Contact surface of flange and outer body:


Gasket sealant:

LG-4

2) Press fit oil seal (14) in inner body (1 l), then assemble snap ring (13).
*

Fit the snap ring securely in the groove.

Set the oil seal with the sleeve on the snap ring
side and fit it close in contact with the snap ring.

3) Assemble

inner body

(11)

in outer

body (15), then

assemble rubber (12).


Whole surface of rubber:

Grease (G2-LI)

Outer surface of inner body:

Grease (G2-LI)

Inner surface of outer body:

Grease (G2-LI)

Between inner body and rubber:


Grease (G2-LI)

423P31OJ

Fill clearance a at four places evenly with 150 g


of grease.

421F3006

23-l 2
0

WASOO-

4) Install flange (IO), and tighten mounting bolts.


&

Contact surface of flange and outer body:


Gasket sealant (LG-4)

2.

Cover
1) Fit the snap ring (6A),

then

fit the snap ring (6)

after press fit oil seal (9) in cover (7).


*

Press fit

the

oil

seal with

the

lip face on the

bearing side.
2) Assemble snap ring (6), bearing (8) and snap ring (4)
in shaft (5). then assemble shaft in cover (7).
6

Shaft splines in contact with inner body:


Molybdenum

disulphide

dry

lubricant

(coat, then leave for 2 - 3 minutes).


&

Contact

surface

of

shaft

and

inner

body

oil seal:
Lithium

type,

molybdenum

disulphide

high pressure grease.


&

Bearing:
Lithium

type,

molybdenum

disulphide

high pressure grease.


3) Press fit oil seal (2) in cover (I), and assemble O-ring.
*

Press fit

the

oil

seal with

the lip face on the

coupling side.
4) Install cover (l), and tighten mounting bolts.

423P3106

WA500-

421

F3008

23-13

REMOVAL

OF TORQUE

Stop the

A!

safety
ment

machine

CHARGING

PUMP

on level ground and install the

bar on the frame.


to the ground

apply the parking

CONVERTER

Lower the work

and stop the

engine.

equipThen

brake and put blocks under the

wheels to prevent the machine from moving.


*

Remove steering and POC pump.


For details,

see 43

REMOVAL

OF

STEERING

AND

POC PUMP.
1.

Torque converter charging pump


1) Disconnect tube (1) between transmission

and pump

at pump end.
2) Disconnect

hose

(2)

between

pump

and filter

at

pump end.
3) Remove torque converter charging pump (3).
Torque converter charging pump:

15 kg

INSTAL .LATION OF TORQUE


CONVE RTER CHARGING
PUMP
1.

Torque converter charging pump


1) Set torque converter

charging pump (3) in mounting

position, then tighten mounting bolts.


2) Connect hose (2) between pump and filter to pump.
3) Connect tube (I)

between transmission and pump to

pump.

Install steering and POC pump.


For
AND

details,

see 43

INSTALLATION

OF

STEERING

POC PUMP.

WA500-1

REMOVAL

Af

Stop

OF TORQUE

the

machine

CONVERTER

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
*

Disconnect
terminal

the

cable

from

the

negative

(-)

of the battery.

Loosen the oil filler cap slowly to release the pres!

sure inside the hydraulic

control

pressure in the hydraulic

Loosen plugs (1) and


tank

filter,

tank.

Then operate the

levers several times to release the remaining


piping.

(2) at the top of the hydraulic

and plug (3),

(4)

of the

pump

piping to

prevent the oil inside the tank from flowing out.

Loosen drain valve and drain air from the air tank.

1.

Hood
1) Remove covers (1) and (2) of under the cab, remove
hydraulic

tank

cover (3) and remove side panel (4)

and (5).

2) Remove engine hood (6), engine side hood (7).


Engine hood:

& kg

Side hood:

2.

60 kg

42 kg

Cab
1) Remove

arm rest (8) and cover

cab wiring

WA500-

(10) from

connector.

(9), then disconnect

AND

TRANSMISSION

2) Sling cab (1 l), remove mounting bolts and lift out.


t

Take

care so that

monitor

cab does not interfere

with

panel.

Cab: 305 kg

3.

Brake, air piping


1) Disconnect air piping (12) and (13) from chamber.
2) Disconnect brake piping (14) and (15) from chamber.
*

Disconnect

air piping (13)

at bottom

part of hy-

draulic tank.
t

4.

Remove each wiring clamp from bulkhead.

POC hydraulic

piping

Disconnect hydraulic

piping as follows:

* Disconnect hose (16) between POC pump and strainer, from tube on strainer.

- Disconnect hose (17) between work equipment valve


and manifold from manifold.
*

Remove clamp.

* Disconnect hose (18) between POC valve and manifold from manifold.
*

Remove clamp.

Disconnect

hose (19) between

relief valve and POC

valve from relief valve.


*

After disconnecting,

23d6

take out from bulkhead.

WA500-

5.

Hydraulic

piping

Disconnect hydraulic

piping as follows:

* Loosen clamp of hose (20) between hydraulic tank


and switch, hydraulic

pump.

* Loosen clamp of hose (21) between hydraulic tank


and steering pump.

* Disconnect hose (22) between hydraulic tank and oil


cooler from tube and its connecting part.

Disconnect
hydraulic

hose (23) between main control valve and


tank from

connector

on left side of trans-

mission.

6.

Bulkhead
Disconnect

electrical

wiring

(24)

of bulkhead

from

connector.
Disconnect hose (25) and remove air intake port (26).

Remove mounting bolts and sling bulkhead


*

(27).

Bulkhead balance is bad so be careful and lift off.

WA500-

Bulkhead:

500 kg

23-17
0

7.

Operators seat
Sling operators seat (28) and remove.
*

After

removing seat, remove seat support and blower

box cover.
Operator seat: 40 kg

8.

Blower box
1) Disconnect wiring from connector as follows:
*
*

Cab wiring (29).


Front and rear wiring (30), (31), (32) and (33).
*

Remove the plate inside of the small box, and


after lowering it forward,

disconnect wiring.

2) Remove circuit breaker (34).

3) Remove blower box (35).


*

Remove

cab

wiring

clamp

and

put

inside

left

console.
*

9.

After removing blower box, remove plate (36).

Steering, switch pump


I)

Disconnect

hose

(37),

then

remove

(38).
2) Disconnect tube (39) and manifold

steering

pump

(401, and remove

switch pump (41).

23-18
0

WA500-

10. Upper drive shaft


Remove drive shaft (42),

1:hen

coupling (43) on

damper side.

11. Hydraulic

and torque converter charging pump

1) Remove

manifold

remove hydraulic
2) Disconnect

tube

(441, disconnect

tube

(451, then

pump (46).
(47)

and

hose (48).

and remove

torque converter charging pump (49).

12. Steering piping


Remove wiring as follows:

* Hose (50) between steering pump and steering valve.


* Hose (51) between oil cooler and steering valve.
*

Hose (52) between switch pump and steering valve.

13. Torque converter piping


1) Remove tube

(53)

between

transmission and torque

converter pump.
2) Remove hose (54) between transmission and filter.

WA500-

3) Disconnect hoses (55), (56) between transmission and


cooler.
*

After disconnecting,

move to rear of machine.

14. Center and rear drive shaft


1) Disconnect center drive shaft (57) from transmission.

4kg

Center drive shaft:

33 kg

2) Disconnect rear drive shaft (58) from transmission.


& kg

15.

Rear drive shaft:

42 kg

Electrical wiring
Disconnect electrical wiring from connector as follows:
*

Wiring (59) of transmission valve.

* Wiring (60) of pickup sensor.


* Wiring (61) of torque converter hydraulic temperature.

16. Torque converter and transmission


1) Remove

mounting

and transmission.
trunnion
*
*

bolts and sling torque

converter

When raised about 10 mm, remove

(62).

Disconnect grease hose.


Be careful
trunnion

not

to

lose shims

inserted

between

and frame.

23620

WA500-

2) Remove bracket
*

Remove
by tapping

lightly

3) Lift out torque


*

Sling torque
fully

Since there
on

WA500-

with

and transmission

plastic hammer.

converter

and transmission

(64).

converter

and transmission,

then care-

is only
the

interference

kg

side.

in bracket

move to rear of machine.

wiring

el

(63) on front

pin inserted

Torque

left

a narrow
side

of

space for the steering


the

machine,

check

and lift out.


converter

and transmission:

1 ,I 73 kg

INSTALLATION
TRANSMISSION
1.

OF TORQUE

CONVERTER

AND

Torque converter, transmission


1) Set torque converter and transmission

(64),

100 mm

in front of mounting position.

2) Install front mounting bracket (63).


t

Align the pin holes correctly.

Mounting bolt:

28.5 f 3 kgm

3) Lower transmission further,


mm from

trunnion,

and when it is about 10

set trunnion

(62)

in mounting

position.
*
*

Connect grease hose.


Insert desired thickness of shims between trunnion
and frame.

2.

Adjusting shim
1) Assemble

desired thickness

nion (62) and frame,

of shims between

and tighten mounting

trun-

bolts to

specified tightening torque.


*

Average shim thickness:

2 mm

Shim
F42501003

2322

WA500-

2) Install

dial

converter,
output

gauge @
and

shaft.

put

to

input

probe

Rotate

coupling

in contact

of torque

with

damper

input coupling of torque con-

verter and adjust position.


*

Runout:

Measure both radial and face runout.

3) After

Within 2 mm

adjusting

position,

tighten

front

and

rear

mounting bolts fully.

3.

Mounting bolt:

28.5 ? 3 kgm

Mounting bolt:

18?

2 kgm

Electrical wiring
Connect electrical wiring to connector as follows:

* Wiring

(61)

of

torque

converter

hydraulic

level

sensor.

* Wiring (60) of pickup sensor.


l

4.

Wiring (59) of transmission valve.

Center and rear drive shafts


1) Connect center drive shaft (57) to transmission.
w

Mounting bolt:

11.5 f 1 kgm

2) Connect rear drive shaft (58) to transmission.


w

5.

Mounting bolt:

11.5 f 1 kgm

Torque converter piping


1) Connect

hoses (55)

and

and cooler to transmission.

WA500-

(56) between

transmission

8.

Upper drive shaft


Fit couplilig

(43) to damper and install upper drive shaft

(42).
m

Mounting bolt:

23if4

11.5 + 1 kgm

WA500-

9.

Steering and switch pump


1) Install switch pump (41), and connect tube (39) and
manifold

(40).

2) Install steering pump (38) and connect hose (37).

10. Blower box


1) Install plate (36), then install blower box (36).
*

Install wiring clamp of cab.

2) Install circuit breaker (34).


3) Connect wiring to connector as follows:

* Wiring for cab (29).


* Wiring of front and rear (30), (31), (32) and (33).
+

WA500-

Install palte inside small box.

12. Bulkhead
1) Sling bulkhead

(27),

set in mounting

position

and

tighten mounting bolts.


*

Insert hoses of each pump into tubes.

2) Install air intake (26) and connect hose (25).


3) Connect

electrical

wiring

(24)

of bulkhead

to con-

nector.

13.

Hydraulic

piping

Connect hydraulic piping as follows:

* Connect hose (23) between main control valve and


hydraulic

tank

to connection

on left side of trans-

mission.

* Connect hose (22) between hydraulic tank and oil


cooler to tube.
B

Hose connector:

20 t 5 kgm
(Width across flats:

41 mm)

* Tighten hose (21) clamp between hydraulic tank and


steering pump.
l

Tighten

hose (20) clamp between hydraulic tank, and

switch and hydraulic

2326

pump.

WA500-

14. POC hydraulic

piping

Connect hydraulic

piping as follows:

* Connect hose (19) between relief valve and POC valve


to relief valve.
m

Hose connector:

14 + 3 kgm
(Width across flats:

Connect

hose (18)

32 mm)

between

POC valve manifold

between

main control

to

manifold.
*
-

Install clamp.

Connect

hose (17)

valve and

manifold to manifold.
*

Install clamp.

* Connect hose (16) between POC pump and strainer at


strainer end.

15.

Brake and air piping


1) Connect brake piping (14) and (15) to chamber.
*

Install clamps on each piping to bulkhead.

2) Connect air piping (12) and (13) to chamber.


+

Connect

air piping

(13)

to bottom

of hydraulic

tank.

16. Cab
1) Sling cab

(11)

and set in mounting

positon,

then

tighten mounting bolts.


*

Be careful not to cause interference

with monitor

panel.

WA500-

23-27
0

2) Connect

cab

wiring

cover (9) and armrests

(10)

to

connector

and

install

(8).

17. Cover
1) Sling engine hood

(6) and side hood

2) Install

covers

cab lower

(1) and

(7), and install.

(2), hydraulic

tank

cover (3), and side panels (4) and (5).

18. Refilling with oil


1) Install
piping

upper filter

plugs of hydraulic

plugs, then add hydraulic

to the specified
m

oil filler

level.

plug at top of filter:

2) Add transmission

tank and pump

oil through

oil through

1.2 f 0.1 kgm


oil filler.

19. Bleeding air


Bleed air from

brakes.

of bleeding

For details

air, see TESTING

AND

AD-

JUSTING.

23

WA500-

DISASSEMBLY

OF TORQUE

CONVERTER

Special tools

Preparatory
Remove

work

torque

For details,

converter

assembly from

see DISASSEMBLY

transmission.

OF TRANSMISSION

ASSEMBLY.

1.

PTO assembly
1)

Set torque converter assembly (1) in tool A.

2) Remove holder (2) and coupling (3).

3) Using eye-botls

(Thread

dia. = 14 mm,

Pitch =

2.0 mm), sling PTO assembly.


4) Screw in forcing screws @

and remove PTO assem.

bly (4).

2.

Turbine,

case asembly

1) Remove mounting

bolts (5) of pump, leaving 2 bolts

on opposite sides.
2) Set with case at top and remove 2 remaining mounting bolts.
3) Lift off turbine and case assembly (6).

WA500-

ASSEMBLY

4) Disassemble turbine and case assembly as follows.


i)
ii)

iii)

Remove pilot (7) and gear (8).


Remove snap ring (9), then remove spacer (IO).

Using forcing screws @

(Thread dia. = 10 mm,

Pitch = 1.25 mm), remove turbine


*

3.

(11).

Pull out from bearing inner race side.

Stator
1) Remove snap ring (12).
2) Remove stator (13).

4.

Stator shaft, pump assembly


1) Remove 8 mounting bolts (14).
2) Remove stator shaft, pump assembly (15).

2320

WA500-

3) Disassemble

stator

shaft

and

pump

assembly

as

follows.
i)

ii)

Remove 2 plugs (16) at stator shaft end.

Knock out inner race of bearing through holes of


removed plugs, then remove pump (17).

iii)

Remove

bolts,

then

remove

collar

(18),

pump

(17) and cage (19).

425F262

DISASSEMBLY
5.

OF PTO ASSEMBLY

Cover
Remove cover (20).

6.

Bearing
Remove bearing (21).

WA500- 1

7.

Nut
Remove nut (22).
*

8.

Tool kit number:

790-101-2300

(Push-puller)

Gear, bearing
1) Using puller @
*

pull out gear (23).

The gear is in contact

with the outer

race, so it

cannot be removed.
2) Remove bearing (24).

9.

Outer race
1) Remove snap ring (25) and spacer (26).

425F263

2) Using gear puller @

pull out outer race (27) about

10 mm.
3) Remove gear (23), outer race (27) and spacer (28).

425 F264

WA500-

ASSEMBLY

OF TORQUE

CONVERTER

Special tools
Part No.

ASSEMBLY
1.

Part name

OF PTO ASSEMBLY

Gear
1) Install bearing (24) (inside diameter:

50 mm) on gear

(23).
2) Set gear (23) in PTO case (29).

2.

Outer race, spacer


1) Install outer race (27) (outside diameter:
t

90 mm).

Be careful to install facing in the correct direction.

2) Install spacer (28).


3) Install outer race (27) (outside diameter:

90 mm).

* Be careful to install facing in the correct direction.

WA500- 1

ASSEMBLY

3.

,,,

Bearing
Using puller @

install

bearing

(24)

,,,,\

(inside diameter:

50 mm).

,,,,,,,,,
,,,,,,
,,,,

,, ,,
,, ,, ,,

425F266

4.

Snap ring
1) Install spacer (25).
2) Install snap ring (26).

5.

Nut
Tighten nut(22).

m
t

Nut:

42 + 2 kgm

Check that the gear rotates smoothly.

2324

WA500-

,,

6.

Bearing
Install bearing (21) (outside diameter:

7.

130 mm).

Cover
1) Install oil seal (30) to cover (20).
*

Be careful not to deform the oil seal.

Oil seal lip:

Grease (G2-LI)

2) Install cover (20).

1) Assemble stator shaft and pump assembly as follows.


i)

Install bearing (31) (outside diameter:

130 mm)

to cage (19).

ii)

Fit cage (19) to pump (17), then tighten bolts.

WASOO- 1

Bolt:

6.7 + 0.7 kgm

iii)

Install seal ring (33) to stator shaft (32).


*

Coat the seal ring with


protrusion

iv)

v)

Install

pump

grease, and make the

(17) to shaft

(32).

Install 2 plugs (16).


w

Plug:

2) Set torque

0.45 + 0.15 kgm

converter

case (34)

in tool

As.
3) Install stator shaft and pump assembly
m
&

39

from the shaft uniform.

Bolt:

6.7 f 0.7 kgm

Bolt:

Thread tightener

23i?6

A, A,,

and

(15).

(LT-2)

WA500-

9.

10.

Stator
1) Install

stator

2)

snap ring (12).

Install

Turbine,

(13).

case assembly

1) Assemble
i)

ii)

turbine

and case assembly

as follows.

Install

bearing

(37)

to case (36).

Install

turbine

(11)

to case (36).

Support

the

inner

race

of the

bearing

case, and push in the turbine.

iii)

Install

spacer

iv)

Install

inner

v)

Install

gear (8) and pilot

w
&

WA500-

(IO)

and install

race (38)

snap ring (9).

to pilot

(7).

(7).

Bolt:

6.7 f 0.7

Bolt:

Thread

kgm

tightener

(LT-2)

in the

2) Fit guide bolt


mm),
mm,

(Thread

using two

dia. = 10 mm,

eye-bolts

Pitch = 1.5

(Thread

Pitch = 1.75 mm), sling turbine,

dia.

12

case assembly

(6) and then install it.


m
&

Bolt:

6.5 f 0.5 kgm

Bolt:

Thread tightener

(LT-2)

11. PTO assembly


1) Fit O-ring, using eye-bolts
Pitch = 2.0 mm),

(Thread dia. = 14 mm,

sling PTO assembly

(4) and then

install it.

2) Assemble

O-ring, and install coupling

(3) and holder

(2).
m

Bolt:

11.5 f 1 kgm

WA500-

DISASSEMBLY

OF TRANSMISSION

Special tools
Part name

Part No.
799-301-I

Preparatory

500

Leak tester

oty
1

work

Sling torque converter assembly (1) and remove bolts (2)


from transmission assembly.

Pilot filter assembly


Remove pilot filter assembly (3) with tube.

Control valve assembly


Remove control valve assembly (5).

Plate
Remove plate (6).

Sleeve
Using eye-bolts

(Thread

mm), remove sleeves (7).

WASOO- 1

dia. = 16 mm,

Pitch = 2

ASSEMBLY

5.

Transfer assembly
1) Set with transfer at bottom.
2) Using 3 eye-botls @

(Thread dia. = 12 mm,

Pitch =

1.75 mm), sling transmission assembly.


3) Screw in forcing screws @

(Thread

dia. = 12 mm,

Pitch = 1.75 mm), and lift off transmission assembly


(6).

6.

Tie bolts
Remove tie bolt (9).
*

Using tool

A, check operating

condition

of piston

before disassembling.
*

Leaved two tie bolts with mark % ,

so that transmis-

sion assembly can be remove from transfer case.

7.

Input shaft, carrier assembly


Using eye-bolts

(Thread dia. = 14 mm,

Pitch = 2.0

mm), lift out input shaft and carrier assembly (10).


*

Disassemble input shaft and carrier assembly according to following

steps:

1) Remove snap ring (11).


2) Support

housing and push out shaft with press and

remove.

23Go

WA500-

3)

Remove

4) Support
with

snap ring (12).


housing

and

push out

carrier

assembly

(13)

press and remove.

,,.

5) Remove
ings (15)

8.

Remove

washers

springs

Springs

Disc,

planetary
(16)

from

gears (14).
carrier

bear-

case.

(18)

(17)

and (18).

are inserted

between

each plate.

plate

Remove

10.

remove

and thrust

Spring
*

9.

pins, then

discs (19)

and plates

(20).

Ring gear
Remove

ring gear (21).

,,,,

WA500-

,,,,

1
2364

11. No. 1 piston, housing


Using eye-bolts

(Thread

dia. = 16 mm,

mm), lift out piston and housing

Remove piston

(24) from

Pitch = 2.0

(22).

housing

(23).

12. Spring
Remove springs (25) and (26).
*

13.

Springs (26) are inserted

between

each plate.

Disc, plate
Remove discs (27) from

plates (28).

14. Guide pin


Remove guide pin (29).

WA500- 1

15. No. 2 piston, housing


Lift out piston and housing (30).

16.

Drum carrier assembly


Using eye-bolts @
mm),

carrier assembly (31

(Thread dia. = 16 mm,

Pitch = 2.0

lift out No. 2 piston and housing (30) and drum

) as one unit.

Disassemble drum and carrier assembly according to


following

steps:

1) Remove snap ring (32), then remove drum (33).


2) Remove bearing (35) from carrier case (34).
3) Remove

pins, then

bearing (37)

remove planetary

and thrust

washer (38)

gears (36).
from carrier

case.

17. Sun gear


Remove sun gear (39).

18. Spring
Remove springs (40) and (41).
*

Springs (41) are inserted between each plate.

WA500-

19.

Disc, plate
Remove discs (42) and plates (43).

20.

No. 3 piston, housing


Using eye-bolts @

(Thread dia. = 16 mm,

Pitch = 2.0

mm), lift out piston and housing assembly (44).

21. Sun gear


Remove sun gear (45)

22.

Sleeve
Remove sleeve (46).

23.

Rotating clutch assembly


Using eye-bolts

(Thread dia. = 16 mm,

Pitch = 2.0

mm), lift off rotating clutch assembly (47) and housing


(48) as one unit.
*

Disassemble clutch assembly according to following


steps:
1) Using puller @

, remove gear assembly (49).

42SP440

WASOO-

2) Remove pin, then remove planetary


(51) and thrust

3) Remove
rotating

washer (52) from

snap ring
clutch

(531, then

assembly

gear (50). bearing

carrier case.

using bar @

(47) from

housing

, remove
(48).

5) Remove discs (561, springs (57) and plates (58).

6) Remove inner gear (59).

7) Remove bearing

WA500-

(60) from

inner gear.

8) Using press fit kit @

(160 mm inner diamter)

com-

press belleville spring and remove snap ring (61).


*

Bellville spring mounting load:

218 kg

9) Remove 3 belleville springs (62).

IO) Using puller

@I

, remove housing (64) from shaft

(63).

11) Remove thrust plate (65) and sun gear (66).


12) Remove snap ring (67) and take out shaft from ring
gear (68).

13) Remove snap ring (691, then remove gear (70).


14) Remove snap ring, then remove bearing (71).

15) Remove

snap ring

(72),

then

remove

bearing

(73)

from housing.

425P454

WA500-

24. Spring
Remove spring (74) and (75).
*

25.

Springs (75) are inserted between each plate.

Disc, plate
Remove discs (76) and plates (77).

26.

No. 4 piston, housing


Using eye-bolts @

(Thread dia. = 16 mm,

Pitch = 2.0

mm), lift off piston and housing (78).

27.

Spring
Remove spring (79) and (80).
*

28.

Springs (80) are inserted between each plate.

Guide pin
Remove guide pin (81).

WA500-

30.

Disc, plate
Remove discs (82) and plates (83).

31.

No. 5 ring gear


Remove ring gear (84).

32.

No. 5 piston, housing


Using eye-bolts @

(Thread dia. = 16 mm,

Pitch = 2.0

mm), lift off piston and housing.

23648

WA500-

ASSEMBLY

OF TRANSMISSION

ASSEMBLY

Special tool
Part name

Part No.
A

1.

799-301-I

500

Oty

Leak tester

No. 5 piston, housing


1) Install seal ring to piston, then install housing.
2) Using eye-bolts

(Thread

dia. = 16 mm, Pitch =

2.0 mm), sling and install piston and housing (85).

2.

Ring gear
install ring gear (84)

3.

Guide pin
Install guide pin (81).

4.

Disc, plate
Install plates (83) and discs (82).

WA500-

5.

Spring
Install
Ir

6.

springs

Springs

No. 4 piston,

and (79).

are inserted

between

each plate.

housing

1) Install

seal ring to piston,

2) Using

eye-bolts

2.0 mm),

7.

(80)

(80)

then

(Thread

sling and install

install
dia.

piston

housing.

= 16 mm,
and housing

Pitch

(78).

Ring gear, shaft


1) Install

bearing

2)

gear

Install

(71)
(70)

on gear.
to

ring

gear

(68)

and

secure

with

with

snap

snap ring (69).

3) Press fit shaft

(86)

to ring gear and secure

ring (67).

23650

WA500-

4) Align teeth of carrier and ring gear then install ring


gear and shaft assembly (87).

8.

Disc, plate
Install paltes (77) and discs (76).

9.

Spring
Install springs (75) and (74).
*

Insert springs (75) between each plate.

10. Sun gear


Install sun gear (66) and thrust plate (65).

11.

Housing
1) Install bearing (73) to housing and secure with snap
ring (72).

WA500-

2) Install thrust washer (52), bearing (51) and planetary


gear (50) to gear case, insert shaft and tap in pin.

3) Using press, press fit gear assembly (49) to housing.

4) Using eye-bolts

(Thread

dia. = 16 mm,

Pitch =

2.0 mm), install housing (48).

12.

Rotating clutch
*

Assemble clutch according to following steps.


1) Install 3 belleville springs (62).
2) Using press fit kit @
compress

belleville

(160

mm inner diameter),

springs and install

(61).
* Belleville spring mounting load:
*

snap ring

218 kg

Check that snap ring is completely

inserted into

ring groove.

2322

WA500-

3)

Install

bearing

(60)

to inner

gear and secure

with

snap ring.
4)

Install

inner

gear (59)

5) Install

plates

6)

case (55)

Install

(58),

springs

and tighten

7) Fit seal rings and install


8) Install

to drum.

(57)

and discs (56).

bolts

clutch

(54).

assembly

(47).

snap ring (53).


,,

WA500-

13. Sleeve
Fit seal ring and install sleeve (46).
14. Sun gear
Install sun gear (45).

15. No. 3 piston, housing


Using eye-bolts @

(Thread dia. = 16 mm,

Pitch = 2.0

mm), sling and install piston and housing assembly (44).

16. Guide pin


Install guide pin (29).

17.

Disc, plate
Install plates (43) and discs (42).

18. Spring
Install springs (41) and (40).
+

Insert springs (41) between each plate.

WA500-

19. No. 2 piston, housing


Sling No. 2 piston and housing (30) and install.

20.

Ring gear
Install ring gear (29).

21.

Disc, plate
install plates (28) and discs (27).

22.

Spring
Install springs (26) and (25).
+

23.

Insert springs (26) betwen each plate.

Drum, carrier assembly


*

Assemble

drum

and carrier

according

to following

steps:
1) Install thrust washer (38). bearing (37) and planetary gear (36) to gear case, insert shaft and tap in
pin.

425P433

WA500-

425P432

23-55
0

2) Install bearing (35) to carrier case (34).


3) Fit sanp ring (33A)

to drum

32A

(331, then install

drum.
4) Align with

32
\

33A
I

roll pin, and assemble plate (32), then

secure with snap ring (32A).


*

Check that the snap ring installed to the drum


is securely set between the plate and carrier.

. ,,

425P43:

11

425FO1013

4) Install sun gear (30).


5) Using eye-bolts
Pitch

1.5

mm),

(Theread

dia. =

10 mm,

sling and install drum

and

carrier assembly (31).


*

Align

teeth

face of planetary

gear and ring

gear and install.

24.

No. 1 piston, housing.


*

Install piston (24) to housing (23).

Using eye-bolts
2.0 mm),

25.

(Thread dia. = 16 mm, Pitch =

sling and install piston and housing (22).

Ring gear
Install ring gear (21).

425P425

WASOO-

26.

Disc, plate
Install plates (20) and discs (19).

27. Spring
Install springs (18) and (17).
*

28.

Insert snap rings (18) between each plate.

Input shaft, carrier assembly


*

Assemble

input shaft and carrier shaft according to

following steps:
1) install thrust washer (16). bearing (15) and planetary
gear (14) to gear case, insert shaft and secure with
pin.

2) Install bearing to housing.


3) Support carrier assembly (13) and press fit housing.
4) Install snapring (12).
*

Check that snap ring is completely

inserted in ring

groove.

WA500-

23-57
Gil

5) Support housing and press fit shaft (89).

6) Install snapring (11).

7) Using eye-bolts
2.0 mm),

(Thread

dia. = 14 mm,

Pitch =

sling and install input shaft and carrier as-

sembly (10).
t

Align

teeth

face of planetary

gear and ring gear

and install.

29.

Tie bolt
Tighten tie bolt (9).
w

23F

Tie bolt:

17 k 1 kgm

WA500-

30.

Checking operation

of piston

Using tool A, check operation and stroke of pistons.


*

Air pressure: 3 - 5 kg/cm2

Piston stroke:
mm

31.

Piston

Stroke

No. 1

4.0

No. 2

4.0

No. 3

4.0

No. 5

4.2

Transmission case
1) Using eye-bolts @

(Thread

dia. = 12 mm,

1.75 mm), sling transmission case (8).


2) Fit O-ring and install transmission case.

32. Sleeve
Fit O-ring and install sleeve (7).

33.

Plate
Fit O-ring and install plate (6).

WA500- 1

Pitch =

34.

Transmission

control valve assembly

Fit O-ring and install transmission control valve assembly


(5).

35.

Filter assembly
Fit O-ring and install filter assembly (3).

36.

Fit O-ring, sling torque converter assembly (2), connect


to transmission

assembly,

and tighten

mounting

bolts

(1).

23-60
0

WA500-

DISASSEMBLY
1.

OF TRANSFER

Transmission assembly
Remove transmission assembly from transfer case.
For details,

see DISASSEMBLY

OF TRANSMISSION

ASSEMBLY.
2.

Input shaft cage


Using forcing screw @

3.

, remove input shaft cage (1).

Input gear assembly


1) Remove input gear assembly (2).
2) Remove worm gear (3), then remove 2 bearings (4).

4.

Coupling
Remove holder (5), then remove coupling (6).

5.

Cage
1) Remove cage (7).
2) Remove oil seal (8) from cage.

WA500-

ASSEMBLY

6.

Speedometer

drive gear

Using forcing screw @


(9).
Sr Check the

number

, remove speedometer drive gear


and thickness

of the shims and

and thickness

of the shims and

keep in a safe place.

7.

Cover
Remove cover (IO).
*

Check the

number

keep in a safe place.

8.

,,

Idler gear assembly

1) Remove idler gear assembly (11).


2) Remove

9.

,,,

::::,:,*I:L,:
,,,
,,: ,,\,>
88:<>i.,
, 8:,:(

2 bearings (12) from idler gear assembly.

Output shaft cage assembly


1) Remove holder

(13),

then remove output shaft cage

assembly (14).
2) Using press fit kit @

, push out coupling (14) and

remove bearing (15).

2322

WA500-

10. Cage
Using forcing
*

Check

the

screw @
number

, remove cage (16).


and thickness

of the shims and

keep in a safe place.

11. Shaft
1) Remove shaft (17).
2) Remove bearing

(18) from

shaft.

12. Gear
Remove gear (19) and collar

(20).

13. Strainer
1) Remove cover (21), then remove spring
2) Take out strainer

WA500-

(22).

(23) and remove case (24).

23-63
0

ASSEMBLY
1.

OF TRANSFER

ASSEMBLY

Strainer

1) Fit O-ring and install case (24).


2) Install strainer (23).

3) Install spring (22). fit O-ring, then install cover (21 ).

2.

Gear
Set collar (20) and gear (19).

3.

Shaft
1) Using press fit kit @

, press fit bearing (18) to shaft

(17).
2) Align shaft (17) with collar and shaft and install.

2324

WA500-

4.

Cage
1) Install outer race (25).
2) Fit O-ring and install cage (16).

5.

Output shaft cage assembly


1) Install coupling
@

(14) to cage, and using press fit kit

, press fit bearing (15).

2) Assemble

shims (26),

fit

O-ring, and install output

shaft cage assembly (14).


3) Fit O-ring and install holder (13).
4

Holder mounting bolt:


Thread tightener

6.

Bolt:

(LT-2)

90 + 5 kgm

Idler gear assembly


1) Install outer race (27)

2) Install 2 bearings (12) to idler gear.


3) Install idler gear (I 1).

WA500-

23-65
0

7.

Cover
1) Install outer race to cover (10).
2) Assemble shims (28), fit O-ring and install cover.

8.

Speedometer

drive gear

1) Install outer race (29).


2) Assemble

shims (30),

fit

O-ring and install speedo-

meter drive gear (9).

9.

Cage
1) Install oil seal (8) to cage.
2) Fit O-ring and install cage (7).
&

Lip of oil seal: Grease (G2-LI)

&

Seal mount surface:

Liquid gasket (LG-4)

10. Coupling
1) Install coupling (6).
2) Fit O-ring and install holder (5).
6
w

23-66
0

Bolt:

Thread tightener

Bolt:

90?

(LT-2)

5 kgm

WA500-

11.

Input shaft gear assembly


1) Install 2 bearings (4) and install worm gear (3).
2) Install input gear (2).

12.

Input shaft cage


1) Install outer race (31).
2) Install input shaft cage (1).

13. Transmission assembly


Install transmission assembly to transfer case.
For details, see ASSEMBLY
SEMBLY.

WA500-

OF TRANSMISSION

AS-

REMOVAL

OF TRANSMISSION

Stop the

machine

CONTROL

VALVE

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
*

Disconnect
terminal

1.

the

cable

from

the

negative

(-)

of the battery.

Operators seat
Remove operators seat (1).
*

Pull the operators

seat out to the ladder, then lift

off.
*

Be careful of the glass in the cab door when removing.


Operators seat: 40 kg

2.

Seat support
Remove seat support (2).

3.

Move the floor mat to the front of the cab.

Remove

blower box cover (3).

Electric wiring
1) Disconnect wiring of cab (4).
2) Disconnect wirings of front and rear (5), (6), (7) and
(8).
* Remove the plate inside the tool box, and push to
the front before disconnecting the wiring.

4.

Circuit breaker
Remove circuit breaker (9).
*

Be careful

not to

let the wiring

connector

hit any

other parts when removing.

23h68

WA500-

5.

Blower

box

Remove blower
*

box (IO).

Remove the clamp of the wiring

for the cab, and push

into the L.H. console.


*

The seat is installed


the

box

and the

at the contact

R.H.

console

surface

so remove

between
seat care-

fully.

6.

Transmission

valve

1) Disconnect

hydraulic

2) Using eye-bolts,
(12).
* This

operation

workers,

hose (11) from transmission.

sling and remove


should

transmission

be carried

and the transmission

out

by

valve
three

valve shold be lifted

horizontally.
*

Remove clamp of hydraulic


Transmission

WA500- 1

valve:

tube

(13).

65 kg

23-69
0

INSTALLATION
1.

OF TRANSMISSION

CONTROL

VALVE

Transmission valve
1) Set transmission valve (12) in mounting position, and
tighten mounting bolts.
*

Position the gasket holes at the matching surface


correctly.

Tighten

the mounting

bolts on opposite

sides in

turn to prevent the valve from being deformed.


*

Remove clamp of hydraulic tube (13).

Mounting bolts:

5 f 0.5 kgm

2) Connect wiring (11) to transmission valve connector.


*

When

installing the connector,

be careful

not to

deform the thread case.

2.

Blower box
Install blower box (IO).
*

Be careful to install the seat at the contact


between

surface

the box and the R.H. console facing in the

correct direction.
*

3.

Install the clamp of the wiring for the cab.

Circuit breaker
Set circuit breaker (9) in mounting position and install.

23ico

WA500-

4.

Wiring
Connect the following wiring to connector.

* Wirings (5), (6), (7), (8) for front and rear.

5.

Wiring (4) for cab.

Install the plate inside the tool box.

Seat support
Install seat support (2).

6.

Set the floor mat in the mounting position.

Install blower box cover (3).

Operators seat
Install operators seat (1).

WA500-

23-71
0

DISASSEMBLY
AND
CONTROL VALVE
DISASSEMBLY

AND

ASSEMBLY

ASSEMBLY

OF TRANSMISSION

OF SPEED VALVE

ASSEMBLY

20

423F421

WA500- 1

23-72
0

DISASSEMBLY

OF SPEED VALVE

1.

Remove

solenoid

2.

Remove

stopper

3.

Remove

valves

4.

Remove

spring

(12)

valve

(2), spring

(I).

(3) and valve

(5) and (6), and shim

and (13),

(8).

then

and spring

5.

Remove

covers

(15)

6.

Remove

spacer

(17).

7.

Remove

spring

(18)

Remove

plug

8.

assembly

(20).

ASSEMBLY

remove
(14)

(4).

(7).

shim

(9),

valves

(1

I),

as a set.

and (16).

and valve
then

(19).

remove

collar

(21)

and spring

(22).

ASSEMBLY
1.

Assemble
then

OF SPEED VALVE
spring

fit O-ring

(22)

in collar

and install

install

in body

Assemble

3.

Install

4.

Fit gasket

and install

Assemble

valve

and spring

(8) in valve (11) and install


in body.

spacer

(18)

(21),

(23),

plug (20).

2.

5.

spring

ASSEMBLY

in valve

(19)

and install.

(17).

shim

(12),

6.

Assemble

7.

Install

valve

(5).

8.

Install

valve

(4), spring

9.

Fit gasket

(16)

spring

(7) in valve

and install

WA500- 1

covers

and (15).

(14).

valve

(6), and install

(3) and stopper


solenoid

(13),

shim

in body.

(2).

valve assembly

(1).

(9)

D\SASSEMBLY

AND

ASSEMBLY

OF MODULATING

VALVE

ASSEMBLY

WASOO-1

DISASSEMBLY
ASSEMBLY
1.
2.

OF MODULATING

VALVE

DISASSEMBLY
ASSEMBLY

Remove cover (1) and (2).

1.

Remove guide (3), then remove spring (4), shim (5),

2.

valves (6), (7) and (9) and spring (8) as a set.


3.

Remove valves (IO),

OF MAIN

RELIEF

VALVE

Remove plug (I), then remove springs (2) and (3).


Assemble

and install shim (4), valves (5) and (6),

spring (7) and valve (8).

(12) and (13) and spring (11)

as a set.
4.

Remove

stopper

(14),

then

remove

quick

return

valve (15).
5.

Remove spacer (16).

6.

Remove cover (17).

7.

Remove

guide (18),

ASSEMBLY
ASSEMBLY
spring (19),

shim (20),

OF MAIN

RELIEF

VALVE

valves
1.

(21), (22) and (24) and spring (23) as a set.

Install together with valve (8), spring (7), valves (6)


and (5) in valve body (9).

8.

Remove valve (25), shim (26) and springs (27) and

Standard shim width:

1.5 mm

(28).
9.

2.

Assemble springs (3) and (2) in valve body.

3.

Fit O-ring and tighten plug (1).

Remove plug (29), washer (30), then remove spring


(31),

valves (32).

(33) and (35) and spring (34) as a

set.

ASSEMBLY
ASSEMBLY
1.

Assemble

OF MODULATING

VALVE
0

spring

(34).

and spring (31),

fit

valves (35),
washer (30)

(33)

and (32),

and O-ring, then

tighten plug (29).


m
2.

Plug:

Assemble

shim

11 + 1.5 kgm
(26)

and springs (27)

and (28)

in

valve (25) and install in valve body.


*
3.

Standard shim width:

Assemble

valve (22)

to

3 mm
valve (21),

then assemble

spring (23), valve (24), shim (20), and spring (19) in


valve body and install guide (18).
4.

Fit O-ring and install cover (17).

5.

Install spacer (16).

6.

Assemble

quick

return

valve (15),

fit O-ring, and

install stopper (14).


7.

Assemble valve (12),

spring (II),

and valve (IO)

in

425F272

valve (13) and install in valve body.


8.

Assemble

valves (9) and (7), spring (8), shim (5),

and spring (4), and install guide (3).


9.

Fit O-ring and gasket and install covers (2) and (1).

WA500- 1

23-75
0

REMOVAL

OF FRONT

DIFFERENTIAL

Special tools

I
I

Part No.

793-520-2610

Bracket

793-520-2510

Bracket

Stop

the

safety
brake

machine

the machine

from

under

Lower

and stop the engine.


and put blocks

Oty

on level ground

bar on the frame.

ground

1.

Part name

and install

the bucket

the

to the

Then apply the parking


the wheels to prevent

moving.

Draining oil
Remove

drain

plugs (I) and (2), then drain oil from

axle

assembly.
&

2.

Axle assembly:

Approx.

75 (I

Tire, wheel
1) Using lift

arm,

raise front

left housing and put block


2) Sliging

left

tire

and

axle, the put stand under


under front

wheel

(3),

frame.

remove

mounting

bolts, then lift off.


Tire, wheel:

3.

660 kg

Covers
Remove left and right covers (4).

23-76
0

WA500-

4.

Axle shaft
Using forcing

screw, pull out axle shaft (5) and sun gear

(6) about 200 mm.


*

Forcing

screw:

(Thread

dia. = 12 mm,

1.75 mm).

5.

Drive shaft
Disconnect

6.

front

drive shaft

(7).

Sling drive shaft and lower carefully.

Remove disc cover (8).

Spring cylinder
1) Remove linkage

pin (9) and air hose (IO).

2) Remove spring cylinder

WA500-

(11).

Pitch

8.

Differential
1) Remove

2 mounting

bolts of differential

(14),then

remove guide bolt (M20 x 55 mm).


*
*

Screw the thread of the guide bolts in fully.


After

screwing

in the

guide

bolts,

remove

the

remaining mounting bolts.


2) Fit lever block @
*

to differential

case (15).

Fit both edges of lever block to inspection

win-

dow.

4) Install tools A and 6 to garage jack, then insert between

differential

and axle housing, and install tool

A to differential.
5) Adjust

height

of lifting

remove differential
Differential:

6) Operate

tool

and garage jack,

and

(14) carefully.
282 kg

garage jack and pull differential

(14)

out

from under the machine body.


7) Remove O-ring (17).

23;8

WA500- 1

INSTALLATION
1.

OF FRONT

DIFFERENTIAL

Differential
11 Install tools A and f3 to garage jack, then
differential (14) in tool A.

install

2) Fit O-ring (17) to differential.


3) Operate garage jack and pull differential
machine body.

in under

4) When

and axle

clearance

between

differential

housing is about 40 mm.

(14)

Install guide bolts (M20 x

55 mm) in axle housing.


5) Fit lever block @
*

Fit

both

to differential

edges of lifting

case (15).

tool to inspection

win-

dow.

6) Adjust

height

of lifting

assemble differential
*

Fit O-ring

tool

and garage jack,

and

along guide bolts.

(17) securely

in the groove and make

sure that it is not caught when installing.

7) When

clearance

differential

between

axle

housing

(16)

and

(14) is about 20 mm, remove tool A and

tighten mounting bolts uniformly.


8) Remove guide bolts and install mounting bolts.
&
w

Mounting bolt:

Thread tightener

Mounting bolt:

56 + 6 kgm

(LT-2)

(Width across flats:

WA500-

30 mm)

23-79
0

IA.

Adjusting shaft shim


*

Adjust the shaft shim when the differential

assembly

or axle housing have been replaced.


1) Tighten

the mounting

bolts of shaft (18) uniformly,

and measure clearance a between

the axle housing

and shaft.
*

Do not assembly any shim.


m

Mounting

bolt:

0.4 f 0.1 kgm


(When measuring clearance)

2) Select a shim of 0.1 f 0.05 mm larger than the meas-

425F535

ured value of clearance a, then assemble the shim.


*

Shim thickness = clearance a + (0.1 + 0.05 mm)


w

Mounting bolt:

18

11.5 * 1 .O kgm

426FO1205A

2.

Parkin g brake caliper


Set

pi

srking

brake caliper

(13)

in mounting

position,

insert plate (12) in groove of caliper and tighten mounting bolts.


*

Insert plate in caliper groove completely.

Check assembly of pad.


&I kg

Mounting

bolt:

Thread tightener

Mounting

bolt:

95 f 10 kgm

(LT-2)

(Width across flats:

3.

36 mm)

Spring cylinder
1) Set spring cylinder

(11)

in mounting

position

and

install.
w

Mounting

bolt:

28.5 + 3 kgm

2) Install air hose (IO) and linkage pin (9).

23zo

WA500-1

4.

Drive shaft
1) Install

front

2) Install

disc cover (8).

drive shaft (7).

When connecting

the drive shaft, clean the contact

&N

surface of th spider and coupling.


w
5.

Mounting

bolt:

11.5 f 1 kgm

Axle shaft
Push in axle shaft (5) together

6.

with

sun gear (6).

Cover
Fit

O-rings

in grooves

of covers

(4) and install

on left

and right sides.


*

Fit

the O-ring

securely

in the groove

and make sure

that it is not caught when installing.


7.

Tire, wheel
1) Raise tire

and wheel

then install mounting


w

Mounting

(3), set in mounting

position,

nuts.

nut:

48 + 5 kgm
(Width

across flats:

30 mm)

2) Remove the stand.


8.

Refilling with oil


Remove

level plug and add oil through oil filler to the

specified level.
*

Set the machine

so that the drain plug of the final

drive is at the bottom when refilling with oil.

Q
9.

Axle oil:

75 Q

Bleeding air from brakes


Bleed air from
*

For details

brakes, then check operation.


of bleeding

air, see 52 TESTING

AND

ADJUSTING.

425P532

WA500-1
23z

REMOVAL

Stop

OF REAR DIFFERENTIAL

the

safety
ground
brake

machine

on level ground

bar on the frame.

Lower

and stop the engine.


and put

the machine

blocks

from

and install

the bucket

the

to the

Then apply the parking

under

the wheels to prevent

moving.

- Put blocks under the front wheels and apply the


parking

- Lift

brake securely.

up the

block

machine

with

garage jack

and put

under the rear frame, then support

lower part of counterweight

with

blocks

the

b.
I

1.

425p548 fj
,f

\
---?I

i :\

,_s---

-___~_

425P549

Tire, wheel
Sling right

and left tires and wheels

(l),

remove mount-

ing nuts, then lift off.


Tire, wheel:

2.

660 kg

Drive shaft
Disconnect

rear drive shaft

Rear drive shaft:

3.

(2) from

rear axle.

42 kg

Brake piping
1) Disconnect

hose

slack adjuster
2) Disconnect

(3)

between

brake

chamber

and

from the slack adjuster.

tubes

(4) and (5) between

slack adjuster

and right and left wheel cylinders.


*

When

lifting

off the axle, there

brake tube may be damaged,

23-82
0

is danger that

the

so always remove it.

WA500-

4.

Grease tube
1) Disconnect

grease tubes (6) and (7) from

rear axle

support.

2) Disconnect grease tube (8) from front axle support.


*

Remove clamp of electric wiring from support.

Ir

Disconnect

hose

(9)

between

torque

converter

pump and filter from filter end.

5.

Rear axle, support


1) Fix axle support and rear axle with a chain.

2) Remove mounting

bolts, then using hoist and jack to

maintain balance, lower rear axle and support.


Rear axle, support:

2,050 kg

3) Pull out rear axle and support from under machine.


*

Support both ends of the axle with jacks.

WASOO-1

6.

Front support
Lift off front support (11) from rear axle.
t

Be careful not to damage the seal.


Front support:

7.

93 kg

Draining oil
Remove drain plug (12) and drain oil from axle assembly.
A

8.

Axle oil:

22 !?

Axle shaft
1) Remove cover

(13).

2) Pull out axle shaft (14).


t

9.

Pull out axle shaft about 200 mm.

Differential
Using forcing screw, lift off rear differential
& kg
*

Rear differential:

(16).

282 kg

Remove O-ring from contact surface.

425PM6

23:4

WA500- 1

INSTALLATION
1.

OF REAR DIFFERENTIAL

Rear differential
Raise differential

(15),

tighten mounting

bolts.

set in mounting

install the differential

Check that there is an O-ring fitted

position,

then

raising it horizontally.
to the mounting

face of the differential.


a
w

Mounting

bolt:

Thread tightener

Mounting

bolt:

56 ?r 5 kgm

(LT-2)

(Width across flats:


IA.

30 mm)

Adjusting shaft shim


Adjust

the shaft shim when the differential

assembly

or axle housing have been replaced.


Tighten

the mounting

bolts of shaft (16) uniformly,

and measure clearance a between

the axle housing

and shaft.
*

Do not assembly any shim.


w

Mounting

bolt:

0.4 f 0.1 kgm


(When measuring clearance)

Select a shim of 0.1 f 0.05 mm larger than the measured value of clearance a, then assemble the shim.
*

Shim thickness = clearance a + (0.1 * 0.05 mm)


m

Mounting

bolt:

11.5 + 1 .O kgm
425F537

2.

Axle shaft
1) Push in axle shaft (14).
*

If the axle shaft


differential

cannot

coupling

be inserted,

lightly.

rotate the

Never try to force

the shaft in.


2) Fit O-ring on cover (13) and install cover.
*

Make

sure that

the

O-ring

is not caught

when

installing.

426FO12056

425P546

WA500-1

23z5

3.

Front support
Lift

up front

support

(11)

and insert on the rear axle

mount.
*

Be careful not to damage seal with the coupling.

&

4.

Rear axle mount:

Grease (G2-LI)

Rear axle, support


1) Pull rear axle and support (10) under machine.
*

Secure the rear axle and axle support with a chain.

2) Using

hoist

mounting

and jack

position,

to

then

maintain
tighten

balance,

mounting

set in
bolts of

axle support.
*

Always

tighten

the mounting

bolts for the front

support on opposite sides in turn.


w

Mounting

bolt:

160?

20 kgm

(Width across flats:

5.

46 mm)

Grease tube
1) Connect

grease tube (8) to front

axle support posi-

tion.

* Install clamp of electric wiring to axle support.


* Connect hose (9) between torque converter pump
and filter.

2) Connect grease tubes (6) and (7) to rear axle support.

WA500-1

6.

Brake piping
1) Install

tubes

(4) and

(5) between

slack adjuster

and

right and left wheel cylinder.


2) Connect

tube

adjuster

7.

(3) between

brake

chamber

and slack

to slack adjuster.

Drive shaft
Connect
*

rear drive shaft

When

connecting

(2) to rear axle.

the drive

shaft,

clean the contact

surfaces before installing.


w

8.

Mounting

bolt:

11.5 + 1 kgm

Tire, wheel
Set right
tion,

and left tires and wheels

then tighten

mounting

Mounting

nut:

(I)

in mounting

48 * 5 kgm
(Width across flats:

Remove

the

support

9.

block

posi-

nut.

under

the

rear

frame

30 mm)
and

the

under the counterweight.

Refilling with oil


Tighten drain plug and add axle oil through
the specified
*

oil filler

to

level.

Set the machine

so that

drive is at the bottom


Axle oil

the drain

when refilling

plug of the final


with

oil.

: 22 L?

10. Bleeding air from brakes


Bleed air from
*

For

details

ADJUSTING.

WA500-

brakes, then check operation


of

bleeding

of brakes.

air, see 52 TESTING

AND

DISASSEMBLY

OF DIFFERENTIAL

GEAR ASSEMBLY

Special tools
Part name

Part No.

Qty

790-501-5000

Unit repair stand

Al

790-901-4

Bracket

A2

793-310-2160

Plate

Preparatory

110

work

Set differential

assembly (I)

on special tools A, AI,

and

A2.

Differential

1.

assembly:

230 kg

Pinion assembly
1) Remove case (2).
2) Remove oil seal (3) from case.

3) Screw

in forcing

screw @

(Thread

dia. = 18 mm,

Pitch = 1.75 mm), and lift out pinion assembly (4).


*

Check number of shims (5).

23z8

WA500- 1

2.

Differential

,,,,,,:,
,,~;\;,,,,;,
,, jj, ,I L ,,G
j_ j ,,

gear case assembly

1) Remove left and right locks (6), and with a bar, turn
nut (7) until it becomes loose.
V<\z::
2,

2) Remove mounting bolts (9) of cap (8).

3) Remove nut and lift out differential


bly (10).

WA500-

gear case assem-

:, ,,

j, ,\Q
,\>;
yy*,,,\,t,**,,*%,,
_\\
&*q?ya,,*\\*
,\*b_,
,\:&

FINE
3.

DISASSEMBLY

OF PINION

ASSEMBLY

Bearing, collar, cage


1) Support

cage (1 1 ), push shaft with

press and take out

pinion.

2) Remove bearing

3) Remove outer

4.

(12) and collar from cage.

races (13) and (14) from

cage.

Pinion, bearing
1) Remove snap ring (15), then remove bearing
2) Remove bearing

23-90
0

(16).

(17).

WASOO- 1

FINE DISASSEMBLY
CASE ASSEMBLY
5.

Remove

mounting

bolts,

using

eye-bolts

Pinion

plate (19) and bevel gear (20).

pinion

gear (211, cross shaft

(23) as one unit.

Bevel gear (small)


Remove bevel gear (24) and thrust

9.

(Thread

gear, cross shaft

Remove

8.

Pitch = 2.0 mm), lift off bevel gear (18).

Bevel gear (small)


Remove thrust

7.

GEAR

Bevel gear (large)


dia. = 16 mm,

6.

OF DIFFERENTIAL

plate.

Bearing
Remove bearing

WA500- 1

(26) from case (25).

(22), and washer

ASSEMBLY

OF DIFFERENTIAL

GEAR ASSEMBLY

Special tools

Part No.

I Qw

Part name

792-525-l

100

Differential
micrometer

BI

792-525-l

230

Adapter

FINE ASSEMBLY
CASE ASSEMBLY
1.

OF

DIFFERENTIAL

GEAR

Bearing
Using press fit kit @

(120

mm inner diameter),

press

fit bearing (26) to case (25).

2.

Bevel gear (small)


Install thrust and small bevel gear (24) in case.
*

3.

Align thrust with dowel pin and install.

Pinion gear, cross shaft


Assemble

pinion gear (21) and washer

(23) with

cross

shaft (22).
*

Align

washer

groove

with

dowel

pin of case and

install.

424P583

4.

Bevel gear (small)


Install bevel gear (20) and thrust (19)

2322

WA500- 1

5.

Bevel gear (large)


Using eye-bolts

(Thread dia. = 16 mm,

Pitch = 2.0

mm), lift and install bevel gear (18).


*

Align

pin hole of thrust

and dowel pin on case side

and install.

FINE
6.

ASSEMBLY

OF PINION

ASSEMBLY

Bearing
1) Using press fit kit @

(26 mm inner diameter),

install

(55 mm inner diameter),

install

pinion bearing (17).


2) Using press fit kit @
bearing (16).
&

Rotating surface of bearing:


Engine oil (E030CD)

3) Install snap ring (15).

7.

Cage
1) Install outer races (14) and (13).
2) Install cage (11) to pinion assembly.

8.

Collar
lnstal collar (27).

9.

Bearing
Using press fit kit @

(76 mm inner diameter),

install

bearing (12).

WASOO- 1
23if3

ASSEMBLY
*

OF DIFFERENTIAL

Set differential

ASSEMBLY

case on special tools A, A,,

and AZ.

10. Pinion assembly


1) Assemble shims (5) removed
*

Standard

when disassembled.

shim thickness:

2) Using eye-bolts

2.1 mm

(Thread

1.75 mm), install pinion

dia. = 12 mm,

assembly

Pitch =

(4).

3) Install oil seal (3) to case.


&

Lip of oil seal:

Grease (G2-LI)

4) Fit O-ring to case, and install case (2).


&
m

Mounting

bolt:

Thread tightener

Mounting

bolt:

2.8 f 3 kgm

5) Install coupling
&
w
*

Fit

(28), fit O-ring and tighten

Mounting

bolt:

Thread tightener

Mounting

bolt:

94 2 10 kgm

the

balancer

to

and measure the rotating


*

11.

Rotating

Differential

hole

of

holder.
(LT-2)

coupling,

torque.

Max. 5.1 kg

gear assembly

Sling differential

23z4

torque:

bolt

(LT-2)

gear assembly

(10) and install case.

WA500- 1

12. Nut, cap


1) Align

nut (7) with

differential

2) Install cap (8) and tighten


&
w
*

case groove and install.

bolt

(9).

Mounting

bolt:

Thread tightener

Mounting

bolt:

95 + 10 kgm

Check

match

marks

on bearing

(LT-2)

cup before

instal-

ling.
*

Rotate

bevel gear 20 -

tighten

bolt.

Bearing pre-load
1) Install tool
2) Measure

adjustment

30 times to settle in, then

steps are as follows:

B1 to cap on both sides,

clearance

between

tool

B1 with

tool

B.

\
3) Add

0.26

0.07

mm to measurement

and set scale on tool


*

The added
bending

425F290
dimension

B.

dimension

becomes

the amoutn

of the case, given before

pre-load

of
and

given after pre-load.


4) Tighten
amount

WA500-

adjusting

nut

with

bar

becomes 0.26 f 0.07 mm.

until

increased

Caution for pre-load adjustment


When adjusting nut is overtightened,

in case the amount

of

satndard

increased

bending

surpasses the

measure-

ment,

return adjusting nut to position before adjusting.

Then,

while

rotating

bevel gear, lightly tap bearing cap

and bevel gear with plastic hammer, and check that there
is no clearance in portion

b.

.No

clearance

425F291

13. Adjusting tooth contact, backlash


Adjust

the backlash, and at the same time adjust tooth

contact.
1) Adjust backlash as follows:

i) Movement
nut (7).

of bevel gear is done with


At this time,

load pressurization

adjusting

so as not to change pre-

of bearing, turn nuts on both

sides, the same amount each, in same direction.


ii)

Put dial gauge @

in vertical

contact

with for-

ward and reverse sides of outer edge of bevel gear


tooth

face,

and

adjust

until

gauge meter

while

turning

adjusting

fluctuation

nut,

becomes

0.3 - 0.4 mm.


*

425F292

Measure at 3 or 4 places, and keep the pinion


gear fixed when measuring.

2) Adjust tooth contact as follows:


i)

Adjust

bevel pinion

differential
ii)

by adjusting shims between

case and bearing cage.

Adjusting tooth contact


For

details,

see ADJUSTING

TOOTH

CON-

TACT.

23-96
0

WA500-

3) Adjusting tooth contact


Coat face of 7 or 8 teeth of bevel pinion lightly with red lead (minimum).

Hold the bevel gear by hand to act

as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth.

2OBF514

Procedure for adjustment

Cause

Tooth contact

The tooth contact pattern should


start from about 5 mm from the
toe of the bevel gear and cover
about 50% of the length of the
tooth.
It should be in the center of the
tooth height.

Adjust the pinion gear by adjusting the shims at the


:age. Adjust the bevel gear in the same way as when
adjusting backlash.

1. Reduce shims at pinion gear to bring closer to bevel

Pinion gear is too far from

gear.

bevel gear.

2. Move bevel gear further away


from pinion gear and adjust

:,

backlash correctly.
?A

2OBF515

Pinion gear is too close

2OBF519

1. Increase shims at pinion gear to move away from

to

bevel gear.

bevel gear.

2. Move bevel gear closer to pinion


gear and adjust backlash

2
c

correctly.
208 F520

Bevel gear is too close to pinion


gear.

1. Reduce shims at pinion gear to bring closer to bevel


gear.
2. Move bevel gear further away
from pinion gear and adjust
backlash correctly.
2OBF519

Bevel gear is too far from


pinion gear.

1. Increase shims at pinion gear to move away from


bevel gear.
2. Move bevel gear closer to pinion
gear and adjust backlash

When adjusting the driven gear, do not change the pre-load of the bearing.
the same amount each (check by the numberof

WA500-

?d

correctly.

2
c

2OBF520

Turn the left and right adjusting nut,

notches), in the same direction.

REMOVAL

n!

OF FRONT AXLE

Stop the
safety

machine

on level ground and install the

bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.

Put blocks under the rear wheels to prevent the machine


from moving, and apply the parking brake sec,urely.
Insert block 0

between frame (2) and the top surface

of rear axle housing (1).

Jack

up the

machine,

and

put blocks @

under the

front frame on the left and right sides.

1.

Tire, wheel
Sling left and right wheels (3), remove mounting

nuts,

then lift off.


Tire, wheel:

2.

660 kg

Drive shaft
Disconnect drive shaft (4) at differential
*

Align

match

marks on the coupling

end.
of drive shaft

before assembling of drive shaft.

23698

WA500-

3.

Brake tube
1) Disconnect brake tube (5) from slack adjuster.
2) Disconnect brake tubes (6) and (7).
*

After

disconnecting

the piping, cover to prevent

dust or dirt from entering.

4.

Air piping
Disconnect air hose (8) from spring cylinder.
*

5.

Loosen drain valve and drain air.

Front axle
1) Sling

front

axle

housing

(9) on one side, and fit

garage jack under other side.


2) Fit garage jack under bottom of differential
t

case.

Be careful not to damage the side face of the parking brake cover.

3) Remove mounting

bolts, then using hoist and jack to

maintain balance, lower front axle.


Sr Be careful

not to parking

brake

caliper bracket

interfere with frame.


*

Be careful not to let the slack adjuster on the top


surface of the axle housing hit against the frame.

& kg

Front axle:

2,100

kg

4) Pull out front axle from under machine.

WA500-

INSTALLATION
1.

OF FRONT AXLE

Front axle
1) Pull front axle under machine body.
2) Fit lifting tool to front axle (9), set garage jack under
differential

case and maintain

balance while

setting

in mounting position.
3) Tighten mounting bolts of front axle.

Mounting bolt:

280 + 40 kgm
(Width across flats:

55 mm)

425Pem

2.

Air piping
Connect air hose (8) to spring cylinder.

3.

Brake tube
1) Install brake tubes (6) and (7).
2) Connect brake tube (5) to slack adjuster.
*

4.

Wipe the connection with a clean cloth.

Drive shaft
Connect front drive shaft (4) at differential
w

23- 100
0

Mounting bolt:

11.5 f

end.

1 kgm

WA500-

5.

Tire, wheel
1) Set left and right wheels (3) in mounting

position,

then install mounting nuts.


m

Mounting

nut:

48 i. 5 kgm
(Width across flats:

2) Jack up machine, then remove block @

30 mm)

from under

front frame.
3) Remove block @

from

between

frame

(2) and top

surface of rear axle housing (1).

6.

Bleeding air from brakes


Bleed air from brakes, then check operation.
*

For details

of bleeding

air, see 52 TESTING

AND

ADJUSTING.

WA500-

23iio1

REMOVAL

Stop

OF REAR AXLE

the

safety

machine

ground

and put

the machine
Put

blocks

Jack

blocks

from

under

chine from
.

Lower

and stop the engine.

brake

on level ground

bar on the frame.

up the

the

to the

Then apply the parking

under

the wheels to prevent

moving.

the front

moving,

and install

the bucket

wheels

to prevent

the ma-

and apply the parking brake securely.

machine,

frame, and put a stand

put
@

block

under

the

rear

under the counterweight.

b
I

1.

425P548

Tire, wheel
Sling

left

and right

wheels

(l),

remove

mounting

nuts,

then lift off.


Tire, wheel

2.

: 660 kg

Drive shaft
Disconnect

rear drive shaft

Rear drive shaft:

3.

(2) from

rear axle.

42 kg

Brake piping
1) Disconnect

tube

slack adjuster
2) Remove

tubes

(3)

between

brake

chamber

and

from slack adjuster.


(4) and (5) between

slack adjuster

and

is danger that

the

right and left wheel cylinders.


*

When

lifting

off the axle, there

brake tube may be damaged,

23-102
0

so always remove it.

WA500-

4.

Grease tubes
1) Disconnect

grease tubes (6) and (7) from

rear axle

support.

2) Disconnect grease tube (8) from front axle support.


*

Remove clamp of electric wiring from support.

Disconnect

hose

(9)

between

torque

converter

pump and filter from filter end.

5.

Rear axle, support assembly


1) Secure alxe support and rear axle with chains.

Remove mounting

bolt, then using thoist and garage

jack to maintain balance, lower rear axle and support.


Rear axle, support:

2,050

Pull out rear axle and support

kg

(10) from under the

machine.

* Support both ends of the axle with jacks.

WA500-

6.

Front support
1) Remove front support (1 I) from rear axle.
*

Be careful not to damage the seal.


Front support:

93 kg

2) Remove bushing (12) from front support.

12

425P606

3) Remove seals (13) and (14) from front support.

425F282

7.

Rear support
1) Sling rear support, remove thrust cap (15)

23-iho4

WA500-

2) Remove

thrust

washer

(16),

thrust

plate

(17)

and

thrust washer (18) from rear axle.

16

425F283

3) Lift off rear support (19).


Rear support:

120 kg

4) Remove bushing (20) from rear support.

5) Remove seal (21) from rear support.

*\

27
425F284

WA500-

425P6:. ?

INSTALLATION
1.

OF REAR AXLE

Rear support
1) Install seal (21) on rear support.
&

Seal lip:

Grease (G2-LI)

2) Install bushing (20) on rear support.


*

Assemble the bushing with the chamfered edge on


the axle housing side.

*
&

Check that the slit of bushing faces sideways.


Bushing:

Grease (G2-LI)

425F285

3) Raise rear support

(19) and set in position

on rear

axle mount.
&

Rear axle mount:

Grease (G2-LI)

4) Install thrust washer (181, thrust plate (17).


a
B

Thrust washer:

Grease (G2-LI)

Mounting bolt:

28.5 f 3 kgm

23-Ao6

WA500-

5) Install thrust washer (16) and thrust cap (15).


&
m

2.

Thrust washer:

Grease (G2-LI)

Mounting bolt:

28.5 + 3 kgm

Front support
1) Install seal (13) and (14) on front support.
&

Seal: Grease (G2-LI)

24
13

14

425F282

2) Install bushing (12) on front support.


*

Assemble the bushing with the chamfered edge on


the axle housing side.

Check that the slit of bushing faces sideways.

Bushing:

Grease (G2-LI)

425F287

3) Raise front support

(1 I), and set in position on rear

axle mount.
*

Be careful not to damage seals with coupling.

WA500-

Rear axle mount:

Grease (G2-LI)

429606

3.

Rear axle, support


I) Pull rear axle and support assembly (10) to underside
of the machine.
*

Secure rear axle and axle support with chains.

2) Using hoist and garage jack to maintain balance, set


in mounting

position, and tighten mounting

bolts of

axle support.
*

Tighten

the mounting

bolts of the front support

on opposite sides in turn.


w

Mounting bolt:

160 + 20 kgm
(Width across flats:

4.

46 mm)

Grease tubes
1) Connect grease tube (8) to front axle support.
*

Install clamp of electric wiring to axle support.

Connect

hose (9) between

torque

converter

and

filter to filter end.

2) Connect grease tubes (6) and (7) to rear axle support.

23-108
0

WA500-

5.

Brake piping
1) Install

tubes

(5) and

(4) between

slack adjuster

and

right and left wheel cylinders.


2) Connect
adjuster

6.

hose (3) between

brake

chamber

and slack

to slack adjuster.

Drive shaft
Connect
*

rear drive shaft

When

connecting

(2) at rear axle end.

the

drive

shaft,

wipe

the contact

surface when installing.


m

7.

Mounting

bolt:

11.5 + 1 kgm

Tire, wheel
I) Set left

and right

then tighten

Mounting

wheels

mounting
nut:

(1) in mounting

48 f 5 kgm
(Width

8.

Bleeding

air from

across flats:

brakes, then check operation.

of

details

30 mm)

brakes

Bleed air from


For

position,

nuts.

bleeding

air, see 52 TESTING

AND

ADJUSTING.

WA500-

23-109
8

REMOVAL

Stop

the

OF CENTER
machine

completely
the

Lower

stop the engine.


put blocks

1.

on level ground,

to the left and install

frame.

from

SUPPORT

the bucket

Then apply

turn

the wheel

the safety

bar on

to the ground

the parking

under the wheels to prevent

and

brake and

the machine

moving.

Drive shaft
1) Disconnect

the

center

drive

shaft

(I)

from

center

support.
*

Set block

under drive shaft and remove.

Center drive shaft:

33 kg

2) Sling front drive shaft (2) and disconnect

from

center

support.
Front

23-110
0

drive shaft:

44 kg

WA500-

INSTALLATION
1.

OF CENTER

SUPPORT

Center support
1) Set center

support

(4)

in mounting

position

and

tighten mounting bolts.


*

Adjust

shims so matching

surface of center

of

center pin and coupling are parallel.


w

Mounting bolt:

56+

6 kgm

(Width across flats:

30 mm)

2) Connect grease tube (3) to center support.

2.

Drive shaft
1) Connect front drive shaft (2) to center support.
B

Mounting bolt:

11.5 2 1 kgm

2) Connect center drive shaft (I) to center support.


*

Clean.mounting

surface of coupling with

cloth.
m

WA500-

Mounting bolt:

11.5 f

1 kgm

a clean

DISASSEMBLY
I.

OF CENTER

SUPPORT

Coupling
Remove center bolt (I), then remove retainer (2), O-ring
(3), and coupling (4).

2.

Retainer
Remove mounting bolts (5) of retainer.
*

3.

Remove all mounting bolts while rotating coupling.

Shaft
1) Set shaft case assembly (6) on press stand.
2) Push out shaft (7) with press.
*

Be careful because the shaft will fall out suddenly.

425F273A

3) Remove spacer (8), bearing cone (9) and retainer (5)


from shaft.

23-l 12
0

WA500-

4.

Oil seal
1) Remove oil seal (IO) and O-ring

(11) from

retainer.

425F274

2) Remove oil seal (12) from


5.

case.

Case
Remove

bearing

cone

(13)

and bearing

outer

race (14)

and (15).

425F275

WA500-

23-&1
3

ASSEMBLY
I.

Bearing

outer

Assemble

OF CENTER

SUPPORT

race

bearing

(14)

and

(15),

in case (16).

425F276

2.

Oil seal
Assemble
&

oil seal (IO)


Outer

in retainer

circumference

(5).

of oil seal:

Grease

(G2-LI)

425F277

3.

Bearing

cone

Assemble

retainer

(5)

shaft

and

press fit

bearing

cone

there

is no

(9).
*
*

4.

After

assembling

bearing,

clearance

at tip of shaft.

Assemble

spacers.

Lip of seal:

&

Inner

Grease

circumference

check

that

(G2-LI)
of bearing:

Grease

(G2-LI)

Case
1) Assemble
*

Insert

O-ring
O-ring

23G14

(11)

in retainer.

completely

in groove.

WA500-

2) Stand shaft and insert case (16).


*

Fill

and b

of case and inner circumference

of oil seal completely

with

grease.

-16
5.

Retainer
Secure retainer
*

(5) in case.

Be careful

that

O-ring

does

not

get caught

when

installing.
Mounting

bolt:

6.7 + 0.7 kgm

425F278

6.

Bearing cone, seal


1) Press fit bearing cone (14) to shaft.
2) Assemble oil seal (12) in case.
*

Dimension

of seal press fit and outer edge of case:


0.5 mm

&

7.

Seal:

Grease (G2-LI)

coupling

(4), install

Coupling
Assemble

(2), and secure center bolt


Center bolt:

O-ring

(3) and retainer

(1).

95 i: 10 kgm
(Width across flats:

8.

36 mm)

425P633

Inspection of end play


Check that end play is within
*
*

End play:
If end play
with

specified

range.

Less than 0.22 mm


is 0,

with

the seal and bearing

grease, check that the free rotating

coated

torque

is less

than 0.4 kgm.

425F279

425Q637

WA500-

425P632

23i5

DISASSEMBLY
Serial
1.

No.

10001

OF DRIVE SHAFT
10222

Splined yoke
Loosen retainer (I) and remove splined yoke (2).

425P616

2.

Bearing assembly
Remove

mounting

bolts

(3), then

remove bearing

assembly (4).
*

Make match marks on yoke and bearing.

425P617

3.

Bearing cap
1) Remove bearing cap (5) from bearing assembly.
*

Remove strap (6) of cap.

425P618

2) When replacing bearing (7), seal (8), and Derling


washer (9) from

bearing cap, replace whole cap

assembly.
*

Carry

out the same procedure

at the sleeve
7

yoke end.
8

425F280

23-&1
6

425P639

WA500-

4.

Sleeve yoke
1) Remove mounting

bolts (11) from sleeve yoke (IO),

then remove bearing assembly (4).


*

Stamp of mutch marks on yoke and bearing.

425P620

2) Remove bearing cab (5) from bearing assembly.

WA500- 1

23iA17

ASSEMBLY
Serial
1.

No.

10001

OF DRIVE
-

SHAFT

10222

Bearing cap
1) Install bearing (7), and seal (8) to bearing cap (5).
a

Bearing, seal: Grease (G2-LI)

425F281

2) Assemble

Delrin

washer (9), and bearing cap (5) to

bearing assembly (4).


a

Bearing cap: Grease (G2-LI)

425P623

2.

Bearing assembly
Assemble bearing assembly (4) to sleeve yoke (10).
+
*

Carefully align match marks.


Clean the mounting face of the bearing cap by wiping
with a clean cloth.

Mounting bolt:

14.5 + 1 kgm

425P624

3.

Splined yoke
1) Assemble bearing (7) and seal (8) in bearing cap (5).
&

Bearing seal: Grease (G2-LI)

7
8
7

425P67

425F280

23-k
*

WA500-

2) Assemble

Delrin

bearing assembly
*

Be careful
welding

washer

(9) and bearing

cap (5) to

(4).

not to damage bearing

with

heat when

strap.

425P625

3) Assemble

bearing assembly

Carefully

Clean

the

wiping

with

(4) to splined yoke

(2).

align match marks.


mounting

face

of the

bearing

cap by

!+
\

a clean cloth.

Mounting

bolt:

14.5 * 1 kgm

425P626

4) Align

match

marks, insert splined yoke

(IO), and secure with


*

Check that

retained

the yokes

in sleeve yoke

(1).

are facing

in the same direc-

tion.
*

If the spline is worn,

replace the whole

drive shaft

assembly.

425P627

WA500-

23i9

DISASSEMBLY
Serial
1.

No. 10223

OF DRIVE SHAFT

and up

Shaft
1) Remove
*

shaft

Make
ensure

marks

that

assembly
*

(2).

match

Cover

a before

direction

removing
of

the

to

spider

does not change.

(1)

places,

the

is caulked

so

it

must

with
not

be

a punch

at four

removed

unless

necessary.
+

When

removing

not to damage
*

When

cover (I), be extremely


cover

removing

caulking

with

careful
a

(1) and yoke (3).


the

caulking,

raise

425FO1628

the

a screwdriver.

Seal
426FO1203A-K

2) Remove

mounting

assembly
+

Make

bolts

(4), then

remove

spider

(5).
match

marks

on yoke and spider.

425FO1629

3) Remove
*

bearing

Remove

strap

caps (6) from


(7) of cap.

spider

assembly.

425FO1630

23-:
9-1

WA500-1

4) When

replacing

washer

bearing

(10) from

(8), seal (9), and Derling

bearing

cap (6), replace

whole

cap assembly.

425F281

2.

Yoke
1) Remove
remove
*

Stamp

mounting
spider

bolts

(11) from

assembly

match

marks

yoke

12

(3), then

425FO1631

A-K

(12).
on the

yoke

and

spider.

11

2) Remove

3) When
Derling
replace

bearing

replacing
washer
whole

caps (13) from

bearing
(16)

from

(14),

spider

seal

bearing

425FO163:

425FO1633

assembly.

(15)
cap

and
(13),

cap assembly.

425F281

WA500-1

B-K

425FO1634

23-A9-2

ASSEMBLY

OF DRIVE SHAFT

Serial No. 10223

and UP

1.

Yoke
1) Install

bearing

(14), and seal (15) to bearing

cap

15

(13).
&

Bearing,

seal: Grease

13

(G2-LI)

14

I
425F281

2) Assemble

Derling

(13) to spider
9r Be careful
when
&

washer

assembly

(16),

Bearing

cap

(12).

not to damage

welding

and bearing

B-K

bearing

with

heat

strap.

cap: Grease

(G2-LI)

Q
16

425FO1635

3) Assemble

spider

Carefully

Clean

the

by wiping
w

assembly

align

mounting
with

Mounting

match

(12) to yoke (3).


marks.

face

a clean

bolt:

of the

bearing

12

cap

cloth.

14.5 *

1 .O kgm

2.

425FO1636

Shaft
1) Assemble

bearing

(8) and seal (9) in bearing

cap

(6).
#??TY=

Bearing

seal:

Grease

(G2-LI)

9
8
8

425F281A-K

23-A9-3

425FO163

WA500- 1

2) Assemble

Derling

washer

(6) to spider assembly


+

Be careful
when

&

(10) and bearing

not to damage

welding

Bearing

cap

(5).
bearing

with

heat

strap.

cap: Grease

(G2-LI)

1'0

3) Assemble
+
+

spider assembly

Carefully
Clean

the

by wiping
m

align match
mounting

425FO163

(5) to shaft (2).

marks.
face

of the

bearing

cap

with a clean cloth.

Mounting

bolt: 14.5 zb 1 kgm

4) Align

match

marks

a, then

install

shaft

(2) to

yoke (3).
*

Checkthat

the direction

of the spider assembly

is the same.
*

If the spline

is worn,

replace

the whole

drive

shaft assembly.
a

Spline:

Grease

(G2-LI)

a
425FO1626

5) If cover (1) has been removed,


i) Insert
(2).

seal and retainer

assemble

cover

punch on diagonally

(l),

do as follows.

to cover (1) and shaft


then

opposite

caulk

with

sides.

426F01203A.K

WA500-1
23-;9-4

DISASSEMBLY

Q7

Stop the
safety

OF FINAL

machine

DRIVE

on level ground and install the

bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
Special tool

Part No.

I Q'tv
I

910

795-520-l

Part name

Fixture

425E355

Tire assembly
Loosen wheel nuts, raise machine with equipment
insert

stand

under

axle,

sling tire

assembly,

tools,
remove

wheel nuts, then remove tire assembly (1).


Tire assembly:

E?lkg

600 kg

Draining oil
Remove drain plug (2) and drain oil.
*
u

Set the drain plug at the bottom.


:

Axle oil

: Approx. 20 J?

Cover
Remove mounting bolts (3), then remove final drive case

425P856

cover (4).

Axle shaft
Screw in bolt @

(Thread dia. = 12 mm,

Pitch = 1.75

mm) to axle shaft and lift out axle shaft assembly (5).

5.

Planetary carrier
Remove

mounting

(Thread

dia.

bolts

= 12 mm,

(6),

and

Pitch

using eye-bolts @

= 1.75

mm),

lift

out

planetary carrier assembly (7).


*

Because balance is bad, adjust the center of gravity


with a bar and remove.
Planetary assembly:

23-A20

90 kg

WA500-

6.

Ring gear
1) Using

tool

A, hold

wheel

hub

(9) and brake

housing

(8) in position.
*

Install

tool

washers

2) Remove
(11)
*

on opposite

mounting

There

bolts

are shims
and

reference

,-.

inside

thickness

when

sides, and use

clearance.

(lo),

and ring gear assembly


number

7.

A to points

to adjust

then

remove

retainer

(12).
the

retainer,

of the

so check

shims,

and

the

use for

installing.

Ring gear:

50 kg

Disassembly of planetary carrier


1) Using a press,

pull

out

shaft

(13)

and

remove

pinion

gear (14).
*

There

is a lock ball (15)

on the shaft,

so be careful

not to lose the ball.


*

Write

a number

moved
2)

Remove

bearing

ring (20),
*

The

on the

parts separately
from
bearing

gether,

case and

(17),

cup

(18),

pinion

gear

(14).

and

so mark

other

keep

all the

re-

in sets.

parts

spacer
have

(19)

and snap

settled

the parts and keep them

in to-

in sets.
423F435A

18
14
19
20
18
423F436A

WA500-

423P938A

23-A2

8.

Disassembly of ring gear


1) Remove

lock

plates (22)

from

ring gear hub (211,

then remove ring gear (23).


2) Pull out bearing (24) from ring gear hub (21).

23-122
0

WA500-

ASSEMBLY

OF FINAL

DRIVE

Special tool
Part name

Part No.
A

1.

795-520-I

oyy

Fixture

910

Assembly of ring gear

1) Press fit bearing (24) on ring gear hub (21).


*

After

press fitting the bearing, check that there is

no clearance between the rib and bearing.


2) Set ring gear hub (21) on ring gear (231, then install

lock plates (22).


*

Install the lock plates with the wider ones on the


inside.

Rmove all grease and oil from the bolt.

Mounting bolt:

Thread tightener

Mounting bolt:

3.2 ir 0.3 kgm

(LT-2)

423F436A

2.

Assembly of planetary carrier

1) Install snap ring (20) and spacer (19) on pinion gear


(14).
2) Press fit cup (18)

on pinion

gear, and set bearing

(17).

3) Set pinion gear in carrier case, insert ball (15) in shaft


(13),
*

then

press fit.

Press fit so that


outside
the front

After

the hole for the lock

circumference,

stop

ball is on the

with

the

hole

at

and align the holes.

press fitting

rotates

then

the shaft, check

that

the

gear

smoothly.

423F435A

WASOO-1
23-;23

3.

Adjusting

method

1) Insert

ring

retainer
(IO),
*

of wheel bearing

gear assembly

(11) tighten

in axle
with

housing

fit
bolts

secure wheel

hub

(9) and brake

(8).

Measure thickness

12

of retainer

before installing.

I
*

housing,

mounting

and remove tool A.

When removing,

(12)

temporarily

425F293

Do not insert shims in the retainer

when tightening

temporarily.
t

Rotate

the wheel

hub 20 -

the bolts to a uniform


w

Mounting

2) Using a depth
measuring
a

bolt:

8 + 0.5 kgm

micrometer

or dial gauge, insert through

hole of retainer

from

retainer

30 times and tighten

torque.

(25) and measure clearance

to face of housing.

Measure at 2 places and take the average.

0.3

mm

C =

a - b, becomes shim thickness.

added

to

Use the smallest


required

3) After
hub,

installing
remove

When
always

tool

difference

of shims which

A to brake

retainer,

tighten

insert

gives the

shims,

the

mounting

after

mounting

tightening

housing

the required

then tighten

assembling

the specified
&

number

value

thickness.

shims and retainer,


t

measured

and wheel
number

installing
bolts

of

10

bolts.
tool

uniformly

A,
to

torque.

Mounting

bolt:

Thread tightener

Mounting

bolt:

28.5 f 3 kgm

(LT-2)

423F439

23-124
0

WA500- 1

Planetary carrier

4.

Fit

O-ring,

using eye-bolts @

Pitch = 1.75

(Thread

mm) sling planetary

dia. = 12 mm,

carrier assembly (7),

set in mounting position and tighten mounting bolts (6).


*

Because balance is bad, adjust the center of gravity


with a bar and install.

5.

Axle shaft
Screw in bolt @

(Thread dia. = 12 mm,

Pitch = 1.75

mm) in axle shaft and insert axle shaft assembly (5).


+

If the position of the sun gear does not match, rotate


the wheel hub to align.

6.

Cover
Fit

O-ring,

install

final

drive cover

(4),

then

tighten

mounting bolts (3).


m
7.

Mounting bolt:

7 * 1 kgm

Refilling with oil


Tighten

drain

plug (2) and add oil through

level plug

(26) to the specified level.


*

Set the

machine

so that the level plug of the final

drive is at the bottom when refilling with oil.


Axle oil

8.

: Approx. 20 Q

425?865

Tire assembly
Sling tire assembly

(I),

set wheel hub, and after tem-

porarily tightening wheel nuts, raise machine with garage


jack and remove support from under axle.
the machine to the ground, and tighten

Then lower

wheel nuts to

the specified torque.


m

Wheel nut:

48 + 5 kgm
(Width across flats: 30 mm)

WA500-

23k25

POWER TRAIN

24 MAINTENANCE

STANDARD

Transmission mount ...........


Torque converter charging pump
Damper .......................
Torque converter ..............
Transmission ..................
Transfer.. ....................
Drive shaft ....................
Center support ................
Differential ....................
Axle mount ...................
Final drive .....................

WA500-

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

.
.
..
.
.

..
.
..

24- 2
24- 3
24- 4
24- 5
24- 6
24-14
24-l 6
24-l 7
24-l 8
24-22
24-24

24-l

-_

TRANSMISSION

MOUNT

Section A - A

!!!i/l
.,

425F132

Unit:
Check item

No.

Criteria

Thickness of shim for mounting

Tightening torque of mounting


bolt

28.2 * 3.2 kgm

Tightening torque of bracket


mounting bolt

28.2 f 3.2 kgm

Tightening torque of bracket


mounting bolt

Tightening torque of mounting


bolt

2mm

Remedy

Adjust

Ff.+ih+P

24-2

18?2kgm

28.2 f 3.2 kgm

WA500- 1

mm

TORQUE

CONVERTER

CHARGING

PUMP

Model SAR (3)-080

Section A - A

\
5

425F134

Unit:
No.

Criteria

Check item

Remedy

Clearance limit

Standard clearance
1

Clearance between gear case


and side plate, gear

0.19

0.10-0.15

Replace

Clearance between inside diameter


of plain bearing and outside diameter of gear shaft

Insertion depth of pin

Rotating torque of spline shaft

0.7 - 1.2 kgm

Tightening torque of bolt

25.2 f 1.7 kgm

Discharge
Oil:

0.20

0.06 - 0.149

WA500- 1

45 - 55C

L
x:9

14:.5

Retighten

Revolution
(rpm)

Pressure
(kg/cm )

Standard
discharge
(Qimin.)

Repair limit
discharge
(Q/min.)

2,500

210

IS4

170

EOlO-CD

Temperature:

mm

24-3

DAMPER
Serial

No.

10001

10809

1
2

/f-T--\

Serial

No.

10810

425F133

and up
m

6.75CO.75kp

-11.25f

1.25kgm

/A-i

/\I\

~sxO+Hqm i 2 1
24-4
0

Section A - A

425FO1213

WA500-1

Backlash of spline

6.75 c 0.75 kgm

WA500-1

24-4- 1
0

TORQUE

CONVERTER

425F135

Criteria

Check item

Inside diameter of seal ring


surface of retainer

Inside diameter of seal ring


surface of sleeve

Width and
thickness of
seal ring

Width

Tolerance

Repair limit

120

+0.035
0

120.5

65

+0.025
0

65.1

3.95

Thickness

4.6

2.1
+0.1

Backlash of PTO gear


(Drive gear)

Tightening torque of bolt

6.7 f 0.7 kgm

Tightening torque of bolt

11.2 t 1.2 kgm

Tightening torque of nut

Tightening torque of bolt

5.5 i: 0.5 kgm

Tightening torque of bolt

6.7 t 0.7 kgm

Tightening torque of bolt

6.7 r 0.7 kgm

0.18 - 0.49

mm

Remedy

Standard size

WASOO- 1

unit:

Repair
chrome
plating or
replace

3.55

Replace

4.14

42.5i2.5kgml

24-5

TRANSMISSION

(l/2)

13 18

14 19 15

\\

17 11 12 5

9'
425F136

24-6

WA500- 1

unit:

mm

No

No.1 clutchsprings
(12 pieces)

No.2 clutchsprings(12 pieces)

3
4

9
10

11

Thicknessof 1 disc

12

Thicknessof 1 plate

14
15
16

17
la

WA500-

24-7

TRANSMISSION

(2/2)

425F137

Unit:
No.

Check item

Criteria

Backlash between No.1 sun gear and


planetary gear

0.13 - 0.31

Backlash between No.1


and ring gear

0.15 - 0.38

Backlash between No.2 sun gear and


planetary gear

0.14 - 0.35

Backlash between No.2 planetary gear


and ring gear

0.15 - 0.39

Backlash between No.3 sun gear and


planetary gear

0.14 - 0.35

Backlash between No.3


and ring gear

0.15-0.39

Backlash between No.5 sun gear and


planetary gear

0.14 - 0.35

Backlash between No.5 planetary gear


and ring gear

0.15 - 0.39

Backlash between No.6 sun gear and


planetary gear

0.14 - 0.35

Backlash between No.6 planetary gear


and ring gear

0.15 - 0.39

10

24-8

planetary gear

planetary gears

mm

Remedy

Replace

WA500- 1

SOLENOID

VALVE

Section A - A
425F142

Unit:

No.

Check item

Criteria

Tightening torque of solenoid valve


mounting screw

0.17 * 0.01

Tightening torque df solenoid valve


terminal screw

0.17 + 0.01

Tightening torque of solenoid valve


terminal screw

0.075 f 0.005

Tightening torque of solenoid valve


connector mountina screw

0.07 t 0.01

Tightening torque of temrinal


mounting screw

0.07 t 0.01

Tightening torque of solenoid valve


mounting bolt

Remedy

WA500- 1

kgm

Retighten

6.7 t 0.7

24-9

TRANSMISSION
.

UPPER

CONTROL

VALVE

VALVE

13
\

425F139

425F140

24-10

WA500- 1

.- _-.

Unit:

I
No.

Check item

Criteria

Clearance between reducing valve


and body

relief valve spool and body


Clearance between torque converter

Clearance between priority valve


soool and body

25

Remedy

-0.045
-0.035

0
+0.013

0.058
0.035 -

25

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

Clearance between quick return


valve spool and body

12

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

Clearance between modulating


valve spool and body

25

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

Clearance between main relief valve


spool and body

28

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

I
I

mm

0.08

Standard size
7

Priority valve spring

Replace

Repair limit

Free
length

Installation
length

Installation
load

Free
length

Installation
load

62

37.7

22.1 kg

59.6

19.9 kg

62

48

12.8 kg

60.6

11.5 kg

Torque converter relief valve spring

Modulating valve spring (Inner)

118

110

5.55 kg

117

5.3 kg

10

Modulating valve spring (Outer)

145.7

144

1.69 kg

141

1.60 kg

11

Main relief valve spring (Inner)

12

Main relief valve spring (Cuter)

13

Thickness of shim for reducing

14

Thickness of shim for modulation valve

3 mm (pressure per 1 piece: 0.20 kg/cm

15

Thickness of shim for priority valve

2 mm (pressure per 2 piece: 0.26 kg/cm

16

Thickness of shim for torque converter


relief valve

4 mm (pressure per 1 piece: 0.26 kg/cm*)

17

Thickness of shim main relief valve

1.5 mm (pressure per 1 piece: 0.39 kg/cm

18

Tightening torque of modulation

I
I
VdVe

108

122

83.5

83.5

30.8 kg

37.9 kg

105

29.3 kg

36.0 kg

118

)
I

3 mm (pressure per 1 piece: 0.65 kg/cm)

Adjust

WA500-

lock nut

4.25 i 0.75 kgnt

)
Retighten

24-11
0

-_

LOWER

VALVE

12
\

425F141

24-12

WA500- 1

Unit:
NO.

Check item

Criteria

Clearance between FORWARDREVERSE spool and body

Remedy

Tolerance

Standard
size

22

Standard
clearance

Clearance
limit

+0.013
0

0.035 0.058

0.08

Shaft

Hole

-0.035
-0.045

mm

Clearance between 1 st speed


spool and body

22

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

Clearance between 2nd speed


spool and body

22

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

Clearance between 3rd speed


spool and body

22

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

Clearance between 4th speed


spool and body

22

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

Clearance between pilot reducing


valve and body

25

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

Clearance
between
lubrication
valve
plunger
and body

22

-0.035
-0.045

+0.013
0

0.035 0.058

0.08

Replace

Standard size

FORWARD-REVERSE,
No. 1, No. 2, No. 3 and
No. 4 speed spring

Free
length

Installation
length

Installation
load

Free
length

Installation
load

78

47

10.9 kg

75

10.4 kg

162

125.6

Pilot reducing valve spring

62

11

Lubrication valve spring

39.4

12

Thickness of shim for accumulator

13

Thickness of shim for pilot


reducing valve

Accumulator

10

WA500-

spring

Repair limit

Transmission
No.lOOl-1599

140kg

1158

/36kg

IReplace

43.7

16.7 kg

60.1

15kg

37

6.2 kg

39.2

5.6 kg

1 mm (pressure per 1 piece: 0.19 kg/cm)


Adjust
3 mm (pressure per 1 piece: 0.26 kg/cma

24-13
0

TRANSFER

Tl

13

9
17

425F138

24-14

WA500- 1

Unit:

mm

Out-side diameter of idler shaft (Rear)

Out-side diameter of output shaft bearing

Out-side diameter of output shaft

WA500- 1

24-15

DRIVE SHAFT

425F144

NO.

torque of front
shaft mounting bolt

drive

Tightening torque of front


shaft mounting bolt

drive

3 ~_ Tightening torque of front


shaft mounting bolt

drive

11.5 * 1 .O kgm

Tightening torque of front


shaft mounting bolt

drive

14.5 + 1 .O kgm

11.5 t 1 .O kgm
I

14.5 i 1 .O kgm

Tightening torque of center support


mounting bolt

56.0 ?:6.0 kgm

Tightening torque of center Idrive


shaft mounting bolt

14.5 r 1 .O kgm

Tightening torque of center


shaft mounting bolt

drive

11.5 ?:1 .O kgm

Tightening torque of center drive


shaft mounting bolt

11.5 * 1.0 kgm

Tightening torque of center drive


shaft mounting bolt

14.5 2 1 .O kgm

10

Tightening torque of rear drive


shaft mounting bolt

14.5 f 1 .O kgm

11

Tightening torque of rear drive


shaft mounting bolt

11.5 * 1 .O kgm

Tightening torque of rear drive


shaft mounting bolt

13

Tightening torque of rear drive


shaft mounting bolt

14

Tightening torque of upper drive


shaft mounting bolt

15

Tightening torque of upper drive


shaft mounting bolt

24-16

Remedy

Criteria

Check item

Retighten

11.5 * 1 .O kgm

14.5 * 1 .O kgm

14.5 i 1.0 kgm

I
I

11.5 + 1 .O kgm

WA500-

CENTER

SUPPORT

425F143
Unit:
:

Check item

No.

Criteria

Shaft
1

Standard
clearance

Clearance
limit

Hole

Clearance between case and bearing


140

-:.018

-0.036
-0.061

-0.018
-0.061

-0.015

130

-:.OlS

-0.036
-0.061

-0.018
-0.061

Clearance between coupling shaft


and bearing

80

+0.051
+0.032

0
-0.015

0.032

0.066

0.029

Clearance between coupling shaft


and bearing

75

+0.051
+0.032

-:.015

0.032

0.066

0.029

Clearance between case and bearing

Standard size

i:
3

Remedy

Tolerance

Standard
size

mm

Tolerance

-0.015

Replace

Repair limit

Wear of oil seal surface

95

0
-0.087

-0.18

Wear of oil seal surface

105

-:.087

-0.18

End play of coupling shaft

Tightening torque of coupling


mounting bolt

Tightening torque of mounting bolt

Repair
chrome
plating or
replace

Preload max. 0.4 kgm

Replace

95 i: 10 kgm
-

WA500-

Retighten

6.7 ? 0.7 kgm

24-17

DIFFERENTIAL

(l/2)

il

Section A -

r--r

ill
A

12
425F145-1

WA500-1

Unit:
No.

Check item

Criteria

I
Standard
size

Clearance of bearing outer lace


in differential gear assembly

Tolerance
Shaft

Hole

Remedy

Standard
clearance

Clearance
limit

180

0
-0.025

+0.054
+0.014

0.014 0.079

Clearance of side bearing inner


lace in differential gear
assemblv

Clearance of outer lace of


pinion shaft bearing

171.45

+0.025
0

+0.026
-0.014

0.026 -0.039

Clearance of inner lace of


pinion shaft bearing

76.2

+0.064
+0.038

+0.013
0

-0.025
-0.064

Clearance of inner lace of


pinion shaft bearing

76.2

+0.030
+0.011

+0.013
0

0.002 -0.030

Clearance of outer lace of


pilot bearing

120

-:.015

+0.034
+0.012

0.012 0.049

pilot
Clearance
bearing
of inner lace of

55

+0.039
+0.020

-0.010
-0.025

cage
Clearance
carrier andbetween
differential

210

-0.060
-0.020

+0.010
+0.046

0.0300.106
-

differential
Clearance between
pinion bushing
spider and

40

-0.050
-0.025

+0.085
0

0.0250.135
-

10

Backlash of bevel gear

11

Backlash of differential

12

End play of pinion gear

131

F ree rotating torque of bevel gear

14

Preload of bevel gear

15

Rear face runout of bevel gear

16

Standard thickness of shims


for stop shaft

-0.030
-0.064
-

Replace

0.30 - 0.41

gear

0.30 - 0.41

Max. 0.11

Max. 0.85 kgm

Max. 800 kg

0.1

Clearance a + (0.1 * 0.05)

WA500-1
24Li9

mm

DIFFERENTIAL

(Z/2)

12
\

11

10
/

425F146-1

WA500-

Unit:

mm

Thickness of side gear washer

ightening torque of mounting

56.0 + 6.0 kgm

Tightening torque of mounting


bolt

94.5 f 10.5 kgm


Retighten

Tightening torque of mounting


bolt (for Fl

28.5 f 3.0 kgm

Tightening torque of mounting


bolt (for F)

28.5 + 3.0 kgm

11

Tightening torque of mounting


bolt

28.5 f 3.0 kgm

12

Tightening torque of mounting


bolt

94.5 t 10.5 kgm

13

Tightening torque of mounting


bolt

,o

WA500-1

1st step:
2nd step:

0.4 * 0.1 kgm (when measuring clearance (no shim))


11.5 c 1 .O kgm (shim installed)

2&21

AXLE MOUNT

425F148

\
L..

T
Section

A - A

)_
425F149

24-282

WA500- 1

Unit:

mm

Clearance of shaft and hole


Front support side

Clearance of shaft and hole

Thickness of wear plate

Thickness of wear plate

81 1.5

WA500-

24-23
0

FINAL

DRIVE

Clearance between planetary


shaft and bearing

tween p anet gear

9 + 3.5 kgm

24-24
0

WA500-1

40 STEERING

SYSTEM

STEERING SYSTEM
41 STRUCTURE

AND

FUNCTION

General ...............................
Hydraulic circuit for steering ............
- Hydraulic circuit diagram for steering . .
- Operations of steering valve ..........
Steering control system ................
- Steering valve ......................
- Steering relief valve .................
. Safety valve (with suction valve) ......
- Operation of demand spool ..........
- Two-way restrictor valve ............
. Rotorseal ..........................
Steering cylinder .......................
Steering column and gear box ...........
Steering linkage .......................
Steering pump ........................
Center hinge pin .......................

WASOO- 1

.
.

.
.
.

41- 2
41- 4
41- 5
41- 6
41- 8
41- 8
41-10
41-11
41-12
41-15
41-16
41-17
41-18
41-19
41-20
41-21

41-1

GENERAL
OUTLINE
.

The oil from


valve

hydraulic

tank

(2) by hydraulic

gear box,

pump

(5) and

When

steering

steering

valve

cylinder

(2)

(2)

is actuated,

and

oil

(8) and the

flows
steering

wheel
by

is operated,

steering

drag link,

column,

and link,

the

movement

universal

and actuates

is

joint,
steering

When steering
oil

which

control

wheel

enters

is not

steering

being

valve

operated,

(2) flows

is

all the
to main

valve.

valve (2).

425FlOO

41-2

to

actuated.

(6).
When steering
transmitted

(3) is sent to steering

and steering

WA500- 1

: Rightturn

c=7:

Left turn

FO425001
A*

1.

Steering cylinder

5.

Hydraulic pump

2.

Steering valve

6.

Steering pump and POC pump

3.

Hydraulic tank

7.

Two-way restrictor valve

4.

Switch pump

8.

Steering cylinder

WA500- 1

41-3

HYDRAULIC

CIRCUIT

FOR STEERING

425FO76

In

neutral,

Therefore,

the

steering

wheel

is not

operated.

steering spool (3) does not move.

motion

of demand

engine is running

spool

The oil from the steering pump flows port A and

further

the oil from

from the steering pump.

the switch pump flows into port B.

Some of the oil from the hydraulic


the work

equipment

circuit

pump flows into

and the rest of the oil

(2)

The merged oil flows to steering spool (3).


ever, since the steering valve is in neutral,

pushes check valve (I) open to flow into port B and

does not flow into the cylinder,


through port t.

41-4

that

the

The merged oil

flows into port A and merges with the oil

merges with the oil from the switch pump.

(The

indicates

at low speed.)

Howthe oil

but into the drain

WA500-

HYDRAULIC

CIRCUIT

DIAGRAM

FOR STEERING

Neutral

Bf
1

A
\(

f1
/

M-

To main control valve

_J

F42101006

1.

Check valve

7.

Steering valve

13.

Safety valve (with suction)

2.

Demand spool

8.

Hydraulic tank

14.

Steering cylinder

3.

Steering spool

9.

Oil filter

15.

Hydraulic pump

4.

Steering pump

10.

Breather

16.

Switch pump

5.

Two-way restrictor valve

11.

Oil cooler

17.

Relief valve

6.

Two-way restrictor valve

12.

Safety valve (with suction)

18.

Orifice

WA500- 1

41-5

OPERATIONS

OF STEERING

VALVE

Turning right

01 valve

425 iF077

When

the

steering

steering

spool

wheel

is turned

to the

right,

(3) moves to the right through

the

activated control linkage.


flows

into

port

valve and merges with

steering

pump.

41-6

equipment

switch

B and port A through

demand

The

Then,

rod through

Some of the oil from the work


pump

spool (3).

the L.H. cylinder

the oil from

port

the oil flows into the bottom

of

and the sides of the R.H. cylinder


C in the spool,

making a R.H.

turn.

the

The oil from the L.H. and R.H. cylinders is drained

the

from

merged oil flows to steering

two-way

restrictor

valve (5) through

port D

in the steering spool.

WA500- 1

Turning left

425FO78

When

the

steering

steering

spool

(3)

wheel

is turned

moves to the

activated

control

the work

equipment

linkage.

Some

to

the

left through

B and port A through

the

of the oil from

the demand

spool (2) and

merged oil flows to steering spool (3).

oil

the

switch pump flows into port

merges with the oil from the steering pump.

WA500-

left,

The

Then, the

flows

from

two-way

side of the

bottom

L.H.

restrictor

cylinder

valve (5)

into

rod

and into the

of the R.H. cylinder through

port D in the

spool, making a L.H. turn.


The oil from the L.H. and R.H. cylinders is drained
from

two-way

restrictor

valve (6) through

port C

in steering spool (3).

41-7

STEERING
STEERING

CONTROL

SYSTEM

VALVE

425FO64

A. To steering cylinder

E.

From steering pump

B. To hydraulic circuit

F.

From switch pump

C. To steering cylinder

G. To hydraulic tank

D.

41-8

From hydraulic pump

WA500- 1

Section A - A

Section B - B

Section C - C
425FO65

WA500-

I.

Demand spool

5.

Lever

2.

Check valve

6.

Relief valve

3.

Orifice

7.

Valve body

4.

Steering spool

8.

Safety valve (with suction)

41-9

STEERING

RELIEF

VALVE
1.

Main valve

2.

Valve seat

3.

Pilot poppet

4.

Spring

5.

Adjustment screw

Function
.

The steering

relief

valve is inside the steering

When

the

steering

stroke

and abnormal

sent from

the

This prevents
(The relief

cylinder

pressure

pump

valve.

reaches the end of its


is generated,

is relieved

through

the oil

this valve.

damage to. the pump or circuit.


valve sets the maximum

pressure of the

circuit.)

Operation

Port A is connected
C is connected
through

to the pump

to the drain

the orifice

B. Pilot poppet

circuit,

circuit.

in main valve

(3) is in contact

and port

The oil passes

~~~
b

(I) and fills port

with

valve seat (2).

56OBFO7

When the pressure inside port


pressure

set

by

the

pilot

poppet

port

B escapes from

poppet

A and B reaches the


spring

(set pressure),

(3) opens and the hydraulic


port

D to port

C.

pressure at
This lowers

the pressure at port B.

When

the pressure

main

valve

between
opened

at port

(1) generates

port

and

port

B drops,
a difference
B.

Main

the orifice

of

in pressure
valve

(1)

is

56OBFO72

by the pressure at port A and the oil at port

A is relieved.

41-10

WA500- 1

SAFETY

VALVE

(with suction valve)

1. Suction valve

2.

Main valve

3.

Main valve spring

4.

Pilot piston

5. Suction valve spring


6.

Valve body

421 F045

Function

- The safety valve (with suction


If shock
der

when

(with

valve)

causes any abnormally


the

suction

protects

is in the main valve.

high pressure in the cylin-

main

valve

valve)

releases the abnormal

the cylinder

is at neutral

from

the safety

valve

pressure

and

B is the drain

cir-

damage.

Operation
As a safety valve

* Port A is the cylinder

circuit

and port

cuit.
The pressure oil in port
in the pilot

piston.

fice consisting
(4).
The

pilot

nut.

a hole
an ori-

is secured

diameter

If abnormally
tion

valve

(cross-sectional

of dz>d,>ds>d4.
A, the suc-

421 F046

because of the relationship

because of the relationship

d3>d4

in port A and

pressure on the main valve (2) is equiva-

to the area difference

between

pressure goes up to the poppet


the poppet

piston

valve by a lock

high oil pressure occurs in port

C, the hydraulic
lent

to the safety

(1) is not actuated

dzX.
However,

(2) and the pilot

of the cross section

area) gives a relationship

A flows

of the mainvalve

piston

The

to port D through

It also flows to port C through

is actuated,

ds and d4.

spring force

If this

(set pressure),

and the oil in port

A flows

into

port B.
As a suction

valve

If negative
negative

pressure is generated

pressure,

with

each other.

port

E.

Hydraulic
between

because

pressure

equivalent

is applied

of the tank pressure in port


hydraulic

and hydraulic

(1).
If the

in port

hydraulic

to

42 1 F047

to the area difference

to the safety

valve because

E.

pressure

pressure a

pressure

pressure)

D also has

D and A are connected

The tank pressure in port B is applied

d2 and dl

Therefore,

in port A, port

port

acts to open the valve

acts to close the suction


drops,

pressure a

(approaching

valve

negative

becomes smaller than oil

pressure e.
When
a

oil

pressure

+ valve spring

becomes

(5) force,

larger than

the suction

oil pressure

valve (1) opens,

causing the oil to flow from

port B into port A. This pre-

vents negative

building

WA500-

pressure from

421 F048

up in port A.

41-11

OPERATION

OF DEMAND

SPOOL

Engine running at idling when turning to the left

The oil from the steering pump (4) flows into port

As its flow increases, the oil pressure at port C rises

A and the oil from the switch pump (16) flows into

because of orifice b in port A, and exceeds the force

port B.

of spring (2A).

The oil from

the work equipment

pushes

Then,

the direction

Then, the oil flows into port B and merges with the

the oil from the hydraulic

oil

work equipment

delivered

from

the

switch

pump

(16).

The

marked +

demand spool (2) moves in

check valve (1) open because the circuit is closed.

. For this reason, some of


pump (15) flows into the

circuit through port D.

merged oil then flows into port A and merges with

Thus, all the oil delivered from

the oil delivered from the steering pump (4).

(4) and the switch pump (16) plus some of the oil

Then,

the merged oil flows into port C through orifice a in

delivered

demand spool (2).

the steering cylinder.


From steering

cylinder

from

the hydraulic

the steering pump

pump

(15)

flow into

To steering
cylinder

425FO73

41-12

WA500- 1

Engine

running at medium

speed when turning

to the

left
.

The oil from the steering pump (4) flows into port

more than that when the engine is running at low

A and the oil from the switch pump (16) flows into

speed, the oil pressure at port C rises because of

port B.
pump

The pressure of the oil from the hydraulic


(15)

increases because the circuit

is closed

and pushes check valve (1) open, overcoming


spring force in the valve.

the

Thus, the oil flows into

orifice b in port A, and exceeds the force of spring


(2A).Then
marked

demand spool (2) moves in the direction

. For this reason, all the oil from the

hydraulic

pump (15) plus some of the oil from the

port B and merges with the oil delivered from the

switch

switch

circuit through port D.

pump

(16).

Then,

the merged oil further

pump

(16)

flow

into the work

equipment

flows into port A and merges with the oil delivered

Ail the oil delivered from the steering pump (4) and

from the steering pump (4).

some of the oil delivered from the switch pump (16)

The merged oil flows through


spool (2) into port C.

orifice

a in demand

flow into the steering cylinder.

As the oil flow has increased


From steering
cylinder

To steering

cylinder

425FO74

WA500-

41-13

Engine running at high speed when turning to the left


.

The oil from the steering pump (4) flows into port

more

A and the oil from the switch pump (16) flows into

medium

that

when

the

engine

is running

at

speed, the oil pressure at port C further

rises because of orifice

port B.

b in port A, exceeding the

force of spring (2A). Therefore,

the demand spool is

its pressure because the circuit is closed and pushes

further

marked

check valve (I),

this reason, the circuit

The

valve.
with

oil

from

the hydraulic

pump

(15)

increases

overcoming the spring force in the

Thus, the oil flows into port B and merges


the oil from

the switch pump

(16).

Further,

the merged oil flows into port A and merges with


The

merged oil flows into port C through

a in demand

spool (2).

As the oil flow

from

moved in the direction

the switch

draulic

pump

pump (16)

(15)

work equipment

is closed.

flow

. For

Thus, all the oil

and that from the hy-

through

port

D into the

circuit.

All the oil from the steering pump (4) flows into the

the oil from the steering pump (4).

than

orifice

steering

cylinder.

increases

From steering
cylinder

To steering
cylinder

~~~$gg;
p------Q

: .. . : ,.

To main control
valve

425FO75

41-14

WA500-

TWO-WAY

RESTRICTOR

VALVE

1.

Body

2.

Spring

3.

Poppet

425FO70

Function

To reduce the shock


machine

when

caused

by the inertia of the

the steering is operated,

an orifice

is installed in the oil line of the return circuit from


the cylinder.
oil,

and

This applies pressure to the returning

regulates

the

movement

of the cylinder

piston.

Operation

When the oil is flowing


spring (2) and flows

to arrow

through

, it pushes

the orifice,

and be-

tween poppet (3) and the poppet seat.


To cylinde
Q

425FO71

When the oil is flowing to arrow


only

from

orifice

, the oil flows

a inside the poppet

(3), so the

flow is controlled.
ForIll
cylinder
*

425FO72

WA500-

41-15

ROTOR

SEAL

Section A - A

Section B - B
421FO44

41-16

1.

Shaft

2.

Lever

3.

Body

4.

Steering spool

WA500-

STEERING CYLINDER

I /

425FO79

1.

Head

2.

Rod

Specifications
Cylinder bore:

110 mm

Rod diameter:

55 mm

3.

Cylinder

4.

Piston

Cylinder max. length:

5.

Piston nut

Cylinder

Stroke:

486 mm
min. length:

1329

mm

843

mm

Width across flats of piston nut: 55 mm

WA500-

41-17

STEERING

COLUMN

AND

GEAR BOX

Outline

The steering gear is a recirculating


In this
thread

type

of

gear there

ball type

gear.

is a round-bottomed

cut in the steering shaft.

There are several

Balls (6) move in the nut groove of the shaft together with the rotating of the steering wheel.
pass from the end of the nut through

balls (6) between the nuts which slide in this thread.

on the

Ball nut (5) moves up and down in accordance with

circulated.

the rotation

outside,

and return

to the

nut to be re-

of the steering shaft, and turns center

shaft.

Y
Section A - A

Section D - D

423FO72
Section B - B

41-18

Section C - C

1.

Steering wheel

6.

Ball

2.

Center shaft

7.

Worm

3.

Steering column

8.

Tilt lever

4.

Gear box

9.

Pitman arm

5.

Ball nut

They

the passage

WA500- 1

STEERING

LINKAGE

Section A - A

\,

\ _.

._

Section B - B

425FO62

WA500-

1. Gear box

5.

2.

Link

6.

Link

3.

Steering valve

7.

Pitman arn-

4.

Steering column

Drag link

41-19

STEERING

PUMP

Steering pump

POCpump

SAR(3)-080

SARI1 j-014
425FO63

Specification
Model:

delivery:

(Front pump)
80.0 cc/rev

Max. delivery pressure: 210 kg/cm2

SAR(l)-14

Theoretical

2.

Front cover

3.

Gear case

4.

Rear cover

5.

Driven gear

delivery:

The steering

pump is installed to the torque

verter case.

It is driven by engine power and sup-

(Rear pump)

The steering pump sucks in oil from the hydraulic


tank, and sends the oil to the steering valve.

14.5 cc/rev

Max. delivery pressure:

210 kg/cm2

Max. speed: 3500 rpm

41-20

con-

plies oil to the steering system.

Max. speed: 2500 rpm


Model:

Drive gear

Outline

SAR(3)-80

Theoretical

1.

WABOO- 1

CENTER HINGE PIN


Outline
.

The front

frame

nected through
(5).
the

(6).

(3) and rear frame

The steering cylinders

left and right front

the cylinders

(4) are con-

a bearing by the center hinge pin


are connected

to

and rear frames, so when

are operated,

the frame bends at the

middle to give the desired angle, that is the desired


turning radius.

425F116

1. Front axle
2.

Rear axle

3.

Front frame

4.

Rear frame

5.

Upper hinge pin

6.

Lower hinge pin

WA500- 1

Section A -

Section B - B

425F117

47-21

STEERING SYSTEM
42

TESTING

AND

ADJUSTING

.. .......
.
Measuring steering wheel play . . .

Standard

Measuring

operating

Operating

The following
shooting
1.
2.

precautions

or during

are necessary when using the Standard

wheel

.....

time of steering

wheel

leaving the plant,


of use.

standard
they

or when estimating

values in these tables

values for the machine

Therefore,

..
.
..
..
..

..
..
..
.

.
.
.
.

.
.
.
.
.

42-4
42-5
42-6
42-7
42-8

. . . . 42-9

Value tables to make judgements

as target values when repairing


The

during

trouble-

should

be used

testing and adjusting.

The values in these tables are based on the values for new machines

standard

force of

.....
.
Testing steering linkage . . . . . .
Adjusting steering linkage.
.....
Steering oil pressure . . . . . . . . .
Troubleshooting
..... ......
steering

. . . 42-2
. . . 42-2
. . . . 42-3

value table

Tool list for testing and adjusting

should

for

judgement

when shipped

be used as reference

wear after a period


when

troubleshooting

from the plant,


in combination

so they

are estimated

values

based on the

and on the results of various tests.


with

repair and operating

records

when making

judgements.
3.

These standard

value tables must not be used for standard

values when judging

claims.

In addition,

do not use

these values alone to make simple judgements.

_I

WA500-1

4%1

STANDARD

VALUE TABLE

Testing and measuring item

Unit

Measurement condition

Steering wheel

Road surface:

* Steering wheel play


. Steering wheel operating force
* Operating time of steering wheel

horizontal, dry, paved surface

Max. 3.0

sec.
3.8 - 4.3

Max. 6.5

2.8 - 3.1

Max. 4.7

mm

S-12

kg/cm2

210:;

210+10
-8

Machine posture:

Specified pressure

Hydraulic temperature:
45-555OC

Main relief oil pressure

Engine speed:

TOOL LIST FOR TESTING


No.

20 - 100

1.5 - 2.0

Tire inflation pressure:

Clearance between front and rear frame

Steering oil pressure

20-70

kg

Facing straight

Steering linkage

mm

Hydraulic temperature:

(High idling)

Permissible value

Flat

45 - 55C

(Low idling)

Standard value

High idling

AND

ADJUSTING

Tool Name

Testing and measuring item

Remarks

Part No.

Steering wheel operating force

Push-pull scale

Steering wheel operating play

Convex scale

Commercially available

Steering wheel operating time

Stop watch

Commercially available

1 /lO second

Clearance between front frame


and rear frame

Convex scale

Commercially available

Steering oil pressure

Hydraulic tester

799-l 01-5000

0 - 250 kg/cm

When carrying
Then apply

42-2
0

adjusting

lower the bucket

the parking

When installing
tank.

A
A

out testing,

bar on the frame,

or removing

measurements,

The oil in the circuit

or troubleshooting,
to the ground,

stop the machine

0-25kg

on level ground,

install

the safety

and stop the engine.

brake and block the tires.


gauges, loosen the oil filler

Then operate the control

When taking

79A-262-0020

cap slowly

to release the pressure inside the hydraulic

levers several times to release the remaining

do not allow unauthorized

is hot, so be careful

pressure in the hydraulic

piping.

persons near the machine.

not to get burnt.

WA500-

MEASURING
*

Measurement

STEERING

WHEEL

PLAY

condition

- Engine speed: Stop


+ Machine posture: Facing straight
Unit:
Standard

Item
Steering

HOW

wheel

TO

Permissible

value

20-70

play

20 -

mm
value

100

MEASURE

1.

Turn

the

steering

counterclockwise
the

neutral

Put

mark

wheel
two

position
(1)

lightly

or three
of

on the

the

outer

clockwise

and

times

and confirm

steering

mechanism.

frame

of the

l-J---Play

vehicle

monitor.
2.

Turn

the

steering

steering

wheel

steering

valve

wheel

starts

to

clockwise,
become

lever starts to move),

on the steering wheel in line with

and when

heavy

the

(when

the

make mark

mark

(2)

(1).
419F302A

3.

Turn the steering wheel counterclockwise,

and when

the steering wheel starts to become heavy

[when the

steering

valve

lever starts to move),

on the steering

wheel

measure the distance


(2) and mark

TESTING

Inspect

AND

in a straight

mark

(I).

line between

mark

ADJUSTING
linakge

(4) and (5) for looseness

If any, adjust the linkage.

1.

Loosen lock nuts (6) on the steering gear box.

2.

Then,

adjust

(3)

Then

(3).

the steering

and free play.

in line with

make mark

by turning

adjustment

sdrew

(7)

in

or out.
*

To decrease the free play, turn the adjustment

screw

(7) in. to increase the free play, turn the screw out.

__

J_
_423F311

WA500-1

4&3

MEASURING
*

OPERATING

FORCE OF STEERING

WHEEL

Measurement condition

*
-

Road surface:

Flat,

Coolant temperature:
Hydraulic

horizontal,

oil temperature:

Tire inflation
Engine speed:

dry, paved surface.

Inside operating range.


45 to 55C

pressure: Specified pressure.


Low idling (bucket unload).

Unit:

Item

Standard

Force of steering wheel

value

Permissible

1.5 - 2.0

mm

value

Max. 3.0

Special tool

Part No.

79A-262-0020

Part Name

Oty

Push-pull scale

Measuring procedure
1.

Hook push-pull scale A to the knob of the steering


wheel.
*

2.

Hook push-pull scale A to the center of knob.

Start the engine.


*

After

starting the engine, raise the bucket about

400 mm and remove the safety bar.


3.

Set push-pull scale A at a tangent, and read the value


when the steering wheel is moving smoothly.
*

Do not read the value at the time the steering


425PO44

wheel starts to move.

42-4
0

WA500-

OPERATING
*

*
*
*
*

TIME

OF STEERING

WHEEL

Measurement condition
Road surface:

Flat, horizontal,

Coolant temperature:
Hydraulic

oil temperature:

Tire inflation

dry, paved surface.

Inside operating range.


45 to 55C

pressure: Specified pressure.

Engine speed:

Low idling and high idling.

Unit:

sec.

425PO45
~

Special tool
Part No.
A

Part Name

Commercially available

/ Qty

Stop watch

Measuring procedure
1.

Start the engine.


*

After

starting the engine, raise the bucket about

400 mm and remove the safety bar.


2.

Turn

the

steering

wheel

so that

the

machine

is

turned fully to the left or fully to the right.


3.

Measure the time taken for the steering wheel to be


turned to the right (left) to the full lock position.
*

Turn the steering wheel as fast as possible without forcing it.

Measure at low idling and high idling, and when


turning to the right and to the left.

WA500-

42-5
8

TESTING
*

Measurement

Hydraulic

STEERING

LINKAGE

condition

temperature:

Road surface:

45 to 55C

Flat, horizontal,

Tire inflation

pressure:

dry, paved surface.

Specified

Engine speed:

1200 rpm

Center

lever:

Square

Pitman

arm:

with

pressure.

the machine

Prependicular

to

the

center

line.

machine

rear

frame.

Unit:

Measuring

procedure

1.

the

Start

engine

to set the front


2.

Loosen

and

mounting

and check

operate

the

steering

and rear frames in a straight


bolt

(1) and nut

play of ball joint

sec.

wheel
line.

(2) of linkage

(3). rod (41, and center


425F205

lever bearing (5).


3.

Check

that

the

to the center
*

center

The steering spool should

4.

Check that the pitman

5.

Start
left

lever

stoppers

to the full

a between

pitman

the steering

wheel to the

lock position.
frame

Check that

and rear frame

value.

14 * 2 mm

measuring

justment
When

angles

be at neutral.

the front

is the standard

Clearance a:
When

is at right

arm (7) is perpendicular.

the engine and turn


and right

clearance

(6)

line of the machine.

the clearance

screw (8) should

to the right,

be in contact

with

adthe

arm.
measuring

justment

screw

the pitman

clearance

to the

left,

be in contact

ad-

423F313

with

arm.

When measuring
(9) and

the

(10) should
the clearance,

(11) do not

in contact

adjustment
with

screws

valve lever

respectively.

42-6
8

WA500-

ADJUSTING
*

Measurement

STEERING

LINKAGE

condition

* Hydraulic temperature:
45 to 50C
* Road surface: Flat, horizontal, dry, paved surface.
- Tire inflation pressure: Specified pressure.

Set

the

safety

machine

facing

Adjustment

Disconnect

2.

Adjust

steering

linkage

linkage

(2)

the

front,

(8) is at the neutral

(I) from the pitman

so that

angles to the center

fit

the

center

lever

(9) is at right

line of the chassis when valve lever


position.

in Step 2, move the steering

In the condition

arm.

valve

lever

to the end of its stroke,

and when the valve lever con-

tacts

(4),

stop

bolts

(3)

secure in position
*
4.

to

procedure

1.

3.

straight

bar, and stop the engine.

Always

Adjust

and

turn

back

l/2

turns

nd

with the nut.

adjust the valve lever first.

the length

is perpendicular

of linkage
to the front

(1) to the pitman

(1) so that
frame,

pitman

then connect

arm (7)
linkage

arm.
425P053A

5.

Remove the safety

6.

Start

the engine,

and right,
stopper
frame

bar.
turn

and adjust

the steering wheel fully


so that

the pitman

bolts (5) and (6) when the clearance


and

rear

frame

stoppers

(clearance

to the left

arm contacts
of the front
a on the

previous

page) is 14 ? 2 mm, then secure with the nut.

making

After

the above adjustment,

check again that

the value is standard.

425PO55

WA500-1

42-7
8

STEERING
*

Measurement

OIL PRESSURE

condition

- Hydraulic temperature:
45 to 55C
- Engine speed: High idling

Unit:
Standard
value

Item
Main

relief

oil

pressure

kg/cm2

Permissible
value

210;;

425PO56

Special tool

Part

799-l

Procedure

No.
01-5000

Loosen

the

inside

the

Hydraulic

for measuring

pressure

oil

steering

maining

Part

wheel

tester

cap

slowly

hydraulic
several

times

1.

Fit safety

bar (1) on the frame.

2.

Remove

plug

for

to

tank.

release

Then

the

operate

to release the

pressure in the hydraulic

(2)

Oty

main relief pressure

filler
the

Name

re-

piping.

measuring

the

right

turn

steering circuit.
3.

Install hydraulic

4.

Start

tester A to the measuring

the engine

steering

wheel

and run at high


to

the right

idling.

and measure

port.
Turn

the

the pres-

sure when the relief valve is actuated.


+

When

removing

steering

the

circuit,

plug

turn

(3)

the

for

the

steering

left

turn

wheel

to

the

hy-

the left and measure.

Testing and adjusting

Always
draulic

stop

the

engine

before

adjusting

pressure.

1.

Stop the engine.

2.

Remove cap nut (4) of the relief valve.

3.

Loosen

lock

nut

(5).

then

turn

adjustment

screw

(6) to adjust.
Amount

of

adjustment

for

1 turn

of

adjust-

ment screw.
1 turn:

Approx.

Adjust

the set pressure as follows.

To INCREASE
To DECREASE
If

the

curately,

relief

24.8 kg/cm
pressure, TIGHTEN
pressure,
pressure

LOOSEN

cannot

screw.
screw.

be measured

ac-

do not try to adjust the pressure.

5
423F315

4&8

WA500-

TROUBLESHOOTING

Steering

wheel does not turn

2.

. _ _ . . _ . . . . . . . . . . . . 42-10
. _ . . . . . . . . . 42-10
Steering wheel is sluggish . . . . . . _ . . . _ _ . 42-11

3.

Steering

wheel moves unsteadily

Troubleshooting
1.

table

is subjected
4.

Before

carrying

page 22-12,
RENCE

out

METHOD

OF TROUBLE

WA500-

the

troubleshooting
OF READING

in this section,
TROUBLESHOOTING

direction

TABLE

in one

when traveling

Left and right turning

read PRECAUTIONS

or

. . . _ . . . . . . . 42-l 2

Machine tends to turn naturally


particular

5.

to large shock

. . . . . . 42-12
. . . 42-12

radii are different

WHEN

TROUBLESHOOTING

page 22-14 and PREVENTING

RECUR-

page 22-16.

4%9

TROUBLESHOOTING
1.

TABLE

Steering wheel does not turn.


Ask the operator the following

Did

the

steering

+ Damage

wheel

questions.

suddenly

to equipment

cease

to turn?

in steering circuit.

* Did steering wheel show signs of being sluggish for


circuit

some time?+

or faulty

Worn

parts in steering

seal.

Checks before troubleshooting.

Is

oil

level

in hydraulic

tank

and type

of oil

satisfactory?

Is there any damage to the steering gear box or


the steering linkage?

- Has the safety bar been removed from the frame?


- Is the steering lihkage properly adjusted?

Steering wheel cannot turn left or right.

Fault of item 1 and also work equipment does not


operate normally.

I Ol I I 11~1

Steering wheel Mn only turn to either left or right.

Steering wheel is sluggish and does not turn properly.

Oil pressure in steering circuit does not rise at all

Because the

steering

ment

are intimately

circuit

check the operation

circuit

and the
related

work

equip-

to each other,

of the work equipment

if the

steering behaves abnormally.


The following symbols are used to indicate the action
to be taken when a cause of failure is located.
X
A

426
O

:
:

Rapalce
Adjust

A:
C

Repair

Clean

WA500-

2.

Steering wheel is sluggish.


Ask the operator the following

- Did the steering

wheel

questions.

suddenly

become

slug-

guish?
Damage to equipment

in steering circuit.

- Did the steering wheel show signs of being sluggish

for

circuit

some

or faulty

time? + Worn

parts

in

steering

seal.

Checks before troubleshooting.

* Is oil level in hydraulic

tank

and type

oil satis-

factory?

* Is there any abnormality


mounting

part,

in the steering gear box

steering

column

or

linkage?

+ Is the adjust of the steering valve control

lever

correct?

- Is there any oil leakage from


hose, valves, cylinders,

Is there any seizure


and bushing
cylinder

the

oil

pressure

etc.?
between

of the center

the pin, pin bearing

hinge and the steering

pin and bushing?

* Check tire inflation

pressure.

Fault check

- Measure the operating


wheel

machine
check
criterion

force

and also the time


when
the

the steering

results

table

of the steering

required

to turn

is operated,

against

to see whether

the

the
then

judgement

or not there

is

any abnormality.

Steering wheel is sluggish in both left and right directions.

Steering wheel is sluggish in one of left and right directions.

Steering wheel is particularly sluggish at low engine speed.

Boom lifting speed is insufficient when engine is at full


throttle.

Steering wheel is sluggish and jerky.

Hydraulic oil overheats.

Steering circuit pressure is low.

Oil pressure in return side piping of steering cylinder rises.

0
0

0
0

00

The following symbols are used to indicate the action


to be taken when a cause of failure is located.

WA500-

42d

3.

Steering wheel moves unsteadily

or is subjected to

large shock.
Checks before troubleshooting.

* Is oil level in hydraulic

tank

and also oil type

satisfactory?

Is there any damage to the steering


mounting

part, steering column

Is there

any

play

in the center

ring or steering cylinder

* Does tire inflation

gear box

or linkage?
pin hinge

bear-

pin bushing?

pressure fluctuate?

Fault check
Operate
check

the
the

wheel

loader

conditions

in a safe place

under

which

and

the steering

wheel becomes unsteady.


*

If,

in

addition

to the

there

unsteady,
sluggishness,

are

steering
other

refer

etc.,

to

wheel

faults
item

being

such

as

2 Steering

wheel is sluggish.

I I
1

Problems

-----.-

Remedy
NO.

Machine body is unsteady when traveljng on bumpy


road surface.

aA
x

X
0

if suddenly turned

4.

Machine body becomes unsteady when traveling at high speed.

Machine body becomes unsteady during engine starting.

Machine

tends to turn

naturally

0
0

in one particular

direction when traveling.


Cause:

Faulty

*
*
5.

steering valve

Incorrect
Faulty

positioning

of spool

safety valve

Oil leakage in steering


Does tire inflation

cylinder.
The following symbols are used to indicate the action
to be taken when a cause of failure is located.
A:
Repair
X : Rep&e
C : Clean
A : Adjust

pressure fluctuate?

Left and right turning radii are different.


Cause:

Incorrectly
Left

adjusted

and right

steering

steering

linkage.

balance,

lock

posi-

tion of stopper.
(Valve

relief

completion

426
2

noise

can

be

heard

upon

of turning.)

WA500-

STEERING

GEAR

BOX

.........
: ...............
Installation
.......................
Disassembly. ......................
Assembly
........................
Removal

STEERING

43-

43-

43-

43-

43-

43-

VALVE

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

Removal

installation

Disassembly and assembly


STEERING

PUMP AND

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

43-11

POC PUMP

. . . . . . . . . . . . . . . . . . . . . . . . . 43-13
Installation
. . . . . . . . . . . . . . . . . . . . . . . 43-14

Removal

STEERING

CYLINDER

Removal

.........................
.......................
Disassembly. ......................

43-15

Installation

43-l 6

Assembly

43-19

CENTER

43-17

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

HINGE

PIN

. . . . . . . . . . . . . . . . . . . . . . . . . 43-22
Installation
. . . . . . . . . . . . . . . . . . . . . 43-28
Removal

Take

the following

method

for air bleeding when you start to operate

cylinders after reassembling cylinder,


1.
2.

hydraulic

pumps and pipings.

Start engine, keep idling.


Operate hydraulic

cylinder 4 -

5 cycles, but do not exceed beyond 100 mm of

stroke end.
3.

Continue to operate cylinder 3 - 4 cycles until stroke end.

4.

After finishing above steps, keep normal engine speed.


NOTE:

WA500-

After long storage, same procedure is required.

43-l
0

REMOVAL

OF STEERING

Stop the

A!

machine

GEAR BOX

on level ground and install the

safety bar on the frame.


ground and stop the engine.

Lower the bucket to the


Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.

After stopping the engine, turn the steering wheel several


times to the left and right to set the steering valve in
NEUTRAL.

1.

Cover
Remove covers (1) and (2) from under the cab.

2.

Pitman arm
Using puller @
t

Before

, remove pitman arm (3).

removing,

make

match

marks on the sector

shaft of the steering gear and pitman arm.

3.

Steering gear box


1) Loosen lock bolt (4), then pull out column joint

(5)

from steering gear shaft.


+

Make

match

marks

on

the

column

joint

and

steering gear shaft.

2) Remove

mounting

bolts, then remove steering gear

(6).

43-2
0

WA500-

INSTALLATION
1.

OF STEERING

GEAR BOX

Steering gear box


1) Set steering gear box (6) in mounting

position, then

install mounting bolts.


w

Mounting bolt:

2) Align

match

gear shaft,

11.5 f 1 kgm

marks of column joint


and insert joint,

(5) and steering

then tighten

lock bolts

(4).
B

3.

Mounting bolt:

5.7 + 0.7 kgm

Pitman arm
Align

match marks of pitman

arm (3) and sector shaft

(7). install pitman arm.


m

Mounting nut:

19 f 3 kgm
(Width across flats:

4.

32 mm)

Cover
Install covers (1) and (2) under the cab.

5.

Checking steering linkage


After

completion

of assembly,

check the

linkage and

adjust if necessary.
*

For details, see 42 TESTING

WA500-

AND

ADJUSTING.

DISASSEMBLY
I,

OF STEERING

GEAR BOX

Side cover
1) Loosen lock nut (3) of adjustment

screw (2), then

remove mounting bolts (4) of cover.

2.

:,w *,

Sector shaft
Turn

steering gear shaft

(5) so that sector shaft is in

Be careful

not to damage the thread and bushing of

sector gear when removing.

3.

,, ,~
::,,,:::
~~~~
,,,,,,
:,LjjI,,,,,,,,,,
,,/,,,,,:
:>i:,
,,,,

,-::ro+s
:, ,,\

vertical position, and remove sector shaft (6).


*

,, ,,,

uu,
_,

,,

Rear cover, shaft, ball nut assembly


Remove rear cover (7). then remove shaft and ball nut
assembly (8).

43-4
0

WA500-

ASSEMBLY
1.

OF STEERING

GEAR BOX

Bearing outer race

1) Press fit bearing outer race (10) on gear box (9) and
rear cover (7).
2) Press fit

oil

seals (ll),

(12)

on gear box

and rear

cover.
*

If bushing

(13)

of the

gear box

is badly

worn,

replace the gear box.


&
2.

Shaft,

Lip of oil seal:


ball nut assembly,

Assemble

shaft

then install
&

Grease (G2-LI)

rear cover

and ball nut assembly

(8) in gear box,

rear cover (7).

Shaft, ball nut assembly,

bearing

(14):
Grease (G2-LI)

If there

is any problem

with

shaft (15) or ball nut (8)

of the shaft and ball nut assembly,

replace the whole

shaft and ball nut assembly.


3.

Adjusting

shim

Select

shim thickness

within

standard

so that

starting

First assemble a larger thickness


reduce the thickness

to adjust.

Measure the starting

torque

Standard

WA500-

range for starting

Mounting

torque

of shaft

is

range.

bolt

with
torque:

than necessary, then


torque

wrench

A.

3.5 - 6.5 kgm

(16) of rear cover:

4.5 + 1 kgm

4.

Sector shaft, side cover


Assemble

so that

sector gear is meshed at center

of ball

nut.
*

If bushing

of the side cover (3) is badly worn,

replace

the assembly.
w

5.

Mounting

Adjusting

bolt:

adjustment

1) Temporarily

screw

install

ly and tighten

4.5 + 1 kgm

pitman

adjustment

arm (17). move arm lightscrew (2) so that

backlash

is 0.

2) Turn

adjustment

shaft is within
*
m

6.

Standard

screw

standard

so that

range for starting

Lock nut:

starting

torque

range, then tighten


torque:

of

lock nut.

3.5 - 7 kgm

2.5 + 0.5 kgm

8;;

Plug, dust cover


Pump

in grease through

plug mount,

install

plugs (18)

. .

.+?g

and (19), then install dust cover (20).


6

43-6
0

Amount

of grease:

Grease (G2-LI)

490 g

WA500-

REMOVAL

n!

Stop

OF STEERING

the

safety

machine

and put

the machine
Loosen

sure

from

wheel

Loosen
tank

prevent
1.

plugs

filter,

the wheels to prevent

cap slowly

to release the pres-

tank.

Then

operate

the

lever several times to the

to release the remaining

pressure

in

piping.

(I)

and

(2) at the top

of the hydraulic

and plugs (3) and (4) of the pump piping to

the oil inside the tank from

flowing

out.

Cover
Remove bottom

2.

the

to the

moving.

and steering

and right

and install

the bucket

Then apply the parking

under

the hydraulic

the hydraulic

blocks

the oil filler

inside

steering
left

Lower

and stop the engine.

brake

!
f-3

on level ground

bar on the frame.

ground

VALVE

Hydraulic
Disconnect

hoses as follows:
hose

(5) between

steering

valve

and main

valve from steering valve.

* Disconnect

cover of cap.

piping

Remove
control

inspection

tube

(6) between

ing cylinder

from

steering valve.

steering valve and steer-

Disconnect

tube

(7) between

hydraulic

pump

and

steering valve from steering valve.

* Disconnect

hose (8) between

switch

pump

ing valve from steering valve.


*

Remove tubes from

WASOO- 1

connectors

of hoses.

and steer-

Disconnect
from

tube

(9) between

steering valve and cooler

steering valve.

- Disconnect

tube

steering cylinder

* Disconnect

(IO)
from

tube

between

steering

valve

and

pump

and

steering valve.

(11)

between

steering

steering valve from steering valve.

3.

Linkage
Remove steering valve linkage

4.

(12) from

steering valve.

Steering valve
Remove

mounting

bolts,

place

valve (13), and pull out from


*

Remove
floor

*
*

Install

the demand

board

below

steering

machine.

spool cover which

is inside the

frame.
eye-bolts

in floor

valve slightly

and pull out.

The steering

valve

and steering

is wet with

valve, raise the

oil, so be careful

not

to let it slip.
Steering valve:

45 kg

WA500-

INSTALLATION
1.

OF STEERING

VALVE

Steering valve
Set steering valve (13) in mounting position, and tighten
mounting bolts.
*

Install eye-bolts

in steering valve and floor,

raise the

valve slightly, and set in mounting position.


*

Install demand spool cover.

After

connecting

hydraulic

piping, tighten mounting

bolts.

2.

Linkage
Install steering valve linkage (12) to steering valve.
*

Check that the steering valve is a tneutral.

Align the key groove correctly.

@EI

Mounting bolt:

Connect

3.2 * 0.3 kgm

hose (8) between switch pump and steering

valve to steering valve.


*

Connect tubes to hoses.

- Connect tube (7) between hydraulic pump and steering valve to steering valve.

WA500-

43-9
0

Connect tube (6). between steering valve and steering


cylinder to steering valve.
Install hose (5) between steering valve and main control valve to steering valve.

4.

Cover
Install bottom

5.

inspection cover of cap.

Refilling with oil


Tighten

plugs at top of hydraulic

tank filter,

and plugs

and pump piping, and add hydraulic oil through oil filler
to the specified level.
w

Plug at top of filter:

1.2 + 0.1 kgm

WA500-

DISASSEMBLY

AND

ASSEMBLY

OF STEERING

VALVE

27

425F294

DISASSEMBLY
1.
2.

OF STEERING

VALVE
5.

Remove tube (1).


Remove main relief valve assembly

Remove

case

(2).

1) Remove
3.

Remove

safety

valve

(with

suction

(14),

(15).
* Disassembly

then

and assembly

bolt

(16),

then

spring (18) and retainer

valve) assembly

(3).

remove

Loosen bolt

spool

of spool assembly.
remove

(19) from

(16) with

assembly

retainer

(17),

spool (20).

the spool assembled in

the body.

4.

Remove case assembly


*

Disassembly

(4).

and assembly

6.

of case assembly.

1) Remove covers (5) and (6).

Remove

plate

(21),

then

remove

orifices

(22) and

(23).

2) Remove dust seal (7).


3) Loosen

bolt

(9) of lever

(8), then

(IO).
4) Remove oil seal (11) and bearing

remove

shaft

7.

Remove cover (24), then remove spring (25), washer


(26) and spool (27).

(12) and (13).


8.

Remove

plate

(30) and poppet

(28),

then

Steering demand

WA500- 1

remove

seat (29),

spring

(31).
valve assembly:

55 kg

43-11
0

ASSEMBLY
1.

OF STEERING

Assemble poppet

VALVE

(31) and spring (30) in valve body

(32).
2.

Fit

O-ring

and backup

ring to seat (29)

in valve

body, then fit O-ring and install plate (28).


3.

Assemble spool (271, washer (26) and spring (25) in


valve body, then fit O-ring and install cover (24).

4.

Assemble orifice

(23) and (22) in valve body, then

fit O-ring and install plate (21).


*

Disassembly and assembly of spool assembly.

1) Assemble

retainer

(191, spring (18) and retainer

(17) in spool (20) and tighten bolt (16).


*

Tighten

bolt (16) with the spool assembled in

the body.
5.

Assemble

spool assembly

(15)

in body, fit O-ring

and install case (14).


*

Disassembly and assembly of case assembly

1) Install bearing (13) and (12) and oil seal (11) in


case.
&

Oil seal: Grease (G2-LI)

2) Assemble

lever (8) in case, then fit

key, install

shaft (IO), and tighten bolt (9).


3) Install dust seal (7).
4) Fit O-ring and install covers (6) and (5).
6.
7.

Fit O-ring and install case assembly (4).


Fit O-ring and install safety valve assembly (3) with
suction valve.
w

8.

Fit O-ring and install main relief valve assembly (2).


m

9.

Safety valve: 4.5 f 0.5 kgm

Main relief valve: 8.5 + 1.5 kgm

Fit O-ring and install tube (I).

43i2

WA500-

REMOVAL

n!

OF STEERING

Stop the
safety

machine

PUMP

on level ground and install the

bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.

9!

Loosen the oil filler cap slowly to release the pressure inside the hydraulic
left

Then operate the

and right to release the remaining

the hydraulic

tank.

steering wheel and steering lever several times to the


pressure in

piping.

Loosen plugs (1) and (2) at the top of the hydraulic tank
filter,

and

plugs (3) and

(4) of the

pump

piping to

prevent the oil inside the tank from flowing out.


1.

Cover
Remove cover (5).

2.

Hydraulic

piping

1) Disconnect

tube

(6)

between

steering

pump

and

pump

and

hydraulic tank at steering pump end.


2) Disconnect

hose

(7)

between

steering

steering valve at steering pump end.


3) Disconnect

hose (8) between

POC pump and POC

strainer at POC pump end.

3.

Steering pump and POC pump


Remove steering pump and POC pump (9).
Steering pump and POC pump:

WA500-

15 kg

AND

POC PUMP

INSTALLATION
1.

OF STEERING

PUMP

AND

POC PUMP

Steering pump and POC pump


Set steering

pump

and

POC

pump

(9)

in mounting

position, then tighten mounting bolt.


t

Fit the O-ring securely

in the groove and make sure

that it is not caught when installing.

2.

Hydraulic

piping

1) Connect

hose

(8)

between

POC

pump

and

POC

strainer at POC pump end.


2) Connect hose (7) between steering pump and steering
valve at steering pump end.
3) Connect tube (6) between steering pump and hydraulic tank at steering pump end.

3.

Cover
Install cover (5).

4.

Refilling with oil


Tighten

plugs (1) and (2) at top of hydraulic tank filter

and plugs (3) and (4) for pump piping, then add hydraulic oil through oil filler to the specified level.
m

43-l 4
0

Plug at top of filter:

1.2 f 0.1 kgm

WA500-

REMOVAL

OF STEERING

Stop the

A
.

machine

CYLINDER

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
Loosen the oil filler cap slowly to release the pres!
;r

sure inside the hydraulic

tank.

Then operate the

steering wheel several times to the left and right to


release

the

remaining

pressure

in the

hydraulic

piping.
1.

Hydraulic

piping

Disconnect hoses (I) and (2) from cylinder.


2.

Steering cylinder
1) Remove bolt at rod end, then remove pin (3).

2) Remove bolt at bottom end, then pull out pin (4).


+

Check and record the number and thickness of the


shims, and use as a guide when assembling.

3) Sling steering cylinder

(5) with

lever block and re-

move steering cylinder.


*

Be careful not to scratch the cylinder rod.

WA500-

Steering cylinder:

47 kg

INSTALLATION
1.

OF STEERING

CYLINDER

Steering cylinder
1) Raise steering

cylinder

(5)

and

set

in mounting

position.

2) Install pin (4) at bottom end, then install bolt.


3) Install pin (3) at rod end, then install lock bolt.

Use a bar to align the pin holes.


p\ .
*

Never use

your fingers.

Adjust shim so that clearance a becomes standard


value.
Clearance a

: Max. 1 .O mm

425F295

2.

Hydraulic

piping

Connect hoses (2) and (1) to cylinder.


m

Hose nut:

14 Itr 3 kgm
(Width across flats 32 mm)

3.

Greasing
Grease cylinder pins well.
*

Wipe off any grease which comes out.

43-l 6
0

WA500-

DISASSEMBLY

OF STEERING

CYLINDER

ASSEMBLY

Special tools

Set cylinder assembly (I) in tool A.


Raise lock

of

cylinder

head

(2),

then

using tool

B,

remove cylinder head (2) from cylinder.

Pull cylinder
cylinder
*

head and piston rod assembly (3) out from

(4), then lift off.

Oil will come out when the piston rod assembly is


removed from the cylinder, so catch it in a container.

Remove cylinder

5.

(4) from tool A.

Set cylinder head and piston rod assembly in tool A, and


using power wrench

6.

Power wrench:

Socket @

and socket @

, loosen nut (5).

x 16

: Width across flats: 55 mm

Remove nut (5), then remove piston assembly (6), and


cylinder head assembly (7) from rod (8).

WA500-

43-l 7
0

7.

Disassembly of piston assembly


1) Remove wear ring (9).
2) Remove piston ring (IO) from piston (11).

8.

Disassembly of cylinder head assembly


1) Remove snap ring (16), then remove dust seal (17).

125P387A

2) Remove rod packing (1 El), retainer

(14) and snap ring

(15).
3) Remove bushing (19) from cylinder

head

125P388A

(20).

4) Remove O-ring (21) and backup ring (22).

125P390A

43-18
0

WA500-

ASSEMBLY

OF STEERING

CYLINDER

ASSEMBLV

Special tools
Part No.

790-502-I

Part name

001

Oty

Stand

790-l 02-2301

Wrench

790-720-I 000

Expander

796-720-I

Ring

660

Clean all parts, and check for dirt or damage.

Coat the

sliding surfaces of all parts with engine oil before installing.

Be careful

not to damage the rod packings, dust

seals or O-rings when assembling.


1.

Assembly of cylinder head assembly


1) Using push tool,

press fit bushing (19)

on cylinder

head (20).
*

Be careful

not to deform the bushing when pres-

sing it in.
2) Install rod packing

(18),

retainer

(14) and snap ring

(15).
* Be careful to install the rod packing (18) facing in
the correct direction.

,,,

,, ,, ,,,,,

,,~,, ,, ,,,,,,,

423PE5iOA
~

18

125P388A

3) Using

push tool,

install

dust seal (17)

to cylinder

head (20).
4) Install snap ring (16).
5) Install buckup ring (22) and O-ring (21).
*

Do not try to force the backup ring into position.


Warm it in warm water

(50 - 60C)

before fitting

it.

125P390A

WA500-

43-19
0

2.

Assembly of piston assembly

1) Using tool C, expand piston ring (10).


*

Use the piston ring on the expander


handle 8 -

and turn the

10 times to expand the ring.

2) Remove piston ring (IO) from tool C, and assemble


on piston (11).

3) Fit tool D on piston ring, then using clamp @

, con-

tact piston ring.


*

Part No. of clamp @

: 07281-01279

4) Assemble wear ring (9).

3.

Set piston rod (8) in tool A.

4.

Assemble cylinder

head assembly (7) and piston assem-

bly (6) no rod, then fit nut (5).

5.

Using power wrench


m

and socket @

tighten nut (5).

Piston nut:
Power of power wrench 0
Width across flats of nut (5)
Tightenins torque of nut

43620

x 16
55 mm
145 t 14.5 kam

WA500-

8.

Remove piston rod and head assembly from tool A.

7.

Set cylinder

8.

Raise piston rod and head assembly


in cylinder

9.

(4) in tool A.
(31, and assemble

(4).

Using tool B, tighten cylinder head nut (2)


w

Cylinder head nut:

95 +_9.5 kgm

10. Bend lock into notch on cylinder side.


11.

Remove cylinder assembly from tool A.

WA500-

43-2 1
0

REMOVAL

OF CENTER

HINGE

PIN

Special tool

-Parto.

790-101-2102

Before starting work,


see 63 REMOVAL

Part name

Qty

Puller

remove the bucket.

OF WORK

Stop the machine

For details,

EQUIPMENT.

on level ground and install the

safety bar on the frame.

Lower the bucket to the.

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
Loosen the oil filler cap slowly to release the pressure inside the hydraulic
steering wheel
release

the

tank.

and control

remaining

Then operate the

levers several times to

pressure

in

the

hydraulic

piping.
Loosen plugs (1) and
tank filter,

(2) at the top of the hydraulic

and plugs (3) and (4) of the pump piping to

prevent the oil inside the tank from flowing out.


Loosen drain valve and drain air from air tank.
Cover
Remove cab bottom

covers (5),

(6) and (7) and trans-

mission inspection cover (8).

Steering cylinder pin


Remove left and right steering cylinder pins (9).
*

Check

the

number

of shims inserted

between

the

frame, and the steering cylinder.

3.

Center drive shaft


Remove guard (lo), then remove center drive shaft (11).
Center drive shaft:

43-22
0

44 kg

WA500-

4.

Air, brake hose


1) Disconnect

air hoses (121, (13), and (14) from tube

connectors.
*

Attach

tags on hoses to be able to identify

them

when intalling.
2) Disconnect brake hose (15) from tube connectors.
*

After

disconnecting

each

hose,

move to

front

frame.

5.

POC hose
1) Disconnect

accumulator

hose (16)

from

tube

con-

nector.
2) Disconnect

POC hoses (17). (181, (19). and (20) from

tube connectors.
*

After

disconnecting

each

hose, move

to

front

tags on hoses to be able to indentify

them

frame.
*

Attach

when installing.

6.

Hydraulic

hose

1) Disconnect hose (21) between steering valve and main


control valve from tube connectors.
*

Remove clamp of hose (22).

2) Disconnect

hose (23) between main control valve and

hydraulic tank from tube connectors.

7,

Electrical wiring
Disconnect

electrical

wiring

(24) from

connector,

and

move to front frame.


*

Remove wiring clamp.

WA500-

43-23
0

8.

Steering linkage
Disconnect

steering linkage

(25) and (26) from

center

lever, and remove linkage (27).

9.

Frame support
1) Using hydraulic

jack on rear frame, insert block @

while adjusting height.


*

Insert the hydraulic jacks and blocks under the left


and right frames.

2) Insert support stand @

under counterweight.

3) Using garage jack under front frame, insert block@

10.

Lower hinge pin


1) Remove mounting bolts, then remove retainer (28).
*

There

are shims between the retainer

so check the number

and frame,

and thickness of the shims,

and keep in a safe place.

43-24
0

WA500-

2) Pull out lower hinge pin (29) while adjusting height.


*

Adjust

the height carefully

until

it is possible to

easily remove the pin by hand.

3) Remove spacer (30).

11. Upper hinge pin


1) Remove mounting bolt, then remove retainer (31).
2) Using

puller

A,

remove

upper

hinge pin

(32)

and

spacer (33).

Front
frame

425F304

12. Disconnecting frame


Remove

safety bar, pull out front

frame to front

and

disconnect frame.
Be careful

not to

let the spacer at the top of the

lower hinge bite into the rear frame.


Be careful to maintain

the balance when carrying out

the operation.
Move the frame about 100 mm at a time.

WA500-

43-25
0

2) Remove dust seal (35) from retainer.

3) Remove

spacer (36)

and dust seal (37) from

front

frame.

4) Remove bearing (38).

43-26
0

WA500-

14.

Upper hinge
1) Remove retainer (39).
+I There are shims between the retainer and frame, so
check the number and thickness of the shims, and
keep in a safe place.

2) Remove dust seal (40) from retainer.


*

Remove dust seal (41) from frame.

3) Remove bearing (42).

WA500-

43-27
0

INSTALLATION

OF CENTER

HINGE

PIN

Special tools

Part No.

Part name

/ Oty
1

790-I 01-l 002

Pump

790-101-2102

Puller

790-I 01-2300

Push-puller

793-520-2640

Push tool

Dl

793-520-2550

Guide (lower)

D2

793-520-2530

Guide (upper)

D3

793-520-2630

Bar

D4

01010-31480

Bolt

01643-31445

Washer

D,

1.

Upper hinge
1) Assemble tools A, B, C, D1, and D3 at top of front
frame

upper

hinge, and set bearing (42)

in tool

D.

Set the upper hinge on from top and press fit.


*

When press fitting, use tool D2 as a guide.

Be careful not to fit the bearing at an angle.

Fill the inside of the bearing with grease.

When

assembling

the

bearing,

do not forget

to

assemble spacer (43).


*

The clearance
adjusted,

of the bearing and spacer (43) is

so do not change the combination.

When replacing the bearing and spacer, replace as


a set.

D3

D2

425F307

425 F306

2) Press fit dust seal (40) on retainer.


*

When

press fitting

the dust seal, fit with

the lip

on the outside.
6

Seal lip:

Grease (G2-LI)

425F308

43-28
0

WA500-

3) Tighten retainer (39) with 3 mounting bolts, measure


clearance a of retainer and hinge at 4 locations on
circumference,

and

select

shims so the

measured

value is less than 0.08 - 0.18 mm.


*

After

selecting

the

shims,

assemble

retainer

to

specified torque.
B

Mounting bolt (when adjusting shims):


6 + 0.6 kgm

Mounting bolt:

18 f 2 kgm

425F309

4) install seal (40) to bottom of front frame.


*

When

press fitting

the dust seal, fit with the lip

on the outside.
a

2.

Seal lip:

Grease (G2-LI)

Lower hinge
1) Using tools A, 6, D, D4 and Ds , press fit bearing (38)
and spacer (37) on front frame.
*

When press fitting, use tool D2 as a guide.

Be careful not to fit the bearing at an angle.

Fill the inside of the bearing with grease.

When

assembling

the

bearing,

do not forget

to

assembling the bearing, do not forget to assemble


the spacer (37).
*

The clearance of the bearing and spacer (37) is adjusted, so do not change the combination

When

replacing the bearing and spacer, replace as a set.

425F310

WA500-

425F311

43-29
0

2) Press fit dust seal (35) on retainer (34).


*

When press fitting the dust seal, fit with the lip on
the outside.

&

Seal lip:

Grease (G2-LI)

3) Tighten retainer (39) with 5 mounting bolts, measure


clearance a of retainer and hinge at 4 locations on
circumference,

and

select

shims so the

measured

values is less than 0.08 - 0.18 mm.


*

After

selecting

the

shims,

assemble

retainer

to

specified torque.
B

Mounting bolt (when adjusting shim):


lot

Mounting bolt:

1 kgm

18 + 2 kgm

425F312

4) Press fit

dust seal (37)

and install

spacer (36)

on

frame.
*

When press fitting the dust seal, fit with the lip on
the outside.

Assemble

spacer (36)

so that

the side with the

large chamfer is on the bearing side.


&

Seal lip:

Grease (G2-LI)

&

Inside circumference

of spacer:
Grease (G2-LI)
425P803

43zo

WA500-

3.

Connecting frame
Move

front

frame

towards

rear frame

and align pin

u se a bar to align the pin holes.

Never use your

holes.
Q7

fingers.
*

4.

Align the pin holes correctly.

Upper hinge pin


Assemble spacer (33), insert upper hinge pin (32), tap
lightly

3 times with a copper hammer

45

until it settles

in.
*

Tap lightly with copper hammer, do not tap hard.

It

Absolutely,

do not coat spacer (33) with grease.

Outer circumference

of hinge pin:
Grease (G2-LI)

Assemble retainer (31).


&

Mounting bolt (45): Thread tightener

Mounting bolt (45):

1822kgm

QEl

Mounting bolt (46):

18*

lf the torque of the mounting

(LT-2)

425F313

2 kgm
bolts (45) and (46)

do not reach the specified there may be grease on


spacer (33), so remove it and tighten the mounting
bolts again.

5.

Lower hinge pin


1) Insert lower hinge pin (29) and assemble spacer (30).
&

Outer circumference

of hinge pin:
Grease (G2-LI)

2) Install retainer
settles
retainer

in

(28) to lower hinge pin, and after it

fully,

and frame

measure

clearance

between

at 4 locations on circumference,

and select shims so the measured value is less than


0.08 - 0.18 mm.

WA500-

425F314

When adjusting the shims, tighten the retainer mounting bolts temporarily
Tighten

to prevent them from turning.

the retainer

tightening

torque,

mounting
then

bolts to the specified

tighten

the

pin

mounting

bolts.
After

selecting the shims, install the retainer with the

specified torque.
Completely

remove grease on the mounting bolts and

mounting holes.
&

Mounting bolts (47) and (48):


Thread tightener

(LT-2)

Mounting bolt (47):


28.5 + 3.0 kgm (When adjusting shim)

Mounting bolt (47):

28.5 f 3 kgm

Mounting bolt (48):

39 + 3.5 kgm

425F315

3) Lock safety bar.


6.

Frame support
1) Remove block @

from front frame.

2) Remove support beam @

from couterweight.

3) Jack up rear frame and remove block 0

7.

Steering linkage
Install linkage (27) and connect steering linkage (25) and
(26) to center lever.
a

Mounting bolt of linkage (27):


Thread tightener

Mounting bolt of linkage (27):

Mounting bolts of linkage (25) and (26):

(LT-2)

18 + 2 kgm

12.5+- 1 kgm

4322

WA500-

8.

Electrical wiring
Connect electrical wiring (24) to connector.
*

9.

Install wiring bracket.

Hydraulic

hose

1) Connect

hose (23)

between

main control

valve and

hydraulic tank to tube.


2) Connect

hose (21)

between

steering valve and main

control valve to tube.


*

Clamp hose (22).

10. POC hose


1) Connect POC hoses (17), (IS),
2) Connect accumulator

(19) and (20) to tube.

hose (16) to tube.

11. Air, brake hose


1) Connect brake hose (15) to tube.
2) Connect air hoses (121, (I 3) and (14) to tube

WA500-

12. Center drive shaft


Fit center drive shaft (11) and install guard (10).
m

Mounting bolt:

11.5 f 1 kgm

13. Steering cylinder pin


Install left and right steering cylinder pins (9).
Q7

u se a bar to align the pin hoels.

Never use your

fingers.
*

Adjust

shims

so clearance

become

specified

value.
Clearance a = less than 1 mm

a
425F295

14. Cover
Install covers (5),

(6) and (7) at bottom

of cab and of

transmission inspection cover (8).

15.

Refilling with oil


Tighten plugs at top of hydraulic

filter cover, and plugs

of pump piping, then add hydraulic oil through oil filler


to the specified level.
m
16.

Plug at the top of filter:

1.2 + 0.1 kgm

Bleeding air
Bleed air from brake system.
t

For details

of bleeding

air, see 52 TESTING

AND

ADJUSTING.

4324

WA500-

STEERING SYSTEM
44 MAINTENANCE

STANDARD

Steering linkage ..............


Steering column and gear box .
Steering pump ..............
Steering valve ...............
Steering cylinder mount ......
Steering cylinder .............
Center hinge pin .............

WA500-

..
..
..
..
.

44-2
...
. . . . . . 44-3
. . . . . 44-4
. . . . 44-5
. . . . . . 44-6
. . . . . . 44-7
. .
44-8

44-1

STEERING

LINKAGE

Section A - A

10
Section B - B

425F151
Unit:
No.

v:er

,everbearing

Interference of press-fitting

Remedy

Criteria

Check item

CStamford
-1

fEZZ2

62.0

+0.020
-0.027

2.013

Clearance of articulation stopper


(at engine speed 1,200 rpm)

Tightening torque of mounting nut

Tightening torque of mounting nut

Tightening torque of lock nut

28.5 f 3.0 kgm

Tightening torque of lock nut

7.75 + 1.25 kgm

Tightening torque of lock nut

3.15 r 0.35 kgm

Tightening torque of lock nut

9.0 r 3.5 kgm

Tightening torque of lock nut

18.0 f 2.0 kgm

IO

Tightening torque of lock nut

7.75 r 1.25 kgm

44-2

10 i 2

0.027 0.033

19It3kgm

12.25 f 1.25 kgm

Retighten

WA500- 1

mm

STEERING

COLUMN

AND

_,

GEAR BOX

Section A - A
77%

Section D - D

Section B - B

Section C - C

423F217A
Unit:

mm

Clearance between sector shaft

5.7 i 0.7 kgm

WA500-

44-3

STEERING

PUMP

SAR(3)-080

425F150

Unit:

No.

Check item

Criteria

Remedy

Standard clearance
1

Clearance limit

Clearance between gear case


and side plate, gear
0.10 -0.15

0.19
Replace

Clearance between inside diameter of


plain bearing and outside diameter of
gear shaft

Insertion depth of pin

Rotating torque of spline shaft

0.7 - 1.2 kgm

Tightening torque of bolt

25.2 + 1.7 kgm

Discharge
EOI O-CD
45 - 55Oc

44-4

0.06 - 0.149

0.20

144.5
-

Retighten

Revolution
(rpm)

Discharge
pressure
(kg/cm )

Standard
discharge
(Q/min.)

Repair limit
discharge
(Qimin.)

2500

210

164

170

WA500-

mm

STEERING

VALVE
4I

5
2.\

/
,,,

425F152

Unit:

mm

Check item

Criteria

Clearance between steering spool


and valve body

Steering spool return spring

Check valve return spring


Tightening torque of steering
relief valve

6
I

42.4

33.5

0.345

kg

0.3 kg

8.5 ? 1.5 kgm

Tightening torque of safety


valve with suction

Tightening torque of plug

WA500-

4.5 f 0.5 kgm

Retighten

3.8 t 0.2 kgm

44-5

STEERING

CYLINDER

MOUNT

425F153

-3.4

425F154

Section A - A

Unit:
No

Criteria

Check item

Clearance between mounting pin


and bushing connection of steering
cylinder rod and frame

Standard
size

60

2
-

Clearance between mounting pin


and bushing at connection of
steering cylinder bottom and frame

60

Width of boss
3

Connection of steering cylinder


and front frame

Connection of steering cylinder


and rear frame

466

mm

Tolerance
Shaft

Hole

Standard
clearance

Clearance
limit

Jo74

+0.174
+0.100

0.100 0.248

0
-0.074

+0.174
+0.100

0.100 0.248

Width of hinge

Replace

Standard clearance
(Clearance a + b)

70+0.8
0

742

1.2 - 6.0

70+0.8
0

74r

1.2 - 6.0

After adjusting
with shim
Max. 1 .O

WA500-

STEERING

CYLINDER

425F155

Unit:

mm

Clearance between rod and bushing

Tightening torque of cylinder head

95 + 9.5 kgm
Retighten

Tightening torque of piston nut

WA500-

145.0 I 14.5 kgm (Width across the flats 55 mm)

44-7

CENTER

HINGE

PIN

425F166

12

23

10

8
21

*17

8
11
7

44-8

Section

A - A

Section B - B

425F167

WA500- 1

Unit:
Check item

No.

Criteria

Clearance between lower hinge


pin and rear frame

I
2

Tolerance

Standard
size

Hole

Shaft

100

Remedy

Standard
clearance

Clearance
limit

-0.036
-0.058

+0.054
+o

0.036 0.112

Clearance between lower hinge


pin and spacer (small)

100

-0.036
-0.058

+0.054
+o

0.036 0.112

pin and bearing


Clearance
between

lower hinge

100

-0.058
-0.036

-:.020

0.058
0.016

Clearance between lower hinge


pin and spacer (large)

100

-0.036
-0.058

+0.054
0

0.036 0.112

Clearance between rear frame and


spacer (large)

120

-0.036
-0.090

+0.090
+0.036

0.072 0.180

upper hinge
bearingfront frame and
Clearance
between

155

-0.025
0

-0.088
-0.048

Clearance between upper hinge


pin and rear frame

100

-0.096
-0.118

+0.071
+0.036

0.132 0.189

Clearance between upper hinge


pin and bearing

100

-0.096
-0.118

2.020

0.076 0.118

Clearance between front frame and


lower hinge bearing

160

0
-0.025

-0.050
-0.090

1o

Clearance between rear frame


and bushing

125

-0.043
-0.083

+0.063
0

0.043 0.146

11

Clearance at press-fitted part of


seal of upper hinge pin

115

+0.280
+0.180

+0.054
0

-0.126
-0.28

12

seal
of lower
hinge pin part of
Clearance
at press-fitted

135

+0.210
+0.310

0
+0.063

-0.147
-0.31

13

Height of lower hinge spacer


(small)

Standard size

I4

Height of lower hinge spacer


(large)

I
Replace

Repair limit
-

kO.1
I

to.1

,5

Shim thickness for lower hinge


and retainer

2.3

16

Shim thickness for lower hinge


and retainer

1.6

Shim thickness for upper hinge


and retainer

1.6

17

-0.025 -0.090

82.5

-0.088
-0.023

Tolerance

35
I

mm

When adjusting with shim: IO f 1 kgm


18

Tightening torque of lower hinge


retainer mounting bolt
Final value:

18 + 2 kgm
Adjust

1g

Tightening torque of lower hinge


retainer mounting bolt

When adjusting with shim: 28.2 2 3.2 kgm


Final value: 28.2 + 3.2 kgm

2.

21

Tightening torque of lower hinge


pin mounting bolt

Tightening torque of upper hinge


pin mounting bolt

39.2 + 4.2 kgm


When adjusting with shim: 6.0 f 0.6 kgm
Final value:

22

23

18 t 2 kgm

Tightening torque of upper hinge


pin mounting bolt

18+2kgm

Tightening torque of upper hinge


oin mountina bolt

18*2kgm

WA500-

IlrrlylIrc,,
44-9

50 BRAKE AND AIR SYSTEM

BRAKE AND AIR SYSTEM


51 STRUCTURE

AND

FUNCTION

General ...................
Air tank ...................
Safety valve ...............
Brake valve ................
. Brake actuated ..........
. Operating in balance .....
. Brake released ..........
Air governor ...............
Two-way valve ............
Brake chamber ............
Slack adjuster .............
Brake .....................
Parking brake .............
Parking brake solenoid valve
Spring cylinder ............
Brake caliper ..............

WA500-1

.
.
.
.
.
..
.

..
..

.
.
.
.

..

.
.

..
..

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

..
..
.
.
.
..
.

..
..
..

51- 2
51- 5
51- 5
51- 6
51- 7
51- 8
51- 9
51-10
51-12
51-13
51-15
51-18
51-20
51-22
51-23
51-24

51-l

GENERAL

Outline

- The air compressed by the air compressor (1) enters

When the brake valves (1 I), (12) are actuated, the air

The

in the dry tanks (6), (7) flows to the brake chamber

air then enters two dry tanks (6), (7) and also flows

and applies pressure to the brake oil in the master

to the parking

cylinder.

The pressurized oil passes through the slack

adjusters

(17),

the wet tank

(5) and the moisture


brake valve (21).

is removed.

The air in the dry

tanks (6), (7) flows to the brake valves (1 I), (12).

- When the air compressed by the air compressor (1)


fills the circuit

and the air pressure in the wet tank

(5) reaches the maximum

set pressure of the air govIt opens

ernor (2), the air governor (2) is actuated.

(18)

and pushes the wheel piston to

apply the brakes (19), (20).


The parking brake (24) is applied mechanically
spring in the spring cylinder (23).
released by air pressure. Therefore,

by the

It is designed to be
if the air pressure

the unloader valve of the compressor, so the compres-

is less than the force of the spring in the spring cylin-

sor (1) is put in a noload condition

der (23), the brake is kept applied.

pressed.

and no air is com-

When the air is used and the air pressure in-

side the tank drops below the minimum


of the air governor
ated.

set pressure

(2), the air governor (2) is actu-

When the air pres-

sure rises and the parking brake release is reached, a


solenoid

valve is actuated to supply air to the spring

cylinder

(23).

This releases the parking brake (24).

It closes the unloader valve of the compressor

and the compressor (1) is actuated.


nor (2)

does not work

inside the tank

properly,

If the air goverand the

pressure

reaches the set pressure, the safety

valve (28) opens and the air pressure is released to the


atmosphere.

51-2

This protects the air circuit.

WA500-

Air compressor
Air governor
3.

WA500-1

Tire inflation

4.

Drain valve (Serial No. 10001

4A.

Drain valve (Serial No. 10428

and up)

10427)

5.

Air tank
:

6.

Air tank (dry)

(wet)

7.

Air tank

Check valve

[dry)

9.

Check valve

10.

Drain valve (Serial No. 10001

IOA.

Drain valve (Serial No. 10428

and up)

11.

R.H..brake

12.

L.H. brake valve

13.

Two-way

valve

14.

Two-way

valve

15.

Front brake chamber

valve

16.

Rear brake chamber

17.

Front slack adjuster

18.

Rear slack adjuster

19.

Front brake

20.

Rear brake

21.

Parking brake solenoid vaive

22.

Parking brake sense:

23.

Spring cylinder

24.

Horn valve

25.

Horn

26.

Brake oil tank

27.

Safety

28.

Air pressure sensor

29.

Emergency

valve

brake switch

30.

Stop lamp switch

31.

Transmission

cut-off

switch

10427)

AIR TANK
WET

DRY

TANK

TANK

IA

BCD

425FO84

A. To air governor (PT l/2)


B. Air pressure sensor pick-up

(PT l/8)

G.

Drain valve (PT 118)

H.

From air tank (wet) (PT l/2)

C. To air tank (dry) (PT 112)

I.

Plug hole (PT l/8)

D. Plug mount (PT l/4)

J.

To brake valve (PT 3/8)

E. From air compressor (PT l/2)


F. To drain valve (PT 114)

Name

Maximum

(!?I

pressure

9.4

9.5 kg/cm2

Dry tank (L)

26.6

9.5 kg/cm2

Dry tank (R)

26.6

9.5 kg/cm2

Wet tank
421

Capacity

F059

The air tank consists of one wet tank and two dry
tanks.
wet

The air from the compressor first enters the

tank

and the

moisture

is removed.

It is then

divided and sent to the left and right dry tanks.

* A safety valve and air pressure sensor are installed in


the wet tank.

SAFETY

VALVE

Function

1. Adjustment

- The safety valve is installed in the wet tank, and acts


as a safety device for the air circuit.
Operation

If the air governor does not work


pressure inside the air tank

properly

and the

rises above the set pres-

sure, ball (4) is pushed up and the air escapes to the


atmosphere.

2.

Spring cage

3.

Spring

4.

Ball

5.

Lock nut

6.

Relief valve

7.

Body

nut

423FO96

WA500-

51-5

BRAKE VALVE

Outline

* There are two brake valves installed in parallel at the


bottom

of the

operators

compartment.

These are

operated by depressing the pedal.

* When the right pedal is depressed, air is sent to the


brake chamber and the brake is actuated.

When the

left pedal is depressed, the brake is actuated


same way

as with

time,

transmission

the

electrically,

the right pedal,


solenoid

in the

but at the same


valve is actuated

and the transmission is put in neutral.

.I

I rIIL
7

Brake pedal

A.

From air tank

2.

Plunger

B.

From air tank

3.

Piston

C.

To front brake chamber

4.

Inlet valve

D.

To rear brake chamber

5.

Piston

6.

Inlet valve

7.

Rubber spring

1.

51-6

423Fo97

WA500-

BRAKE

ACTUATED

Upper part

- When pedal (1) is depressed, the operating


passes through
is transmitted

force

plunger (2) and rubber spring (71, and


to piston (3).

When piston (3) moves

down, exhaust port (9) is closed, and at the time inlet


valve (4) is moved down and air from the air tank
(11) flows from port A to port C.

This actuates the

front brake chamber (12).

Lower part

* When pedal (1) is depressed, the operating


passes through
is transmitted
down,

force

plunger (2) and rubber spring (7), and


to piston (3).

When piston (3) moves

inlet valve (4) is moved down,

and air from

the air tank flows from port B to port D. This actuates the rear brake chamber.
To front

slack

*To, rear slack


adjuster

423FO98

Operation

of brake when lower valve fails

* Even if there is leakage of air in the lower piping, the


upper part will operate normally.
The brake for the lower circuit will not operate.

423FO99

WA500- 1

51-7

Operation

of brake when upper valve fails

* Even if there is leakage of air in the upper piping, if


pedal (1) is depressed, piston (5) will be pushed down
mechanically

and the upper part will operate normal-

ly.
The brake for the upper circuit will not operate.

OPERATING

IN BALANCE

To rearslack
adjuster

Upper part

* When the pressure in the space below piston (3) and

423FlOO

the air pressure from the brake chamber become high,


the pressure pushes rubber spring (71, and piston (3)
moves up to close inlet valve (4).
exhaust port (9) stays closed.
ing the brake chamber

When this happens,

The air pressure enter-

is retained

and the brake is

kept applied.

Lower part

Upper piston (3) moves up, and inlet valve (4) closes.
Piston

(3)

is pulled

up by an amount

equal to the

amount

of movement

and inlet valve (6) closes. The

exhaust

valve is closed, so the air pressure is main-

tained and the brake is kept applied.


The air pressure in the space at the upper part balances the operating force of the pedal.

The pressure

in the space at the lower part balances the pressure in


the space at the upper part.
When pistons (3) and (5) move to the end of their
stroke, inlet valves (4) and (6) are fully opened.

The

spaces in the upper and lower parts, and the air pressure in the

left and right brake chambers

equal to the air pressure in the tank.


braking
brake

effect
pedal

can be adjusted

is depressed.

Therefore,

the

by the amount

the

When the

om frontslack

become

pistons move

down to the end of their stroke, the brake is applied

ont rearslack

fully.
423FlOl

51-8

WA500- 1

BRAKE

RELEASED

Upper part
-

When the pedal (1) is released and the operating pressure is removed from the top of the piston, the air at
the bottom of the piston, and the piston return spring
move the piston up.

Exhaust port (9) is opened and

the air pressure in the brake chamber

is released to

the atmosphere.

Lower part

- When the pedal is released and the air at the top of


piston (5) is let out, the air at the bottom
(5) and spring (13) pull the piston up.
(10)

opens at the

of piston

Exhaust port

air pressure in brake chamber

is

released to the atmosphere.

Om

rear slack

423F102

WA500- 1

51-9

AIR GOVERNOR

1.

Spring

2.

Exhaust port

3.

Piston

4.

Unloader port

5.

Exhaust stem

6.

Inlet valve

7.

Tank port

8.

Filter

Specifications

* Cut-out pressure:
* Cut-in pressure:

8.3 + 0.3 kg/cm*


7.0 t 0.3 kg/cm*

423F091A

Function

* The air governor maintains the pressure in the air


circuit to the specified range.

OPERATION
Compressor working

* The air pressure in the wet tank (9) passes from the
tank

port

(7) through

the filter

(8) and acts on the


Compressor

bottom of the piston (3).


When

the air pressure in the tank

specified

pressure (cut-out

(9) is below the

pressure) the piston (3)

pushed down by the spring (1).

* When this happens, the air at the unloader port (4)


passes through

the exhaust

stem (5) to the atmos-

To dry
+

Check valve

phere and the compressor is actuated.

Compressor loaded
421

51-10

WA500-

F057A

Compressor stopped

* When the pressure in the wet tank (9) rises, and


reaches the set pressure (cut-out pressure), the piston
(3) is pushed up against the spring (1).

- When the piston (3) is pushed up, the exhaust stem


(5) is closed and the inlet valve (6) opens.

- The pressure from the tank passes through the inlet


valve (6) and unloader port (4), and acts on the unloader valve of the compressor.
This

puts the compressor in a no-load condition.

* When the air pressure inside the tank drops, the pisCompressor

ton (3) is pushed down by the spring (I ).

- When the pressure drops below the specified pressure


(cut-in pressure),

the inlet valve (6) closes and the ex-

haust stem (5) opens.


port (4) passes through

The pressure at the unloader


the exhaust stem (5) and is

released in the atmosphere, so the compressor starts

To wet
+=

Check valve

to work again.

Compressor no-load
421 F058A

WA500- 1

51-11

TWO-WAY

VALVE

Function

* The two-way
valves.

valve is installed

It acts to prevent

ing from

between the two brake

the air pressure from

one brake valve when the other

escap-

brake valve

is depressed.

Operation

- The air circuit


connected
actuated

of the

so that

the

left

and right

brakes

brake

on all four

valves is

wheels are

when either of the pedals is depressed.

The air pressure entering

from

port A of the two-way

valve moves seat (2) and shuts off the circuit


B.

Therefore,

the air pressure flows

and actuates the brake chamber

only

to port

to port

(5).
423F103

1.

Body

4.

Cap

2.

Seat

5.

Brake chamber

3.

Plug

423F104

51-12

WA500-

BRAKE CHAMBER

lo -

01

425FO85

View Z

1.

Air cylinder

6.

Piston

2.

Air piston

7.

Master cylinder

3.

Spring

8.

Piston valve

4.

Rod

9.

Body

Specifications
1.

Air cylinder
Cylinder bore:

5.

Breather

10.

Sensor

2.

133.5 mm

Cylinder capacity:

3,600

cc

Master cylinder
Cylinder bore:

WA500-

180 mm

Stroke:

68 mm

Stroke:

132.5 mm

Delivery:

472 cc

51-13

OPERATION
Brake operated
When the

brake

pedal

is depressed, compressed air is

supplied from the brake valve to the brake chamber.

Air

piston (2) moves rod (4) and pushes piston (6) of master
cylinder

(7) to the right.

Brake oil is sent by piston (6)

to the brake piston to actuate the brake.

From brake
valve
@

425FO86

Brake held in position


When the

brake pedal is kept depressed at a constant

force,

hydraulic

the

pressure is kept

constant,

so the

brake is kept applied.

From brake
valve
@

425FO87

Brake released
When

the operating

force on the brake pedal is partly

released, the compressed air supplied to the back of piston (2) of the brake chamber
valve, and the hydraulic
(7)

drops.

is released from the brake

pressure inside master cylinder

If the brake pedal is released further,

the

brake oil sent to the piston of the brake is sent back to


the

inside of master cylinder

(7) by the force of the

brake return spring.


From slack
adjuster

To brake
valve
0

425Foaa

51-14

WA500-

SLACK

ADJUSTER

Function

- The slack adjuster is installed in the brake oil line


from the brake chamber to the brake piston.
to keep the clearance
discs constant

It acts

between the brake piston and

even when the brake discs are worn.

In

this way it acts to keep a constant time lag when the


brake is operated.

5
423F109

1.

Bleeder

2. Cylinder
3.

WASOO- 1

A.

Inlet port

B.

Outlet port

Check valve

4.

Piston

5.

Spring

51-15

OPERATION
1.

Brake pedal depressed

Serial
Brake

No. 10566

and up

oil tunk

425F504

When

the brake pedal is depressed, the oil dis-

charged from brake chamber


the slack adjuster.

(6) enters port P of

It is then divided and enters

left and right cylinders

(2),

and moves left and

right pistons (4) to the left and right by a distance equal to the total travel S.

Brake

Because of this, an amount

oil tunk

of oil equal to travel

S flows from port C to brake cylinder

(7).

When this happens, the clearance between brake


piston (8) and the plate becomes 0, but no braking force is generated.

WA500-1

If the brake
oil pressure

is depressed

further,

inside brake chamber

(6) goes above

pressure,

the oil flows

to ports P and C and brake cylinder

(7).

The

check valve

discs and plates

tightly

as the braking

(3) opens and

are then

by brake piston

425F506

and the

the specified

gether

2.

pedal

pushed

to-

(8), and this acts

force.

Brake pedal released

425F507
-

When

the

brake

pedal

is released,

the force

brake return

spring (9) causes brake piston

return,

the

piston
brake.

and

oil

equal

(4) to its original

to

travel

position

of

(8) to

S returns

to release the

In addition,

the

brake cylinder
travel

amount

S of piston

oil returning

from
of

(4), so travel T of brake piston

(8) does not change.


diaphragm

of

(7) is only equal to the amount

is always

In other
constant

words,

the brake

regardless

of the

wear of the brake discs.

WA500-1

51-17
8

BRAKE
Function

* The brakes are wet-type mutiple disc brakes,and are


fitted to all four wheels.

Detail P

c
L

425FO89

51-18

1.

Guide pin

5.

Inner gear (teeth 112)

2.

Return spring

6.

Plate

3.

Brake piston

7.

Disc

4.

Outer gear (teeth 164)

WA500-

Operation

- When the brake pedal is depressed, pressure is applied


to the brake oil by the master bylinder
chamber.

Brake piston

disc (7) is kept


(7) rotates
the rotation

in close contact

together

with

is stopped

of the brake

(3) is moved to the right, and


with

wheel,

plate

so when

(6).

Disc

it is held,

and the brakes are applied

to

From slack
adjuster
I@

stop the machine.

425FO90

When the brake pedal is released, the pressure on the


rear of brake piston
moved

to the

left

(3) is released.
by the force

and the brake is released.

The piston

of return

is then

spring

(2)
TO
adj

425FO91

WA500-

51-19

PARKING

BRAKE

Outline

* The parking
the front

brake

is a disc type

and is installed

on

axle.

ferential

* The force of the spring inside the spring cylinder


is used to apply

* The parking

the brake mechanically;

(2)

it is released

brake

caliper

is fixed

to the front

dif-

case.

The disc is installed


tates together

to the differential

yoke

and ro-

with the coupling.

by air pressure.

425FO94

51-20

1.

Parking brake disc

2.

Spring cylinder

WA500-

Brake operated

- When the parking brake switch lever is moved to ON,


solenoid
tank

valve is actuated

and the air from the air

is shut off by valve.

At the same time, the air

from the spring cylinder is released to the atmosphere


from between valve and body.
of spring cylinder

Therefore,

the piston

(1) is pushed by the tension of the

spring, so when lever (2) is pushed, the parking brake


is applied.

* Lever (2) rotates piston shaft (3) and moves piston


(4) to the axial direction.

Therefore,

the pads are

pushed against the disc, and the parking brake is applied.

425FO97
Brake released
When the parking brake switch is turned to OFF, the
/OFF

solenoid valve is actuated and valve closes the exhaust

I,-.
,-\:
I__,/

port.
At the same time,

Neutral

the air in the air tank enters the

top part of the piston of spring cylinder

(1).

solenoid

It over-

comes the force of the spring and pushes the piston.


This pulls rod (51, moves piston (4) and releases the
brake.
Therefore,

air pressure is applied to the spring cylin-

der and the parking brake is kept released.


However,

if the air pressure inside the tank drops to a

level where

it cannot maintain

the normal operation

of the brake, the pressure sensor installed to the tank


sends an electric signal to the solenoid valve. This releases the

spring

cylinder

brake is automatically

circuit,

and the

parking

applied.

Ii
425FO98

WA500- 1

51-21

PARKING

BRAKE SOLENOID

VALVE

425FO1155

1. Core

Function

The

parking

brake

air to the parking


and

actuated

ment.

5i22

solenoid

valve

is a valve to switch

brake spring cylinder.

by a switch

2.

Spring

3.

Body

4.

Seat

5.

Filter

6.

Filter

7.

Valve

8.

Plunger

9.

Coil

It iscontrolled

in the operators

compart-

10.

Connector

A.

Outlet port

B.

Exhaust port

c.

Inlet port

WA500-1

OPERATION

- Parking brake actuated


When the parking brake switch in the operators compartment

is turned ON (actuated),

is turned

OFF

(no current

the solenoid valve

flows),

so plunger

(8) is

moved down by spring (2).


The air from the tank enters port C, but valve (7) is
seated, so no air flows.

In addition,

the air from the

spring cylinder enters port A, then enters port B from


seat (4), and is released.
Therefore,

the parking brake is actuated by the force

of the spring in the spring cylinder.

To dry tank

425FO1156

Parking brake released


When the parking brake switch in the operators compartment

is turned

OFF (released), the solenoid valve

is turned ON (current flows), and plunger (8) moves


up. Valve (7) that are connected

by a rod also move

up at the same time, and exhaust port B is shut off


by seat (4) and valve (7).
The

air from

the tank

passes from

port C around

valve (7), enters port A, sends air to the spring cylinder, and releases the parking brake.

Todry

tank

425FO1157

WA500-1

5-i2-

.-

BRAKE CALIPER

425FO95

Section A - A

1.

Caliper

2.

Pad

3.

Piston

4.

Piston shaft

5.

Lever

6.

Adjustment bolt

Outline
There

is a piston

guide

provided

on the

Piston (3) and piston shaft (4) are fitted


the

rotation

of the

piston shaft

caliper.

in this, and

makes the piston

The caliper body moves according to the wear of the


pad and slides in the axial direction.

* Adjustment

bolt (6) of lever (5) is used to adjust the

move in an axial direction to press against pad (2).

clearance

Lever (5) is connected

kept stationary,

by a spline to the splined end

of the piston shaft.

between

the pad and disc.

the adjustment

With the lever

bolt is turned to ad-

just the clearance.

Pad (2) is held in the caliper mount support with caliper.

To INCREASE
To DECREASE

51-24

clearance, turn COUNTERCLOCKWISE.


clearance, turn CLOCKWISE.

WA500- 1

BRAKE AND AIR SYSTEM


52 TESTING

AND

ADJUSTING
...................
...........
Measuring brake pedal ..................
Measuring air ........................
Brake performance ....................
Checking brake oil pressure ..............
Measuring wear of brake disc .............
Air bleeding from brake line ..............
Parking brake performance ...............
Checking and adjusting parking brake ........
......................
Troubleshooting

The following

Standard value table

52- 2

Tool list for testing and adjusting

52- 3
52- 4
52-

52- 8
52- 9
52-10
52-11
52-12
52-13
52-15

precautions are necessary when using the Standard Value Tables to make judgements during trouble-

shooting or during testing and adjusting.


1.

The values in these tables are based on the values for new machines leaving the plant, so they should be used as
target values when repairing or when estimating wear after a period of use.

2.

The standard values in these tables for judgement

when troubleshooting

are estimated

values based on the

standard values for the machine when shipped from the plant, and on the results of various tests. Therefore,
they should be used as reference in combination
3.

with repair and operating records when making judgements.

These standard values tables must not be used for standard values when judging claims.

In addition,

do not use

these values alone to make simple judgements.

WASOO-

52-l
0

STANDARD

VALUE TABLE

Testing and measuring item

Measurement condition

Standard
value

Unit

Permissible
value

T
Brake pedal

- Operating
- Operating

force

. Engine speed: Low idling

angle

- Air pressure: 7 kg/cma


- Brake pedal operating force:

- Play

kg
degree

39-47

Max. 61
Max. 27

16.5 - 20.5

43 kg

Max. 10

4-8

Air system
* Air governor cut-in pressure
* Air governor cut-off pressure

- Safety

* Coolant temperature:
inside operating range

kg/cm2

valve actuating pressure

6.7 - 7.3

6.7 - 7.3

8.0 - 8.6

8.0 - 8.6

9.1 - 9.9

9.1 -9.9

Warning buzzer

- Actuating

starting pressure

- Actuating stopping pressure

. Coolant temperature:
Inside operating range

* Road surface:
paved surface

5.9 - 6.1

5.9 - 6.1

6.0 - 6.4

6.0 - 6.4

Max. 5

Max. 5

kg/cm2

Max. 5

Max. 5

3.34 - 4.26

Max. 6.3

kg/cm

Flat, horizontal, dry,

- Speed

when applying brakes:


20 km/h

Brake performance

* Time lag when pressing the pedal:


0.1 sec.

* Air

pressure: 6 kg/cm2

. Brake pedal operating force:


38 kg
* Tire inflation pressure:
Specified pressure

Drop in brake oil pressure

* Coolant temperature:
Inside operating range

- Test

Wear of brake disc

pressure: 53 kg/cm/5

min.

* Piston stroke

mm

* Tire inflation pressure:


Specified pressure
Parking brake performance

* Road

surface:
Flat, dry, paved surface with
115 (1 l20) gradient

- Machine:

In operating condition

. Thickness of pad

* With back plate

* Clearance between disc and pad

* Total of both side

52-2
0

Machine
stopped

mm

31.7

/
0.88

12.7

- 1.24

WA500-

2.3

TOOL LIST FOR TESTING

AND

ADJUSTING
7-

Testing and measuring item


1

Tool name

Part number

Remarks

Brake pedal operating force

Push gauge

799-l01-I001

O-110

Brake oil pressure

Brake test kit

793-520-I

0 - 100 kg/cm2

Wear of brake disc

Vernier calipers

Commercially available

150mm-2OOmm

Brake distance

Tape measure

Commercially available

30 m

Clearance of pad

Feeler gauge

Commercially available

0.1 - 3.0 mm

Hydraulic tester

799-l 01-5000

0 - 25 kg/cm
0 - 50 kg/cm>

Nipple

790-301-I190

6-1

Measuring air

6-2

801

kg

6-3

Connector

When carrying out testing, adjusting or troubleshooting,

20PF
(Commercially available1

stop the machine on level ground, install the safety

bar on the frame, lower the bucket to the ground, and stop the engine.
Then apply the parking brake and block the tires.

When taking measurements, do not allow unauthorized

WA500-

persons near the machine.

52-3
0

MEASURING

BRAKE

*
.

Measurement condition

Engine speed:

Air pressure: 7 kg/cm

Coolant temperature:

PEDAL

Inside operating range.

Low idling

Item

Standard
value

Permissible
value

4 - 8

Max. IO

<

Brake pedal

Play

Special tool
Part No.

Part Name

799-l 01-l 001

Push gauge

1.

Measuring operating force of pedal

1)

Oty

Fit push gauge A to the operators foot.


*

Align the center of the push gauge with the


center of the pedal.

2)

Start

the engine and run at low idling, then

depress the

pedal and measure the operating

force.
2.

Measuring travel of pedal


1)

Fit push gauge A to the operators foot.


*

Align the center of the push gauge with the


center of the pedal.

2)

Start

the engine and run at low idling, then

depress the

pedal with

an operating

force of

43 kg and measure the travel of the pedal with


an angle meter B.
3.

Measuring play of pedal


1)
2)

Start the engine.


Push the brake pedal in lightly by hand, and use
an angle meter

B to measure the travel of the

pedal to the point where

it starts to become

heavy,

WA500-

MEASURING

AIR

Measurement condition

Coolant temperature:

inside operating range.

Air governor
Unit:

Standard

kg/cm

value

Permissible
value

Cut-in pressure

6.7 - 7.3

6.7 - 7.3

Cut-off pressure

8.0 - 8.6

8.0 - 8.6

Item

Warning buzzer
Unit:

kq/cm2

Item

Standard
value

Permissible
value

Actuating starting pressure

5.9 - 6.1

5.9 - 6.1

Actuating stopping pressure

6.0 - 6.4

6.0 - 6.4

Safety valve
Unit:
Standard
value

Item

Actuating pressure

kg/cm*

Permissible
value

9.1 -9.9

9.1 -9.9

Special tools
Part Name

Part No.

790-301-I190

Qty

Hydraulic tester

Nipple

1 1

20PF
C

( co~$ear;;~llY

Connector

When measuring, connect nipple B, connector


gauge A, then insert in the tire inflation

C to

coupler on

the machine.
1.

Measuring set pressure of air governor


Open the drain

valve and drain

air from the

tank.
Start

the engine and raise the pressure inside

the tank.
Measure the pressure at which the air governor
is actuated

and the air compressor

is cut-off

(no-load rotation).
With

the engine at low idling,

pedal to

lower the air pressure.

pressure at which
(Start of operation).

WA500-

use the brake


Measure the

the air compressor

cuts in

Adjusting
1)
2)

Stop the engine.


Loosen

lock nut

(I),

and turn adjustment

screw (2)

to adjust.
*

Turn the adjustment


To DECREASE
To INCREASE

Amount

After

screw as follows.

set pressure, TIGHTEN


set pressure, LOOSEN

of adjustment

screw.
screw.

for 1 turn of screw.

Approx.

1.4 kg/cm*

adjusting

as above,

measure

again

and

check that all values are standard.

425F206

2.

Measuring

cut-off

pressure of

air

pressure alarm

buzzer
1)

Start the engine and run at low idling.


brake

pedal

to

lower

the

air

Usethe

pressure,

and

measure the pressure at which the buzzer starts


to sound.
2)

If the pressure is not standard


switch.
*

If the

pressure

the switch.
*

After

value, check the

If necessary, replace the switch.


is not standard

value, check

If necessary, replace the switch.

replacing

the

switch,

measure

the

pressure again.

52-6
0

WA500-1

3.

Measuring safety valve


1)

Loosen
nor

the adjustment

and set the

governor

above

screw of the air gover-

actuating
the

pressure

actuating

of the air

pressure

of the

safety valve.
2)

Start the engine and measure the pressure when


air comes out of the safety valve.

After

measuring,

governor
*

If the

do

not

to the specified
safety

valve

forget

to

return

the

air

pressure.

is defective,

replace

the

valve

assembly.
Do not try to adjust it.
*

Hook

the

tool

removeing.
*

on

part

Never use part b

Install so that the exhaust

port

when

tightening

or

when tightening.
(c) face down.

a
423F318

WA500-

BRAKE
*
.
.
.

PERFORMANCE

Measurement condition
Time lag when pressing the pedal : 0.1 sec.
Air pressure: 6.0 kg/cm2
Road surface:
Fiat, horizontal,

Machine speed:

Tire inflation

straight, dry, paved surface.

Speed when applying brakes:

20 km/h

pressure: Specified pressure.

Unit: m

Standard

Item

Permissible
value

value

Brake
performance

Max. 5

Max. 5

Special tool

Part No.

Part Name

Oty

Commercially
available

Tape measure

Conditions for measurement


1)

Start the engine and then start the machine.

2)

Place the speed control

lever in the highest speed

range and drive the machine.


3)

When the machine

is traveling at 20 km/h,

depress

the left brake pedal with 38 kg.


*
Decide the run-up road and point to apply the
brakes, then apply the brakes when the braking
point is reached.
Turn

the transmission

cut-off

selector switch

ON.
4)

Measure the distance from the braking point to the


point where the machine stops.

Carry out the test three times and take the average
value.

Braking point

Stopping point

I
Braking distance

Brake pedal operating


position

Runup

road
423F319

5G8

WA500-

CHECKING

BRAKE PISTON

*
.

Coolant temperature:

Test pressure:

Air pressure:

Measurement

LEAKAGE

condition
Inside operating range

53 kg/cm*
Inside operating range
Unit:

Item

Standard
value

Drop in pressure

Max. 5.0

kg/cm

Permissible
value

Max. 5.0

Special tool

Part No.

793-520-I

Q1

Part Name

Brake test kit

801

Qty

Block the tires securely.

Measuring procedure
1.

Remove

bleeder

screw (I),

then

install tool A in

bleeder screw mount.


2.

3.

Start the engine and bleed the air.


*

Bleed air from plug (2).

Turn the transmission cut off switch ON.

Depress the left brake.


53

kg/cm*,

leave for

When the gauge reading is


5 minutes

and check how

much the pressure drops.


4.

After

measuring,

stop the engine,

and loosen the

bleeder screw.
Lower the pressure, then remove tool A.
*

After

completing

operation,

the brake circuit again.

WA500-1

bleed the air from

MEASURING
*
.
.

WEAR

OF BRAKE

DISC

Measurement condition
Coolant temperature:
Air pressure:

Inside operating range

Inside operating range


Unit:

mm

Item

Standard
value

Permissible
value

Piston stroke

3.34 - 4.26

Max. 6.3

Special tool

Part No.

Commercially
available

Part Name

Qw

Vernier calipers

Stop the machine on level ground and block the


tires.

Method of testing
1.

Remove plug (1).

2.

Depress the brake pedal to the end of its travel.

3.

Measure depth b from the end face of the housing


to the spring guide.
*
Keep the brake pedal depressed when measuring.

4.

Install a vinyl hose to bleeder (2). loosen the bleeder


and bleed the brake oil.
*
After bleeding the brake
brake

piston

has returned

oil, check that

the

to the end of its

stroke.
5.

Measure depth a from the end face of the housing


to the spring guide.

Calculating piston stroke


S=b-a
S = Max. 6.3 mm

425F204

526
O

WA500-

AIR BLEEDING

FROM

BRAKE

LINE

Block the tires securely.

Order of operation
Remove cap (I)

of the bleeder screw, insert vinyl

hose (2) into the screw and put the other end in a
container.
Start the engine.
Depress the brake pedal, loosen the bleeder screw
and bleed the air.

Then tighten the bleeder screw

and slowly release the brake pedal.


*

Two

workers

are needed for this operation:

one depresses the pedal and the other bleeds


the air from bleeder screw.
*
*

Depress the left brake pedal.


Keep adding brake oil so that the oil circuit is
always full.

Repeat this operation

until no more bubbles come

out from the hose. Then depress the pedal fully and
tighten the bleeder screw while oil is flowing out.
*

Follow

the

same procedure

to bleed the air

from each cylinder.


After

bleeding all the cylinders,

check the level

of the oil tank and add oil.


*

To bleed the air completely,

bleed the air first

from

from

the

cylinder

furthest

the

master

cylinder.
+

When the air has been bled from


inders, confirm

all the cyl-

that rod (4) for the over-stroke

sensor of brake chamber

(3) is in place.

If it is

out of place, push it in as far as the sensor


installation

WA500-

end face of chamber.

52-11
0

PARKING
*

Measurement condition

.
.

Tire inflation

pressure: Specified pressure

Road surface:
(1 I207

PERFORMANCE

BRAKE

Flat,

dry,

paved surface with

l/5

gradient.

Machine:

In operating condition

Standard
value

Item

Permissible
value

Keeps machine on l/5


gradient

Parking brake performance

423F321

(1120)

Measuring procedure
1.

Start the engine and drive the machine straight up a


l/5 gradient with the bucket unloaded.

2.

Depress the brake, place the F-R lever in neutral,


then stop the engine.

3.

Turn

the

parking

brake

switch

ON,

then

slowly

release the brake pedal and keep the machine must


be kept stopped.
.
The measurement

must

be

made

with

the

machine facing either up or down the slope.


423F322

WA500-

CHECKING
*
.

AND

Measurement

condition

Air pressure:

Maximum

ADJUSTING

PARKING

set pressure
Unit:

Thickness of pad
(with back plate)

mm

Permissible
value

Standard
value

kern

31 .J

12.7

Block the tire securely.

Remove front

Method
1.

BRAKE

frame

inspection

cover (1).

for measuring

Turn

the

main

switch

ON,

and turn

brake switch

OFF to release the brake.

the

Operate

parking

it is not operated

brake

slowly,

the

switch

parking

slowly.

If

it may be impossible

to release the brake.


2.

Measure the thickness

of pad (3).

When the main switch


ing brake

is applied,

is turned

OFF, the park-

so be careful

not to turn

it

OFF.
For

details

of removing

ASSEMBLY

AND

the pad, see 53 DIS-

ASSEMBLY.

Measure 2 pads.
If

the

thickness

is not

within

the

standard

value, replace the 2 pads as one set.


For details
BLY

Measuring

AND

of replacement,

see 53 DISASSEM-

ASSEMBLY.

clearance
Unit:

mm

Item

Standard
value

Permissible
value

Clearance between disc and


pad (a + b)

0.88 - 1.24

2.3

Measurement

procedure

1.

Turn the parking

brake switch

2.

Insert thickness

gauge between

OFF to release brake.


disc (4) and pad (3),

then measure the clearances.


*

The clearance
the total

value mentioned

value of both

above indicates

sides. (a + b)

425F208

WA500- 1

52153

Adjustment
*

If the value is not within

the standard range, adjust

as follows.
.
Remove inspection cover (1) of front frame.
1.

Turn the starting switch ON, then turn the parking


brake switch OFF to release the brake.
*

If the starting switch is turned OFF, the parking brake will be actuated,

so be careful not to

switch it off.

2.

Turn adjustment

bolt (2) at the caliper lever clock-

wise until pad (3) is lightly in contact with disc (4).


*

If the adjustment

bolt is tightened

too much

and pad (3) and disc (4) are brought strongly


into contact,

it may cause the brake to squeak

or the discs to overheat.


3.

Turn

adjustment

bolt

notch) counterclockwise.

180

+ 30 (three

or four

This will adjust the total

clearance (a + b) on the left and right between pad


(3) and disc (4) to 0.88 *

1.24 mm.

When replacing the pad, always replace in sets


of two pads.

After

adjusting,

measure the

brake

performance

again and check that it is within the standard value.

425F208

52-l 4
0

WA500-

TROUBLESHOOTING
does not rises at all

2.

does not rise to the

Air pressure
specified

5.

.....

range

Brake is ineffective
effective

4.

Parking

Before

carrying

RENCE

WA500-

out the troubleshooting

METHOD

OF TROUBLE

OF READING

in this

section,

TROUBLESHOOTING

..

52-16
52-l

52-l

52-l

or not very

...... ... . .

Brake does not release,

or drags

51-19

brake does not release,

ordrags......................

page 22-12,

..

table

1. Air pressure

3.

. ...

Troubleshooting

52-20

read PRECAUTIONS
WHEN TROUBLESHOOTING
TABLE
page 22-14 and PREVENTING
RECUR-

page 22-16.

52i5

TROUBLESHOOTING
1.

TABLE

Air pressure does not rise at all.


Ask the operator the following

questions.

Did the air pressure suddenly


Damage in air circuit

Was the air pressure difficult


time?

+ Air

leakage,

cease to rise? -+

or equipment.
to raise for some

performance

drop

in air

equipment.

Check before troubleshooting

.
.

Damaged

air hose or tube,

external

equipment

associated with

air system.

Is the drain cock completely

damage to

closed?

Fault check

.
.

Check the air pressure by air gauge.


If the
ment
air

pointer

of the air gauge on the

panel remains at 0

drain

pressurized,

valve

and

despite

confirming

instru-

opening

that

the

the air is

the gauge is faulty.

om discharge pipe of compressor

engine is running but pressure does not build up.

The following symbols are used to


to be taken when a cause of failure
A:
X: Replace
C:
A: Adjust

52-16
0

indicate the action


is located.
Repair
Clean

WA500-

2.

Air pressure does not rise to the specified


range.
Checks before troubleshooting

Check

for

possible

air

leakage from

air hose,

tube and air equipment.


.

Is the drain cock completely

Check

for

intake

hose.

deformation

closed?

of compressor

or air

Fault check

Install

a pressure

measure
measured

the

air

value

gauge in the air circuit


pressure,
with

table to see whether


specified

the

then

and

compare

judgement

the

criterion

or not it deviates from the

value.

Air discharge from compressor discharge pipe is weak


when engine is running.

Compressor starts to build up pressure when circuit


between air governor and unloader is disconnected.

Air comes out of discharge pipe of compressor when


engine is running but pressure does not build up.

II

The following symbols are used to


to be taken when a cause of failure
A:
X: Replace
A: Adjust
C:

WA500-

indicate the action


is located.
Repair
Clean

52-17
0

3.

Brake is ineffective

or not very effective.

Ask the operator the following questions.


.
Did the brake suddenly ceases to be effective?
+ Damge in air or brake equipment.
.
Did brake gradually deteriorate? + Deterioration of seal or packing, wear of lining.
Checks before troubleshooting

.
.
f

.
.
.
.

Is kind of brake oil correct? (SAEIOW-CD)


Is air pressure and brake oil quantity satisfactory?
Is there any leakage of air or brake fluid when
the brake is operated?
Is there any external damage to air or brake
piping or equipment?
Check residual thickness of brake lining.
Check tire inflation pressure and tire tread.
Measure the pressure in the air circuit. If there
is an abnormality,
refer to item 1 Air pressure
is completely ineffective and item 2 Air presIf
sure does not rise to the specified value.
the measured value is normal,
following problems.

move on to the

Fault check
Check it against the valve in the judgement
criterion table to see whether or not braking

performance is bad.
The left and right wheels at both front and rear.

Air leaks from brake valve when a certain brake pedal is


depressed. Braking action is action when other brake

, abnorma

noise IS

at the air inlet of the brake chamber is disconnected and

The following symbols are usad to indicate the action


to be taken when a cause of failure is located.

526
8

WA500-

4.

Brake does not release, or drags.


Checks before troubleshooting

Does brake pedal return completely?

Does parking brake completely

disengage?

Fault check

.
.

NO.

Abnormal

heat generation in brake.

Inertial travel on flat ground.

Problems
Atr comes out and brake disengaged if brake chamber air
input is disconnected when brake pedal is released.

Clrcult pressure fails off and brake


21I from
air bleeder when brake pedal
,
3

disengages if oil is bled


is released.

A particular wheel rotates sluggishly when the machIne


is raised with a 4.wheel jack, the wheel axles placed on a
stand, the engine shut down and the tires rotated by hand
with the parking brake released.

The following
symbols are used to indicate the action
to be taken when a cause of failure is located.

WASOO- 1

5229

5.

Parking brake does not release, or drags.


(Applies to machine equipped with air parking brake.)
Checks before troubleshooting
.
Is the pressure in the
specified

range?

4.0 kg/cm2
valve will
parking

No.

air circuit

(if the air circuit

or less, the parking


automatically

operate

within

the

pressure

is

brake solenoid
to engage the

brake.)

Problems

Parking brake not released even when parking brake switch


is turned OFF.

When parking brake switch turned to OFF, air leaks from


spring cylinder, and cylinder rod does not return fully.

The spring cylinder operates normally and the rod and lever
return. however the brake draas.

The following symbols are used to indicate the action


to be taken when a cause of failure is located.
A: Repair
X : Repalce
C : Clean
A : Adjust

52-20
0

WA500- 1

AIR SYSTEM
53

AIR

DISASSEMBLY

AND

GOVERNOR
Disassembly.

Assembly
BRAKE

BRAKE

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

Removal

53- 3

Installation

VALVE

..........................
.......................
Disassembly .......................
Assembly
........................
Removal

53- 4
53-

SPRING

Removal

53- 8

Installation

CHAMBER

.........................
Installation
.......................
Disassembly.
......................
Assembly
........................

53-12

PARKING

the

1.
2.

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

53-23

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

53-25

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

53-28
53-30-2

.
.
.
.

.
.
.
.

.
.
.
.

.
.
_
.

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

53-34

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

53-35

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

53-36

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

53-36

53-17

Installation

BRAKE

53-20

Removal

53-20

Installation

..

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

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

53-37

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

53-40

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

53-43

PAD

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

53-43

53-22

following

method

for

air bleeding

cylinders,

when

you

start

to operate

hydraulic

pumps and pipings.

Start engine, keep idling.


Operate

hydraulic

cylinder

4 -

5 cycles,

but do not exceed beyond

100 mm of

end.

3.

Continue

4.

After
NOTE:

. _.
.. .
_. _
.. .

53-21

after reassembling

stroke

WA500-

.
....
. . _.
....

Removal

PARKING

.........................
Installation
.......................
Disassembly.
......................
Assembly
........................

cylinders

..
..
_.
..

BRAKE

53-14

ADJUSTER

Take

..
..
..
_.

53-10

Removal

.
.
.
.

CYLINDER

...
.
Disassembly .
Assembly
..

53- 6

Removal

SLACK

_. .
.
Disassembly .
Assembly
..

53- 2

Installation

BRAKE

ASSEMBLY

to operate

finishing
After

cylinder

3 - 4 cycles until stroke

above steps, keep normal

end.

engine speed.

long storage, same procedure

is required.

53-1
0

DISASSEMBLY
1.

OF AIR GOVERNOR

cover
Remove cover (15), then remove retaining

2.

ring (14).

Spring seat
1) Remove

spring

seat assemblies

(IO),

(II),

(12).

(13), (16) and (17).


t

Remove

lock

assembly

before removing

2) Remove

exhaust

top of piston
3.

nut

(16)

stem

inside

the spring

seat

the assembly.

(9) and spring

(8) from

(3).

Piston
I) Turn
piston

body

(I)

upside

(3) from

bottom.

2) Remove spring
*

If the piston
lightly

from

down

and tap to remove

(4) and valve (5) from


does not come out,

piston

(3).

blow

in air

port a.

/
3

'1

425F296

WA500-

ASSEMBLY
&

Inside

OF AIR GOVERNOR

surface

of

body,

outside

surface

of

piston, O-ring groove, spring guide, adjustment


screw:
1.

Grease (G2-LI)

Piston assembly
I) Insert O-ring (6) in stem hole of piston (3). then
install washer and insert spring (8) and exhaust
stem (9).

2) Insert valve (5) in bottom


spring

(4),

of piston

(31, insert

fit in groove, then install on O-ring

(18) and assemble piston assembly in body (1).


2.

Spring seat assembly


Assemble lower spring seat (11A) spring guide (lo),
lower spring seat (11). spring (12) and upper spring
seat (13) in order on adjustment screw (17).

Tight-

en lock nut (16) so that distance from bottom face


of adjustment

screw to top face of upper spring seat

(13) is b = 47.6 mm.


*

Check that
correctly

exhaust stem (9) and spring (8) are

fitted on piston (31, then insert the ad-

justment screw assembly in the body.


3.

Cover
Stop cover (15) with retaining ring (14). then install.

4.

Filter
Install filter
*

423F443

(2).

Install the governor on the machine and connect


the air piping.

Check the air pressure when the

air compressor

is increasing

sure.

If the

and decreasing

pressure is outside

pres-

the specified

value, adjust it.

423F444A

WA500-

53-3
0

REMOVAL

OF BRAKE VALVE

Stop the

machine

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.

1.

Cover
Remove cover under the cab.

2.

Draining air
Loosen drain valve and drain air from air tank.

.
3.

Air piping, wiring


Disconnect

air pipings (I),

(2), (3), (4) and (5). connec-

tor (6) and wiring (7).

4.

Pedal
Pull out cotter

pin

(9) of pin

(8),

remove

pin, then

remove pedal (10).


*

5.

Remove floor mat.

Brake valve
1) Remove mounting bolt (11).
*

Loosen bolt (12).

2) Remove bolt (12) and disconnect valve body (13) and


mount flange (14).
*

When

bolt

(12)

fall, therefore,
*

is removed valve body

(13) will

remove carefully.

Pull otu plunger (15) from mount flange.

WA500-

INSTALLATION
1.

OF BRAKE VALVE

Brake valve
1) Set

valve

body

(13)

in

mounting

position,

then

tighten mount flange (14) and bolt (12).


*

Assemble of plunger in mount flange.

Plunger:

Brake oil

2) Tighten mounting bolts (11) and secure valve.

2.

Pedal
Set pedal

(10)

in mounting

position,

insert pin

(8),

align stopper hole on left side of pin and assemble on


right with cotter pin (9).

3.

Bend the cotter pin securely.

Check assembled spacers.

Air piping, wiring


Connect air pipings (5), (4), (3), (2) and (I),
and connector

4.

wiring

(6)

(7).

Air leakage check


Tighten drain valve, start engine, then check for leakage
of air, and check operation

5.

of brakes.

Cover
Install cover from under the cab.

WA500-

DISASSEMBLY
1.

OF BRAKE VALVE

Body assembly
1) Make

match

mark

on upper

body

and lower

body.

2) Loosen mounting

bolts (I),

remove upper body (2)

and lower body (3). then disconnect them.

2.

Upper valve assembly


1) Hold slot-head screwdriver

in vice @

and fit in

slot in stem inside exhaust passage of relay piston.

2) Loosen nut (4). then remove washer (5), plain washer


(6), spring seat (7). rubber spring (8), upper piston
(9), return spring (IO),

relay piston spring (II),

relay

piston (12), and stem assembly (13).


When loosening the nut, the piston may fly
out under the force of the return spring, so
hold the piston by hand when loosening the
nut.

53-6
0

WA500-

31 Remove

snap

(15) from

ring

(14),

then

remove

primary

valve

upper body.

56OBP376

4) Remove
valve

snap

into

ring

washer

(19) and (20).

(16),
(17),

then
O-ring

disassemble
retainer

upper valve spring

primary

(18).

O-rings

(21), valve retainer

(22), and upper valve (23).

,,56OBPJY-J .,,,,

3.

Lower

valve assembly

1) Remove

exhaust

valve assembly

cover

(24),

2) Remove O-ring (26) from

3) Remove

snap ring

valve assembly

then

(27),

then

into washer
(31).

disassemble

secondary

(28), O-ring retainer

(30) and

retainer

(33). and lower valve (34).

secondary

lower body.

O-rings

WA500-

remove

(25).

lower valve spring

(29),

(32), valve

ASSEMBLY
I_

OF BRAKE VALVE

Lower valve assembly


1) Set lower
sembly

valve (34) with

valve

retainer

O-ring retainer

valve seat at bottom,

(33).

lower

valve spring

as(321,

(29) and washer (28), then secure with

snap ring (27).


*

Assemble
retainer

O-rings

(30)

and

(31)

on

the

O-ring

first.

,,,,,,,,,
,,,,,,
,,,,
56OBP379-

2) Assemble
body,

secondary

then

valve

install exhaust

assembly

(25)

in lower

cover (24).

56OBP378

2.

Upper valve assembly


1) Set upper valve (23) with
semble

valve

O-ring

retainer

with
t

retainer
(18)

(22).

valve seat at bottom,


upper

and washer

valve spring
(171, then

as(211,

secure

snap ring (16).

Assemble
retainer

O-rings

(19)

and

(20)

on

the

O-ring

first.

56OBP377

2) Assemble

primary

then secure with

valve assembly

(15) in upper body,

snap ring (14).

S6OBP376

53-8
0

WA500-

._,

3) Hold slot-head screwdriver


relay piston spring (11).

in vice @

, assemble

relay piston (12) and stem

assembly (13) in bottom of upper body, then set with


screwdriver.
Do not forget to fit an O-ring on the relay piston.

4) Assemble return spring (IO), upper piston (9), rubber


spring

(8), spring seat (7). and washers (5) and (6)

from top of upper body, then tighten with nut (4).


Do not forget to fit an O-ring on the upper piston.

The piston may fly out under the force of


!
G

the return spring, so hold the piston by hand


when assembling.

3.

Nut:

0.55 f 0.15 kgm

Body assembly
1) Install O-ring (35) on lower body (3).

2) Align match marks a on upper body (2) and lower


body (3), assemble and tighten mounting bolts (1).

WA500-

REMOVAL

Af

OF BRAKE CHAMBER

Stop the

machine

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
1.

Draining air
Loosen drain valve (1) and (2) drain air from air tank.

2.

Hood
Remove engine hood (3).

el
kg

3.

Engine hood:

60 kg

Brake air piping


1) Disconnect

hose

(4)

between

brake

chamber

and

brake oil tank at brake chamber end.


*

The oil will come out of the tank, so catch the oil

Disconnect electric wiring (5) from connector.

in a container.

2) Disconnect

hose (6) between slack adjuster and brake

chamber at brake chamber end.


3) Disconnect

tube

(7) between

brake valve and slack

adjuster at brake chamber end.

53i20

WA500-

4.

Brake chamber
1) Temporarily

sling brake

chamber

(8)

and

remove

mounting bolts (9).


2) Remove brake chamber bracket (IO).
*

Remove upper and lower brackets.

3) Sling brake chamber (8).

Remove

carefully

because working

space is nar-

row.
wkg
*

Brake chamber:

20 kg

The front brake chamber is removed after the rear


brake

chamber,

the front

brake

however,

the steps for removing

chamber

is the

same

as for

the

rear.

WA500-

53-11
0

INSTALLATION
1.

OF BRAKE CHAMBER

Brake chamber
1) Sling and set brake chamber

2) Install bracket
*

(10) of chamber.

Install both upper and lower brackets.

3) Tighten

2.

(8).

mounting

bolts (9) of chamber

(8).

Brake and air piping


1) Connect
chamber
2) Connect
adjuster

3) Connect
chamber
*

tube

between

hose (6) between


at brake chamber

hose (4) between


at brake chamber

Connect

53i2

(7)

at brake chamber

connector

brake

valve

and

brake

end.
brake

chamber

and slack

oil tank

and brake

end.

brake
end.

(5) of electric

wiring.

WA500-

3.

Hood
Remove engine hood (3).

4.

Air bleeder of brake system


Fill

brake

oil tank

with

oil, then

bleed air of brake

system.
*
*

Always keep the brake oil tank full.


For

details

of

air

bleeding,

see TESTING

AND

ADJUSTING.
*
*

Push in caution sensor rod of brake line.


Install the front frame chamber the same as tl ne rear
frame chamber.

WA500-

DISASSEMBLY
1.

OF BRAKE CHAMBER

Accessories
Remove breather (I), bleeder (2) and sensor (3).

2.

Cylinder
Loosen lock nut (4), then remove cylinder
*

(5).

There is O-ring fitted on the thread of the cylinder, so


remove it.

3.

Piston assembly
1) Move

retainer

(6)

to

right,

remove

pin

(7),

then

remove piston assembly (8).


+

Use a guide pin (Outer dia. = 2.5 mm,

length = 50

mm) to remove the pin.

423F446

2) Remove rod (9), then remove O-ring.

4.

Disassembly of piston assembly


1) Remove snap ring (IO), then remove seat (11). spring
(12) and valve (13).
t

Spring (12) is small, so be careful not to lose it.

2) Remove packing (15) from piston (14).

423 F447

53d4

423P%%

WASOO- 1

5.

Body
Hold body (16) with hand, remove mounting bolt, then
remove body.
The tension
!
Q
t

of the spring on the body is 25

kg, so be careful when removing it.

Remove the O-ring from the contact surfaces of the


body and air cylinder.

6.

Disassembly of body
1) Remove

snap

ring

(17),

then

remove

ring

(18),

packing (19), seat (20) and packing (21).

2) Remove

snap ring (22).

then remove ring (23)

and

seal (24).

7.

Air piston
1) Remove spring (27) and piston assembly
air cylinder

WA500-

(25).

(26) from

2) Remove nut, then remove piston (28) and rod (29).


3) Remove packing (30) and ring (31) from piston (28).

4) Remove O-ring (32) and washer (33) from rod.

53-16
0

WA500-

ASSEMBLY
1.

OF BRAKE CHAMBER

Assembly of piston assembly


1) Install washer (33) and O-ring (32) on rod (29).
*

When

fitting

threads

of

the
the

O-ring,
rod to

wind

tape around

prevent

damage

the

to

the

O-ring.
4

O-ring:

Brake oil

2) Assemble packing (30) and ring (31) on piston (28).


6

Packing:

Grease (G2-LI)

3) Insert rod (29) in mount of piston (28), then secure


with nut.
+

After

tightening

the

nut, check that there

is no

clearance between the stepped part of the rod and


the piston.
&

Piston mounting hole:

m
2.

Nut:

Grease (G2-L .I)

14 + 2 kgm

Assembly of body
1) Install seal (24)

and ring

(23)

in body

(1 6), then

secure with snap ring (22).


*

Install the seal with the lip facing the outside.

Check that the snap ring is fitted

securely in the

groove.
6

Seal:

Brake oil

23

24

16

423F449

WA500-1

2) Turn over body, assemble packing (21), seat (20) and


packing

(19),

insert ring (18). then secure with snap

ring (17).
t

Install the seal with the lip facing the outside.

Check that the snap ring is fitted

securely in the

groove.
a

Packing:

Brake oil

423F450

3.

Piston assembly
Insert piston assembly (27) in air cylinder

(25).

Coat inside of air cylinder with grease.


When inserting the piston assembly, tilt at an angle
of about 30,

insert about l/3,

then lay the air cyl-

inder on its side and insert the piston fully.


Check that the piston assembly moves smoothly.
4.

Body assembly
Insert spring

(26)

in mount

of air cylinder,

fit O-ring

(34) in body assembly (16), then install in air cylinder.


*

Push in the
in

body by hand, install 2 mouting

diametrically

opposite

positions,

then

bolts

tighten

together with bracket (35).


w

5.

Mounting bolt:

4.4 f 0.6 kgm

Assembly of piston
1) Insert valve (13), spring (12) and seat (11) in piston
(14), then secure with snap ring (10).
*

Be careful to insert the spring facing in the correct


direction.

Check that

the snap ring fitted

securely

in the

groove.

53d8

WA500-

2) Assemble packing (15) on piston.


*

Install the packing with the lip facing the outside.

6.

Packing:

Grease (G2-LI)

Piston assembly
Blow air into air cylinder
assembly

(8) in mounting

and blow out rod.


position,

Set piston

then connect with

pin (7).
*

The pin hole is hidden by the retainer,

so move the

retainer to the right and insert the pin.


*

After

inserting

the pin, check that the retainer

has

moved back to its original place and the pin is hidden.

7.

Cylinder
Install

nut

(4) and O-ring

(36)

on cylinder

(5), screw

into mount, then secure with nut.


*

Screw the cylinder

in fully,

then turn back until the

breather and bleeder are in a straight line.

8.

Inside surface of cylinder:

Nut:

142

Brake oil

3 kgm

Sensor
Fit O-rings on rod

(9) and sensor (3). then install in

mounting position.
*

Insert the rod until it is level with the body.


m

9.

Sensor:

5.6 f 0.6 kgm

Accessories
Install breather (1) and bleeder (2).
w

WA500-

Bleeder:

0.95 + 0.25 kgm

53-19
m

REMOVAL

n!

OF SLACK

Stop the

machine

ADJUSTER

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
1.

Brake piping
1) Remove cover (1).
2) Disconnect tube (2) between slack adjuster and brake
chamber at slack adjuster end.
*

Tube (3) at rear.

3) Disconnect

tube

(4) between

slack adjuster and left

and right brake pistons at slack adjuster end.


2.

Slack adjuster
Remove mounting bolts, then remove slack adjuster (5).
t

There is little space, so be careful when working.

INSTALLATION
ADJUSTER
1.

OF SLACK

Slack adjuster
Set slack adjuster

(5) in mounting position, then tighten

mounting bolts.
*

Tighten

the mounting

bolts partially,

then tighten

fully after connecting the piping.


2.

Brake piping
1) Connect tube (4) between slack adjuster and left and
right brake pistons at slack adjuster end.
2) Connect

tube

(2) between

slack adjuster and brake

chamber at slack adjuster end.


*

Tube (3) at rear.

3) Install cover (1).


3.

Bleeding air
Bleed air from brake system, and check that there is no
leakage of oil from connections.
*

For details

of bleeding

air, see 52 TESTING

AND

ADJUSTING.
t

Bleed the air from the brake end and slack adjuster
end.

53620

WA500-

DISASSEMBLY
1.

OF SLACK

ADJUSTER

Bleeder
Remove bleeder (2) from body (1).

2.

Cylinder
Remove mounting
cylinder

bolts, then disconnect

body (1) and

(4) together with bracket (3).


There

is spring tension

hold the contact

inside the cylinder,

so

surfaces and be careful when

removing.

3.

Piston

1) Remove spring (5) and O-ring (6).

2) Remove piston (7), then remove O-ring.


*

Use a rod of 10 mm diameter

and push out the

piston slowly.
*

Be careful not to damage the thread with the rod.

423F451

4.

Poppet

._ ji

1) Remove

cover (8) from

cylinder

(4),

then

remove

plug (9), spring (10) and poppet (11).


When removing the poppet,

blow in air from the

oil hole in the cylinder.


Hold the oil port of the cylinder

by hand, and do

not pump in air suddenly.


Be careful

not

to

change

the

combination

of

poppet (11) and cylinder (4).


When replacing, replace the poppet and cylinder as
an assembly.
2) Remove O-ring (12) from poppet.

WA500-1

53-21

ASSEMBLY
1.

OF SLACK

ADJUSTER

Poppet
1) Fit O-ring (12) on poppet (11 ).
2) Install poppet

(II),

spring (IO),

(8). then assemble cylinder

2.

plug (9) and cover

(4).

Piston
1) Install O-ring (13) on piston (7).
2) Insert piston (7) in cylinder
*

3.

(4).

Check that the piston moves smoothly.

Cylinder
1) Install O-ring (6) and spring (5) in cylinder.
*

Installed road of spring: 4.4 kg

2) Install

body

(1)

and

cylinder

(4)

together

with

bracket (3).

4.

Bleeder
Install bleeder (2).

WA500-

REMOVAL

OF BRAKE ASSEMBLY

Special tool
Part name

Part No.
A

793-520-I

A.

Stop

Qty

Fixture

910

the machine

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.

1.

Tire, wheel
Jack up axle, put stand under axle, then lift off tire and

,,,,,,
,,,

wheel (1).
Tire, wheel:
2.

600 kg

Draining oil
Remove drain plugs (2) and (3), and drain oil from axle
assembly.
t

Set with the drain plug at the bottom.


- :

3.

Axle assembly:

30 Q

Cover
Remove

bolts

mounting

(4),

then

remove

final

case

cover (5).

4.

Axle shaft assembly


Using forcing screw

01

(Thread dia. = 12 mm,

Pitch =

1.75 mm), pull out alxe shaft assembly (6).

5.

Remove

mounting

(Thread

dia.

bolts

= 12 mm,

(7),

and

Pitch

using eye-bolts @

= 1.75

mm),

lift

off

planetary carrier assembly (8).


*

Since the balance

is bad, adjust center of gravity

with

a bar and remove.


Planetary

WA500-

carrier assembly:

90 kg

53-23
0

6.

Ring gear assembly


Using tool

A,

hold wheel

hub

(9) and brake

(IO)

in

position.
t

Install tool

A to points on opposite

sides, and use

washers to adjust clearance.

7.

Remove

mounting

bolts

(11)

of

retainer

(121, then

remove ring gear assembly (13).


*

There are shims between the retainer and axle housing, so check the number and thickness of the shims,
and use for reference when installing.
Ring gear assembly:

50 kg

8.

Remove brake hose (14).

9.

Sling brake an wheel hub assembly (161, remove mounting bolts (15). then lift off assembly.
Brake, wheel hub assembly:

IO.

270 kg

Axle housing
Remove bearing

(18) and retainer

(19) from axle hous-

ing (17).

53-24

WA500-1

INSTALLATION

OF BRAKE ASSEMBLY

Special tool

Part No.
793-520-I 910

1.

Qty

Part name

~I

Fixture

Axle housing
Press fit retainer
(17).
* After

(19) and bearing (18) on axle housing

press fitting

the retainer and housing, and the

retainer and bearing, check that there is no clearance


425P689

at any point.
2.

Brake, wheel hub assembly


Use tool

A to hold brake assembly and wheel hub in

position.
+

As far as possible, install tool A to points at diametrically

opposite

positions

and adjust clearance

using

with washer.
3.

Raise brake and wheel hub assembly (16), set in position


on axle

housing mount,

(15).
* Be careful
zontally,

then tighten

mounting

of the center of gravity,

bolts

and sling hori-

then install it.

&

Mounting bolt:

Thread tightener

Mounting bolt:

56+

6 kgm

4.

Install brake hose (14).

5.

Wheel bearing adjusting method


1) Raise ring gear assembly
housing and, tighten

425P866

(LT-2)

(131, then

retainer

insert in axle

(12) temporarily

with 3

bolts, then remove tool A.


*
*

Measure thickness lb of retainer first.


Do not insert shims in the retainer when tightening
temporarily.

Rotate

the wheel hub to settle the bearing, then

tighten to a uniform torque.


D

Mounting bolt of retainer:

12

8 f 0.5 kgm

425F293

425P645

WA500-

53-25
0

2) Insert a depth micrometer through measuring hole of


retainer

(20), and measure clearance a between end

face of housing and end face of retainer.


*

Measure at 2 places and take the average.

0.3

mm

c = a -

added

to

measured

value

b, becomes shim thickness.

difference
(Round off

fraction to next highest decimal 0.1 mm,)


*

Use the smallest number of shims which gives the


required thickness.

3) Install tool A to brake assembly and wheel hub, and


remove retainer.

Install requried thickness of shims,

then install retainer again.


f

Always install tool A before assembling the shims.

Rotate

the wheel hub and tighten

bolts uniformly

the mounting

to the specified tightening torque.

&

Mounting bolt:

Thread tightener

Mounting bolt:

28.25 f 3.25 kgm

(LT-2)

425F297

6.

Planetary carrier assembly


Fit

O-ring,

mm,

and using eye-bolts @

(Thread

Pitch = 1.75 mm) sling planetary

dia.

= 12

carrier assembly

(8) and set in mounting position, then tighten mounting


bolts (7).
*

Since the balance is bad, adjust the center of gravity


with a bar and install.

7.

Axle shaft assembly


Install

bolt @

to axle shaft and install axle shaft as-

sembly (6).
*

If the position of the sun gear does not match, rotate


the wheel hub to align.

8.

Cover
Fit O-ring in groove in cover, then install cover (5) with
bolt (4).

53-26
0

WA500-

9.

Refilling with oil


Tighten drain plug (3) and (2) and add oil through level
plug (21) to the specified level.
*

Set the

machine so that the drain

plug of the final

drive is at the bottom when refilling with oil.


Axle assembly:

approx. 30 Iz
(Width across flats: 30 mm)

10. Tire, wheel


Install tire and wheel (I), then remove stand.
w

11.

Mounting nut:

48 + 5 kgm

Bleeding air from brakes


*

For details

of bleeding

air, see 52 TESTING

AND

ADJUSTING.

WA500-

53627

DISASSEMBLY

OF BRAKE ASSEMBLY

(Front, rear)

Special tool
Part No.
A

1.

Part name

793-502-1910

1 Fixture

Cylinder

A_
Using eye-bolts u

(Thread dia. = 16 mm,

mm), lift out cylinder

I Qtv

Pitch = 2.0

(1).

Disassemble cylinder with following

steps:

1) Screw in eye-bolts @ (Thread dia. = 16 mm, Pitch


= 2.0 mm), push in spring with bar @ , then pull
out pin (2).
2) Remove spring (3) and shaft (4).

3) Remove piston (5).

53-28
0

WA500-1

2.

Plate, disc
1) Remove plate (6).

2) Remove disc (7).


*

When

removing

marks

on the inner

the

disc and

plates,

put

match

gear and disc, and outer

gear

and plate before removing.


*

The discs are made of soft material,

so be careful

not to damage them when removing.


*

3.

Remove discs and plates alternately.

Outer drum
*

Remove tool A.

1) Using eye-bolts

(Thread

1.75 mm), lift out outer drum

WA500-

dia. = 12 mm,

Pitch =

(8).

53-29
0

2) Remove outer race (9).


3) Remove retainer (IO).

4) Remove floating seal (11).

5) Remove oil seal (12).


6) Remove floating seal (13).

53-30
0

WA500-

ASSEMBLY
Special

OF BRAKE ASSEMBLY

tools
Part name

Part No.

1.

(Front, rear)

793-502-1910

792-520-21

Bl

792-530-l

Outer

IO
600

Qty

Fixture

Installer

Push puller

drum

1) Using

tools B and

BI,

install

floating

seal (13)

to hub.
425F298

&

Seal contact

Assemble

Using

face: Engine

O-ring

alcohol,

Remove

contact

Tighten

tool BI

of the O-ring

press fitting,

uniformly

measure
between

so that there

height
the

seal

of the hub.

of the floating

the circumference,

difference
within

powder

from the floating

surface

twisting
around

seal.

all the white

surface.

all the grease

and O-ring

to floating

remove

from the O-ring


*

(13A)

oil (E030-CD)

is no

seal. After

t at four places

and check that the


measurements

is

1 mm.
425FO1807

425FO1808

2) Install oil seal (12).


&

Seal contact face: Grease

Mating

surface

(G2-LI)

of oil seal and hub:

Thread

tightener

(Loctite

#648)

425FO1809

53-30-2
0

WA500-1

3) Using

tools B and BI,

in retainer
&

install

floating

Seal contact face: Engine


Ir Assemble
*

Using

O-ring

alcohol,

Remove

+- Tighten

contact

powder

from the floating

measure
between

so that there

height
the

seal

of the retainer.

of the floating

the circumference,

difference

seal.

all the white

surface

of the O-ring

press fitting,

within

to floating

tool BI uniformly

twisting

oil (E030-CD)

surface.

all the grease

and O-ring

around

(1 IA)

remove

from the O-ring


f

seal (1 1)

(IO).

is no

seal. After

t at four places

425FO1806

and check that the


measurements

is

1 mm.

11A

t
::-p:l
425FO1811

11A
11

425FO1810

WA500-

53631

4) Match

retainer

(IO)

with

dowel

pin and install re-

tainer.
5) lnstal outer race (9).

425P707

6) Using eye-bolts @

(Thread

dia. = 12 mm,

Pitch =

1.75 mm), lift and install outer drum (8).

7) Install tool A.

425P705

2.

Disc, plate
1) Install disc (7).

5322

WA500-

2) install plate (6).


*

Align notched portion

of outer teeth of plate and

assemble.
*

Align the match marks on the disc and inner gear,


and plate and outer gear, then assemble the plates
and discs in turn.

3.

CyliQder
*

Assemble cylinder with following

steps:

1) Set piston (5) at bottom.

2) Install shaft (4) and spring (3).


3) Screw in eye-bolts @

(Thread dia. = 16 mm,

2.0 mm), push in spring with bar @

Pitch

, then install

pin (2).

4) Fit O-ring, and using eye-bolts @


16 mm,

(Thread dia. =

Pitch = 2.01, match with guide bolt @

and lift and install cylinder assembly (1).


&

Mounting bolt:

Thread tightener

Mounting bolt:

18 f 2 kgm

(LT-2)

425P710

WA500-

53iif3

REMOVAL
a

Stop the

OF SPRING
machine

CYLINDER

on level ground and install the

safety bar on the frame.


ground and stop the engine.

Lower the bucket to the


Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
1.

Cover
Remove cover (1) at front of front frame.

2.

Linkage
1) Turn adjusting bolt (2) in counter clockwise direction
and check that there is play in the linkage (3).
2) Remove

pin

(4)

and

disconnect

linkage

(3) from

adjuster (5).

Air piping
Disconnect air piping (6) of spring cylinder.
*

Drain the air.

After

removing,

cover to prevent dust or dirt from

engine.

4.

Spring cylinder
Remove mounting nut, then remove spring cylinder

53634

(7).

WA500-

INSTALLATION
1.

CYLINDER

Spring cylinder
Set spring cylinder
w

2.

OF SPRING

(7) in mounting position, and install.

Mounting nut:

28.5 + 3 kgm

Air piping
Connect air piping (6) to spring cylinder.

3.

Linkage
1) Connect linkage (3) to adjuster (5) with pin (4).
2) Turn adjusting bolt (2) in clockwise direction,

and at

point adjusting bolt cannot be tightened further, turn


back 180 or 3 or 4 notches.
*

For details of adjusting the linkage, see 52 TEST-

Check the operation of the parking brake.

ING

4.

AND

ADJUSTING.

Cover
Install cover (1) at front of front frame.

WA500-

1.
2.

Remove boot (3).


Support

rod (4) with

press and remove bolt

(5), then

slowly raise press and separate.


3.

Remove

cover

from cylinder

(7), spring (8) and piston assembly

(9)

(6).

4.

Remove rings (11) and (12) from piston (10).

5.

Remove ring (13) and (14) from cylinder.

ASSEMBLY OF SPRING
CYLINDER ASSEMBLY
1.

Assemble rings (14) and (13) to cylinder

2.

Assemble rings (12) and (11) to piston (10).

3.

Assemble

spring

(8), piston assembly

(6).

(9) and cylinder

(6) to cover (7), then set in press.


*

Coat sliding portion with grease.


Grease:

4.

G30M

Push rod section with press and slowly compress spring.


Then align bolt holes of cylinder and cover, and tighten
mounting bolt (5).
w

5.

Mounting bolt:

11 f 1 kgm

Assemble boot (3).

53-36
0

WA500-

REMOVAL

Stop

OF PARKING

the

safety

machine

brake

Lower

and stop the engine.


and put

the machine
1.

on level ground

bar on the frame.

ground

blocks

from

BRAKE
and install

the bucket

the

to the

Then apply the parking

under

the wheels to prevent

moving.

Drive shaft
Disconnect

front

drive

shaft

(I)

from

differential,

and

remove disc cover (2).


Drive shaft:

2.

Air hose
Disconnect

3.

44 kg

air hose (3) from spring cylinder.

Linkage
Remove pin (4) and disconnect
*

For

details

ADJUSTING

4.

on adjusting

linkage.

screw,

see TESTING

section.

Spring cylinder
Remove nut, then remove spring cylinder

5.

Caliper
1) Remove plate (6).
*

Remove pad.

WA500-

(5).

AND

2) Remove caliper (7).


*

Use two men to remove caliper.

m
6.

Caliper:

32 kg

Disc
Remove disc (8)

7.

Disassembly of caliper
1) Remove snap ring (9) and pull out adjuster (IO).

425P720

2) Remove washer (11) and (12) and seal (13).

3) Remove

bolt,

then

remove

caliper

(14) and gasket

(15).

425P322

53638

WA500-1

4) Remove

piston shaft

(16)

and thrust

bearing

(17)

,
,,

,,

from piston.

,, \ ,,
5) Remove piston (19) and piston seal (20) from caliper

,,

(18).

WA500-

,,
i*

, ,j,
,,

INSTALLATION
1.

OF PARKING

BRAKE

Assembly of caliper
1) Install

piston seal (20)

in caliper

(18).

then insert

position (19).
&

Piston, piston seal: Grease (G2-LI)

4253724

2) Screw in piston shaft

(16)

into piston, then install

thrust bearing (17).


*

Be careful

of

direction

of thrust

bearing,

then

install.
&

Thrust bearing:

Grease (G2-LI)

3) Fit gasket (15), then install cap (14).


w

Mounting bolt:

18 f 2 kgm

d25P722

4) Install seal (13) and washers (11) and (12).


*
a

53-40
0

Insert seal in groove completely.


Seal:

Grease (G2-LI)

WA500-

5) Assemble adjuster (IO) and secure with snap ring (9).

425P720

2.

Disc
Install disc (8).

3.

&

Mounting bolt:

Thread tightener

Mounting bolt:

28.5 + 3 kgm

(LT-2)

Caliper
1) Set caliper (7) in mounting position.
*

Check that pad is assembled.

2) Install plate (6).


+

Raise the caliper slightly and align the caliper and


the groove of the pad, then assemble.

Insert the pin of the plate completely.

&

Mounting bolt:

Thread tightener

Mounting bolt:

95 t 10 kgm

(LT-2)

(Width across flats:

4.

36 mm)

Spring cylinder
Set spring cylinder

(5) in mounting position and tighten

nut.
w

WA500-

Nut:

28.5?

3 kgm

5.

Linkage
Assemble
*

6.

pin (4) and connect

For details, see TESTING

linkage.
AND

ADJUSTING.

Air hose
Connect

53-42
0

air hose (3) to spring cylinder.

WA500-

REMOVAL

Stop the

OF PARKING
machine

BRAKE

PAD

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
*
1.

Release the parking brake.

Turn the adjusting bolt (1) in a counter clockwise direction, and increase the clearance between the pad and the
disc.

2.

Remove cover (2), then remove plate (3).


*

3.

Remove either the right or left plate (3).

Raise the parking brake caliper slightly and remove pad


(4).

INSTALLATION
BRAKE PAD
1.

OF PARKING

Insert pad (4) between caliper and disc.


*

Since the pad is new, turn the adjusting bolt further


in

counter clockwise

direction

to

increase

the

clearance.
*

Lift the caliper up slightly and the pad will be able to


be smoothly

2.

inserted.

Fit plate (3) and install ocver (2).


*

Align the caliper and groove of the pad completely


with the left and right plates.

&

Mounting bolt of plate: Thread tightener

Mounting bolt of plate:

95 + IO kgm

(Width across flats:


3.

Turn

the adjusting

bolt

(LT-2)

(1) clockwise

36 mm)

and adjust pad

clearance.
*

For

details

of

adjusting,

see 52

TESTING

AND

ADJUSTING.

WA500-

53-43
0

BRAKE AND AIR SYSTEM


54 MAINTENANCE

STANDARD

Brake valve. . . . .
Brake chamber
.
Slack adjuster . .
Brake...........
Parking brake
..
Spring cylinder . .

WA500-

.
.
..
..

.
.

.
.
.
..
.

..
..
.
..

..
..
.
.
..

54-2
54-4
54-5
54-6
54-8
. . 54-9

54-1

BRAKE VALVE

425F156

54-2

WA500-

Unit:
No.

Check item

Criteria

I
1

mm

Remedy

Tolerance

Clearance between pedal mounting


pin and mount plate
10

-0.015
-0.050

+0.036
0

0.086 0.015

Pin:
Hole:

10

-0.015
-0.050

+0.058
0

0.015 0.108

Pin:
9.85
Hole: 10.1

26.5

-0.020
-0.160

+0.033
0

0.020 0.193

Plunger:26.16
Hole: 26.65

9.85
10.1

Crearance between roller and pin

Clearance between mount plate


and plunger

Clearance between primary piston


and upper body

60

+0.150
+0.050

+0.401
+0.325

0.175 0.351

Clearance between relay piston


and lower body

66.5

0
-0.10

+0.76
+0.10

O.lO0.86

Outside diameter of roller

Standard size

14.4

Free height of rubber spring

26.0

+0.2
-0.2

Piston return spring

Free
length
65.3

Repair limit

Installation
length

lnstallatioin
load

Free
length

14.6

10.5 kg

54

Primary valve spring

Replace

12.0

Standard size

Repair limit

+0.1
-0.1

26.2

Tolerance

Installation
load

4.5 kg

10

Inner stem spring

35.6

16.0

2.8 kg

30

11

Outer stem spring

41 .o

16.0

4.0 kg

34

12

Relay piston spring

39.5

12.1

4.7 kg

33

13

Secondary valve spring

16.5

10.2

3.0 kg

14

14

Tightening torque of nut

WA!iOO- 1

0.55 * 0.15

kgm

Retighten

54-3

BRAKE CHAMBER

Section A - A

425F157
Unit:
NO.

Check item

Criteria

Remedy

Tolerance

Clearance between cylinder and


piston

Standard
size

Standard
clearance

Clearance
limit

Shaft

Hole

68

-0.030
-0.076

+0.046
0

0.030
0.122

0.15

69.6

+0.500
-0.300

+0.046
0

0.346
0.500

1 .o

Replace

Outside diameter of oil seal

Air piston stroke

Tightening torque of nut

14.0 ? 3.0 kgm

Tightening torque of nut

4.4 F 0.6 kgm

Min. 133.5 (Normal pressure: Max. 9.5 kg/cm21

Retighten

54-4

WA500-

SLACK

ADJUSTER

421F150

Unit:
Remedy

Criteria

Check item

NO.

Tolerance

Clearance between body and


piston

Standard
size

55

Shaft

Hole

-0.030
-0.076

+0.074
0

Free
length

Spring

Installation
length

Clearance
limit

0.03 0.15

0.03 0.25

Repair limit

Standard size

Standard
clearance

Installation
load

198

38

4.4 kg

39.2

33

6.8 kg

Spring

Tightening

torque

of bolt

6.7 t 0.7 kgm

Tightening

torque

of plug

5.7 ? 0.7 kgm

WA500-

Free
length

Replace

Installation
load

Retighten

mm

BRAKE

.--T--J
,

Detail

425F158-1

WA500-

Unit:
No

Check item

Criteria

Remedy

Standard size
1

Return spring

Repair limit

Free
length

Installation
length

Installation
load

Free
length

Installation
load

96.9

80.6

74 kg

95.3

66.6 kg

Standard size

Repair limit

2.4 f 0.1

2.0

5.1 i: 0.1

4.6

47.4 t 1.3

41.6

Thickness of plate

Thickness of disc

Total thickness of plate and disc

Wear of contact surface of seal

Standard size

Tolerance

430

Repair limit

-EL55

Wear of surface in contact with piston


seal

420

Wear of surface in contact with piston


sea I

455

Deformation of friction surface of


plate and disc

Backlash between outer gear and plate

0.28 - 0.61

10

Backlash between inner gear and disc

0.16 - 0.52

11

Tightening torque of bolt

12

Tightening torque of bolt

13

Tightening torque of bolt

18 f 2 kgm

14

Tightening torque of bolt

56 f 6 kgm

mm

+;.097

I
+0.097
0

Max. 0.4

18+2

Il.52

kgm

1.0 kgm
Retighten

WA500- 1
5&7

PARKING

BRAKE

View Z

425F160

Unit:
Check item

Criteria

Standard size

Wear
of pad

Remaining thickness
of friction material

22.7

Including backing plate

31.7

Tolerance

Remedy

Repair limit

Replace

3.7
-

12.7

0.8

Face runout of disc

Wear of rod connecting pin

12

-0.10
-0.17

Wear of disc
(Thickness of disc plate)

22.0

to.5

Rebuild

Thickness of plate
must be under 20 mm.
Replace

Less than 20 mm

Clearance between pad and disc


(Total of both sides)

1.06

+0.18

2.3

Clearance between brake body


and plate

1.25

kO.85

Tightening torque of nut

Tightening torque of bolt

94.5 * 10.5 kgm

Tightening torque of bolt

28.5 f 3.0 kgm

10

Tightening torque of bolt

Adjust

7.25 i 1.75 kgm

Retighten
-

54-8

28.5 f 3.0 kgm

mm

WASOO- 1

SPRING

CYLINDER

425F159

Unit:
NO.

Check item

Criteria

Remedy

Tolerance
Standard
size

Clearance between cylinder and


piston

2
-

Standard
clearance
Shaft

Clearance between piston insert


center boss

Hole: 159
Shaft :I 58.65

0.35

Hole: 38.8
Shaft 138.04

0.76

Free
length

Piston spring

Replace

Repair limit

Installation
length
I

260

Clearance
limit

Hole

Standard size

Installation
load
I

Free
length
I

Installation
load
I

560+50

Play of rod in axial direction

2.1

Installed dimension of rod

65

Tightening torque of rod, lock nut

Adjust

WA500-

mm

7.25 * 1.75 kgm

Retighten

60 WORK EQUIPMENT

SYSTEM

WORK EQUIPMENT SYSTEM


61 STRUCTURE

AND

General

FUNCTION

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

................
Hydraulic circuit diagram ................
Work equipment lever linkage ............
Hydraulictank
.......................
- Oil filter bypassvalve ................
- Breather .........................
Hydraulic pumps .....................
- Hydraulic pump ....................
- Switch pump ......................
- POCpump
.......................
POC valve ..........................
Main control valve ....................
* Reliefvalve .......................
- Safety valve (with suction valve) .........
- Suction valve ......................
- Float selector valve and unloader valve .....
Hydraulic cylinder
....................
Bucket positioner and boom kick-out ........
Bucket linkage .......................
Bucket ............................
Accumulator
........................
Hydraulic

WA500-1

circuit system

61-

61- 4
61-

61-5-1
61-

61-

61-

61-

61-

61-

61-

61-10
61-18
61-20
61-21
61-22
61-23
61-30
61-32
61-34
61-36
61-37

61-1
8

GENERAL
The work equipment

system consists of the hydraulic

circuit and steering circuit.

The hydraulic circuit con-

The

maximum

regulated

pressure of the

hydraulic

circuit

is

by the relief valve inside the main control


There

are two

safety

valves (with

suction

trols the operation of the bucket and attachment.

valve.

The

valve) and an unloader valve in the dump cylinder cir-

oil in hydraulic

tank

(5) is sent by hydraulic

pump (71, to main control valve (1).


and

lift

HOLD,

spools

of the

main

When the dump

control

valve are at

the oil passes through the drain circuit of

the main control valve. It is then filtered

by the filter

in the hydraulic tank, and returns the tank.


The dump or lift spool in POC valve is activated
operating

the work equipment

control

each spool in the work equipment


lically activated.

Thereby,

from the work equipment


dump cylinder

cuit to protect the circuit.


Even when engine is at rest, the lift arm can be lowered to the ground because accumulator
Hydraulic

by

lever, causing

valve to be hydrau-

(3) is pro-

vided in the circuit.


tank

has a breather

(5) is a pressurized,
with a relief valve.

sealed type and


This acts to pres-

surize the tank and at the same time prevents negative


pressure. This protects the pump from cavitation.

the oil is allowed to flow


valve to lift cylindertll

)or

(21, thus operating the lift arm or the

bucket.

61-2

WA500- 1

425FlOO

1. Main control valve


2. Dump cylinder
3. Accumulator
4. POC valve
5. Hydraulic

tank

6. Switch pump
7. Hydraulic pump
8. Steering, POC pump
9. Steering valve
10. Steering cylinder
11.

WASOO-1

Lift cylinder

61-3

HYDRAULIC

CIRCUIT

SYSTEM

Engine running, hydraulic control lever in HOLD

,
I?$//
21

425F114A

WA500- 1

HYDRAULIC

CIRCUIT

DIAGRAM

19

Float

Lower

Raise

Dump

Tilt

Hold

425Fl 15A

1) Volume

Note

of nitrogen gas: 300 cc


Minimum actuating pressure: 12 kg/cm*

Note 2) Relief valve setting pressure


Serial No. 10001-10153:
30 kg/cm,at
33Q/min
Serial No. 10154 and up: 40 kg/cm, at 33Q/min
1. Hydraulic tank

12.

Steering valve

23.

POC lift spool

Hydraulic filter

13.

Check valve

24.

Relief valve

2.
3.

Breather

14.

Demand spool

25.

Dump spool

4.

Switch pump

15.

Relief valve

26.

Safety valve (with suction)

5.

Hydraulic pump

16.

Steering spool

27.

Lift spool

Safety valve (with suction)

28.

Float selector valve

6.

Steering pump

17.

7.

POC pump

18.

Two-way restrictor valve

29.

Unloader valve

8.

Pilot oil filter

19.

Steering cylinder

30.

Suction valve

9.

Check valve

20.

Oil cooler

31.

Lift cylinder

10.

Accumulator

21.

POC valve

32.

Dump cylinder

11.

Relief valve

22.

POC dump spool

WA500-1

61-5
0

WORK

EQUIPMENT

Section

LEVER LINKAGE

A - A

421FO65

1.

Lock lever

2.

Lift control lever

3.

Dump control lever

4.

Solenoid valve for boom kick-out

5.

Solenoid valve for bucket positioner

6.

POC valve

61-5-l
0

WA500-

HYDRAULK

TAWU

Outline

- The oil from the hydraulic

is sent from

the

pump through the control valve to the cylinders.

In

the return

tank

The hydraulic filter (2) filtersall


If the hydraulic

of

through

the

oil

is cooled

hydraulic

in the

filter

oil

cooler,

the oil in the.circuit.

(2) becomes clogged:, a bypass

valve (1) acts to allow the oil to return directly to the

circuit, the oil from various parts merges.

A part

filter

tank (4).

passes

This prevents damage to the filter (2).

The.

bypass valve (1) is also actu.ated when negative pres-

(2) and returns to the

sure is generated in the circuit.

tank (4).

l-

2-

Section A-A

425F101

61-6

1.

Filter bypass valve

4.

Hydraulic

2.

Hydraulic

5.

Drain valve

3.

Breather

6.

Oil level sight gauge

filter

tank

WAXIO- 1

OIL

FILTER

BYPASS

VALVE

When the filter is clogged.


Bypass valve (1) opens and the oil returns directly to the
tank without

passing through the filter.

Bypass valve set pressure:

From main
control valve

1.27 kg/cm

423Fl31
When negative pressure is formed in the return circuit.
Valve (2) moves up and acts a check valve.
Check valve set pressure: 0.26 kg/cm2

c3 To main
control valve

423F132

BREATHER

.
Preventing negative pressure inside the tank
The tank

is a pressurized, sealed type, so negative pres-

sure is formed

inside the hydraulic

level drops during operations.


difference
atmospheric

tank when the oil

When this happens, the

in pressure between the tank and the outside


pressure opens the poppet (3), and air from

the outside is let into the tank to prevent negative pressure.


Preventing rise in pressure inside the tank
When the hydraulic
in the hydraulic
rises.

cylinder

circuit

If the hydraulic

are being used, the oil level

changes and the temperature

pressure rises above the set pres-

sure, sleeve (4) is actuated to release the hydraulic


sure inside the tank.

pres2.

Filter element

3. Poppet
4.

Sleeve

423F133

WASOO-1

61-7

HYDRAULIC PUMPS
-

HYDRAULtC

* SWtTCH

PUMP

PUMP

SectionA-A
425FO12

1.

Drive gear (Teeth 12)

2.

Front cover

Model

Gear case

Theoretical

3.

61-8

4.

Rear cover

5.

Driven gear (Teeth 12)

Specifications
SAR(331-100
discharge

1:00.5 c&w.

Max. pressure

210

Max. pump speed

2,500

kg/cm2
rpm

wA500- 1

POC PUMP

Steering pump

POC pump

SAR(3bO80

SAR(1)-014

425F103

1.

Drive gear (Teeth 12)

Specifications

2.

Front cover

POC pump

3.

Drive gear (Teeth 12)

4.

Gear case

5.

Rear cover

6.

Driven gear (Teeth 12)

WA500- 1

Model
Theoretical

SAR(1 J-014
discharge

14.5 cc/rev

Max. pressure

210 kg/cm

Max. pump speed

3500 rpm

61-9

pOC VALVE (Pilot operated control valve)

View 2
421 Fe69

61-10

1.

Port A,

(To lift cylinder bottom)

(PA,)

2.

Port B,

(To lift cylinder head) (PB,)

3.

Port P (From POC pump)

4.

Port A, (To dump cylinder bottom)

5.

Port B, (To dump cylinder head) (PB,

(PA,

6.

Port T (Drain)

WA!XO- 1

Section A-A
section B-B

421FO70

7.

Spool with variable throttle valve


(for operating lift arm)

8.

Lever

equipment

9.

Spool (for operating lift arm)

control

Function

* The POC valve is installed at the bottom

Spool (for operating bucket)

11.

Lever

control

12.

Return spring

the

Return spring

14.

Spool with variable throttle valve

lever,

and

of the work

is connected

to

the

lever by a linkage.

* The oil from the POC pump is supplied to the spool

10.

13.

control

end of the control

valve according

lever is moved.

operating

force

to the amount

the

This oil actuates the spool, so

needed

small, and as a result, operator

for

the control

fatigue

lever is

is reduced.

(for operating bucket)

WA500-

61-11

POC RELIEF

VALVE

1.

Main valve

2. Valve seat
3.

Pilot poppet

4.

Spring

5.

Adjustment screw

421 F071

Function

* The POC relief valve is between the POC pump and


the

POC valve.

actuated,

When the

or when abnormal

POC valve is not being


pressure is generated, the

oil sent from the pump is relieved through this valve


to protect the pump and circuit from damage.
(Sets maximum

pressure in the circuit)

Operation

* Port A is connected to the pump circuit, and port C is

Fig. 1
421 F072

connected to the drain circuit.


The oil passes through
and fills port B.
with valve seat (2).

the orifice

of main valve (1)

Pilot poppet (3) is in close contact


(Fig. 1)

* If the pressure at ports A and B reach the pressure set


by the poppet spring, pilot poppet (3) opens and the
pressure oil at port B flows through port D to port C.
As a result, the pressure at pot-t B drops.

(Fig. 2)

* If the pressure at port B drops, a pressure difference


is generated between ports A and B due to the orifice
in main valve (1).

Main valve (1) is pushed open by

the pressure at port A, and the oil at port A is relieved.

(Fig. 3)

Fig. 3

61-12

421 F074

WASOO-1

FUNCTION
LIFT AND

OF POC VALVE
DUMP LEVERS AT HOLD
Lift lever

POSITION
Dump lever

0
0
0

Hold
From pump
To tank

F42101008

Operation

* The oil from the pump enters port a, but the circuit is
closed by spool (I),
valve (3).

so the oil is drained from relief

The oil at port B2 of the main control

valve is connected to the drain circuit through port j


and k of spool (I);

the oil at port A2 is connected to

the drain circuit through port i and k of spool (1).

WASOO-1

61-13

DUMP LEVER AT DUMP


LIFT LEVER AT LOWER
Lift lever

(I)

(Intermediate position)
Dump lever

Dump

cower

Hold

Frompump

To tank

F42101069

Operation

* When the control levers are moved to the left, POC

control

valve.

The oil of chamber E passes from port

spool (1) for lift lever moves up and spool (2) for it

j of spool (1) to port k, and flows to the drain circuit.

moves down,

Therefore,

and spools (I)

and (2) for dump lever

the pressure oil acting on ,port A2 of the

main control

move conversely.

- The oil from the pump enters port a, passes through

valve is constant, so a difference

sure is generated at port Bz.

chambers C and F, and flows to port Bs of the main

the main control

control

portion to the movement of the control lever.

valve.

In addition,

ber F passes through


from

61-14

chamber

the pressure oil at cham-

in pres-

As a result, the spool of

valve only moves an amount in pro-

port h of spool (2) and flows

E to the port A2 circuit c. the main

WASOO- 1

DUMP LEVER AT DUMP


LIFT LEVER AT LOWER

(2) (End of travel)


Dump lever

Lift lever

@
0
0
0
0

Dump
Lower
Hold
From pump
To tank

F42101010

Operation

- When the control levers are moved further to the left,


port h closes a little at a time, and the pressure acting
on port A2 of the main control valve drops a little at
a time.
Therefore,
and A2

the pressure difference

between ports B2

increases more, and the spool of the main

control valve moves to its specified stroke.

WA500- 1

61-15

DUMP LEVER AT TI LT
LIFT 1-EVER AT RAISE

(I 1 (Intermediate

position)

HQIcI

Raise

Tilt

From pump

F4210107

To tank

Operation
When the control
RAISE),

lever is moved to the right (TILT

POC spool

moves down

and spool

moves up, and spools (1) and (2)

for

or

(2) for it

dump

lever

move conversely.
The oil from
chambers
control

the pump

In addition,

ber E passes through


from

61-16

enters port a, passes through

chamber

port

F to the

to port Az of the main

valve.

* Therefore,
main

B and E, and flows


valve.

control

The oil at port 8s passes from

spool (I) to port k, and flows to the&r&n


control

main control

the pressure
valve

valve only

tion to the movement

oil acting

is constant,

on port

patii of

circr13t.
Bs of

moves an amount

in propor-=

of the cantra4~ rever.

the pressure oil at chamg of spool

port

B2 circuit

the

so the sprk@ of the

(2) and flows


cL the main

WAS

DUMP LEVER AT T I LT
LIFT LEVER AT RAISE

(2) (End of travel)

Hold

Raise

Tilt

From pump

To tank

~42101012

Operation
* When the control
port

lever is moved

further

to the left,

g closes a little at a time, and the pressure acting

on port

B2 of the main control

valve drops a little at

a time.
Therefore,
and

A2

control

the pressure
increases

more,

difference

valve moves to its specified

WA500- 1

between

and the spool

ports

of the

B2

main

stroke.

61-17

MAIN

CONTROL

VALVE

MBir

1.

Main relief valve

MA1

2.

Dump spool return spring

MA2:

3.

Lift spool return spring

4.

Lift spool

5.

Dump spool
Body

7.
8.
9.

MB1
MB2:
Al

6.

61-18

From PA1 of POC valve


From PA2 of POC valve

From PBl of POC valve


From PB2 of POC valve
To dump cylinder bottom side.

A2:

To lift cylinder bottom side

Bl :

To dump cylinder rod side

Suction valve

82:

To lift cylinder rod side

Unloader valve

P:

Pump port

Safety valve (with suction)

T:
Dl

10.

425f104

MB2

Float selector valve

D2:

Drain port (to hydraulic tank)

Drain port
Drain port

WASOO-1

section

A-A

Section D-D

Section B-B
Section E-E
425F105

Outline
*

The main control valve controls the actuation


attachments

and the bucket

It has a tandem

circuit

in the hydraulic

of the
system.

which gives priority

to the

bucket circuit.
pressure is set by the main relief valve (1).
passes through

the circuit

if abnormal

ated in the bucket circuit.

pressure is gener-

If one of the two safety

a suction valve to make up any lack of oil.

The oil

the bypass circuit of dump spool (5)

and lift spool (4).


the tank.

to protect

valves is acting as a relief valve, the other valve acts as

- The oil from the pump enters port P. The maximum

drain circuit,

* There are two safety valves (with suction valves) (9)

It then flows from port T to the

passes through the filter and returns to

If the dump and lift spools are actuated,

the oil flows to the dump and lift cylinders.


However,

the circuit

gives priority

to the bucket, so

when the dump spool is being operated,

even if the

lift spool is operated, the lift arm will not move.

WANO- 1

61-19

RELIEF

VALVE

1.

Main valve

2.

Valve seat

3.

Pilot poppet

4.

Pilot poppet spring

5.

Adjustment screw

6.

Locknut

,,

42 1 FO80

Function

* The relief valve is installed


control

valve.

at the inlet

of the main

When the oil goes above the set pres-

sure, the relief valve drains the oil to the tank.


way,

it sets the

circuit

maximum

and protects

pressure

In this

in the hydraulic

the circuit.

Operation

* Port A is connected
connected
the

to the pump circuit

to the drain circuit.

orifice

of

Pilot poppet

main

valve

and port C is

The oil passes through

(1) and flows

(3) is in close contact

with

to port

B.

Fig. 1

421 FO61

Fig. 2

421 FOB2

Fig. 3

42 1 PO83

valve seat (2).

(Fig. 1)

* When the hydraulic


A and

port

poppet

spring

pressurized

pressure in the circuit

B reaches the set pressure


(4).

oil from

pilot

poppet

port

B flows from

C, so the pressure at port

inside port
of the pilot

(3) opens,

B drops.

port

and the
D to port

(Fig. 2)

* When the pressure at port C drops, the orifice effect


of main

valve

between

port A and port

open

(1) generates

and the oil from

a difference

in pressure

B. The main valve is pushed


port

and flows

to the drain circuit

pressure.

(Fig. 3)

A passes through

port

to release the abnormal

* The set pressure can be varied by changing the tension of pilot


pressure,
turn

61-20

poppet

remove

adjustment

spring

cap nut,

(4).

To change the set

loosen

lock

nut

(6) and

screw (5) as follows.

WAMO- 1

SAFETY

VALVE

(with suction valve)

1.

Suction valve

2.

Main valve

3.

Main valve spring

4.

Pilot piston

5.

Suction valve spring

6.

Valve body

Function

. The safety valve (with suction


cylinder

circuit

abnormally

high

pressure

main valve is at neutral,


valve)

from

If shock causes any

in the cylinder

when

the safety valve (with

releases the abnormal

cylinder

valve) is in the dump

in the main valve.

the

suction

pressure and protects

the

damage.

Operation
As a safety valve

* Port A is the cylinder

circuit

and port

B is the drain

circuit.
The pressure oil in port
hole

in the pilot

through

an orifice

the pilot

piston

The pilot
lock

sectional
d,.

to port

D through

(4).

It also flows

to port

consisting

of the main

valve and

(4).

piston

nut.

A flows

piston

(4) is secured to the suction

The diameter

valve by

of the cross section

area) gives a relationship

(cross-

of ds > dI > ds >

(Fig. 1)
Fig. 1

If abnormally

high oil pressure occurs

suction

valve (1) is not actuated

tionship

d2 > dI.

However,

because of the relationship

A and C, the hydraulic


is equivalent
d,.

in port

A, the

because of the relad3 > d4 in port

pressure on the main valve (2)

to the area difference

between

d,

and

If this pressure goes up to the main valve spring

force

(set pressure),

the main

and the oil in port A flows

valve

(2) is actuated,

into port B. (Fig. 2)

Fig. 2

WASOO- 1

61-21

As a suction valve

If negative

pressure is generated

has negative

pressure,

nected with

each other.

is applied

to port E.

Hydraulic

pressure

ence between

in port A, port D also

because port

The tank
equivalent

ds and dI

D and A are con-

pressure in port 6

to the area differ-

is applied

to the safety valve

because of the tank pressure in port E.


Therefore,

hydraulic

pressure

valve and hydraulic


tion

pressure a

acts to open

the

acts to close the suc-

valve (1).

* If the pressure in port A drops, (approaching


pressure)

hydraulic

pressure

becomes

negative
smaller

than oil pressure e.


When oil pressure
sure a
opens,
A.

becomes

larger than oil pres-

+ valve spring (5) force, the suction


causing the oil to flow

This prevents

negative

from

port

pressure from

421FO48

valve (1)

B into
building

port
up

in port A.

SUCTION

VALVE

1. Main poppet
2. Sleeve
3.

Spring

421 F088
Operation

If negative

pressure is generated

in port

A (lift cylin-

der rod end) (if the pressure is lower than in port


the tank

circuit),

the main poppet

oil then flows

from

at the cylinder

port end.

port

B in

(1) opens because

B at the tank end to port A

421 F089

61-22

WA500- 1

FLOAT

SELECTOR

VALVE

AND

UNLOADER

VALVE

Function

* The float selector valve and unloader valve are installed inside the main control valve.
trol

lever is placed in FLOAT,

When the lift conthe float selector

valve detects pressure oil from the POC valve and acts
to actuate the unloader
spool in the FLOAT

TO POC valve

Fro

valve, which places the lift

position.

Operation

- When the lift lever is placed at FLOAT,


valve is set to LOWER.

the POC

Port A becomes high pres-

sure, and port B becomes low pressure.

- The oil from the steering valve fills chambers E and F.


421 F094

LIFT

LEVER

AT

FLOAT

Operation

* If the difference in pressure between port A and port


B exceeds the standard pressure, flow selector valve

To POC valve
A

(2) is moved to the right, and port C and port D are


connected.

* Port D is open, so the hydraulic

pressure at port E

drops and unloader valve (4) moves to-t

and the oil

flows from the steering valve to the drain circuit.

At

the same time, the oil also flows to the rod end of the
lift cylinder,

and the oil at the bottom

nected to the drain circuit,

end is con-

so the lift arm is set at

FLOAT.

4
From steering valve
42 1 F095

WA500- 1

6&23

LIFT

AND

DUMP

SPOOLS AT

HOLD

Dump

Float

Hold

Lower

qaise

Tilt

0
@

Hydraulic tank
Oil cooler

(ZJ

Steering valve

To steering cylinder

Filter

69

Check valve

Accumulator

Switch pump

Hydraulic pump

Steering pump

POC pump

Operation

- The oil from the pump enters port A and the maximum pressure is set by the relief valve (11).

* Dump spool (1) is at HOLD, so the bypass circuit is


open.

The oil in chamber A passes around the spool

and flows to port B.

Lift spool (2) is also at HOLD,

so the bypass circuit is open.

The oil in chamber B

passes around the spool and flows to chamber C in


the drain

circuit.

From

here it passes

rough the

filter and returns to the tank.

61-24

WA500- 1

LIFT

SPOOL AT

RAISE

Dump

Float

Hold

Lower

Raise

Tilt

Hydraulic tank

Oil cooler

Steering valve

To steering cylinder

Filter

Check valve

Accumulator

Switch pump

Hydraulic pump

Steering pump

POC pump

425F107

Operation
-

When

the

lift

lever (3) is pulled,

pressure oil from

port L of the POC valve flows to ports N and S. The


oil in port T passes through
drain circuit.

port M and flows to the

The pressure oil in port S pushes the

by the spool, so the oil pushes up check valve (IO).


The oil then flows from port H to port I, and goes to
the bottom end of the cylinder.

* At the same time, the oil at the rod end of the cylin-

push piston against the force of the spring and moves

der flows from port K to drain port C, and returns to

lift spool (2) to the RAISE

the tank.

position.

Therefore,

the lift arm rises.

* The oil flows from the pump through the bypass circuit of the dump spool, and then flows to the bypass
circuit

of lift spool (2).

WA500- 1

The bypass circuit is closed

61-25

LIF T SPOOL AT

LOWER

Dump

FIoat

Hold

0
8
0
0
@

Lower
Raise
Titt
Hydraulic tank
Oil cooler

Steering valve

To steering cylinder

Filter

Check valve

0
@
8

Accumulator
Switch pump
Hydraulic pump

Steering pump

POC pump

425F108A
Operation
-

When

the

lift

lever

(3) is pushed,

pressure

oil

port L of the POC valve flows to ports M and T.


oil in chamber

S is connected

from

The

to the drain circuit.

The pressure oil in chamber T pushes the push piston


against the force of the spring and moves lift spool
(2) to the LOWER

position.

by the

spool,

so the

oil pushes

up check valve (10).

The oil then flows from port J to port K, and goes to


the rod end of the cylinder.

* At the same time, the oil at the bottom end of the


cylinder flows from port I to drain port C, and returns to the tank.

Therefore,

the lift arm goes down.

* The oil flows from the pump through the bypass circuit of the dump spool, and then flows to the bypass
circuit

of lift spool (2).

6626

The bypass circu;

is closed

WA500- 1

LIFT

SPOOL AT

FLOAT

Dump

Float

Hold

Lower

Raise

Tilt

0
@

Hydraulic tank
Oil cooler

Steering valve

To steering cylinder

Filter

@
0
8
8
8
@

Check valve
Accumulator
Switch pump
Hydraulic pump
Steering pump

POC pump

425F109

Operation
When the lift lever (3) is pushed to the FLOAT

posi-

right and opens ports C1 and C to connect them to

tion, the spool of the POC valve moves further

from

the drain circuit.

the LOWER

Pres-

drain circuit,

position

to the FLOAT

position.

sure oil from port M of the POC valve flows to port M


and also to ports T and W.

At the same time, pres-

When port C1 is connected to the

valve (8) moves up, and the oil from the

pump flows to the drain circuit.


Therefore,

the oil at the rod end of the cylinder flows

sure oil from port S of the POC valve flows to port N.

from

K, and then flows from unload valves (8)

The pressure oil in chamber T pushes the push piston

to the drain circuit.

against the force of the spring and moves lift spool

bottom

12) to the LOWER

C, and then flows to the drain circuit.

position.

If the pressure difference

between port W and port X

port

At the same time, the oil at the

I to

port

Therefore,

the

end of the cylinder flows from port

lift arm floats.

goes above the specified level, valve (7) moves to the

WA500- 1

61-27

DUMP

SPOOL AT

TILT

BACK

@I

Dump

F,koet

Hold

Luwer

Raise

0T

TiPt

Hydraulic tank

Oil cooler

Beefing uehve

To steeringqlinder

Filter

Check valve

.@

Accufnulator

Switch

pump

Hydraulic .pump

Steehg

WC pump

pump

425Flll

Operation
-

When the dump lever (4) is pulled, pressure oil from

from

port

goes to the bottom end of the cylinder.

L of the POC valve flows to port R via port P.

The oil in port V is connected


The

pressure oil in port

to the drain circuit.

R pushes the push piston

against the force of the spring and moves dump spool


(1) to the TILT

port A then flows from port !D to pol;t E, and

* At the same time, the oil at the rod end of the q&-tder flows from port G to drain port C, -and returns to
the tank.

Therefore,

the bucket is-tilted.

position.

* The bypass circuit is closed by the spool (I), so the


oil from port A pushes up check valve (1C

61-28

The oil

WASOO-1

DUMP

SPOOL AT DUMP

Dump

Float

Hold

Lower

Raise

Tilt

Hydraulic tank

@
@
0

Oil cooler
Steering valve
To steering cylinder

Filter

Check valve

Accumulator

Switch pump

Hydraulic pump

Steering pump

POC pump

425FllO

Operation
*

When the dump lever (4) is pushed, pressure oil from


port

L of the POC valve flows to port V via port 0.

The oil in chamber


cuit.

R is connected to the drain cir-

The pressure oil in port U pushes the push pis-

ton against the force of the spring and moves dump

enters port G, and goes to the rod end of the cylinder.

- At the same time, the oil at the bottom end of the


cylinder

flows from

turns to the tank.

port D to drain port C, and re-

Therefore,

the bucket is dumped.

spool (1) to the DUMP position.

* The bypass circuit is closed by the spool (1). so the


oil from

from

port

check

WA500-1

pushes

up check valve (9).

valve (9) then

flows

from

port

The oil
F and

61-29

HYDRAULIC
LIFT

CYLINDER

CYLINDER

1.

Head

2.

Rod

3.

Cylinder

4.

Piston

5.

Lock ring

Specificatim
Cylinder bore
Rod diameter
Cylinder max. length

2334.5 -Jzwal

Cylinder min. bngth

jI

35m mm-l

Stroke

61-30

DUMP

CYLINDER

425Fll3

1.

Head

2.

Rod

3.

Cylinder

4.

Piston

5.

Lock ring

WA500- 1

Specifications
Cylinder bore

225 mm

Rod diameter

120 mm

Cylinder max. length

1817 mm

Cylinder min. length

1252 mm

Stroke

565 mm

61-31

BUCKET

61-32

POSITIONER

1.

Contact switch

2.

Contact switch

3.

Dump cylinder rod

4.

Lever

5.

Plate

AND

BOOM

KICK-OUT

Bucket positioner
-

The bucket

positioner

is electrically
obtain

used to automatically

actuated and is

the optimum

digging

angle for the bucket.


When the bucket is moved from the DUMP
to the TILT
the

from

the

Lever (4) is secured by bolts to dump cylinder

rod

TILT

(3).

dump

position

position, and it reaches the desired angle,


lever

is automatically

moved

position to the neutral.


A proximity

switch (1) is fixed by bolts to the

cylinder.

* When the bucket is moved from the DUMP position


to the TILT
to the left.
the left.

position,

the dump cylinder

rod moves

At the same time, lever (4) also moves to

When it reaches the desired position,

(4) separates from proximity

lever

switch, and the bucket

lever returns to neutral.


421Flll

Boom kick-out

* The boom kick-out

is electrically

to stop the lift arm.

operated

and acts

When the lift arm reaches the

desired position before the maximum

height, the lift

arm lever is returned to neutral.

* Plate (5) is secured to the lift arm.


switch (2) is fixed to the frame.

A proximity

When the lift arm is

moved from the LOWER

position to the RAISE

tion,

When it reaches the desired

the lift arm rises.

position,

the proximity

posi-

switch and lever come into

contact and the lift arm lever is returned to neutral.

421F112

WASOO- 1

61-33

BUCKET

LINKAGE

_....
r

__.

I=__-,

425Fl I8

1. Bucket

5.

Lift arm

8.

Cord ring

2.

Tilt lever

6.

Bucket link

9.

Cord ring

3.

Dump cylinder

7.

Bucket hinge pin

4.

Liftcylinder

(Serial No. 10001-11463:

oil type)

(Serial No. 11484 and up : grease type)

61-34
0

WASOO- 1

SerialNo. 10001-11463

SerialNo.11464andup

Section A - A

Section A - A

Section

B -

9
Section C - C

Section F -

Section D - D

Section G - G

Section E - E

Section H - H

Section J - J

425F119-1

WA500-

61-35

BUCKET

B-i

A-i

SectionA-A

Section B - B
Section C - C

425Flrn
1.

Bucket

2.

Corner teeth

3.

Teeth

61-36
0

WA500- 1

ACCUMULATOR
Function

The accumulator

is installed between the hydraulic

pump and the POC valve.


raised, and the control
engine

stopped,

nitrogen

the

gas inside

When the lift arm is left

levers are operated with the


pressure of the
the

pressure to the control

accumulator

compressed
sends pilot

valve to actuate it and allow

the lift arm and bucket to come down under their


own weight.

After operation

Before operation

421 F077

421 F076

1.

cap

2.

Nut

Operation

After

the engine is stopped,

at neutral,
3.

Body

4.

Bladder

5.

Oil port

6.

Nut

hydraulic

and the POC valve is

bladder chamber A is compressed by the


pressure in chamber B.

If the POC valve is operated,

the hydraulic

in chamber B goes below 40 kg/cm,

pressure

and the pres-

sure of the nitrogen gas in chamber A expands the


bladder.

As a result, the oil in chamber B becomes

the pilot pressure and actuates the control valve.

WA500-1

61-37
8

WORK EQUIPMENT SYSTEM 0


62 TESTING

AND

ADJUSTING
..
.
Measuring dump and lift control levers . .
Adjusting dump and lift control levers .
Standard value table

...

. . _. . .
.

Tool list for testing and adjusting

Measuring hydraulic
work equipment

..
.
..
..

...

.. ...
.. ..

...
...

Measuring hydraulic drift of work equipment


Adjusting bucket positioner
Adjusting boom kick-out

The following

62- 4
62-

pressure of

Measuring work equipment

Troubleshooting

62- 2
62-

.
...

. .. , .
.
.
......
..
..
.

62- 6
62s 9
62-10
62-11
62-12
62-13

precautions are necessary when using the Standard Value Tables to make judgements during trouble-

shooting or during testing and adjusting.


1.

The values in these tables are based on the values for new machines leaving the plant, so they should be used
as target values when repairing or when estimating wear after a period of use.

2.

The standard values in these tables for judgement

when troubleshooting

are estimated

values based on the

standard values for the machine when shipped from the plant, and on the results of various tests. Therefore,
they should be used as reference in combination
3.

with repair and operating records when making judgements.

These standard value tables must not be used for standard values when judging claims.

In addition,

do not use

these values alone to make simple judgements.

WA500-

62-1
0

STANDARD
. Serial No. 10001
*

serial

No.

VALUE TABLE
-

10001

10186
10146

(Except D sPeo.1
(b SPoo.)
Standard
value

Permissible
value

(Hold 3 Raise1

2.7 - 3.5

Max. 5.3

(Raise--e Hold)

2.7 - 3.5

Max. 5.3

(Hold -

2.7 - 3.5

Max. 5.3

Testing and measuring item

Dump

and lift control

Measurement condition

,.

levers

Lift arm control lever operating force

Lower)

(Lower + Hold)
(Lower -

Float)

kg

(Float + Hold)

Dump control lever operating force


(Hold + Dump)
(Hold + Tilt)
(Tilt + Hold)

* Lift

. Hydraulic temperature:
45 -55Oc

* Engine speed: Low idling


. Coolant temperature:
Inside operating range

4.0 - 5.5

Max. 8.3

2.7 - 3.5

Max. 5.3

3.0 - 3.5

Max. 5.3

3.0 - 3.5

Max. 5.3

3.0 - 3.5

Max. 5.3

arm control lever travel


(Hold + Raise)

32 -62

17-777

(Hold + Lower)

25 - 55

lo;70

42-72

27 - 87

(Hold -* Float)
mm

Dump control lever travel


(Hold -

Dump)

(Hold -t Tilt)

3;4-64

19-79

34 - 64

19-79

Relief oil pressure


* POC valve
. Main control valve

30+3
0

. Hydraulic temperature:
45-55Oc

21.0+1Q

210+;

* Engine speed: High idling

30M

Operating speed

- Lift arm lifting time


- Lift arm lowering time
- Bucket dumping time
. Bucket tilt back time
(Full stroke)

6.8 - 7.4

. Hydraulic temperature:
45-55C

. Engine speed: High idling


. Steering position: Neutral
. Bucket: unloaded

sec.

Bucket tilt back time


(Horizontal position of bucket)

Max. 8.9

3.0 - 4.0

Ma %..4 B

1.4 - 2.0

Max. 2.4

1.9 - 2:5

Man. 3.0

1.3 - 1.3

r&x. 2.3

Hydraulic drift of lift arm and bucket

Retraction of lift cylinder rod

- Retraction of dump cylinder rod

* Stop engine, leave for 5 minutes,


then measure for next 15
minutes,

.
.

Lift arm horizontal

,Max

Max.,40

Max. 20

Max. 20

3 -.5

Bucket horizontal

Bucket positioner

40

mm

Clearance of switch
* Hydraulic temperature:
45 -55C

Boom kick-out
- Clearance of switch

62-2
0

3-5

WA%Xb 1

Serial No. 10187 and up (Except

D spec.)

- Serial No. 10147 and up (D spec.)


Measurement condition

Tasting and measuring item

Unit

Permissible
value

Standard
value

Dump and lift control levers

Lift arm control lever operating force


(Hold -)- Raise)

2.7 - 3.5

Max. 5.3

(Raise -+ Hold)

2.7 - 3.5

Max. 5.3

(Hold -+ Lower)

Max. 5.3

(Lower + Hold)

2.7 - 3.5
-

(Lower * Float)

4.0 - 5.5

Max. 8.3

2.7 - 3.5

Max. 5.3

kg

(Float -+ Hold)

Hydraulic temperature:
45 -55C

* Dump control lever operating force


(Hold + Dump)

Engine speed:

(Hold + Tilt)

Coolant temperature:
Inside operating range

(Tilt * Hold)

3.0

3.5

Max. 5.3

3.0

3.5

Max.

5.3

3.0

3.5

Max.

5.3

Low idling

* Lift arm control lever travel


(Hold -r Raise)

50 - 80

(Hold -r Lower)

33 - 63

18-78

(Hold + Float)

50 - 80

35 - 95

(Hold -t Dump)

42 - 72

27 - 87

(Hold -f Tilt)

42 - 72

27 - 87

40+;

40:;

210+05

21o+O

35 - 95

mm

* Dump control lever travel

Relief oil pressure

* POC valve
- Main control

. Hydraulic temperature:
45 -55c

* Engine

valve

kg/cm

speed: High idling

Operating speed

* Lift arm lifting time


- Lift arm lowering time
* Bucket dumping time
* Bucket tilt back time

* Hydraulic temperature:
45-55OC

- Engine speed: High idling


- Steering position: Neutral
* Bucket: unloaded

(Full stroke)

sec.

Bucket tilt back time


(Horizontal position of bucket)

6.8

7.4

Max. 8.9

3.0

4.0

Max. 4.8

1.4

2.0

Max. 2.4

1.9

2.5

Max. 3.0

1.3

1.9

Max. 2.3
--

Hvdraulic drift of lift arm and bucket


. Hydrru/i;&perature:
* Retraction

of lift

cylinder

* Retraction of dump

cylinder

. Stop engine, leave for 5 minutes,


then measure for next 15
minutes.

rod

rod

Max. 40

Max. 40

Max. 20

Max. 20

mm

Lift arm horizontal


Bucket horizontal

Bucket positioner

- Clearance

3-5

of switch
* Hydraulic temperature:
45-55Oc

mm

Boom kick-out
* Clearance of switch

WA500-

3-5

62i2-

TOOL LIST FOR TESTING

No.

Testing end measuring item

AND

ADJUSTING

Part number

Tool name

Remarks

Hydraulic pressure

Hydraulic tester

799-l 01-5000

0 - 300 kg/cm2

Oil temperature

Thermistor

799-l 01-6000

o-1000c

Engine speed

Tachometer

799-203-8000

60 - 19999 rpm

Dump lever and lift lever


operating force

Push-pull scale

79A-262-0020

0 - 25 kg

Measuring travel

Convex scale

Measuring operating time of


work equipment

Stop watch

kit

Commercially available

1 /lO second

When carrying

cut testing, adjusting or troubleshooting,

stop the machine on level ground, install the safety

bar on the frame, lower the bucket to the ground, and stop the engine.
Then apply the parking brake and block the tires.

Do not allow unauthorized

persons near the machine.

When measuring the engine speed, one worker


operators seat to operate the controls.

should measure the engine speed while the other sits in the

Always check that the operation

is safe, and use agreed signals.

Be careful not to get caught in rotating parts.

WA500-

62-3
0

MEASURING

DUMP

*
.
.

Coolant temperature:

Engine speed:

AND

LIFT CONTROL

LEVERS

Measurement condition
Inside operating range

Hydraulic oil temperature:

45 - 55C

Low idling
Unit:

kg (mm)

Item

Float
Dum

423F324

Special tool

Part No.

79A-262.0020

Part Name
Push-pull scale

~~/ &y
I

Install the safety bar on the frame.

Measuring procedure
1.

Operating force of dump and lift control levers

Fit push-pull scale A on dump and lift control


levers and measure operating force.
*

Hook the push-pull scale A on the center of


the knob.

Operate
measure

at the same speed as normal


the

minimum

force

needed

and
to

operate the knob.


2.

Travel of dump and lift control levers


.
Measure the travel of the dump and

lift control

levers at each position.


*

Mark the knob of the lever and use a scale to


measure.

62-4
0

WA500-1

ADJUSTING
1.

2.

AND

LIFT CONTROL

LEVERS

Remove cover (1).

Place bucket lever and lift lever in HOLD.


*

3.

DUMP

Apply

lever lock to hold in position.

Loosen nut, then adjust length of rod (2) so that


POC valve is in HOLD.
*
If the plate (3),

roller

(4) and spring (5) are

damaged, replace them.


+

Operate
that

the

DUMP,

the bucket
lever
RAISE

and lift levers, and check

is held
and

in position

at

TILT,

FLOAT.

421

WA500-

F205

MEASURING
Ir

Conditions

Engine

HYDRAULIC

PRESSURE

OF WORKEQUIPME,NT

of measurement

coolant

temperature:

Within

operating

range
.

Hydraulic

oil temperature:

45 -

55T

Special

tool
Part No.

1.

799-101-5000

Measuring
1) Raise

POC
the

Part Name

Qty

Hydraulic tester

relief valve

lift arm,

then

the lift arm and remove

pressure.
put a support

front frame

under

inspection

cover (1).
Loosen the oil filler cap slowly to release
the pressure

inside

Operate

control

release

the

the

the pressure

hydraulic

levers

tank.

slowly

to

in the accumulator

completely.

2)

Remove

plug (2) for measuring

in dump cylinder
3) Install hydraulic
Install a 90

pressure

of oil

circuit of main control

valve.

test kit A in measuring

port.

elbow

kit in the measuring

for the

hydraulic

port, then connect

test
the

hose.
Check

that there

is no leakage

of oil from

any joint.
Use a hydraulic
the operators

hose long enough

to reach

comppartment.

4) Start the engine, operate the control lever to


lower the lift arm, and measure the pressure
when

the relief valve is actuated.

Set the bucket

Do

not

hydraulic
*

A4

& When
gauge,

apply

pressure
removing
release

way as when

62-6
0

horizontal

suddenly

to the ground.
pressure

to

the

gauge.
the hydraulic
the pressure

installing

pressure

in the same

the gauge.

WA500-

Adjustment
Always

stop the engine before

hydraulic
1.

Stop engine and remove cover (1).

2.

Remove cap nut (2) of relief valve.

3.

adjusting

the

pressure.

Loosen locknut

(3), then turn adjustment

screw (4)

to adjust.
*

One turn of the adjustment

screw changes the

425PO87

pressure by about 9.78 kg/cm2.

Turn the adjustment

screw to adjust as follows.

To INCREASE

pressure, TIGHTEN

screw.

To DECREASE

pressure, LOOSEN

screw.

If it is impossible to measure the relief pressure


exactly, do not try to adjust the pressure.

425PO88

423F315A

WA500-

62-7
0

2.

Method

for measuring work equipment

relief valve

pressure.

Loosen the oil filler


pressure

inside

operate

the

cap slowly to release the


Then
hydraulic
tank.

the

control

levers

release the remaining

several

times

to

pressure in the hydraulic

piping.

1)

Remove

plug

(1)

for

measuring

pressure of

oil in dump cylinder circuit.

2)

Install hydraulic
*

test kit A in measuring port.

Check that there is no leakage of oil from


any joint.

Use a hydraulic

hose long enough to reach

the operators compartment.


3)

Start
400

the engine and raise the lift arm about


Then

mm.

operate

the control

lever to

tilt the bucket back and actuate the relief valve.


Measure the pressure when the valve is relieved.
*

Do

not

hydraulic
When

suddenly

apply

pressure

to

the

pressure gauge.

removing

the

hydraulic

pressure gauge,

release the pressure in the same way as when


installing the gauge.
Adjusting

Always
hydraulic

stop the engine before

adjusting

1.

Remove inspection cover (1) of front frame.

2.

Remove locknut (3) of relief valve (2).

3.

the

pressure.

Turn adjustment screw (4) to adjust.


*

One turn

of the adjustment

screw changes the

pressure by about 52.9 kg/cm2.

*
3

Turn the adjustment

screw to adjust as follows.

To INCREASE

pressure, TIGHTEN

screw.

To DECREASE

pressure, LOOSEN

screw.

If it is impossible to measure the relief pressure


exactly, do not try to adjust the pressure.
4

421

S8

F206A

WA500-

MEASURING

WORK

Measurement

.
.
.
.

Coolant temperature:

EQUIPMENT

condition

Steering position:

n Lifting time of lift arm


Inside operating range

Neutral

Hydraulic temperature:
Engine speed:

45 - 55C

High idling

Unit:

sec.

Item

Standard
value

Permissible
value

Lift arm lifting time

6.8 - 7.4

Max. 8.9

Lift arm lowering time

3.0 - 4.0

Max. 4.8

Bucket dumping time

1.4 - 2.0

Max. 2.4

Bucket tilt back time (Full stroke)

1.9 - 2.5

Max. 3.0

Bucket tilt back time (From horizontal position of bucket)

1.3 - 1.9

Max. 2.3

423F327

Lowering time of lift arm


r>

Special tool
Part No.
A

Part Name

Qty

Stop watch

Measuring procedure

423F328

Lifting time of lift arm

Dumping time of bucket

Set the bucket near the maximum

tilt back position

and at the lowest position on the ground.


bucket

and measure the time taken

reach the maximum

Raise the

for bucket

to

height of the lift arm.

Lowering time of lift arm


Set the bucket
maximum

horizontal

with the lift arm at the

height, lower the bucket and measure the

time taken for the bucket to reach the lowest position on the ground.
Dumping time of bucket
Raise the lift arm to the maximum

height and meas-

ure the time taken for the bucket to move from the
maximum

tilt back position to the maximum

dump

423F329

Tilt back time of bucket

position.
Tilt back time of bucket
1)

Raise the lift arm to the maximum

height and

measure the time taken for the bucket to reach


the maximum
2)

tilt back position.

Set the bucket horizontal


taken

and measure the time

for the bucket to move from the hori-

zontal position to the maximum

tilt back posi-

tion.
423F330

WA500-

62-9
0

MEASURING

HYDRAULIC

Measurement

.
.
.

Coolant temperature:

EQUIPMENT

condition
Inside operating range

Hydraulic temperature:
Stop engine,

DRIFT OF WORK

45 - 55Oc

leave for 5 minutes, then measure for

next 15 minutes.

Lift arm horizontal

Bucket horizontal

Unloaded

(operating load)

Unit:

mm

Standard
value

Permissible
value

Retraction of lift cylinder rod

Max. 40

Max. 40

Retraction of dump cylinder rod

Max. 20

Max. 20

Part No.

Part Name

Qty

Commercially available

Convex scale

Item

Special tool

423F331

Fit the safety locks on the control levers.


Do not go under the work equipment.

Measuring procedure
1)

Set the lift arm and bucket horizontal,

then stop the

engine.
2)

Stop

the

engine,

wait

for

5 minutes,

then

start

measuring.
3)

Measure the amount the lift B and dump A cylinder


rods retract during 15 minutes.

62-10
0

A:

Retraction of dump cylinder rod.

B:

Retraction

423F332

of lift cylinder rod.

WA500- 1

ADJUSTING

BUCKET

POSITIONER

Testing
1.

Check that
angle

(2)

the clearance
with

the

between

engine stopped

switch

(1) and

is within

the

standard value.
2.

Start

the engine and check the actuating

position

at low idling.
(Check three times and take the average.)

Adjusting
1.

Lower the bucket to the ground, operate the bucket


to the desired digging angle, then return the lever to
the HOLD

2.

position and stop the engine.

Secure switch protector


bracket

(3) to the dump

cylinder

so that the center of the switch is aligned

with the end face of angle (2).


3.

Adjust
from

nut (6) of switch

so that clearance a

(1)

the end face of switch

protector

(3) to the

switch response surface is within the standard value,


then lock in position.
*

Clearance a:

m
4.

5.

0.5 -

\\

1 .O mm

Switch mounting nut:

,;::_
u

1.8 f. 0.2 kgm

Remove cover (4) of the switch.

425FO1343

Using washer, adjust so that clearance b between


the response surface of switch

(1) and angle (2) is

within the specified value, then lock in posiiton.


Using washer, adjust the angle so that the clearance between the response surface of the switch
and the angle is within

the specified value over

the whole stroke of the angle, then lock in.position.


Check

that

neither

the

response face

of

the

switch nor the angle are off center before locking


in position.
After
that

adjusting,
the

operate

positioner

the bucket lever, check

is actuated

position, then lock in position.


Clearance lb:

3 - 5 mm

Install cover (4) of the switch.

WA500- 1

at the desired

425FO1344

ADJUSTING

BOOM

KICK-OUT
Unit:

Standard
value

Item
Clearance between switch
and plate

1.

Inspection
1)

3-5

procedure

With the engine stopped,


ante

mm

Permissible
value

between

switch

check that the clea-

(1) and plate

(2) is the

standard value.
2)

Start the engine, run at high idling and check


the actuation

position.

(Measure three times

and take the average.)


2.

Adjusting
11

Raise the lift arm to the desired position,


mark

the

lifr arm at the position

center of the switch

then

where

is at the bottom

the

edge of

the plate.
2)

Lower the lift arm and stop the engine.

3)

Align the marks, adjust the position of the plate


so that the center of switch (1) is level with the
bottom

of

plate

(21, then

lock the

plate

in

position.
4)

Remove switch cover (3).

5)

Adjust the switch so that the clearance between


the sensing surface of the switch and plate (2)

!:

423F335-1

is the standard value.


*

Clearance a.

Mounting

3 - 5 mm
nut of switch:
1.8 + 0.2 kgm

After

adjusting,

operate

the

lift

lever and

check that the lift arm stops at the desired


position.

62-12
0

WASOO- 1

TROUBLESHOOTING
Troubleshooting table . . . . . . .
.. .
l.Liftarmdoesnotrise
. . . . . . .._..__.....
2. Lift arm moves slowly or does not have
sufficient lifting power . . . . . . . .
3. Lift arm movement becomes slow after it
reaches a certain height.. . . .
..
4. Bucket cannot be held down with lift
cylinder . . . . . . . . . . . . . . . . . . . . . . . . ..___.
5. Lift arm has large hydraulic drift .
..
6. Lift arm movement is unsteady
duringwork . . . . ..___..........__.....
7. Lift arm descends momentarily
when control lever is shifted
from Hold to Raise . . . . . .
8. Bucket does not tilt back .
.. . ...
9. Bucket moves slowly or has insufficient
tilt back power . . . . . . . . . . . . . . .
10. Bucket movement becomes slow during
tiitback . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1. Bucket cannot be held down by the
bucket cylinder . .
.
. . ..
12. Bucket has large hydraulic drift
.
13. Bucket moves unsteadily when
machine travels under load
...
.
(Main control valve in Hold)
14. Bucket dumps momentarily when
control lever is shifted from
Hold to Tilt back . . . . . .
.. .
1 5. Control levers of lift arm and dump
move stiffly and sluggishly . . . . _ .

Before carryinq out the troubleshooting in this section,


page 22-12,
RENCE

WA500-

METHOD

OF TROUBLE

OF READING
page 22-16.

TROUBLESHOOTING

read PRECAUTIONS
TABLE

WHEN

62-l 6
62-l 6
52-l 7
52-l 8
52-l 8
62-l 8
62-18

62-18
62-l 9
62-20
62-21
62-2 1
62-21

62-21

62-21
62-22

TROUBLESHOOTING

page 22-14 and PREVENTING

RECUR-

TROUBLESHOOTING
1.

TABLE

Lift arm does not rise.


Ask the operator the following

questions

Did the boom suddenly fail to rise? + Seizure


or damage to various units.
Was an unusual noise produced?

(Where did it
emanate from?)
Were there previous signs of the boom slowing
down. + Wear of parts of flattening of spring.

Checks before troubleshooting

.
.

Is oil level in hydraulic tank correct?


Is stroke of lift control lever and spool correct?

Tank -pump

Problems

No.

I6 ucket

I
cannot operate and lift arm is unable to ascend.

l0lOl0lOl0l0i
I

The machine body can be lifted up by the lift arm however,


the lift arm is unable to ascend. Alternatively, the bucket
operates but the lift arm is unable to ascend.

The lift arm can ascend under no load but cannot ascend
under load.

The hydraulic pump produces an unusual noise.

Lift cylinder has large amount of hydraulic drift.

When the engine is at high idling, steering action is light and


excessively fast.

When the engine is at high idling, steering action is heavy


and slow.

idO/ I
I

0
0
~

IMO

0
0

The following symbols are used to indicate the action


to be taken when a cause of failure is located.
X : Repalce
A: Repair
A : Adjust
C : Clean

62-14
0

WA500- 1

8.

Bucket does not tilt back.


Ask the operator the following

Did the bucket

suddenly

questions
ceases to move? +

Seized or damaged equipment.


Was any

unusual

noise emitted

(where did it

emanate from)?

Were there previous signs of the bucket slowing


down? + Worn parts of flattened

spring.

Checks before troubleshooting

.
.

Is amount of oil in hydraulic tank satisfactory?


Is the stroke of the bucket

control

lever and

spool correct?

Lrft arm cannot operate and bucket is unable to tilt back.

The machine can be lifted up by the bucket but the bucket


cannot tilt back. Alternatively, the lift arm operates but the
bucket cannot tilt back.

The bucket can tilt back under no load but cannot excavate
or scoop.

The hydraulic pump produces an unusual noise.

Bucket cylinder has large hydraulic drift.

Steering action is light and excessively fast when the engine


is at high idling.

Steering action is heavy and slow ,when the engine is at


high idling.

I I

lolololololol
0

I I I I I I I MO
0
0

The following symbols are used to indicate the action


to be taken when a cause of failure is located.
X : Repalce
A:
Repair
A : Adjust
C : Clean

WASOO- 1

62G7

9.

Bucket moves slowly or has insufficient tilt


back power.
Check before troubleshooting

Is the oil quantity in the hydraulic tank and the


type of oil satisfactory?

Is the stroke of the bucket control lever and the


main control valve spool correct?

Seizure of bushing in bucket linkage.


(Does emits unusual noise)

Fault checks

Check the amount


by performing

of deficient

titlt

back force

actual work.

Measure the operating

speed of the bucket and

check it against the judgement criterion table to


determine

whether or not it is normal.

No.

lol I I I

Lift arm lifting force and lifting speed are abnormal and also
bucket tilt back force and tilt back speed are abnormal.

Lift arm lifting force and lifting speed are normal but bucket
tilt back force and tilt back speed are abnormal.

Phenomena of item 1 become particularly bad when the oil


temperature increases.

The hydraulic pump emits an unusual noise.

Steering action is light and excessively fast when the engine


is at full throttle.

Steering action is heavy and slow when the engine is at full


throttle.

The dump cylinder has a large amount of hydraulic drift.

The relief pressure of relief valve of main control valve is


also low.

I I I- I I IMoldd

The discharge volume of the hydraulic pump is low.

lolololol

000

0
0

0
0
000

iol

The following symbols are used to indicate the action


to be taken when a cause of failure is located.

62&8

WA500- 1

10. Bucket movement becomes slow during tilt


back.

13. Bucket moves unsteadily when machine


travels under load. (Main control valve in
Hold).

Checks before troubleshooting

External deformation

Checks before troubleshooting

of dump cylinder.

.
.

Swollen

Is oil

level in hydraulic

tank and type of oil

correct?

Cause
or internally

damaged dump

cylinder

Regarding

Excessive play
equipment

tube.
other

faults which

occur when the

in pin

and

bushing

of

work

linkage.

Was an unusual noise produced?

bucket operates, refer to item 9 Bucket moves


slowly or has insufficient

Cause

tilt back power.

.
.
11. Bucket cannot be held down by the bucket
cylinder.

Faulty piston seal of dump cylinder.


Faulty
If the
other

Refer to item 9 Bucket

moves slowly

safety valve with suction

valve for the

bottom side of dump cylinder.


above

symptoms

symptoms,

occur together

with

refer to the problems

items

corresponding to each fault.

or has in-

sufficient tilt back power.


Check before troubleshooting

.
.

Is oil level in the hydraulic tank satisfactory?


Is the stroke of the main control

14. Bucket dumps momentarily when control


lever is shifted from Hold to Tilt back.

valve dump
The

spool correct?

bucket

wieght

when

dumps

momentarily

the dump

control

under

its own

lever is gradually

Cause

shifted from the Hold

Faulty seat of safety with suction valve of con-

position while the engine is at low idling.

trol valve for the bottom side of dump cylinder.

When the control

Oil leakage from seal of dump cylinder piston.

Tilt back position, the bucket behaves normally.

position to the Tilt back

lever is put completely

into the

Cause

12. Bucket has large hydraulic drift.

Faulty

seating

of

main

control

valve dump

spool check valve.


Ask the operator the following

Did the hydraulic

questions.

drift suddenly become large?

+ Dirt lodged in valve or damaged parts.

Did the hydraulic

drift gradually become large?

+ Worn parts.
Check before troubleshooting

Is the type and temperature

of the oil in the

hydraulic tank correct?

Is the dump spool in the neutral

position? --f

Seized link bushing, faulty spool detent.


Fault check

Use the

judgement

whether

or

not

criterion

the

table

hydraulic

to

drift

check
of the

bucket is actually large.

If hydraulic drift is large.


Cause:

Oil leakage in dump cylinder.

If hydraulic drift returns to normal.


Cause:

Faulty

seating of overload relief valve

or suction valve on rod side.


Faulty

oil sealing on spool of dump

control valve.

WA500- 1

62-19
a

15. Control levers of lift arm and dump move


stiffly and sluggishly.
Fault check
Using the judgement

criterion

table, check whether

or not the operating force of the lever is large.

load is applied and oil pressureincreases.

Movement of lift arm and bucket becomes p

when the link of the control lever is disconnected at

The following symbols are used to indicate the action


to be taken when a cause of failure is located.

WASOO- 1

WORK EQUIPMENT SYSTEM 0


63

HYDRAULIC

DISASSEMBLY

TANK

DUMP

.......................
tnstallation
.............. ...... .

Removal

HYDRAULIC

HYDRAULIC

Removal

63-

Installation

63- 4

Installation

Disassembly

63-

Assembly

63-

Removal

63-

Installation

63-

POC VALVE

63-20

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

63-24

......

63-27

......

63-29

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

63-32

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

63-41

63-22

63-25

CYLINDERS

...... ......
.
. . . . _. .

EQUIPMENT

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

63-36

COUNTERWEIGHT

.......................
Installation
.....................
Disassembly .....................
Assembly
......................
Removal

MAIN

DUMP

WORK

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


Installation
... .......... .... ...

AND

.,............
..........,.

63-

PUMP

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

CYLINDER

Removal

LIFT

Removal

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

63- 4

FILTER

.......................
Installation
.....................

u!

CYLINDER

LIFT

Removal

ASSEMBLY

63-

PUMP

........... .. .........
Installation
.................. ..

Removal

SWITCH

AND

CONTROL

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

Installation

63-41

63-12
63-12

VALVE

.......................
Installation
.....................
Removal

Disassembly and assembly

Removal

63-10

Take

63-13
63-l 5

...........

the following

63-18

method

for air bleeding when you start to operate

hydraulic

cylinders after reassembling cylinders, pumps and pipings.


1.
2.

Start engine, keep idling.


Operate hydraulic

cylinder 4 -

5 cycles, but do not exceed beyond 100 mm of

stroke end.
3.

Continue to operate cylinder 3 - 4 cycles until stroke end.

4.

After finishing above steps, keep normal engine speed.


NOTE:

WA500-

After long storage, same procedure is required.

63-1
0

REMOVAL

Qt

OF HYDRAULIC

Stop the

machine

TANK

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine. Then apply the parking


brake and put blocks under the wheels to prevent
the machine from moving.

0!

Loosen the oil filler cap slowly to release the pressure inside the hydraulic
control

pressure in the hydraulic

tank.

Then operate the

levers several times to release the remaining


piping.

Loosen plugs (1) and (2) at the top of the hydraulic tank
filter,

and

plugs (3)

and (4) of the

pump

piping to

prevent the oil inside the tank from flowing out.


1.

Hood
Lift off tank hood (5).

2.

Hydraulic

piping

Disconnect hydraulic

piping as follows:

1) Disconnect tube (6) between hydraulic tank and steering + POC pump, from tank.
2) Disconnect

tube

(7)

switch and hydraulic


3) Disconnect

between

hydraulic

tank,

and

pump, from tank.

tube (8) between main control

valve and

hydraulic tank, from tank.


t

3.

Loosen tube clamp.

Hydraulic

tank

Temporarily

sling hydraulic

tank

(9). remove mounting

bolts and lift out.


*

Be careful that tubes (6) and (8) do not cause interference with tank.
Hydraulic

63-2
0

tank:

290 kg

WA500-

INSTALLATION
1.

Hydraulic
Set

OF HYDRAULIC

TANK

tank

hydraulic

tank

(9)

in

mounting

position,

then

tighten mounting bolt.


*

Be careful that tubes do not cause interference

with

tank.
m

Mounting bolt:

56 * 6 kgm
(Width across flats:

2.

Hydraulic

30 mm)

piping

Connect hydraulic

piping as follows:

I) Connect tube (8) between main control

valve and

hydraulic tank, to tank.


*

Install tube clamp.

2) Connect tube (7) between hydraulic tank, and switch


and hydraulic

pump, to tank.

3) Connect tube (6) between hydraulic tank and steering


+ POC pump, to tank.

3.

Hood
Install hood (5).

4.

Refilling with oil


Tighten
of

pump

plugs at top of hydraulic


piping,

then

add

tank filter,

hydraulic

and plugs

oil through

oil

filler to the specified level.


*

Run the engine to circulate hydraulic

oil and water.

Then check the oil and water levels again.


m

WA500-

Plug at top of filter:

1.2 + 0.1 kgm

REMOVAL

n
!

OF HYDRAULIC

Stop the
safety

machine

PUMP

on level ground and install the

bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
*

See REMOVAL

OF SWITCH

PUMP and remove switch

pump.
1.

Hydraulic

piping

Disconnect hydraulic piping as follows:

* Disconnect

tube

(I)

between

hydraulic tank, from hydraulic

* Disconnect

tube

(2)

between

steering valve, from hydraulic


2.

Hydraulic

pump

and

hydraulic

pump

and

pump.

pump

Remove hydraulic
*

hydraulic
pump.

The working

pump (3).
space is restricted,

so be careful when

working.
Hydraulic

pump:

15 kg

INSTALLATION
OF
HYDRAULIC
PUMP
Hydraulic

1.

pump

Set hydraulic

pump (3) in mounting position and tighten

mounting bolts.
2.

Hydraulic

piping

Connect hydraulic

piping as follows:

* Connect tube (2) between hydraulic pump and steering valve, to hydraulic

* Connect

tube

(1)

pump.
between

hydraulic tank, to hydraulic


*

See INSTALLATION

hydraulic

pump

and

pump.

OF SWITCH

PUMP

and installa-

tion switch pump.

63-4

WA500-

REMOVAL

a
1.

OF HYDRAULIC

FILTER

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Cover
Loosen

plug

(1)

and

remove

mounting

bolts,

then

remove cover (2).


The tension of the spring is pushing the cover,
!
Q
*

so be careful when removing.

Be careful

not to damage the O-ring (3) on the con-

tact faces of the cover and tank.


2.

Filter
Remove

spring (4)

and bypass valve (5), then remove

filter (6).

INSTALLATION
OF
HYDRAULIC
FILTER
1.

Filter
Install filter

(6). then install bypass valve (5) and spring

(4).
2.

Cover
Fit O-ring (3) in groove of cover, then intall cover (2) to
tank and tighten plug (1).
+
*

Replace the O-ring with a new part.


Fit the O-ring securely in the groove, and make sure
that it is not caught when installing.

@Kl

WA500-

Plug:

1.2 f 0.1 kgm

63-5
0

REMOVAL

n!

OF SWITCH

Stop the machine

PUMP

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine. Then apply the parking


brake and put blocks under the wheels to prevent
the machine from moving.

G!

Loosen the oil filler cap slowly to release the pressure inside the hydraulic
control

tank.

Then operate the

levers several times to release the remaining

pressure in the hydraulic

piping.

Loosen plugs (1) and (2) at the top of the hydraulic tank
filter,

and

plugs

(3) and

(4) of the pump

piping to

prevent the oil inside the tank from flowing out.

1. Cover
Remove cover (5).

2.

Hydraulic

piping

Disconnect

hydraulic

piping from switch and POC pump

as follows:

* Tube (6) between hydraulic tank and switch pump.


* Tube (7) between switch pump and steering valve.
*

3.

Remove clamp of tube (7) and let it remain free.

Switch pump
Remove switch pump (8).
*

The working

space is restricted,

so be careful when

working.
Switch pump:

15 kg

425P738j

WA500-

INSTALLATION
1.

OF SWITCH

PUMP

Switch pump
Set switch pump

(8) in

mounting bolts.

3.

Cover
Install cover (5).

4.

Refilling with oil


Tighten

plugs at top of hydraulic

of pump piping, then add hydraulic

tank filter,

and plugs

oil through oil filler

to the specified level.


Plug at top of filter:

WA500-

1.2 2 0.1 kgm

REMOVAL

OF POC VALVE

Stop the

A!

machine

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
Loosen the oil filler cap slowly to release the pres-

_$;
!

sure inside the hydraulic


control

tank.

Then operate

the

levers several times to release the remaining

pressure in the hydraulic

piping.

Loosen plugs (1) and (2) at the top of the hydraulic tank
filter,

and plugs (3) and

(4) on the pump

piping to

prevent the oil inside the tank from flowing out.


1.

Cover
Remove cover (5) under cab and cover (6) of console
box on right side of operators seat.

2.

Hydraulic

piping

- Disconnect

hoses (7) and

(8) of lift spool at POC

valve end.

* Disconnect hose (9) between POC valve and hydraulic


tank at POC valve end.

* Disconnect hose (10) between POC pump and POC


valve at POC valve end.

- Disconnect hoses (11) and (12) of dump spool at


POC valve end.
*

After

disconnecting

the

hoses, mark

with

a tag to

distinguish when installing.


425P74S

425?342

63-8
2

WA500-

3.

4.

(L

Linkage
Remove

cotter

connect

linkage

pin and loosen

locknut

(131, then

dis-

(14).

POC valve
Remove plate (15). then remove POC valve (16).
*

The working

space is restricted,

so be careful

when

working.
*

There

is a washer between

console box, so be careful


*

the plate and valve and the


not to lose it.

Lift out POC valve.

WA500-

63-9
0

INSTALLATION

2.

OF POC VALVE

Linkage
Set linkage

(14)

in mounting

position,

tighten

locknut

(13), then secure with cotter pin.


t

For details of adjusting

linkage, see TESTING

AND

ADJUSTING.

3.

Hydraulic

piping

* Connect hoses (11) and (12) of dump spool at POC


valve end.

* Connect hose (10) between POC pump and POC valve


at POC valve end.

- Connect hose (9) between POC valve and hydraulic


tank at POC valve end.

* Connect hoses (7) and (8) of lift spool at POC valve


end.

425P742

63-10
0

WA5bO- 1

4.

Cover
install cover (5) under cab and cover (6) of console box
on right side of operators seat.

5.

Refilling with oil


Tighten

plugs at top of hydraulic

tank filter,

and plugs

of pump piping, then add hydraulic oil through oil filler


to the specified level.
w

WA500-

plug at top for filter:

1.2 + 0.1

kgm

63-11
0

DISASSEMBLY
1.

OF POC VALVE ASSEMBLY

Loosen nipple (1). then remove bottom cover (2).


*

It is only necessary to loosen the nipple if it catched


on the lower cover.

2.
3.

Remove bracket (3).


Remove

plug

(4),

then

remove shim

springs (7), (El), (9) and (lo),


*

(5). spacer (6),

and spacer (11).

Make match marks to prevent

mistakes in the com-

bination of spool and spring.


4.
5.

Remove case assembly (12).


Remove

set screw

(13),

207P432

and pull out

levers (14)

207P433

and

(15), then remove spools (16) and (17).

ASSEMBLY
ASSEMBLY
1.

OF POC VALVE

Make spools (17) and (16) into a set, then install levers
(15) and (14). and tighten set screw (13).
*

2.
3.

Lock securely with wire.

2072434

Fit O-ring and install case assembly (12).


Assemble

spacer

(1 I),

springs (IO),

(9),

(8) and

(7),

spacer (6) and shim (5), then install plug (4).


+

Be careful

not to mistake the combination

of spool

and spring.
4.
5.

Install bracket (3).


Fit O-ring

and install

bottom

cover

(2), then tighten

loosened nipple (1).

207P435

207P436

63-12
0

207P438

207P437

WA500-

REMOVAL

OF MAIN

Stop the
safety

machine

CONTROL

VALVE

on level ground and install the

bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
Loosen the oil filler cap slowly to release the pres-

Q
!

sure inside the hydraulic


control

pressure in the hydraulic


Loosen plugs (1) and
tank filter,

tank.

Then operate

the

levers several times to release the remaining


piping.

(2) at the top of the hydraulic

and plugs (3) and (4) of the pump piping to

prevent the oil inside the tank from flowing out.


Cover
Remove inspection cover (5) of front frame.
Dump cylinder
1) Disconnect electric wiring (6) from connector.
2) Disconnect grease tube (7) from front frame.
*

Remove clamp of grease hose.

3) Disconnect hydraulic

piping (8) and (9).

4) Sling cylinder

remove

(10).

pin

(ll),

then remove

cylinder.
*

Be careful

to check the center

of gravity when

attaching the lifting tool.


*

There are shims at the mounting

pins, so check the

number and thickness of the shims, and keep in a


safe place.
Hydraulic

wiring

* Disconnect hoses (12), (13), (14) and (15) between


POC valve and main

control

valve at main control

valve end.
*

Remove the tube clamp.

After

disconnecting

the tube, move it toward

the

between

and

rear of the machine.


*

Disconnect

hose

(16)

hydraulic

tank

main control valve at main control valve end.

WA500-

63-13
0

Remove tubes (17) and hose between

main control

valve and dump cylinder.

Remove tubes (18)

between

main control

valve and

lift cylinder.

Disconnect tube (19) from manifold

Remove tube bracket (20).

Remove

hose (21)

between

end.

main control

valve and

steering valve at main control valve end.


l

Remove tube (22) between hydraulic

tank and main

control valve at main control valve end.

Remove

tube

(23)

and hose between

main control

valve and dump cylinder at main control valve end.

* Disconnect

tube

(24)

between

main

control

valve

and lift cylinder at main control valve end.


*
4.

Loosen the tube clamp first.

Main control valve


1) Remove mounting

bolts and turn main control

valve

(25) 90.
2) Using eye-botls, lift out main control valve (25).
*

Be careful of bleeder screw of slack adjuster and


remove.
Main control valve: 88 kg

6 3-l 4
0

WA500-

INSTALLATION
1.

OF MAIN

CONTROL

Main control valve


1) Using eye-bolts, set main control valve (25) in mounting position.
*

When

setting

in the mounting

position,

operate

the hoist to maintain

the balance

interference

bleeder screw of the slack

with

the

and to avoid

adjuster.

2) Turn main control valve (25) 90 and tighten mounting bolts.


+

The

lift

cylinder

tube

will cause interference

so

push the tube upward.

2.

Hydraulic

piping

Connect hydraulic

piping as follows:

* Connect tube (24) between main control valve and


lift cylinder, to main control valve.
+

Tighten tube clamp.

* Install tube (23), together with hose, between main


control valve and dump cylinder.
*

Be careful of angle of tube when installing clamp.

* Connect tube (22) between hydraulic tank and main


control valve, to main control valve.

* Connect hose (21) between steering valve and main


control valve. to main control valve.

WA500-1

VALVE

Install

tube

(18)

between

main

control

valve and

lift cylinder.
+

Install tube (19) to manifold.

Install tube clamp (20).

* Install tube (17), togehter with hose, between main


control valve dump cylinder.

* Connect hose (16) between hydraulic tank and main


control valve, to main control valve.

- Connect

tubes

(12),

(13).

POC valve and main control

(14)

and

(15)

between

valve, to main control

valve.

3.

Dump cylinder
1) Set cylinder
hole.
uniform

(10) in mounting

Adjust

with

position,

shims so that

and align pin

clearance

on left and right, then drive in pin (11

is

) and

lock the pin.


Q

Use a bar to align the pin hole.

Never use

your fingers.
*

Clearance a = 1.5 mm

425F299

WA500-

4.

Cover
Install inspection cover (5) of front frame.

5.

Refilling with oil


Tighten

plugs at the top of hydraulic

plugs of pump piping, then add hydraulic

tank filter,

and

oil through oil

filler to the specified level.


m

WA500-

Plug at top of filter:

1.2 i 0.1 kgm

63-17
0

DISASSEMBLY

AND

jo

ASSEMBLY

OF MAIN

!
20

CONTROL

VALVE

il

0
0

425F301

425F300

63-18
0

WA500-

ASSEMBLY

DISASSEMBLY
1.

Spool assembly
1) Remove

1.

sleeve

(I)

(3), spring

2) Remove

piston

3)

Remove

springs

(6),

4)

Remove

spools

(10)

Assemble
body

and case (2).


(4) and retainer

(7) and (8),

valve

(30),

Main

relief

2) Loosen

(9).

2.

relief

valve assembly

main

nut

3) Remove

(13),

relief

then

snap

ring

3.

(12).
holder

(14)

and

(18)

is any defect

If there
whole

from

then

sleeve

assembly.

remove

valve

(17)

(19).

in spool
These

or valve,

4.

valve assembly

with

Remove

safety

Suction

valve assembly

Remove

suction

Fit O-ring

replace

parts are not avail-

suction

valve assembly

w
5.

valve

valve assembly

Remove

selector

6.

(21).

valve

(22).

Main

plate

(23),

(30).

remove

spring

(24)

4)
flange

and unload

(26),

then

valve

(29).

Do not disassemble
pressure
installed

cannot

remove

the safety
be adjusted

on the machine.

spring

(27).

valve further
after

the

seal
as the

valve

is

nut

Spool

valve assembly

(20).

19 + 1 kgm

(17)

and

spring

(18)

in sleeve

backup

ring

and

assemble

seat

fit O-ring

and

(19).

(13)

into

holder

in sleeve

(19),

and

backup

O-ring

valve assembly
Main

(14).

then

tighten

ring,

nut (13).

then

install

main

(12).

relief

valve:

33 t 4.5 kgm

assembly

1) Assemble
2) Install

spools

retainer

3) Assemble
fit O-ring

WA500- 1

(21).

snap ring (16).

and

in sleeve

Fit

safety

valve

O-ring

B
7.

valve assembly

19 + 1 kgm

valve:

and install

assemble

and

(25).

(22).

valve assembly

3) Screw
then

valve assembly

suction

and install

relief

2) Fit

valve assembly

Remove
(28)

in body

7 * 1 kgm

valve:

Safety

relief
7.

(24)

Safety valve assembly with suction valve

(19),

valve assembly

valve:

Suction

(15)
Remove

in

(23).

selector

and install

Fit O-ring

(20).

valve assembly

Selector

Check

(27)

Suction valve assembly

1) Assemble

6.

(26).

spring

plate

and install
Selector

5.

spring

Selector valve assembly

able individually.

4.

(25) and

and install

Fit O-ring

valve assembly.

remove

(16),

and spring

Safety

and
flange

Check valve assembly


Assemble valve

and (1 I).

seat (15).

3.

(28)

valve assembly

I) Remove main
* Disassemble

the

seal

and install

(5).

and retainer

fit O-ring
2.

(29).

fit O-ring

(11)

and (10)

(9) and springs

retainer
and install

(5),

spring

in body.
(8),

(7) and (6).

(4) and

case (2) and sleeve

piston

(3),

(1).

63-19
0

REMOVAL

OF DUMP

Stop the

machine

CYLINDER

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine. Then apply the parking


brake and put blocks under the wheels to prevent
the machine from moving.
Loosen the oil filler cap slowly to release the pressure inside the hydraulic
control

pressure in the hydraulic


1.

tank.

Then operate

the

levers several times to release the remaining


piping.

Bucket positioner wiring


Disconnect wiring (1) from connector.

2.

Grease tube
Disconnect tube (2) from bottom pin end.
*

3.

Remove clamp and move tube.

Hydraulic

piping

1) Disconnect hose (3) at rod end from cylinder.


2) Disconnect

hose (4) of bottom

end from

cylinder

end.

4.

Rod pin
Sling cylinder,
*

remove lock bolt, then remove pin (5).

When raising the cylinder,

sling at two places and be

careful to maintain the balance.

425P759

63-20
0

WA500- 1

5.

Dump cylinder
1) Remove

lock bolt,

then

remove pin (6) at bottom

end.
*

There are shims installed, so check the number and


thickness of the shims, and keep in a safe place.

2) Remove dump cylinder


*

(7).

Be careful not to damage the cylinder rod.

_,.- ._.~

Dump cylinder: 283 kg


_ -~ ^._._..__~__.. .__ _.. -

WA500- 1

_ --

63-21
0

INSTALLATION
1.

OF DUMP

CYLINDER

Dump cylinder
1) Raise dump

cylinder

(7) and set in mounting

posi-

tion.

25P761

2) Align pin hole at bottom

end, assemble shim so that

clearance a between cylinder and frame on left and


right is within specified range, then install pin (6) and
lock with bolt.
Clearance a + b = Max. 1.0 mm

425F299A

2.

Rod pin
Align

pin hole at rod end, then install pin (5) and lock

with bolt.

Use a bar to align the pin holes.

Never use your

fingers.

425P759

6322

WA500- 1

3.

Hydraulic

piping

1) Connect hose (4) at bottom end.


2) Connect hose (3) at rod end.

4.

Fit the O-ring securely in the grooves.

Install the hose without

twisting or interference.

Grease hose
Connect hose (2) to front frame.

5.

Bucket positioner wiring


Connect wiring (I) to connector.

WA500-

63623

REMOVAL

OF LIFT CYLINDER

Stop the

machine

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
1.

Fender
Remove fender (I ).
Fender:

2.

48 kg

Rod pin
1) Sling lift cylinder

(2). remove lock bolt, then remove

pin (3).
2) Start

engine, and operate

control

levers to retract

cylinder rod on side where pin has been removed.


Loosen the oil filler cap slowly to release the
pressure inside the hydraulic
operate

the control

tank.

Then

levers several times to

release the remaining pressure in the hydraulic piping.

3.

Hydraulic

piping

1) Disconnect hose (4) at rod end from connector.


2) Disconnect hose (5) at bottom end from connector.
4.

Lift cylinder
1) Place lever block under lift cylinder
rear of machine with lever block @
2) Using forcing screw (Ml2

(2) and pull to

x 50 mm), remove pin (6)

of bottom end.
*

There are shims installed, so check the number and


thickness of the shims, and keep in a safe place.

3) Remove lift cylinder (2).


*
/

Be careful not to damage the cylinder rod.


Lift cylinder:

---i

425P7645

280 kg

425P765

63-24
0

WA500- 1

INSTALLATION
1.

OF LIFT CYLINDER

Lift cylinder
1) Raise lift cylinder

2) Sling cylinder,

(2) and set in mounting position.

then align pin hole using lever block

0.

3) Assemble

shim so that clearance a between cylin-

der and frame

on left and right is within

specified

range, then install pin (6) and lock with bolt.

Use bar to align the pin holes.

Never use

your fingers.
Clearance a + b = Max. 1 .O mm

425F302A

425P768

WASOO- 1

63625

2.

Hydraulic

piping

1) Connect hose (5) at bottom end.


2) Connect hose (4) at rod end.

3.

Fit the O-rings securely in the grooves.

Install the hoses without

twisting or interference.

Rod pin
Start engine and operate

control

levers to extend

rod.

Align pin hole, install pin (31, then lock with bolt.

4.

Fender
Install fender (1).

63-26
0

WA500-

DISASSEMBLY

OF LIFT AND

DUMP

CYLtNDERS

ASSEMBLY

Special tool

Part No.

Part name

790-502-1001

Cylinder repair stand

1.

Set cylinder assembly (1) in tool A.

2.

Remove mounting bolts (2) of cylinder head.

1 Qtv
1

207P490

3.

Pull cylinder
cylinder
*

head and piston rod assembly (3) out from

(4). then lift off.

Oil will come out when the piston rod assembly is


removed from the cylinder, so catch it in a container.

207P49

4.

Remove piston bolts (51, then remove spacer (61, piston


assembly (7) and cylinder head assembly (8).

-.

419Pl254

9
5.

Remove O-ring

(IO)

and backup

ring (11) from piston

rod (9).

423F484

WA500-

63-27
0

6.

,, ,

Disassembly of piston assembly


Remove wear ring (12) and piston ring (13) from piston
(14).

_,

iZOXF24

7.

IB

Disassembly of cylinder assembly


1) Remove O-ring (15) and backup ring (16).
2) Remove snap ring, then remove dust seal (17).

207P494A

207P495A

3) Remove rod packing (18).


4) Remove bushing (19).

207P496A

63-28
0

18

19

207P497A

WA500-

ASSEMBLY

OF LIFT AND

DUMP

CYLINDERS

ASSEMBLY

Special tools

A--

Part No.

Part name

~~

Cylinder repair stand

Expander

790-502-1001

~790-720-1000

1 Ring

796-720-1690
796-720-I

Cl

Oty

720

Ring

Clean all parts, and check for dirt or damage.

Coat the

sliding surfaces of all parts with engine oil before installing.

Be careful not to damage the U-packings, dust seals

or O-rings when assembling.


Assembly of cylinder head assembly
1) Using push tool @

, press fit bushing (19) on cyl-

inder head (20).


t

Be careful

not to deform

the bushing when press

fitting.

9n
207P498A

207P497A

2) Assemble rod packing (18).


*

Be careful to install the rod packing facing in the


correct direction.

200F240A

3) Install backup ring (16) and O-ring (15).


t

Do not try to force the backup ring into position.


Warm it in warm water

(50 - 60C)

before fitting

it.

207P499A

WA500-

207P494A

63-29
0

, install dust seal (17) to cylinder

4) Using push tool @

head, then secure with snap ring.

,.
2.

a-

207P495A

-S207P500

Assembly of piston assembly


1) Using tool B, expand piston ring (13).
*

Set the piston ring on the expander

and turn the

handle 8 - 11 times to expand the ring.


2) Remove

piston

ring from

tool

B, and assemble on

piston (14).
3) Fit tools C and C1 on piston ring, then using clamp
@

, compress piston ring.

Part No. of clamp:

Part No. of clmap:

07281-02169
07281-02429

(for lift cylinder)


13

(for dump cylinder)

207P502A

4) Assemble wear ring (12) on piston.

C
207P503

3.

Assemble

O-ring

(10)

and backup

ring (11) on piston

rod (9).

423F484

63-30
0

WA500- 1

4.

Assemble cylinder

head assembly (8) and piston assem-

bly (7) on piston rod.


*

Coat backup ring (11) with grease so that it does not


stick out, and assemble carefully.

5.

Assemble spacer (6), then tighten piston bolts (5).


Piston bolt:

18.0 f 2.0 kgm


(Width across flats:

&

6.

Mounting

Set cylinder

bolt:

22 mm)

Adhesives (LT-2)

(4) in tool A, then raise piston rod and head

assembly (3), and assemble in cylinder

(4).

207P49

Tighten cylinder head mounting bolts (2).


m

Cylinder head mounting bolt:


47.5 ? 14.5 kgm (Lift cylinder)
117.5 f 12.5 kgm (Dump cylinder)

Remove cylinder assembly (1) from tool A.

207P490

WA500-

632

REMOVAL

Q
7

OF WORK

Stop the machine

EQUIPMENT

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine. Then apply the parking


brake and put blocks under the wheels to prevent
the machine from moving.
1.

Bucket link
1) Remove mounting pin (1) of bucket link.
*

Remove cord ring.

Tie the bucket link to the tilt lever with wire.

2) Remove

mounting

bolt

(5A)

of flange (4 pieces at

left and right).


3) Remove mounting pin (2) of bucket hinge.
*

Before removing pin (2), loosen retainer mounting


bolts, remove retainer (3) and shim (3A).

Remove lock bolt and cam, then pull out pin (2)
at left and right.

P425C1197

4) Move machine to rear and disconnect bucket (4).

2.

Flange
1) Remove flange (5) from lift arm.

425P811

63-32
0

WA500-

2) Remove

seal (6), oil seal (6A)

and O-ring (7) from

flange (5).
*

Serial No. 11464 and up: seal (6) only

Serial

No.

Serial

10001-11463

No.

11464

and up

5
6
7
._

425F401

FO425C1130

3.

425P81i
,.

Dump cylinder pin


Temporarily

sling dump cylinder

(8), pull pin (9), then

disconnect cylinder rod and tilt lever.


+

Attach

lifting tool to dump cylinder and secure in the

rear.
Dump cylinder:

285 kg

4.

425P813

Lift cylinder pin


Attach

lever

block @

to

lift

cylinder

(10).

pull ma-

chine to rear and remove mounting pin (11).


+

Secure other end of lever block @

to hole of front

frame.
Lift cylinder:

280 kg

425P814

,,

5.

Tilt lever, bucket link


1) Temporarily

sling tilt

remove mounting

lever and

bucket

link

(12),

pin (13), then lift out from lift arm

(14).
* 3 men should be used for removal of mounting
pin operation.
2-s

~92

Tilt lever and bucket link:

A
cig2

Mounting pin:

480 kg

59 kg

425P815

WA500-

63-33
0

2) Temporarily

sling bucket

link (75).

remove mount-

ing pin (16). then lift out from tilt lever (17).
*

Remove cord ring.


Bucket link:

95 kg

There are shims installed, so check the number of


shims for reference when installing.

425P816

6.

Lift arm
1) Remove boom kickout switch (18).

2) Temporarily

sling lift arm (14). pull out mounting pin

of lift arm, then lift out lift arm.


*

Shims are installed

at connecting

point of front

frame and lift arm, so check the number of shims.


Lift arm:

7.

2,000 kg

Dust seal, bushing


1) Pull out bushing (19) from lift arm (14).

19

19

425F31/

63-34
0

425P819

WA500- 1

2) Pull out dust seal (20)

and bushing (21)

from tilt

lever (17).

3) Pull out dust seal (22) and bushing (23) from bucket
link (15).
*

After

using for

makes

it

a long time,

difficult

to

remove

it wear of the pin


a

15

and use it to

the

jig such as the one shown below,

pin,

make

23

remove the pin.

pump

425F319

426F384A

3-l6x2Depth30
Perforation depth 40
(circumference of equal parts)

-Y

i
\

-_--

\
Dimension of pin hole
(For adapter mounting bolt)

427F2053

WA500-

INSTALLATION

a
1.

OF WORK

Use a bar to align the pin holes.

EQUIPMENT

Never

use your

fingers.

Dust seal, bushing


Using a press, press fit bushing

(19) in bucket

link,

tilt

lever, and lift arm.


*

Assemble dust seal only

R??K

Bushing:

in bucket

lever.

Grease (G2-LI)

Hydraulic

arm

Lift

link and tilt

cylinder
425P819

419F471

419P1063

2.

Lift arm
1) Sling

lift

arm

and

set in mounting

assemble mounting

pins and lock with

holes of front

Align

mounting

and insert shims so that

position,

frame

clearance

then

bolt.
and lift

arm

on left and

right are equal.


*

Clearance

After

a:

less than 1.5 mm

installing

the pin,

set a support

under

the

tip of the lift arm.

425F320

2) Install boom kickout


*

For

details,

switch

(181.

see TESTING

AND

.-\DJUSTING

section.

63-36
ii

WA500-

3.

Tilt lever, bucket link


1) Assemble cord rings on bucket link (151, align hole of
tilt lever (17), assemble mounting pin (16). then lock
with bolt.
*

Secure bucket link to tilt lever with wire.

Be careful not to get cord ring caught.

Insert shims so that clearance b on left and right


is equal.

Clearance b:

16

less than 1.5 mm

425P816

425F321

425P815

2) Align holes of tilt lever (12) and lift arm (14), assemble mounting pin (13), then lock with bolt.
4.

Lift cylinder pin


While adjusting lever block @
mounting

position,

then

, set lift cylinder (10) in

assemble mounting

pin (11).

and lock with bolt.


*

Remove lever block 0.

:,425P?14

5.

Dump cylinder pin


Temporarily

sling dump

cylinder

(8), adjust operating

levers, align pin hole, assemble mounting

pin (9). then

lock with bolt.

WA500-

63-37
0

6.

Serial No. 10001-10123

Flange
1) Assemble dust seal (6), oil seal (6A) and O-ring (7) in

Do not make

flange (5).
*

Press dimension

clearance

Serial No. 11464 and up: seal (6) only.

Press fit seal uniformly

Check that there is no clearance between dust seal

on circumference.

Check that seal is not sticking out from the side of

and oil seal. (Serial No. 10001-11463)


the flange face.
6
*

Seal lip space, O-ring: Grease (G2-LI)


Dimension of press fit dust seal
(Serial No. 10001-11463):
(Serial No. 11464 and up)

O-O.5

mm

: 0.25-0.8

Serial No. 10124-I

Dimension of press fit oil seal


(Serial No. 10001-l

1463):

FO425C1131

mm
1463

8 mm
Press dimension

2) Assemble flange (5) to pin (2). and insert in lift -7:~.


t
&

Do not make
clearance

Insert pin slowly, until flange seal touches bushing.


Bushing: Grease (G2-LI)

F42501005

Serial No. 11464 and up

Serial No. 10001-l

Press dimension
0.25-0.8

1463

Seal contacts bushing

427F2069

425F402

Serial No. 11464 and up

Seal contacts bushing

..25F403

5
425P820

425P812

63-38
0

WA500-

3) Using pin as a guide, while rotating flange to left and


right by hand, insert lift arm.
*

After

inserting,

rotate

flange

1 to 2 times with

hand to settle in with seal.


+

Pull the flange out about 5 mm from the lift arm


and check that there is no abnormality

in the dust

seal.
*

Insert the flange until

the inside surface contacts

the end face of the bushing, then tilt the mounting


bolt hole part of the flange about 25 towards the
FO425C1132

rear of the lift arm.


*
*

Never strike flange with hammer.


Follow the same steps for the flange on the other
side.

7,

Bracket
1) Bring bucket

and lift arm together,

lever to align bucket mounting

operate

control

pin holes, then insert

pin.
When doing this, be careful not to let the bucket
hit the flange.
When installing the pin, check that the air bleed
hole on the pin is at the top.
Align the flange bolt holes and the mounting

bolt

holes of the bucket flange.

2) Select shim
(Serial No. 10001-l

1463)

Push flange evenly towards boss of lift arm and measure clearance cl. Assemble shims so that clearance is
within standard value.
*

Clearance c: Max. 0.2 mm

When
both

selecting
the top

the shim,
and bottom

the most suitable

measure clearance

for

split shims, assemble

shim for each, and be careful

that the flange is not at an angle.


425F323

WA500-

Flange mounting

bolt: 23 + 8 kgm

63if9

(Serial No. 11464 and up)


*

After

selecting

clearance

the number

at the

lift

of shims to make the

arm boss (*

mark)

less than

0.5 mm, remove two 0.5 mm shims and install flange


so that the clearance (* mark) is 1.5 mm.
*

When selecting the shim, measure clearance for both


the top and bottom

split shims, assemble the most

suitable shim for each, and be careful that the flange


is not at an angle.

425F404

3) Tighten

bolt

(24)

temporarily

so that

cam

(24A)

contacts mounting pin.


*

Tighten fully after installing retainer (3).

4) Install

retainer

(3),

and

measure

Assemble shims so that clearance

clearance

is within

d.

standard

425P824

425P825

value.
t

Clearance d: Max. 0.2 mm

After

installing the retainer,

fix the flange to the

bucket.

Clearance

425F324

5) Adding oil (Serial No. 10001-11463)


Remove bolts (27) and (28) of bucket pin and add oil
until
*

oil comes out from hole of air bleed bolt (27).

After

adding

fitted

to bolts (27) and (28). then install the bolts.

aL

oil,

Check

that

there

are O-rings

Pin oil: Gear oil (G0140)


Pin oil: Approx.

3ifo

50 cc

WA500-

6) Greasing (Serial No. 11464 and up)


Add

grease from

the

central

grease fitting

of the

bucket pin until grease comes out from the dust seal.
a,,

8.

Bucket pivot portion:

Grease (G2-LI)

Bucket link
1) Sling bucket link, align hole of mounting pin (I) and
assemble, then lock bolt.
*

Be careful not to get the cord ring caught.

2) When exchanging only cord ring:


i) Insert cord ring (25) in groove.
*

Stretch

cord

ring slightly

while

inserting

in

groove.
ii) Insert bolt (26) in cord ring and secure.
*

Tighten

the bolt

enough

so that

it does not

change shape of cord ring.


9.

Refilling with oil


Refill each pin with oil or grease.

WA500-1

63-40-l
0

REMOVAL

Stop the

OF COUNTERWEIGHT
machine

on level ground and install the

safety bar on the frame.

Lower the bucket to the

ground and stop the engine.

Then apply the parking

brake and put blocks under the wheels to prevent


the machine from moving.
1.

Radiator

grille

Lift off radiator grille (1).

2.

Counterweight
Sling counterweight

(2), remove mounting bolts, then lift

off counterweight.
*

When slinging the counterweight,

be careful to main-

tain the balance.


*

When removing the counterweight,

be careful not to

let it hit the lamps.


Counterweight:

880 kg
(Serial No.lOOOl--10452)

: 1465 kg
(Serial No. 10453 and up)

425P829

INSTALLATION
OF
COUNTERWEIGHT
1.

Counterweight
Raise counterweight

(21, set in mounting

position, then

tighten mounting bolts.


*

When installing the counterweight,

be careful not to

let it hit the lamps.


m

Mounting bolt:

160 Itr 20 kgm


(Width across flats:

2.

Set radiator grille (1) in mounting

position,

46 mm)

42513830

and tighten

mounting bolts.

WA500-1

63641

WORK EQUIPMENT SYSTEM


64 MAINTENANCE

STANDARD

Main control valve .................


Dump cylinder .....................
Lift cylinder .......................
Bucket linkage .....................
Bucket positioner and boom kick-out
Bucket ............................
Hydraulic and switch pump .........
POCpump ........................
POCvalve ........................

WA500-

0
E

..
..
.
..

.
.

.
.
.
.
.
.
.

64- 2
64- 4
64- 5
64- 6
64- 8
64- 9
64-10
64-l 1
64-12

64-1

MAIN

CONTROL

VALVE

Section A-A

Section

C-C

16

Section 0 -

section B-B

Section

E-

425F163

64-2

WA500-

Unit:

Remedy

Criteria

Check item

No.

Repair limit

Standard size

Spool return spring

Installation
load

Free
length

Installation
length

Installation
load

Free
length

83.8

82.0

7.7 kg

83.4

6.2 kg

Spool return spring

84.1

82.0

9.9 kg

83.7

7.9 kg

Spool return spring

63.0

60.5

23.5 kg

62.5

18.8 kg

Spool return spring

25.1

17.5

23.5 kg

23.6

18.8 kg

Main valve spring

52.3

38.0

2.8 kg

Check valve spring

78.2

52.0

1.92 kg

Suction valve spring of safety valve

27.9

18.1

0.69 kg

Suction valve spring

27.9

19.0

0.65 kg

Float selector valve spring

44.4

35.6

9.85 kg

10

Unloader valve spring

82.7

47.0

5.0 kg

11

Relief valve poppet spring

49.3

43.3

21.4 kg

12

Tightening torque of check valve bolt

13

Tightening torque of suction valve

14

Tightening torque of main relief valve

15

Tightening torque of float selector valve

16

Tightening torque of safety valve

19.0 i- 1 .O kgm

17

Tightening torque of nipple

2.25 t 0.25 kgm

18

Tightening torque of plug

15.5 + 2.5 kgm

WA500-

mm

Replace

9.0 i 1 .O kgm

19.0 + 1.0 kgm

32.75 * 4.75 kgm

7.0 2 1 .O kgm

Retighten

64-3

DUMP

CYLINDER

425F165

Unit:
No.

Check item

Criteria

Remedy

Tolerance

Clearance between
bushing

rod and

Standard
size

Standard
clearance

Clearance
limit

Shaft

Hole

120

-0.120
-0.207

a.277
+0.062

0.484 0.182

0.784

Clearance between piston rod


mounting pin and bushing

120

-0.036
-0.090

+0.307
+2.220

0.256 0.397

1 .o

Clearance between cylinder


bottom mounting pin and bushing

120

-0.036
-0.090

f0.307
f2.220

0.256 0.397

1 .o

Cylinder bore

225

+0.46
0

Tightening torque of cylinder


head mounting bolt

Tightening torque of piston


mounting bolt

Replace
buhsing

Replace

117.5 i 12.5 kgm

64-4

mnl

Retighten

16.0 ?:2.0 kgm

WA500- 1

LIFT CYLINDER

425F164

Unit:

No.

:1

Check item

Clearance between rod and bushing


I

Criteria

-_-__---_-_c----

110

-_.

~
~
1

to.274
+0.060

-0.036
-0.090

io ,307
+0.220

0.2560.397

0.481 0.180

Clearance
between
piston
pin
and inside
diameter
of rod
holemounting

120

Clearance between cylinder bottom


mounting pin and bushing

120

~
/

-0.036
-0.090

+0.307
+0.220

0.256 0.397

Cylinder bore

200

+0.45
0

Tightening torque of cylinder head


mounting bolt

Tightening torque of piston mounting


bolt

Remedy

-0.120
-C.207

WA500-

mm

0.81

Replace
bushing

1 .o
1 .o

Replace

47.5 f 14.5 kgm

. Retighten
18.0 t 2.0 kgm

64-5
0

BUCKET LINKAGE

425F169

(Oil type)

Serial No. 10001-11463

Serial No. 7 1464 and up (Grease type)

12
/

Section A-A

SectionA-A

9
/

Section B - B b

14

15
/

Section C - C

Section D - D

Section E - E

10

a
Section F - F

d
Section - - G

b
Section H - H

---L.-f
SectionJ-J
425F! 70-l

64-6
0

WANO- 1

Clearance between pin and bushing at


boss ends of bucket link

n and bushing at

between pin and bushing at

Clearance between pin and bushing at

Clearance between pin and bushing at


cylinder bottom and frame

Joint of lift armand bucke


on both sides
to make clearance on both
sides less than

16

Joint of lift cylinder and lift arm

125

122

3.0

17

Joint of lift cylinder and frame

123

120

3.0

WA500-

64-7

BUCKET

POSITIONER

AND

BOOM

KICK-OUT

r---1

425F172

Unit:
Criteria

Check item

No.

Clearance of bucket positioner switch

5-8

Clearance of boom kick-out switch

5-8

Remedy

Adjust

I
4

64-8

Tightening torque of mounting bolt for


adiuster
Tightening torque of mounting bolt for
switch

I
I

9.0 f 3.5 kgm


Retighten
1.8 ? 0.2 kgm

WA500- 1

mm

BUCKET

Section A - A

Section B-B

Section C - C

425FlJl

Unit:
No.

Check item

Criteria

Remedy

Standard size

Repair limit

61

23

Wear of bucket tooth

Thickness of shims for tooth


(Clearance between tooth and bucket)

Tightening torque of mounting bolt for


bucket tooth

180?20kgm

Tightening torque of mounting bolt for


corner tooth

180+

Max. 0.5

mm

Replace

Adjust

Retighten

WA500-

20 kgm

64-9

HYDRAULIC

AND

Hydraulic pump SAR(3)-100


Switch pump SAR(SI-100

SWlfCH

PUMP

>

Section A - A

425F134

Unit:

Check item

No.

Clearance between gear case and side


plate gear

Clearance between inside diameter of plain


bearing and outside diameter of gear shaft

Insertion depth of pin

Rotating torque of spline shaft

Tightening torque of bolt

Remedy

Criteria

I___

mm

Rep,ace

0
l4 -0.5

0.7 -

1.2 kgm

25.2 f 1.7 kgm

Retighten

Discharge

64-10

Oil:
EOlO-CD
Temperature:

45 - 55C

WA500-

POC PUMP
SAR(l)-014

425F162

Unit:

Remedy

Criteria

Check item

No.

mm

Clearance limit

Standard clearance
Clearance between gear case and side
plate gear

0.19

0.10-0.15

Replace
2

Clearance between inside diameter of plain


bearing and outside diameter of gear shaft

0.06 - 0.144

0.20

Insertion depth of pin

Rotating torque of spline shaft

0.2 - 0.5 kgm

Tightening torque of bolt

11.2 f 1.2 kgm

Retighten

Revolution
(rpm)

Discharge
6

Oil:
EOlO-CD
Temperature:

lo -:.5

Standard
discharge
(Q/min)

Repair limit
discharge
(Q/min)

210

47

43

45 - 55Oc
3,500

WA500- 1

Discharge
pressure
(kg/cm )

64-11

POC VALVE (Pilot operated control valve)

3
421F155

Unit:
No.

Remedy

Criteria

Check item

Repair limit

Standard size
Spool return spring

Free
length

Installation
length

Installation
load

57.3

33

8.0 kg

installation
load

Free
length

6.4 kg

Spool return spring

157.3

33

8.0 kg

Spool return spring

33.8

31

1.5 kg

1.2 kg

Spool return spring

33.8

31

1.5 kg

1.2 kg

Tightening torque of plug

0.75 * 0.15 kgm

Tightening torque of plug

0.75 + 0.15 kgm

Tightening torque of set screw

2.25 t 0.25 kgm

Tightening torque of lock nut

2.25 * 0.25 kgm

Tightening torque of plug

0.75 + 0.15 kgm

Main valve spring

11

Poppet spring

Free
length

Installation
length

47

26

33.6

30.5

6.4 kg

Replace if
damaged or
deformed.

Retighten

Repair limit

Standard size

10

Free
length

Installation
load

Installation
load

Replace
if damaged
or deformed.

2.1 kg

5.97kg

33

4.8 kg

Replace

Adjust

6422

mm

WA500- 1

ELECTRIC AND ELECTRONIC


SYSTEM
81 STRUCTURE

AND

FUNCTION

Electric and electronic

system

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

Electrical wiring diagram circuit

81-

81- 3

Electrical circuit diagram for

..................
.................
Engine stop circuit ....................
Preheating circuit .....................
* Preheating and after-heating with
heater switch ......................
* Preheating with starting switch ..........
- Automatic preheating ................
Combination switch ...................
............
Electrical transmission control
* Transmission cut-off switch ............
- Transmission cut-off selector switch .......
* Neutralizer relay ....................
Electrical parking brake control ............
intermittent

wiper.

Engine starting circuit

Electronic vehicle monitoring

WA500-1

81-

81-

81-

81-

81-10
81-11
81-12
81-13
81-14
81-15
81-16

system

..........................
* Monitor panel .....................
* Indication on monitor panel ............
- Controller ........................
. Wiring harness .....................
* Sensor ..........................
* Contact switch .....................
Operation of proximity switch ............
(EVMS)

81-6-1
.81-6-2

81-25
81-25
81-27
81-29
81-30
81-32
81-37
81-38

8&-

ELECTRICAL

Serial No. 11249

CIRCUIT

DIAGRAM

FOR INTERMITTENT

WIPER

and up

To air conditioner
unit

Relay

unit for intermittent

wiper

/^ ^_^CN4zL

Wiper

switch

connecting

II

7-d06

table

--

F42501010

WA500-1

*it-

ENGINE

Serial

STARTING

No. 10001

CIRCUIT

- 10388

Transmission
F-R lever

Starti
Starting motor

421F118A

Function

Operation

* To ensure safety when starting the engine, the system

* When the directional lever is placed at the N

is equipped with a neutral safety circuit.

position,

This marks it impossible for the engine to start if the

switch

are closed.

switch

is turned

directional

lever is not at the N (Neutral)

position.

In this condition,
to

the

flows in the following


@

Battery

starting motor
In

position,

current

circuit.

C + starting motor terminal

terminal

E -+ directional

C +

lever switch

N + ground.

addition,

terminal
battery

START

lever

if the starting

(+I --f starting switch terminal B +,start-

ing switch terminal


terminal

(Neutral)

the neutral contacts of the directional

current

BR -+ battery

flows

starting

switch

relay coil + ground,

from

so the

relay switch is closed. This forms the follow-

ing circuit.
@

Battery

terminal

(+)

If the directional
(Neutral),

battery

relay

-+ starting

circuit

lever is at any position other than N


@

is not formed,

and the engine

does not start.

*it2

motor

B, and the engine starts.

WA500-1

Serial No. 10389 and up


End
.--

Start

Engine stop motor


k
(hatched area)
Transmission
F-R lever

Battery relay

Battery
421 FO1047

Function

When

* To ensure safety when starting the engine, the system

the same time.

is equipped with a neutral safety circuit.

the motor

terminal

reaches

This marks it impossible for the engine to start it the

terminal

directional

from the battery

lever is not at the N (Neutral)

position.

rotates,

terminal

D also rotates at

When the non-conductive


terminal

A to B is opened,

B,

the

portion

circuit

of

from

and the flow of current

to the motor is shut off. The motor

tries to continue to rotate under inertia, but when the


Operation

conductive

* When the directional lever is placed at the N (Neutral)

both poles of the motor are discharged to the ground.

position, the neutral contacts of the directional


switch

are closed.

switch

is turned

In this condition,
to

flows in the following


@

Battery

ing switch terminal

(2) current

position,

current

circuit.

C + starting motor terminal

terminal

BR

current
+

E + directional

C +

lever switch

flows

through

from

starting

switch

relay terminals

so the relay coil is excited


relay terminals

(3) and

and
(5).

- The current from the battery flows from engine stop


motor terminals
motor,

A -

B,

the motor stops rotating.

Under this condition,


fully,

D contacts terminal

the stop motor

and the fuel injection


position,

cable extends

pump stop lever is set to

so the circuit is set to operating

condition.
In

addition,

terminal

current

BR +

battery

flows

starting

switch

relay coil + ground,

from

so the

battery relay switch is closed.


flows

engine stop motor

(1) + ground,

Therefore,

the FULL
6 + start-

N -+ ground.

* In addition,
terminal

START

(+) + starting switch terminal

starting motor
terminal

the

lever

if the starting

portion of terminal

B + relay terminals

(5) - (3)+

This forms the following


Battery

+ battery

circuit.

relay + starting motor terminal

B,

and the engine starts.


If the directional
N (Neutral),

circuit

lever is at any position other than


@

is not formed,

and the engine

does not start.

and rotates the motor (the cable is extended).

WA500-1

*z3

ENGINE

STOP CIRCUIT

Serail No. 10001 - 10388

Fuel cut solenoid

To starting motor

424FO72

Operation
.
W

When the starting switch


rent flows in following
(1)

Battery

is turned

ON, electric cur-

(+) + starting switch terminal

ing switch terminal

B + start-

BR + fuel cut solenoid + ground

voltage

flows to the fuel cut solenoid,

but the engine is rotating,


at terminal

reason, the following


(2)

connection,
When electric current

When the starting switch is turned OFF, circuit (1) is


shut off,

circuit.

Alternator

BR aground

the fuel governor is put in the FREE position by the

The battery

fuel control linkage.

diode

Fuel flows to the fuel injection

pump and the engine

so there

R of the alternator.

is still

For this

circuit is formed.

terminal

R + battery

relay terminal

connection.
relay is maintained,

inserted

into the circuit,

but because of the


no electric

current

flows to the fuel cut solenoid, so the engine stops.

starts.

WA500- 1

81-7
8

Serial No. 10389 and up

Start

Engine stop motor

@a-

Non-conductive
parts (hatched area)

Alternator

Starting motor

421 FO1048

. When the motor rotates, terminal

Function

* Ease of operation is improved by the use of an elec-

the same time.

trically

operated fuel cut system (engine stop motor).

terminal

which

enables the engine to be started and stopped

terminal

by turning

reaches

continues

positions.

ductive

terminal

A to C is opened,

from the battery

the starting switch to the ON and OFF

D also rotates at

When the nonconductive


C,

the

portion
circuit

and the flow of current

to the motor is shut off. The motor

to retate under inertia, but when the con-

portion

of terminal

D contacts

terminal

C,

both poles of the motor are discharged to the ground.

Operation

* When the starting switch


switch terminals

is turned

OFF,

B, BR and C are opened.

the starting switch, so the coil is deactivated,


circuit between terminals

Therefore,

starting

- The coil for the engine stop motor relay is shut off by
and the

the motor stops rotating.

Under this condition,


ed fully,

the stop motor cable is retract-

and the fuel injection

pump stop lever is set

to the STOP position, so the engine stops.

(3) and (6) closes.

- The current from the battery flows from engine stop


motor terminals
motor,

of

from

A -

C + relay terminals

(6) -

(3) +

and rotates the motor (the cable is retracted).

81-7-1
0

wA500-1

WITH

PREHEATING

STARTING

SWITCH

Preheat switch

timer

I1
I

.I
Electrical air intake heater

To electronic vehicle
monitoring system
(for pilot display)

424FO74

Operation

* If the starting switch is turned one stage to the left


from

the

electric

OFF

position

current

to the HEAT

from terminal

flows in the following

circuit.

(1)

terminal

Starting

switch

BR +

battery

the

B flows to terminals

The electric current from terminal

BR and R,.

terminal

position,

BR

The

electric current

BR

battery

relay

relay coil + ground connec-

from

Starting switch terminal


-t heater

relay

RI + heater relay signal

coil + ground connection,

and the heater relay is CLOSED.


Because of circuits

(1) and (2), the electric

from battery flows through the following

terminal

(3)

Battery

electrical

(+) +

battery

relay +

current

circuit.

heater

relay +

air intake heater + ground connection,

and

the engine is preheated.

tion, and the battery relay is closed.


following

(2)

terminal

RI

flows in the

circuit.

WA500- 1

81-9

AUTOMATIC

PREHEATING

Preheating

Preheat switch

c vehicle
monitoring system
(for pilot display)

Running

vehicle
stem
W

424FO75
In cold areas, when the starting switch is turned to

(4)

ON, the bimetal

electrical

timer

is at low temperature,

so the

As a result, electric

current

flows in the following

(+) -f starting switch terminal

ing switch terminal

B + start-

BR --f bimetal timer terminal

Bimetal

timer

terminal

ground

connec-

heater

relay +
and

(2) sends electric current

the resistor inside the bimetal timer,

resistor heats up and the bimetal

so the

between

bimetal

, timer terminal 2 and terminal 1 is heated.


bient

temperature)

the

bimetal

bends (opens)

and

circuit (3) is shut off.

tion.
(3)

relay +

As a result, after a time (the time depends on the am-

+ (2) and (3).


(2)

When this happens, circuit


through

circuit.
Battery

(+) -+ battery

air intake heater + ground connection,

the engine is preheated.

contacts are closed.

(1)

Battery

Bimetal timer terminal

nal 3

1 + glow switch termi-

+ glow switch terminal

signal terminal

2 + heater relay

+ heater relay coil + ground connec-

of electric

stops.

electric

relay.

current

in circuit

(3) closes the heater

As a result, electric current flows in the follow-

ing circuit.

current

to the heater relay coil

Even after the preheating stops, electric cur-

rent continues

tion.
The

The flow

stops, so the heater relay is opened and preheating

of the

heated.
straight

to flow

bimetal

Therefore
until

between

timer,
the

terminals

so the bimetal

bimetal

the starting switch

does not
is turned

become
OFF,

after the engine is started, there is no preheating.

81-10

and

is kept

wA500-1

so

COMBINATION
.. .

SWITCH

677

423F188

Outline
-

The FORWARD-REVERSE
the speed control

lever has three contacts;

lever switch has four contacts.

switch alone has no detent


mechanism

mechanism.

is in the combination

The detent

switch itself.

switch is held at two places by pins.

The

In addiiton,

switch is secured to the base by three screws.


When the lever is moved to the desired position, the
switch,

which

is connected

by a shaft,

moves and

Each

electric current flows in only that circuit to move the

each

machine.

Function
\
1

FORWARD-REVERSE

Speed control lever switch

Selecting machine speed range

Speed control lever stopper

Prevents speed control lever from going into 3rd or 4th speed
during operations

1 Direction indicator lamp

Selecting FORWARD,

lever switch

Self cancel

I
I

indicates direction

REVERSE

or NEUTRAL

when turning left or right

Returns direction indicator


after turning left or richt

lamp lever to neutral automatically

Lamp switch

Selects clearance lamps, headlamps, parking lamps

Dimmer switch

Selects travel beam, low beam

Emergency flasher switch

Makes left and right winkers flash at the same time

Emergency flasher pilot lamp

Lights up when emergency flasher lamp is ON.

WASOO-1

81-11

ELECTRICAL

TRANSMISSION

CONTROL

Transmission cut-off
sele

Combination switch

FORWARD-REVERSE

Floor wiring harness

lev

Speed control le

Circuit breaker

Transmission cut-off switch

Transmission wiring harness

IW

423F189

Function

Selection of FORWARD,

REVERSE

and NEUTRAL

/ Selection of travel speed range

Transmission cut-off function

FORWARD-REVERSE

lever

Speed control lever


Transmission returned to neutral when left brake pedal is
operated.
c

Transmission cut-off selection function

Selects if transmission cut-off function is used or not used.


With this function, the left brake pedal can be used to get even
better performance than conventional loaders in digging operations or ease of steering when loading on to trailers.

Neutralizer

To prevent the operator from driving off when the parking brake
is still applied and causing seizure of the parking brake, the transmission is returned to neutral when the parking brake is applied.

Neutral safety function

function

The engine can only be started if the FORWARD-REVERSE


lever is in neutral. In any other position the engine will not
start. This prevents the machine from starting suddenly.
(For details, see STARTING

Warning function

CIRCUIT)

When the machine is driven in reverse, a back-up lamp lights up


and a back-up horn sounds to warn people standing near the
machine.

81-12

WASOO-1

TRANSMISSION
-

CUT-OFF

SWITCH

When the left pedal is operated,

the switch detects

the air pressure in a brake circuit.


power

supply

of the solenoid

FORWARD-REVERSE

It shuts off the

valve circuit

for the

clutch, and returns the trans-

mission to neutral.

From rear air tank

Two-way check valve


Stop-lamp switch
From rear brake tank
Two-way check valve
To rear brake
Transmission

From front brake tank


-

To front brake

From front air tank

Diaphragm
\

To transmission

power supply

0
00

To transmission
directional circuit

IDFF
Restored
Low voltage -

Actuated
High voltage
421F123

WA500- 1

81-13

TRANSMISSION

CUT-OFF

SELECTOR

SWITCH

Outline
*

Operation

The transmission cut-off


waterproof

toggle switch.

the transmission
side

of

selector switch is a L-circuit

the

cut-off

It is installed in series with


switch at the power supply

transmission

When

the

turned

to OFF

transmission

selector

switch

is

(switch points in contact),

cut-off

(+)24V

is

applied through this switch to the circuit of the sole-

FORWARD-REVERSE

noid valve for the directional

circuit.

pedal then

clutch.

operates as a normal

The left brake

brake in the same

way as the right brake pedal.


.

When the transmission cut-off switch is turned to ON


(switch points not in contact),

if the left brake pedal

is depressed, it will act as a normal brake, and at the


same time the transmission will be placed in neutral.

r----I

--__-

~.v-

Neutralizer relay
(battery power source)

Transmission
cut-off selector
switch (manual)

Transmission
cut-off selector
switch (manual)

~,----t

-.-

i:
2-i
4 k&

Neutralizer relay
(battery power source)

;wy;gission

_-.

cut-off

(actuated by air pressure)

TrlY;;nission cut-off
(actuated by air,pressure)

If

To Buck-up
lamp relay

Machine monitor
system neutral
terminal

To Buck-up
lamp relay

Machine monitor
system neutral
terminal

421 F124

81-14

WASOO-1

NEUTRALIZER
*

RELAY

When the parking

brake

is being used, no electric

current flows to the relay coil.


connected to output terminal

The input terminal

is

6.

WARD-REVERSE

circuit

of the transmission which

is connected to output terminal

5.

When the park-

ing brake is being used, the transmission

For this reason, no electric current flows to the FOR

Parking brake
switch (manual)

neutral.

is kept

in

Machine will not start.

Parking brake Parking brake


relay
safety relay

Neutralizer relay.

OFF

Battery relay

Battery

Startingswitch
~_
-.__
_-

switch (manual)
ion cut-off switch

Starting motor
(terminal E)

Machine monitor system


natural terminal

Back-up lamp
power source
Back-up lamp
relay

421 F125

WA500- 1

81-15

ELECTRICAL

PARKING

_-

BRAKE CONTROL

Outline

- When electric current flows to the parking brake valve


(solenoid
tank)

valve), air pressure from the air tank

(wet

is applied to the spring cylinder and the parking

brake is released.

When the electric current

is stopped, the air pressure

from the air tank is cut off.


the spring cylinder

The air pressure inside

passes through the parking brake

valve and is released.

The parking brake is then actu-

ated by the force of the spring.

425F510

1. Neutralizer

relay

2.

Parking brake valve

3.

Parking brake switch

4.

Parking safetv relay

5.

Parking brake relay

6.

Air tank (wet)

7.

Emergency brake switch

8.

Spring cvlinder

WA500- 1

Function

Actuation
2

and release of parking brake

Automatic

Parking brake switch used.


Parking brake is automatically
applied when engine is stopped
(starting switch is turned to OFF).
This prevents the machine

parking brake

from running away when the operator


3

leaves his seat.

The parking brake is automatically applied when it is impossible


to maintain braking power because of a drop in the air pressure
inside the tank caused by damage to the air circuit. In this way,

Emergency brake

the parking brake acts as an emergency brake.


4

After the automatic parking brake is actuated, it is dangerous if


the parking brake can be released simply by turning the starting

Parking brake safety

switch to ON.
Therefore, after the starting switch has been turned ON, the parking brake switch must be operated to release the brake.
This
ensures safety.

If the machine is driven with the parking brake still applied, the
parking brake will seize up.
Therefore, the caution lamp lights up and the caution buzzer
sounds to warn the operator of this mistake in operation. At the
same time, when the parking brake is applied, the transmission is
moved to neutral, so it is impossible for the machine to move.
However, when the parking brake is used as an emergency brake,
if the transmission is returned to neutral, the braking distance will

Neutralizer

increase and the machine may stop in a dangerous place (for


example, on a railroad crossing).
For this reason, the circuit is
designed so that the transmission is not returned to neutral when
the emergency brake is applied.

Parking brake switch


Large size multi-pin connector
? pole blue) with lock

Connection table

1
ON (actuated)

3
YSY
Water proof O-ring
for panel face

2
View Z

423F195

WA500-

81-17

PARKING

BRAKE

VALVE

Valve actuation table

chamber

Exhaust

port No.1

Port No.3

423F196

PARKING
BRAKE RELAY
PARKING SAFETY RELAY
NEUTRALIZER
RELAY

Relayconnectionchart

Relay actuation table

Terminal No.1
Terminal No.5

Terminal No.2

ierminal

Black/

No.6
423F197

EMERGENCY

BRAKE

SWITCH

Diaphragm

Contact
~

423F198

*2*

WA500- 1

._
1. STARTING
SWITCH OFF
* When the starting switch is turned OFF, the battery

relay is opened, so no electricity

the parking brake circuit.


starting

switch

flows to

For this reason, if the

is OFF, no electricity

flows to the

parking

brake

valve regardless of whether

parking

brake

switch is ON

(released).
tuated.

(actuated)

the

or OFF

As a result, the parking brake is ac-

(Automatic

parking brake)

Parking brake
switch (manual)

r$ing

--

OFF

Parking brake
safety relay
---

brake

___-

ON

Neutralizer

relay

Battery

---&-c__-+

Battery

relay

----

--__2+

Starting switch
24-l

To transmission
*.
.
spew cwcun

Emergency
cwitrh

brake

..,._.,

(with wet tank)

421F126

WA500- 1

81-19

2.

STARTiNG

2-1. When

SWITCH

parking

brake

ON

switch

is turned

ON

relay terminal

before

3 + parking safety relay termi-

starting switch is turned ON.

nal 5

+ parking safety

- Elecrric current flows as follows.

parking

safety

(1)

Battery

The

so the battery relay is

circuit

of the parking

CLOSED.

closed because of circuit

Electric current also flows as follows.

switch is turned OFF.

(2)

Battery

(+) + battery

switch terminal

In this condition,

relay -+ parking brake

parking

3 --f parking brake switch ter-

minal 2 + parking safety relay terminal


parking safety relay terminal

brake

until the starting

no electric current flows to the


valve, so the

Also, in this condition,

1 + ground con-

actuated

and circuit

following

circuit is formed.

Battery

parking safety

is closed.

I+) + battery

so no electric current

relay is

Therefore,

2 +
ground

safety relay remains


3

parking

brake

REVERSE

the

circuit

relay is open,

flows to the FORWARD-

of the transmission,

and the

transmission is kept in neutral.


relay + parking safety

Parking brake
relay

Parking brake
switch (manual)
---1

Parking brake
safety relay
---1

Neutralizer relay
----

Battery relay
----

Battery
----

Alternator
terminal R

To transmission
clrcun

is

the circuit between termi-

nal 3 and 5 of the neutralizer

When this happens, the

actuated.

2 +

nection.

(3)

relay terminal

terminal

connection.

(+) + starting switch + battery relay

coil + ground connection,

relay

Emergency brake
switch
(with wet tank)
421F127

WA500- 1

-.
2-2. Parking brake switch turned

OFF

(released) before

actuated.
the

starting switch is turned ON.


Electric current flows as follows.

automatic

(I)

starting

Battery

(+) + starting switch + battery relay

coil -* ground connection,

so the battery relay is

OFF

in this case, the parking brake switch is

(released), so the parking safety relay is not

Parking brake
switch (manual)

brake valve.

parking
switch

is turned

no electric

FORWARD-REVERSE

Therefore,

flows to
after

the

brake is actuated, even if the

brake is not automatically


In addition,

CLOSED.
However,

For this reason, no electricity

parking

to

ON,

the

parking

released.
current
circuit

flows

to

the

of the transmis-

sion, so the machine does not move.

Parking brake
relay

Parking brake
safety relay

Neutralizer

relay

Starting switch

To transmission
FORWARD-REVERSE
circuit
To transmission
speed circuit

;c
U
Emergency brake
switch
(with wet tank)
421F128

WA500- 1

81-21

2-3. Parking brake OFF

(released), after starting switch

is turned ON.
*

ing circuit if formed.

If the parking
leased), circuits

brake switch

is turned

OFF

1 and 2 of the parking

switch are connected.

(re-

brake

When this happens, elec-

tric current flows as follows.


(1)

Battery

(+) + battery

Emergency

brake

switch

parking

brake

relay coil + ground connection.


(3)

Neutralizer

(4)

Battery

relay terminal

relay + parking brake

3 + parking brake relay terminal

parking

relay are

circuit is formed.

(5)

(+I

Battery

relay terminal

battery

relay -+ neutralizer

3 + neutralizer

relay terminal

When
WARD

the transmission
or REVERSE,

switch

5+

circuit.
is put to

FOR-

the machine will move.

actuated, and the circuit between terminals 3 and

Parking brake
switch (manual)

a-

Parking brake
relay

Parking brake
safety relay

Neutralizer relay

----

Battery relay

Starting switch

To transmission

speed circuit

Emergency brake
switch
(with wet tank)

421 F129

81-22

brake is released, and at the same

the following

transmission FORWARD-REVERSE

relay coil -+ ground connection.

The parking brake relay and neutralizer

(+) + battery

+ parking brake valve + ground connection.


The

relay + parking safety

relay + parking brake switch -+ (2) and (3).


(2)

5 of each relay is closed. As a result, the follow-

WA!NO-1

24.

Parking brake switch ON (operated)

* After operating with the parking brake switch at


OFF

(released),

if the

turned to ON (operated),
No electric

current

At

the same time,

the neutralizer

restored,

so the circuit

the circuit becomes as

and 5

is OPEN.

brake switch

between

flows to the parking

brake

circuit

mission, so the transmission

valve, so the air pressure from the air tank acting

In this way, when the parking

the neutralizer

time,

At the same

the air pressure inside the spring cylinder

of the trans-

is placed in neutral.

on the spring cylinder

is shut off.

relay is also
terminals

No electric current flows to

the FORWARD-REVERSE

shown below.
*

is

parking

brake is operated,

relay shuts off the electric current

to the transmission

solenoid valve and puts the

passes through the parking brake valve and is re-

transmission

leased, so the parking

no seizing of the parking brake caused by the ma-

brake is actuated

by the

force of the spring.

chine

in neutral.

being driven

As a result, there will be

with the parking

brake still

applied.

Parking brake
switch (manual)
--

Parking brake
relay
---

Parking brake
safety relay

Neutralizer
relay
-__
-

Starting switch

To transmission
circuit

Speed

Emergency brake
switch
(with wet tank)

421 F130

WAXKb 1

81-23

2-5. When air pressure drops (emergency brake actuated)


Operation

* If the air pressure drops, the emergency brake

For this

reason,

electric

FORWARD-REVERSE

switch installed to the wet tank is opened.

current

circuit

flows to the

of the transmis-

For this reason, no electric current flows to the

sion, and it is possible to connect the transmis-

coil

sion clutch.

of the

parking

brake

brake relay is restored,


terminals

3 and 5

tric current

relay.

The

parking

becomes OPEN.

is re-

leased and the parking brake is actuated.

How-

ever, this case is different


brake

switch

is turned

the same time,


ated,

the emergency

if the emergency

brake is actu-

and it is necessary to move the machine

(for example,

if the emergency

brake was actu-

ated on a railroad crossing), the machine can be

from when the parking


ON (operated).

when

the engine also acts as a brake.

This makes the braking distance shorter, and at

No elec-

flows to the parking brake valve, so

the air pressure inside the spring cylinder

Therefore,

brake is actuated,

and the circuit between

driven by operating the transmission lever.

In this

case, there is electric current flowing to the coil


of the neutralizer

relay.

Parking brake
switch (manual)

r__pi
To transmission
speed circuit

Parking brake
relay

Parking brake
safety relay
----

Neutralizer relay
---

To transmission
FORWARD-REVERSE
circuit
Emergency brake
switch
(with wet tank)

421 F131

81-24

WAMO- 1

ELECTRONIC

VEHICLE

MONITORING

SYSTEM

(EVMS)

1
Serial No. 10001

- 10662
MONITOR

Outline

PANEL

. The electronic vehicle monitoring system is a system


to inform
chine.

the operator

of the condition

The

of the ma-

of the machine,
machine

which observe the condition

and process the information

display the situation on the monitor

TION

of the

speedily,

module

and

panel, sensors, controller,

items (1) and CAUTION


play warnings
chine;

(including

Each module

into

module

gauge module

(5),

service meter),

(21, CAU-

speedometer

the case, and vari-

(excluding

the service meter)

has its

which processes the signals from

The panel uses a liquid crystal display.

CHECK

CHECK

items (2) and (3), which dis-

and gauges (5). speedometer

(3).

components.

CAUTION

the sensor and gives a display.

divided

if any abnormality

module

(l),

own microcomputer

warning buzz-

er, warning lamp and power source.

. The displays can be broadly

consists of the following

module

ous other components.

panel.

. The electronic vehicle monitoring system consists of


the monitor

monitor

CHECK

It consists of sensors installed in various parts

and CAUTION

The microcomputer

(7). and service

meter (9), which always display the condition

(I),

(2) and (3) modules all

use common parts.

arises in the ma-

judges which module

it is from

the wiring harness to which it is connected.

of the

machine.

Warning lamp

Warning buzzer

Do0
a:
c

,.:::.
::.:
::.
.A..
...I
:..::

Battery
-

24V

Buzzer signal

421F116A

WA500- 1

8(i25

SB

1A

5A

2A

28

1B

30
3E

48

View 2

423F170-1 K

1.

Check

38.

Engine oil pressure

1 A.

Brake oil level

3c.

Coolant level

5A.

Air pressure

1 B.

Engine oil level

3D.

Air pressure

58.

Coolant temperature

Coolant level

3E.

Coolant temperature

5C.

Torque converteroil

Caution (Warning)

3F.

Torque converter oil


temperature

5D.

Fuel level

1 C.
2.

2A.

Battery charge

28.

Fuel level

4.

3.

2C.

Transmission oil filter

2D.

Emergency steering

Pilot indicator
4A.

Transmission cut-off

48.

Parking brake

4C.

Work lamp

4C.

Preheat monitor

Caution (Emergency warning)


3A.

Brake line failure

8626

5.

Gauge

6.

Turn signal pilot lamps

7.

Speedometer

8.

Head lamp (High beam)

temperature

9
_. Service meter
10.

Service meter indicator

11.

Night lighting lamp

WASOO-1

Serial No. 10663 and up


Outline

. The electronic vehicle monitoring system is a system


to

inform

machine.

the

operator

of

the

condition

It consists of sensors installed

of the

in various

parts of the machine, which observe the condition


the machine

and process the

and

the

display

The electronic
the monitor

situation

information

on the

vehicle monitoring

of

speedily,

monitor

panel.

system consists of

panel, sensors, warning buzzer, warning

lamp and power source.


The

displays

items

(1)

display
machine,

can be broadly

and CAUTION

warnings

if

any

divided

items

into

CHECK

(2) and (3), which

abnormality

arises in the

and gauges (51, speedometer

(7). and service

meter (91, which always display the condition

of the

machine.

Warning lamp

Warning buzzer

Battery

Sensor

425FO1198

WA!NO- 1

*-2-l

1A
18

5i

io

210

ic

425FOll99
View Z
4.

1. Check
1A.

Brake oil level

4A.

Transmission cut-off

1 B.

Engine oil level

48.

Parking brake

IC.

Coolant level

4C.

Work lamp

40.

Preheat monitor

2. Caution (Warning)

3.

Pilot indicator

5.

Gauge

2A.

Battery charge

2B.

Fuel level

5A.

Air pressure

2C.

Transmission oil filter

5B.

Coolant temperature

2D.

Emergency steering

5C.

Torque converter oil temperature

Caution (Emergency warning)

5D.

Fuel level

3A.

Brake line failure

6.

Turn signal pilot lamps

38.

Engine oil pressure

7.

Speedometer

3c.

Coolant level

6.

Head lamp (High beam)

3D.

Air pressure

Service meter

3E.

Coolant temperature

3F.

Torque converter oil temperature

*-e2

IO. Service meter indicator

WA500-

_,
ON MONITOR

INDICATION
Catf
!JOP

Symbol

PANEL

Indication

item

I Indication range

Brake oil level

Description

Below low mark


Displayed when starting switch is turned

Engine oil level

Below low mark


I

IIaJ

Display goes out when normal.


Display flashes when abnormal.

Coolant level

Below low mark

Battery charge

When charging is
defective.

Fuel level

to ON with engine stopped.

Below low mark

Displays when engine is running.


Display goes out when normal.
Display flashes when abnormal and lamps
flash at same time.

.
(0?

Brake line failure

When stroke is
over.

Engine oil pressure

Below specified
pressure

Displays when engine is running.

Coolant level

Below low mark


I

I=

Dispaly goes out when normal.


Display flashes when abnormal;

buzzer

and lamp actuated.


Below specified
pressure

4ir pressure

-I
Zoolant temperature

Above lb2C

I
Torque converter oil
:emperature

Above 102C

arking brake

When operated

work lamp

When operated

Displays when starting switch is turned ON.


Lights up when operated

rransmission cut-off

When operated

REHEAT

When preheating

WA500-

Displays when starting switch is turned ON;


lights up during preheating.

81-27

Category

Indication

Symbol

---

item

Indication

Description

range

l-ravel speed

I-

iigh beam

Nhen operated

Digital display

100 km/h

Displays when starting switch is turned ON;


lights up when operated.

QD

Winkers (right, left)

Nhen operated

aD

iazard

Nhen operated

0
0

jervice meter

I-

Lights up when operated.

Actuated

99999/h

when engine oil pressure is normal.

Advances 1 for every hour of operation.

Iisplayed

jervice meter indicator

Flashes when service meter is operating.

Air pressure

One lamp lights up to indicate level.

Coolant temperature

One lamp lights up to indicate level.

H
Red

13oT

El
12OC
110-C

Torque converter oil


temperature

GWIJ

WC

One lamp lights up to indicate level

70L
5oC

FULL

I&

*if*

Fuel level

All lamps light up below indicated level.

WA500- 1

CONTROLLER
Serial No.10081

-10662

Function

* The auxiliary controller acts as the power source box


and provides electric power to the panel.
The

power

source (battery,

chine has a large difference


controller

alternator)

for the ma-

in voltage, so the auxiliary

converts this to a stable voltage and sup-

plies it to the panel.


Even if excessive voltage is generated by failure in the
alternator

or regulator,

it is cut by the auxiliary

con-

troller.

Controller

Lamp
Buzzer

Battery

_-_--_

Battery relay
terminal E

WA500- 1

423F172A

WIRING

HARNESS

Serial No. 10001 - 10662

W-P8

(16P)

CWPB
(16P)

CN-PO
(SP)

CN.PZ
(1E.P)

CN.P4

(16P)

423F182A

Operation

of monitor panel

If the monitor
the monitor

panel is working

normally,

the lamps on

panel will work as follows.

1) When the starting switch is turned to ON.


a) All monitor lamps will light up for 3 seconds.
b) The warning buzzer will sound for 1 seconds.
2) CHECK

MONITOR

a) All monitor

if there is any abnormality


(About

in any check item, that

0.8 seconds ON, then 0.8

seconds OFF repeated.)


b) If the outside air temperature
-lOC),

CHECK

engine
running

the flashing interval will change slightly,

lamps will

go out

(Judge whether

when the

the engine is

by the rise in the engine oil pressure, or


is a voltage of over

1OV from

MONITOR

a) All monitors

GROUPS

are working from the time the engine

starts to the time the engine stops and the starting


switch is turned to OFF.
is any abnormality

in the machine,

the

lamp for that item will start to flash (0.8 seconds


ON, 0.8 seconds OFF).

but this is not an abnormality.

81630

the

alternator.)

If there
is low (below about

item

is started.

see if there
3) CAUTION

GROUP

lamps will light up for 3 seconds, then

item will flash.

c) The

WASOO- 1

Serial No. 10663

and up

CNPl
(16P)
CNP4
(12P)

CNP3
(16P)

To sensor

U41901066

Operation

of monitor

If the monitor
the monitor

panel

panel is working

normally,

the lamps on

panel will work as follows.

1) When the starting switch is turned to ON.


a) All monitor

lamps will light up for 3 seconds.

b) The warning buzzer will sound for 1 seconds.


2) CHECK

MONITOR

a) All monitor

GROUP

if there is any abnormality

in any check item, that

0.8 seconds ON, then 0.8

seconds OFF repeated.)


b) If the outside air temperature
-

IOC),

engine
running

the flashing interval will change slightly,

lamps will

go out when

(Judge whether

the engine

the
is

by the rise in the engine oil pressure, or


is a voltage of over 10 V from

the

alternator.)
MONITOR

a) All monitors

GROUPS

are working from the time the engine

starts to the time the engine stops and the starting


switch is turned to OFF.
If there

is low (below about

item

is started.

see if there
3) CAUTION

lamps will light up for 3 seconds, then

item will flash. (About

cl The CHECK

is any abnormality

in the machine,

the

lamp for that item will start to flash (0.8 seconds


ON, 0.8 seconds OFF).

but this is not an abnormality.

WASOO- 1

*(i3

SENSORS
FUNCTION
*

There are three types of sensor: contact type, resistor

If the contact

type, and solenoid type.

rectly

* With contact type sensors, one end of the wiring is

is closed, the monitor

If the contact

the signal from the sensor directly

the monitor

or

sends it through a relay.

of the sensor that sends the signal to

through

a relay is opened, the monitor

judges the signal tob normal.

(The signal is reversed

by the relay.)
Sensor actuation table

1 Sensor type

1 When normal

Enaine oil level

Contact

ON

Brake oil level (Serial No. 10001-10565)

Contact

ON

Check item

1 When abnormal

I
I

OFF
OFF

Brake oil level (Serial No. 10566 and up)

Contact

OFF

ON

Coolant level

Contact

ON

OFF

Fuel level

Resistor

Engine oil pressure (Serial No. 10001-10243)

Contact

ON

OFF

Engine oil pressure (Serial No. 10244 and up)

Coolant temoerature
Toroue converter oil temperature

Contact
Resistor

Resistor

I
I

OFF

I
I

ON

Travel speed

Solenoid

Brake line failure

Contact

ON

OFF

Transmission oil filter cloaaina

judges

the signal to be normal.

grounded at the chassis end, and the other end sends


to the monitor

of the sensor that sends the signal di-

to the monitor

Contact

ON

OFF

WA500-1

.._
COOLANT

TEMPERATURE,

TORQUE

CONVERTER

OIL

TEMPERATURE

SENSOR
1.

Connector

2.

Wire

3.

Tube

4.

Plug

5.

Thermistor

0P

(beat type)

---tY
Circuit structure

423FlJ6

Function

These

sensors are installed

block and transmission

case.

on the engine cylinder


They use a thermistor

to detect the temperature,

and when the temperature

goes above the specified

temperature,

monitor

ENGINE

the machine

lamp lights up to indicate the abnormality.

OIL

PRESSURE,

PARKING

BRAKE

SENSOR

:
0@

1.

Connector

2.

Wire

3.

Switch

4.

Diaphragm

5.

Plug

Oil

Circuit StruCtWe
423F177

Function
-

These are installed on the engine block and parking


brake solenoid

valve.

The diaphragm detects the oil

and air pressure, and when the pressure goes over the
specified

pressure, the machine

monitor

lamp lights

up to indicate the abnormality.

WA500- 1

81-33

ROTATIONAL

SPEED

SENSOR

Function

The

rotational

mission
the

output

rotation

the

speed

sensor

gear.

A pulse

of the

machine

is installed
voltage

gear teeth,

monitor,

and

is generated

a signal is then
this

Section A-A

on the trans-

displays

by

sent to

the

travel

speed.

1. Connector
2.

Magnet

3.

Case

t
Circuit structure

423F178

FUEL

GAUGE

SENSOR

Function

The

fuel

The

float

level.

gauge

The

is installed

moves

movement

of the

gear to actuate

a variable

to the machine

monitor

When

the display

certain
ules

level,
inside

on top

up and down

the

float

resistor.

the

is sent through

the fuel
monitor

machine

monitor,

tank.

This sends a signal

machine

is generated

fuel

to the fuel

to display

on the

a signal

of

according

level.
drops to a

between
and

the

the

mod-

warning

lamp lights up.

1.

Connector

2.

Variable resistor

3.

Float

4.

Gear

5.

Contact

.!Y

Emtw

Circuit structure
423F179

81-34

WA500- 1

4) FUEL GAUGE SENSOR


FUNCTION

* The fuel gauge is installed on top of the fuel tank.


The float

moves up and down according to the fuel

level. The movement

of the float

is sent through

arm to actuate a variable resistor. This sends a signal


to the machine monitor to display the fuel level.
When the display on the machine monitor drops to a
certain level, a signal is generated between the
modules inside the machine monitor,

and the warning

lamp lights up.

1. Connector
2.

Variable resistor

3.

Arm

4.

Float

Emptv
423F179C

5) ENGINE

01 L PRESSURE SENSOR

Serial No. 10001-10243

:
@
0

1.

Connector

2.

Wire

3.

Switch

4.

Diaphragm

5.

Plug

Oil
Circuit structure
423F177A

Serial No. 10244 and up

1. Contact ring

2.

Contact

3.

Diaphragm

4.

Spring

Circuit structure

427FO1023

FUNCTION

- The engine oil pressure sensor is installed on the


engine block.

The diaphragm

detects the oil and air

pressure, and when the pressure goes below the specified

pressure, the machine

monitor

lamp lights up

to indicate the abnormality.

WA500- 1

81-35
0

6) PARKING

BRAKE SENSOR

Air

1.

Connector

2.

Wire

3.

Switch

4.

Diaphragm

5.

Plug

((E+=@
Circuit structure
423F177A

FUNCTION
- The parking

brake sensor is parking

valve. The diaphragm

brake solenoid

detects the oil and air pressure,

and when the pressure goes below the specified pressure, the machine monitor

lamp lights up to indicate

the abnormality.

7) AIR PRESSURE SENSOR


FUNCTION
- The air pressure sensor is installed to the wet air tank.
It acts through

a diaphragm

sistor according

to changes in the air pressure. This

to actuate

sends signals to the machine monitor

a sliding re-

to indicate the

air pressure. If the air pressure drops below the specified level, it generates a signal to the module inside
the machine

monitor,

and the warning lamp flashes.

1. Connector
2.

Ventilation

tube

3.

Wire

4.

Resistor

5.

Resistor selector contact

Circllit structure
423F181

8&36

WA500-1

_CONTACT

SWITCH

To battery relay

Contact switch
for bucket positioner

10A

lot----

2
3

2o.p
30.7

Positioner relay

AI

Contact switch
for boom kickaut

II

Kick-out relay

Solenoid for kick-out

421F117

Function
l

Contact switches are installed by a support to the lift


and dump
and

the

match
tions

cylinders.

TILT

BACK position

the operating
are

reached,

WA500- 1

The lift arm RAISE position


conditions.

can be selected to
When these posi-

a pulse is generated

from

the

switch, the electric current flows to a magnet and the


lift or dump lever is returned to the neutral position.
When this happens,

the main control

returned

and the

to

neutral

movement

valve is also
of the

lift

arm or bucket stops.

81-37

OPERATION
LIFT

ARM

OF CONTACT

SWITCH

RAISE
Contact switch for
boom kick out

* When the lift arm is lower than the set position for
the boom kick-out,

the detection

unit (steel plate) is

not on the sensing surface of the contact switch.


relay switch is at OFF

The

and the electric current of the

solenoid is shut off.


Kick-out relay
Solenoid for kickout

Lift lever

Contact switch

Lift arm

Cjetection unit

425F122

When the lift control

lever is moved to the

position, the lever cam and the cam follower


lift spool in the RAISE

position,

RAISE
Contact switch for
boom kick-out

keep the

so the lift arm goes


_~--~a-

UP.

Battery relay

/ !

Kick-out relay

Solenoid for kick-out

,Lift

lever

Lift arm

Contact switch

Cjetection unit

425F123

81-38

WASOO-1

.. When the lift arm goes up and reaches the set position
for

the

plate)

kick-out

(that

is in contact

is, the

detection

unit

(steel

to the sensing surface of the con-

tact switch), the contact switch and relay circuit act


to send electric current to the solenoid.

This actuates

the magnet, the cam is pulled out of the cam detent,


and the lift spool is returned to the neutral position
by the return spring.

Contact switch for


boom kick-out

Kick-out relav

Solenoid for kickaut


V

Lift lever

Cam

Detection unit

Contact switc

\
LIPOC

Solenoid

valve
425F124

Movement

of contact switch

Position

Contact switch display

Contact switch load circuit


(relay switch circuit)
Relay switch load circuit
(solenoid circuit)

WA500- 1

Sensing surface of contact switch


is in contact with detection

ON

unit.

Sensing surface of contact switch


separated from detection unit.

OFF

Current flows

Current shut off

Current flows

Current shut off

81-39

BUCKET

TILT

When the bucket is lower than the set position for the
bucket

leveler, the detection

unit (steel plate) is on

the sensing surface of the contact switch.


flows through the contact switch.
at OFF

and the electric

Contact switch for


bucket positioner

current

Electricity

The relay switch is


from the battery

is

shut off.

Positioner relay

Bucket lever

n
Cam
/

Detection unit

When the bucket control

Contact switch

lever is moved to the TILT

position, the lever cam and the cam follower


dump spool in the TILT

keep the

Contact switch for


bucket positioner

position, so the bucket tilts.

_a;--j :

Battery relay

i I

Solenoid for positioner

Bucket lever

/I

Detection unit

Contact switch

hi--

81-40

POC valve
425F126

WA500- 1

. When the bucket tilts and reaches the set position for
the bucket
plate)
contact

leveler (that

is separated
switch),

is, the detection

from

unit (steel

the sensing surface of the

the contact switch and relay circuit

act to send electric

current

to the solenoid.

This

actuates the magnet, the cam is pulled out of the cam


detent,

and the dump spool is returned to the neutral

position by the return spring.


Contact switch for
bucket positioner
---

Battery relay

1
j
,

Positioner relay

Bucket lever

Detection unit

id

Contact switch

4-d\

Movement

POC valve

425F127

of contact switch

Position

Contact switch display

Contact switch load circuit


(relay switch circuit)
Relay switch load circuit
(solenoid circuit)

WA500- 1

Sensing surface of contact switch


is in contact with detection unit.

ON

Sensing surface of contact switch


separated from detection unit.

OFF

Current flows

Current shut off

Current shut off

Current flows

81-41

ELECTRIC AND ELECTRONIC


SYSTEM

82 TESTING

AND

ADJUSTING

Standard value table for electrical system


Adjusting speedometer
machine monitor

..

. . 82-2

module of

. . . . . . . . . . . . . . . . . . . 82-2-3
in fuel level sensor . . 82-2-5
. . . . . . . . . . . . . . 82-3

Checking for abnormality


Troubleshooting

The following

..

precautions are necessary when using the Standard Value Tables to make judgements during trouble-

shooting or during testing and adjusting.


1.

The values in these tables are based on the values for new machines leaving the plant, so they should be used
as target values when repairing or when estimating wear after a period of use.

2.

The standard values in these tables for judgement

when troubleshooting

are estimated

values based on the

standard values for the machine when shipped from the plant, and on the results of various tests. Therefore,
they should be used as reference in combination
3.

with repair and operating records when making judgements.

These standard value tables must not be used for standard values when judging claims.

In addition,

do not use

these values alone to make simple judgements.

WA500- 1

82-l
0

STANDARD
Serial No. 10663
Systen

VALUE TABLE FOR ELECTRICAL


and

SYSTEM

up

Name of component

:onnectol

Measurement
conditions

Judgement table

No.

If the condition is as shown in the table below,


the sensor is defective

Radiatorwater
sensor

level

Starting
switch ON

Short connector connected

Monitor OFF

CN278 disconnected

Monitor ON

CN278
If the condition is as shown in the table below,
the sensor is normal

Starting
switch OFF

il

Oil level, water level abnormal

If the condition is as shown in the table below,


the sensor is defective

CN299

(female) grounded

Monitor OFF
Monitor ON

CN299 disconnected
Engine oil level sensor

Air pressure sensor

Torque converter oil


temperature sensor,
engine water temperature
sensor

Starting
switch ON

CN299
If the condition is as shown in the table below,
the sensor is normal

Starting
switch OFF

If the condition is as shown in the table below,


the sensor is normal

Starting
switch OFF

CN92

Air pressure 1 kg/ems

Approx.

1 kn

Air pressure 5 kg/cm

Approx. 600 51

If the condition is as shown in the table below,


the sensor is normal

Starting
switch OFF

If thecondition is as shown in the table below,


the sensor is normal

Starting
switch OFF

When engine is running (l/2


27.5 - 29.5%

Start engine

CN84
CNlO 1

Fuel level sensor

Alternator

throttle or above):

If the battery is old, or after starting


in cold areas, the voltage may rise
for some time.

WA500-1

Name of component

Zonnector
No.

nspection
nethoc

Measurement
conditions

Judgement table

If the condition is as shown in the table below,


the sensor is defective

Starting
switch ON

$1

Transmission filter
sensor

CN153
If the condition is as shown in the table below,
the sensor is normal

Starting
switch OFF

ni

If the condition is as shown in the table below,


the sensor is defective

Brake stroke limit


switch

Short connector connected

Monitor OFF

CN87.88

Monitor ON

disconnected

Starting
switch ON

CN87
CN88
If the condition is as shown in the table below,
the sensor is normal

Starting
switch OFF

ni

If the condition is as shown in the table below,


the sensor is defective

Engine oil pressure


sensor

Parking brake switch

WA500- 1

Terminal wiring harness disconnected

Monitor OFF

Terminal wiring harness grounded

Monitor ON

Starting
switch ON

If the condition is as shown in the table below,


the sensor is normal

Engine
started

If the condition is as shown in the table below,


the sensor is defective

Starting
iwitch ON

f the condition is as shown in the table below,


:he sensor is normal

Starting
witch OFF

:N36

822-1

InsrJecti&
method

b
5
E
E
z
,o
v)
Brake oil level sensor

Measurement
conditions

Judgement table

If the condition is as shown in the table below,


the sensor is defective
Short connector connected

MonitorOFF

CN86 disconnected

Monitor ON

Starting
switch ON

CN86

822-2

If the condition is as shown in the table below,


the sensor is normal

Starting
switch OFF

WA500-1

ADJUSTING
MONITOR
The speedometer

SPEEDOMETER

on the machine

monitor

MODULE

OF MACHINE

is common

for all models, but the input signals for the travel speed
differ

according

to

the

model,

so it is necessary to

adjust to make the speedometer applicable to the model


on which it is being used.
the diameter

of the tires differs according

to the type of tires fitted,

In addition,

so it is necessary to adjust the

travel speed to match this.

Procedure for adjustment


Turn

starting

(Serial No. 10001-10662)

switch OFF.

Remove the machine moni-

tor, and adjust at the adjustment

portion at the rear of

the speedometer.
1) Remove

rubber

caps II

and III

at the

rear of the

speedometer.
2) Inside

the

rubber

caps there

Using a flat-headed

are rotary

screwdriver,

switches.

turn the switch to

adjust as shown in the diagram on the right.


*

Switch

1 has no connection

speedometer,

with

adjustment

of the

Driver (-)

423F336

so do not touch it.

I
Switch I

Tire size

Switch II

I (reference) I

Rotary
Switch

Switch III

P
423F337

3) After

completing

adjustment,

fit

the

rubber

caps

securely, and install the machine monitor.


Suitable setting for switch III

Reference
Switch
position

Suitable
setting

-14

-12

-10

-8

-6

-4

-2

Switch
position

1 +2

1 +4

1 +6

$?;e

WA500- 1

+8

/ +lO

1 t12

1 +14

82z-3

Procedure for adjustment

Turn

starting

monitor,

(Serial No. 10663 and up)

switch

Remove

OFF.

and adjust at the adjustment

the

machine

portion

CNpl

at the

CIjP4

CFP5

rear of the speedometer.


1) Remove

rubber

caps 1 and 2 at the rear of the

speedometer.
2) Inside the rubber

caps there are rotary

Using a flat-headed

screwdriver,

switches.

P3

turn the switch

to adjust as shown in the table.


*

Switch

3 has no connection

the speedometer,

with

adjustment

of

Rotary switch

Switch 1

Tire size
Km/h

MPH

Switch 2

26.5-25-20PR

7 (or 8)

29.5-25-22PA

3) After

428FO1416

so do not touch it.

completing

adjustment,

fit the rubber caps

securely, and install the machine monitor.

Reference

Suitable setting for switch 2


F41E01113

Switch
position

Suitable
setting

+14

+12

+I0

+8

+6

+4

+2

Switch
position

Suitable
setting

-2

-4

-10

-12

-14

82:-4

-6

-8

WA500-1

CHECKING

FOR ABNORMALITY

If there

is any

displayed

and the amount

marked

fuel tank (for example,


gauge does not indicate

difference

between

of fuel remaining

the

IN FUEL LEVEL SENSOR

level

inside the

the fuel tank is full but the fuel


FULL),

measure the resistance

at the five positions of the float shown in the diagram


on the right with the fuel level sensor as an individual
part.

Method of measuring
l

Connect

one

pole to terminal

other pole against terminal

(11, and touch

the

(2) to measure the resist-

ance.

Resistance value of fuel level sensor at each point


Unit:

.zqzqzF

2
View

425FO1009

The standard values are only a guide.

WA500-1

82-2-5
0

TROUBLESHOOTING

Check before troubleshooting


Method of using YES-NO

. . . _ . . . . . . . . . 82- 4

Troubleshooting

......... .........
numbers. . . . . . . .
Precaution when handling connector
..
Electrical wiring diagram . . . . . . . . . .
Electrical circuit system . . . . . . . . . . .
flow chart

Connector terminal

Troubleshooting

monitoring
Troubleshooting
(Electronic

Before carrying
page 22-12,
RENCE

out the troubleshooting

METHOD

OF TROUBLE

WA500-1

OF READING
page 22-16.

in this section,
TROUBLESHOOTING

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

82-

82- 7
82-11
82-13
82-14

. . . . . . . . . . . . . . . . . . . . . . 82-19
chart for electronic vehicle

system (M-l to M-l 1)

. . . . . . . . 82-42

table
vehicle monitoring

read PRECAUTIONS
TABLE

.
.
.
.
.

chart for electric system

(E-1 to E-15)
Troubleshooting

.
.
.
.
.

WHEN

system)

. . . . . 82-44

TROUBLESHOOTING

page 22-14 and PREVENTING

RECUR-

CHECK

BEFORE TROUBLESHOOTING
Item

Standard value

1. Check fuel level

Remedy
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 brake oil level

Add oil

6.

Add oil

Check engine oil level (Level of oil in oil pan)

7. Check cooling water level

Add water

a.

Check condition of dust indicator

Clean or replace

9.

Check air pressure

Refer to troubleshooting

IO.

Check for loose or corroded battery terminals

Tighten or replace

Il.

Check for loose or corroded alternator terminals

Tighten or replace

12. Check for loose or corroded starting motor terminals

Tighten or replace

13. Check for abnormal noise or smell

Repair

14. Check for oil leakage

Repair

15. Bleed air from system

16. Check battery voltage (engine stopped)


17. Check level of battery electrolyte

23 - 26V

Replace

Add or replace

Repair

18. Check for discolored, burnt, or bare wiring


19. Check for missing wiring clamps, hanging wires

Bleed air

Replace

!O. Checks for water leaking onto wiring (check carefully water
leakage at connectors and terminals)

Disconnect connector
and dry connection

!l Check for broken or corroded breaker

Replace

!2. Check alternator voltage


(engine running at overhalf throttle)
!3. Noise when battery relay is operated
(switch starting switch from on to off)

27.5 - 29.5V

Replace
Replace

WA500- 1

\_

OF USING

METHOD
CHART

YES-NO

TROUBLESHOOTING

FLOW

The electric system can be broadly divided into the following two parts.
1.
2.

Starting system, transmission electrical control system, brake system.


ELECTRONIC

VEHICLE

MONITORING

SYSTEM.

The charts for these systems are marked as E-xx, and M-xx respectively.

TrogMe$h$gting

1.

Item

E-xx

Troubleshooting of starting system, transmissionelectrical control n/stem. brake system.

M-XX

Troubleshooting of electronic vehicle monitoring system.

Method for troubleshooting


.
Check or measure the items inside the rectangle

YES
[-H-I
NO

According

to the result, follow the YES arrow or the NO arrow and proceed to the next rectangle.

The number given at the top right of the rectangle is a reference number.

(Note:

It does not indicate the order for

troubleshooting.)
.

If the result of the check or measurement


action given in the REMEDY

leads directly

The value for the check and the measurement


the answer is yes, follow the YES arrow;

to the CAUSE

column,

note the cause and take the

column.
method

Below the rectangle, there is a list giving preparatory


values needed for checking and measuring.
ing or handling is used, or the judgement
always read the procedure carefully

is given inside the rectangle.

If the value is correct, or

if the value is not correct, or the answer is no, follow the NO arrow.
work, methods of operating and handling, and judgement

If the preparatory

work is ignored, or the wrong method of operat-

is wrong, this could result in damage to the equipment.

before starting the check or measurement,

Therefore,

and carry out the operations

in the order given.

2.

Precautions when carrying out troubleshooting


The precautions to be followed
tion of the failure.

3.

when carrying out troubleshooting

for each failure is marked *under

the descrip-

Always follow these precautions when making measurements.

Tools needed for troubleshooting


The tools needed for troubleshooting

Troubleshooting
tools

foreach

I
I

problem are listed as follows.

I
I

Prepare these tools before starting troubleshooting.

4.

Place to install connectors, connector pin numbers


When troubleshooting

some problems,

step during the troubleshooting


connector
the YES -

pin number)

measurements have to be made of continuity,

procedure.

The location

is shown in a photograph or diagram.

NO type troubleshooting

for measurement

voltage and resistance at each

at each step (location

of connector,

For this reason, use these photographs together with

flow charts to carry out troubleshooting

quickly and accurately.

WA500- 1

82-5
0

Example
*

When disconnecting

or connecting the T-adapter

(or socket adapter)

or short socket adapter, or when disconnect-

ing the connector for checking, turn the starting switch OFF to prevent accidents.
*

When connecting the T-adapter

When disconnecting

(ro socket adapter), connect to the connector specified.

(CNxx(

connectors or connecting T-adapters, return them to the orifiganl condition

))
immediately

after

checking, then go to the next check.


a)

($1

(BRAKE

OIL

LEVEL)

FLASHES.
Remedy

Defective

brake oil level

Replace

SeWOr

ES
w
1 I Connect short
socket adapter
to CN86
(female) (brake
oil level sensor)
7JTum starting
switch ON.

Defective CHECKES
STARTING module

BEFORE

I
1 )Connect short
socket adapter

1 )Connect
T-adapter (or
socket adapter)
to CN66
(female).
2)Turn starting
switch OFF.

socket adapter)
to CNP4 (female).

,
Troubleshooting
tools

POSITION

Short socket adapter

T-adapter

T-adapter or socket adapter


(for Econoseal)

(for DLI)

After inspection,
repair Mean) or
repalce

Disconnection in wiring
harness between CN86
(female) (2) - CN91 (5) chassis ground.

After inspection.
repair (clean) or
repalce

CONNECTOR

Procedure No. 1 and No. 2


CN86

OF

Tester

Disconnection in wiring
harness, or defective COntSCt
between CN86 (female) (1)
CN91 (6) - CN64 (11)
- CNP4 (female) 14)

(female)

Procedure No. 3
CN4 (female)

82-6
0

WA500- i

CONNECTOR

TERMINAL

NUMBERS

.-

Connector

ECONOSEAL

CONNECTOR

Female terminal (Socket)

Male terminal (Pin)

CN21, CN92
CN35, CN96
CN36, CNl 01
CN83, CN163
CN84, CN201
CN86, CN202
CN87, CN204
CN88, CN266

CN41

142F401

142F400A

CN42
Y

142F403A

CN43

KDI
2

142F402A

1
142F405A

142F404A

CN63

31

25
142F406A

142F407A

CN15
CN16
CN39
CN60
CN97

ii
142F409A

WA500-1

26
142F408A

*&

Connector

-r

DLI

CONNECTOR

(For monitor panel)

Male terminal (Pin)

Female terminal (Socket)

CNPl
CNP3

CNPB
CNP7

a
0

142F418

CNPZ

12

'6

142F420

142F419

12

142F421

CNP4
CNP6
CNP8
CNPIO

142F422

82-8
0

142F423

WASOO- 1

Connector

N-SLC

CONNECTOR

Male terminal (Pin)

Female terminal (Socket)

CN12

a!

CN17
CN26
CN76

1
423F349

CNll
CN13
-

CN48

423F351

423F352

423F353

423F354

423F355

423F356

CN18

CN40

II
423F357

WA500-1

423F358

*zT9

MIC

CONNECTOR

Male terminal (Pin)

Female terminal (Scoket)

CNP9

142F410

742F411

BENDIX

CONNECTOR

CN85

I
N

FM

423F347

423F346

RELAY

CONNECTOR

CN51
CN52

CN53
CN54

8220

WA500- 1

PRECAUTION WHEN HANDLING CONNECTOR


1.

If the connector

has a lock, always release the lock

before disconnecting the connector.

When connecting, align


this arrow and push in.
Be sure to fit rubber
cover tightly.

When removing, press


this part and pull
the connector out.

F142A092

2.

When removing, press in


on both sides and pull
the connector out.

F142A093

Never pull the cord to disconnect the connector.

F142AO94

3.

When connecting, align


the guide inside the
connector and push in.

If the connector

is difficult

to disconnect,

F142A095

do not

try to pull it out.


-

(If it is difficult

to reach by hand, remove the clamp

and move the wiring harness.)

This must be removed.

F142A096

WA500-1

82-l 1
0

4.

After

pulling out the connector,

cover with a vinyl

bag to protect the contacts from dirt or oil.

F142A097

5.

When

cleaning

the connector,

agents such as trichloroethane


If the connector
agent.

After

immediately.

never use cleaning


or trichloroethylene.

is very drity, use a neutral cleaning

cleaning wash well and dry completely


(Do not use any connector which has

deposits left on it after drying.)


Coat with contact restorer.
(When drying, be particularly

careful to dry the gaps

in the rubber.)

6.

When assembling the connector,

be sure to fit it
F142A098

correctly.
(For connectors with locks, it should be possible to
heat

the

locks click

as they

fit

completely

into

position.)

F142A099

F142AlOO

Correct any protrusion of the boots.

82-12
m

WANO- 1

ELECTRICAL

WIRING

DIAGRAM
1, Preheating

CN65
CN52

CN58

CN!

lamp switch

3. Parking

brake switch

4. Starting

W<

CN55\

switch

2. Working

switch

5. Transmission
6. Circuit

cut-off

breaker

7. Air conditioner

CN130
CNll

View

CN13

N4g \

CN88

CN87

9. Warning

buzzer

10. Lift proximity

relay

8. Controller
(Serial No. 10001-10662)

CN163
\

I /

/
CN131

Y
CN86

CN12

-. _- .^
vim;~?I/L*278

switch

switch

11. Brake oil level sensor

CN2
CN83

12. Heater

relay

13. Engine

oil level sensor

14. Coolant

CN20
\

water

level sensor

15. Alternator
16. Breaker
17. Battery

Serial No. 10001 -

18. Fuel level sensor

10662
CNPlO

CNP6

ZNP8

relay

CNP2

CNP4

19. Starting

motor

20. Brake chamber

CN254

21. Engine

oil pressure

22. Torque

converter

sensor

oil temperature

sensor
23. Emergency
24. Air pressure
CNP;

kNP9

CNP;

View

bNP3

bNP1

Serial No. 10663 and up


CNP2

CNPl

FNP4

CNP5
I

Ii 1

i,,

View X

WA500-1

26. Parking

brake display

27. Parking

brake solenoid

28

24
,NP/

sensor

25. Speed meter sensor


/

brake sensor

23

Bucket

proximity

switch
valve

switch

CN204

CN92

15

425FOlOll-1K

82i3

ELECTRICAL
1.

ENGINE

CIRCUIT

STARTING

Serial No. 10001

Transmission
control switch

CIRCUIT

SYSTEM
SYSTEM

10388

II
Main braker

425F210

2.

ENGINE

STOP CIRCUIT

Serial No. 10001

SYSTEM

10388

425F211

WA500-

ENGINE STARTING
Serial

No. 10389

AND STOP CIRCUIT

SYSTEM

and up

Starting switch
CN95

CN14
-01
---a2
L-03
04

CN254

ccc0

relay
Transmission
control switch

Banery

To transmission
control valve

I
Main breaker
-

To circuit breaker

I
Main fuse

Alternator

CN97

To monitor panel -

Engine stop motor


_.

fuse

CN29,

Engine stop motor relay

Engine stop motor

42 1 FOl 1 ZOA-K

WA500-1

82-A4-1

3.

TRANSMISSION

CONTROL,

TRANSMISSION

CUT-OFF

CIRCUIT

SYSTEM

Parking
brake valve
CN 15
Parkzng brake relay

To wiper

switch

Meter panel

Tranrmirrlon
select switch

cut-off

Main

braker

L-

To battery

relay

425F212-1

WA500-1

82d5

4.

PARKING

BRAKE

CIRCUIT

SYSTEM

Parking brake switch

Parking

425F213-1

5.

PREHEATING

): Serial

CIRCUIT

No.

10663

SYSTEM

and

up

425F214A-K

82P

WA500-

C158

A/C camprerror

7.

VEHICLE
Serial

MONITOR

No. 10001-I

SYSTEM
0662

---warninglamp

CN

1,

._

425F218

WA500- 1

Serial No. 10663

and UP

w-L.H. head lamp


421FO1127A-1K

WA500-1

82-18-1
n

TROUBLESHOOTING

E-

CHART FOR ELECTRIC


(E-l. to E-l 5.)

1. Engine does not start (Serial No. 10001-10388)

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

82-20

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

E- IA.

Engine does not start (Starting motor rotates) (Serial No. 10389 and up)

E-

2.

Engine does not stop

E-

3.

Engine stop when traveling

E-

4.

.....................
b) Parking brake does not work (Air pressure less than 2.0 kg/cm)
................
Parking brake is not released ...........................................
Parking brake is released when starting siwtch is turned to ON ....................
Transmission is not returned to Neutral when parking brake is applied ...............
Machine does not travel Forward ........................................
Machine does not travel Reverse ........................................
Transmission does not shift gear (F-R direction normal) .........................
Machine travels when transmission cut-off switch is ON .........................
Transmission cannot be cut-off .........................................
Transmission does not return to Neutral ...................................
Preheating display does not go out .......................................
Preheating does not work .............................................

E-

5.

E-

6.

E-

7.

E-

8.

E-

9.

E- IO.
E- 11.
E- 12.
E- 13.
E- 14.
E- 15.

a)

WA500- 1

SYSTEM

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

Parking brake does not work (Parking brake switch ON)

82-21-I
82-21-4
82-22
82-24
82-24
82-26
82-28
82-28
82-30
82-32
82-34
82-36
82-37
82-38
82-40
82-41

TROliJBLESHOOTlNG

CHART

Serial No. 10001-I


0388
,Failure mode: ENGINE DOES NOT
*

When disconnecting

or connecting

No. E-l.

START.

the T-adapter

(or socket adapter)

or short socket adapter, or when disconnect-

ing the connector for checking, turn the starting switch OFF to prevent accidents.
*

When connecting the T-adapter

When

disconnecting

the original

(or socket adapter), connect to the connector specified.

connectors

condition

or connecting

immediately

after

T-adapters,

checking,

then

(CNxx

))

return them to
go to the next

Cause

Remedy

check.
*

If the head lamps and other

electrical

parts are not working

normally,

check battery - battery relay - starting switch first.


(a)

Checking starting circuit

YES

Defective starting motor


assembly.

YES

1)

3)Turn starting
switch OFF.

CN102 (female) (1)


chassis ground

and

1) Measure with
starting switch
at START.
2) Disconnect
CN102 (starting
motor assy).

continuity
between CN14 (3)
(female) and (1 I?

1) Connect
T-adapter (or
socket adapter)
toCN14.
2) Measure with
starting switch
at START.
Tester

Troubleshooting
tools

After checking,
repair or replace

F-R switch.

L
NO

Defective

starting switch

After checking,
repair or replace
(1)

Replace

T-adapter or socket adapter


(for Econoseal)

CONNECTOR

Procedure No. 1 and No. 2


CN102

OF

Defective

Defective contact or
disconnection in wiring
harness between CN102
(female) - CN97 (4) CN63 (5) - CN14 (3).

Isthere
.

After checking,
repair or replace

NO

4 r

POSITION

Connect

T-adapter (or
socket adapter)
toCN16.
2) Place F-R lever al
N.
3)Turn starting
switch OFF.

Defective contact or
disconnection in wiring
harness between CN102 (3)
(female) - CN97 (7) CN64 (9) - CN16 (9)
(female) ordefective contact
or disconnection in wiring
harness between F-R switch
and chassis ground.

(female)

Procedure No. 3

* Procedure No. 4
CN14 (female)

- Battery relay

* Starting switch

CN16 (male)
10 12

11

425F217

425F216

82-20

WA500-

Cause

(b)

Remedy

Checking battery - battery relay - starting switch


YES

Is voltage between
both thick
terminals of battery
relay and chaws
around 20 - 3OV?

YI

1) Turn starting
switch ON.
2)Measure voltaae
between two terminals
connected by
thick insulated
cable.

Is there sound of

1 )Turn starting
switch ON OFF.

NO

Defective contact or
disconnection in wiring
harness between battery
relay and starting motor
assembly.

After checking,
repair or replace

If NO for both terminals


defective contact or
disconnection in wiring
harness between battery and
battery relay.
If NO for one terminal
defective battery realy.

After checking,
repair or replace

ReplaCe

YFS

Defective

YES

Is voltage between
N

Defective contact or
disconnection in wiring
harness between grand battery relay CN254 (3) (female) - CN95 (1) (diode) - CN95 (2) CN63 (21 - CN14 (2) starting switch terminal BR

51

YES
chassis ground 20

NO

terminal Band
chassis ground 20

11 Turn starting

battery relay

switch ON.

Replace

After checking,
repair or replace

Defective starting switch


switch

ON.

1I connect
T-adapter (or
socket adapter)
toCN14
(female).
2)Turn starting
switch OFF.

Tester

Troubleshooting
tools

POSITION

JO

T-adapter or socket adapter


(for Econoseal)

>efective contact or
jisconnection in wiring
wness between battery
,elay - CN254 (21 - CN63
17) - CN58 (1) - fuse
ZN58 (2) - CN14 (1) starting switch terminal B.

After checking,
repair or replace

I
OF

CONNECTOR

CN58

* Procedure No. 3
CN254

(female)

CN63

Procedure No. 4 and No. 5


CN14 (female)

CN97

WASOO- 1

82-21
0

TROUBLESHOOTING

CHART

No. E-IA

Serial No. 10389 and up


Failure mode: ENGINE DOES NOT START. (STARTING
*

When

disconnecting

disconnecting

or connecting

the connector

When

connecting

When

disconnecting

after checking,

the

for checking,

the T-adapter
connectors

T-adapter

(or socket

turn the starting

(or socket adapter),


or connecting

MOTOR ROTATES)

connect

T-adapters,

adapter)

switch

or short

OFF to prevent

to the connector
return

socket

adapter,

specified.

them to the original

(CNxx
condition

( ))
immediately

then go to the next check.

YI

11

1
Does engine stop
motcn move?

I)

Turn starting
switch ON OFF and check
visuallv.

2
4

YES
I

Is voltagebetween

NO

chassis 20 -

2)

voltage

Is
bvetween
CN 293 (4) and
chassis 20 - 3OV?

YI

3OV?

T-adapter to
CN293 @-pin)
Turn starting
switch ON.

1)

connect
T-adapter
CN293.

to

NO

(Stays OFF1
1) Connect
T-adapter to
CN293.
2) Continuous
when starting
switch is OFF,
and cut when
switch is ON.

Go to appropriate

stem

YES
57

(Stays continuous1

7
2)

T-adapter

stop relay).
Turn starting
switch ON.

NO

or socket adapter

(for Econoseal)
Tester

82-%
-

or when

accidents.

WA500-1

Cause

Defective adjustment between


engine stop motor and lever.

Defective engine stop motor, or


defective contact, or
disconnection in wiring harness
between CN293 (8) - CN290
(3) - chassis ground.

Defective engine stop motor, or


defective contact. or
disconnection in wiring harness
between CN292 (5) - CN293
(5).

Broken fuse (CN291). or


defective contact. or
- disconnection in wiring
harness between CN293 (4) CN291 (2).

Defective contact, or
disconnection in wiring harness
between engine stop motor
relay (CN292) or CN293 (7) CN292 (3). CN292 (6) - CN293

Remedy

Adjust

After
inspection,
repair or rep,ace

Afterinspection,
repair or replace

After inspection,
repair or replace

After isw,_tion,
repair or replace

(31.

WA500-1

Defective engine stop relay. or


defective contact. or
disconnection in wiring harness
between CN292 (2) (female) chassis ground.

After inspection,
repair or replace

Defectwe circuit between


battery and starting switch.
Check accroding to E-l-(b).

After inspection,
repair or replace

CN293 (For engine stop motor)


ECONOSEAL connector 8 pins.

CN293

Engin s&p motor


425FO1362A-K

82-&1
-3

WA500-1

TROUBLESHOOTING
Failure
Sr

mode:

When

ENGINE

disconnecting

disconnecting
*

When

connecting

When

disconnecting

after checking,

No. E-2

NOT STOP.

or connecting

the connector

CHART

DOES

the

for checking,

the T-adapter

T-adapter

(or socket

turn the starting

(or socket adapter),

connectors

or connecting

connect

T-adapters,

adapter)

switch

or short

OFF to prevent

to the connector
return

or when

specified.

( ))

(CNxx
condition

immediately

then go to the next check.

Cause

Remedy

Defective adjustment of linkage


between fuel cut solenoid and
governor

4djust

Defective fuel cut solenoid

%?plXX

YFS

Does spool of fuel


cut solenoid work,

Turn starting
switch ON OFF and check
visually.

adapter,

accidents.

them to the original

Serial No. 10001-10388

1)

socket

?I
ls voltage between
both terminals of
fuel Cut solenoid

ND

approx.

Contact or disconnected wiring


between + 24V and wiring
harness between CN14 (male)
(2) - CN63 (2) - CN97 (male)

YES

OV?

Wer inspection,
.epair or replace

(11).
I)

Turn starting
switch OFF.

Is voltage between
starting switch BR
- chassis approx.
OV?

b
NO

1)

Turn starting
switch OFF.
NO

Serial No. 10389

and up

Defective adjustment between


engine stop motor and stop

4djust

IWW

ES

Defective engine stop motor

Does engine stop

1)

Turn starting
switch ON OFF and check

1)

2)

Connect
T-adapter to
CN293 (engine
stop motor
coector)
(B-pin).
Turn starnng
switch OFF.

YES

Defective contact, or
disconection in wiring harness
between CN293 (3) (female) CN292 (6) (female). or CN292
(3) - CN293 (7) (female), or
defective relay (CN292).

4fter mspectio.
repair or replace

Defective engine stop motor

?eplace

Isvoltage

1)

2)

between
CN293 (3) and (8)
20 - 3OV

connect
T-adapter to
CN293.
Turn starting
switch OFF.

YEE

Is voltage between

1) Connect
T-adapter
CN293.

to

I
NI

Defective contact, or
disconnection in wiring harnes
between CN293 (4) (female) CN291 (2) (female). or broken
fuse (CN291).

After inspection.
repair or replace

Tester
Troubleshooting
tools

WA500-1

82-&
-4

TROUBLESHOOTING CHART NO. ~-3


Failure mode: ENGINE STOPS WHEN TRAVELING
*

When

disconnecting

disconnecting
+

When

connecting

It

When

disconnecting

after checking,

Serial

or connecting

the connector

the

for checking,

the T-adapter

T-adapter

(or socket

turn the starting

(or socket adapter),

connectors

or connecting

connect

T-adapters,

adapter)

switch

or short

OFF to prevent

to the connector
return

socket

adapter,

or when

accidents.

specified.

them to the original

( ))

(CNxx
condition

immediately

then go to the next check.

No. 10001-l

Remedy

Cause

0388

3efective adjustment
of linkage
letwee
fuel cut solenoid and

YE:

4
between both
terminals
of fuel
cut-off solenoid

Does spool of fuel


cut solenoid work?

1)

1)

Turn staning
switch ON OFF and check
visually.

Is voltage between
starting swtch
terminal
BR and
chassis ground 20
- 3OV?

YES
-

1)

Is voltage between
starting switch
terminal
B and
chassis ground 20
- 3OV?

L
NO

1)

2)

Disconnect
wiring of fuel
cut-off
solenoid.
Turn starting
switch OFF.

I
NO

Serial
*

No.

10389

fuel cut solenoid

Defective

starting

switch

Xsconnection
in wirina
wrness or defective c&act
Jetween starting switch
terminal 8 and battery relay

after inspection,

Defective adjustment
between
engine stop motor and stop
lever

idjust

Defective

engine

stop motor

leplace

Defective

engine

stop relay

teDlace

epke

and up

Check if the starting


check accroding

motor rotates.

to E-l A (Engine

If it does not rotate,

does not start).

YES

Does engine stop


motor work?

Defective

6fter inspection,
eptace

Turn staning
switch ON.

Turn starting
switch OFF.

Disconnection
in wiring
harness or defective contact
between starting switch
terminal BR - CN14 (2) CN63 (2) - CN97 (11). or fuel
cut solenoid - CNS7 (12) chassis ground

YES

_
2

1)

Turn starting
switch ON OFF and check
visually.

L
NO

Does voltage
between CN293 (7)
and (8) switch
between OV and 20
- 3OV?

1)
2)

connect
T-adapter to
CN293.
Turn starting
switch ON OFF.

YES

3
Is voltage between
CN292 (2) (female)
and (1) (female) 20
- 3OV?

_
NO

1)

2)

Troubleshooting
tools

82-22

Disconnect
CN292 (engine
stop relay).
Turn starting
switch ON.

NO

Defective circuit between


battery and starting switch.
Check according tQ E-l -(bJ.

\fter inspection,
epair or replace

T-adapter or socket adapter


(for Econoseal)
Tester

WA500-1

Serial No. lOOQl-10388

Fuel cut-off

solenoid

No. 10001-10388

Serial

STARTING

SWITCH

425F217

CN97

(Intermediate

ECONOSEAL

connector)

connector

12 pins

425P105

Serial

CN293
Serial

(For engine
No. 10389

ECONOSEAL

No.

10389

and

UD

stop motor)
and up

connector

8 pins

/
CN293

Engin

st&

motor

425F01362A.K

WA500-1

82:3

TROUBLESHOOTING
Failure mode: a) PARKING
*

When disconnecting

CHART
BRAKE

or connecting

No. E-4.

DOES NOT WORK.

the T-adapter

(PARKING

(or socket adapter)

BRAKE

SWITCH

ON)

or short socket adapter, or when disconnect-

ing the connector for checking, turn the starting switch OFF to prevent accidents.
*

When connecting the T-adapter

When disconnecting

connectors

(or socket adapter),


or connecting

connect to the connector specified.

T-adapters,

(CNxx

return them to the original condition

( 1)
immediately

after

checking, then go to the next check.


*

Parking brake lamp does not light up.

Even when air pressure drops, parking brake does not work.

YES
,

YES

CN35

(1) (male)

j Connect

T-adapter (or
socket adapter)
to CN35.
PITurn parking
brake switch ON
(parking).
3) Start engine (air
charge).

b
Is there continuity
between CN 11
(male) (1) and (2)
as shown in table?

YES
L
1) Replace CN54
(back-up lamp
relay) and CN51
(parking brake
relay).
2)Turn parking
brake switch ON
(parking).
3) Start engine (air
pressure gauge).

1) Disconnect
CNll.
2)Turn starting
switch OFF.
NO

1 )Disconnect
CN51.
2)Start engine (air
pressur<gauge).

Failure mode: b)PARKlNG


BRAKE
2.0 kg/cm2 1

DOES

NO

NOT

WORK.

(AIR

PRESSURE

LESS

THAN

YES
Is work parking
brake when
disconnect
CN204?
NO
1) Starting switch
ON.
21 Parking brake
switch OFF.

,
Troubleshooting
tools

T-adapter or socket adapter


(for Econoseal)

Short socket adapter

Tester

82Li?4

WA500- 1

Cause

YES

Remedy

Defective
solenoid

parking

brake

RE$bX

Defective

parking

brake relay

ReplaCe

Abnormal
contact or
mistaken wiring between
CNl 1 (male) (1) - CN63 (41
- CN204 (1). (21 - CN63
(6) - CN51 (2).

After inspection,
repair or replace

Defective
switch

Replace

NO

WASOO- 1

perking

brake

Abnormal
contact or
mistaken wiring between
CN51 (5) (male) - CN39
(11) - CN35 11).

After inspection,
repair or replace

Defective
switch.

emergency

Replace

Defective

parking

brake

brake.

Repair

CNl 1 (Parking brake switch)


N-SLC

CN35

connector

(Parking

ECONOSEAL

3 pins

brake solenoid
connector

valve)

2 pins

solenoid

CN39

(Intermediate

ECONOSEAL

valve

425P108

connector)

connector

12 pins

connector

8 pins

CN63
ECONOSEAL

82-$5-1

WA500-1

serial No. 10001-10662


CN51

(Parking

brake relay)

CN54

(Back-up

lamp relay)

RELAY connector

5 pins

Serial No. 10663 and up

CN297

WY

l&V

I4

Warning buzzer

CN5<

CN5b

CN53

CIj52

dN51

kN50
425F551

CN204

(Emergency

ECONOSEAL

brake switch)

connector

WA500-1

2 pins

82-F2

TROUBLESHOOTING
Failure mode:
*

PARKING

When disconnecting
ing the connector

CHART

BRAKE

or connecting

No. E-5.

IS NOT

RELEASED.

the T-adapter

(or socket adapter)

or short socket adapter, or when disconnect-

for checking, turn the starting switch OFF to prevent accidents.

When connecting the T-adapter

When disconnecting

(or socket adapter),

connectors

or connecting

connect to the connector specified.

T-adapters,

(CNxx

return them to the original condition

( ))
immediately

after

checking, then go to the next check.


f
*

Parking brake lamp does not light up.


Even when air pressure drops, parking brake does not work.

1
Y ES

YES

Is there continuity
between CN35 (2)
(male) and chassis ground?
NO

1
Y

CN35 (1) (male)


and chassis ground

1 )Connect
T-adapter (or
socket adapter)
to CN35.
2)Stari engine (air
pressure charge).

1) Connect Tadapter (or


W&OW;papter)
2) Turn starting
switch OFF.

1
JO

iS

Is problem
removed when
relays are
interchanged?

1) Interchange
CN54 (back-up
lamp relay) and
CN5 1 (parking
brake relay).
2)Start engine (air
press&charge).
BITurn parking
brake switch ON
- OFF.

rl

Is air pressure in
reservoir normal I7
- 8.3 kg/cm2)

YE

Is voltage between
CN5 1 (2) (male)
and chassis ground
20 - 3OV?
1 )Disconnect
CN51.
2) Start engine (air
pressure charge).
3)Turn parking
brake switch ON
- OFF.

Is voltage between
CN51 (31 (female)
and chassis ground

1 )Start engine (air


pressure charge).
1I

NO
1 )Connect short
socket adapter
to CN204
(fern&).
2)Start engine lair
pressure charge).
3)Turn parking
brake switch ON
- OFF.

NO

NO

giiynect

2)Turn starting
switch ON.

1) Interchange
CN54 (back-up
lamp relay) and
CN52 (parking
brake relay).
2) Stan engine (air
pressure charge).
3) Turn parking
brake switch ON
- OFF.

IO
t

Troubleshooting

for air circuit

Table 1

Troubleshooting
tools

T-adapter or socket adapter


(for Econoseal)
Short socket adapter

WAMO- 1

Cause

Defective parking
solenoid valve

Remedy

brake

Disconnection
in wiring
harness, or defective contact
between CN25 (2) (male)
and chassis ground

Defective

parking

4fter inspection,
.eplace

brake relay

Disconnection
in wiring
harness, or defective contact
between CN51 (5) (male) CN39 (11)
CN35 (1).

After inspection,
reolace

Defective
switch

emergency

Replace

Defective

parking

safety

Defective
switch

parking

brake

brake

YES
relay

Replace

1)Disconnect
CNll.
2)Turn starting
switch OFF.

YES

HI
NO

Disconnection
in wiring
harness, or defective contact
between CNll
(1) (female) CN63 (4) - CN204 (1). (2) CN63 (6) - CN51 (2). or
braker - CN60 (4) - CN51,
52 (3) or CN51 (2) - CN52 l5L
(2) - CNl 1 (2).

Disconnection
in wiring
harness, or defective contact
between braker - CN60 (4)
- CN51 (31.

WA500- 1

Replace

After inspection,
replace

8227

CNl 1 (Parking brake switch)


N-SLC connector 3 pins

CN35 (Parking brake solenoid valve)


ECONOSEAL connector 2 pins

solenoid valve

425P108

CN39 (Intermediate connector)


ECONOSEAL connector 12 pins

CN63
ECONOSEAL connector

82-F

8 pins

WA500-1

Serial No. 10001-10662

CN51

(Parking

brake

relay)

CN54

(Back-up

lamp

relay)

RELAY

connector

5 pins

Serial No. 10663 and up

CN297
I
T\K

h&v
I

I
7

I?

Y-f-T-e 1

CN55 CN54

CN53 Ci52

dN51 CN50
425F551

CN204

(Emergency

ECONOSEAL

WA500-1

brake

connector

switch)
2 pins

82-$7-2

TROUBLESHOOTING
Failure mode:
*

PARKING
TO ON.

When disconnecting
ing the connector

CHART
BRAKE

or connecting

IS RELEASED

the T-adapter

WHEN

STARTING

(or socket adapter)

SWITCH

IS TURNED

or short socket adapter, or when disconnect.

for checking, turn the starting switch OFF to prevent accidents.

When connecting the T-adapter

When disconnecting
the original

No. E-6.

connectors

condition

(or socket adapter),


or connecting

immediately

after

connect to the connector specified.

T-adapters,

checking,

then

return

(CNxx

( ))

them to

go to the next

check.
Remedy

Defective parking brake


safety relay

1 )Interchage
parking brake
relay (CN51) and
back-up lamp
relay (CN54).
2) Start engine and
charge air
pres?.ure.
3)Turn starting
switch ON.

back-up lamp
relay (CN54).
2)Start engine and
charge air
pressure.
3)Turn starting
switch ON.

TROUBLESHOOTING
Failure mode:

Defective

parking brake relay

Defective
switch

parking brake

l---_l
I__1) Disconnect
CNll.
2) Start engine and
charge air
pressure.
3)Tum starting
switch OFF ON.

CHART

TRANSMISSION
IS NOT
BRAKE IS APPLIED.

YES

Replace

Is problem
removed when
CNll
is
disconnected?

&connection
in wiring
lerness. or defective confect
Jetwee +24V terminal and
:N35 (1) - CN39 (11)
CN51 (5) or CNll (1)
CN51
2).

4fter inspection,
replace

No. E-7.
RETURNED

TO NEUTRAL

1
1

Replace

WHEN

PARKING

Cause

Defective neutralizer

Remedy

relay

Is problem removed
when relay is
replaced?

1) Interchange
neutralizer relay
(CN53) and backup lamp relay
(CN54).
2) Stan engine and
charge air
pressure.
3) Turn staning
switch ON.

82-28
a

NO

1 Disconnection in wiring
harness, or defective contact
between + 24V terminal and
CN53 (5) - CN21 (l), (2) CN75 (8) - CN85 (A).

After inspection,
replace

WA500- 1

CNl 1 (Parking
N-SLC

CN35

brake

connector

(Parking

ECONOSEAL

switch)

3 pins

brake

solenoid

connector

valve)

2 pins

-_

solenoid

CN39

(Intermediate

ECONOSEAL

connector

valva

display switch

425Pt08

connector)

connector

CN85 (For transmission


BENDIX

-.)

,,,,,,,,

12 pins

control

valve)

14 pins

425P112

WA500-1

8229

CN51

(Parking

brake relay)

CN52

(Parking

brake safety

CN53

(Neutralizer

CN54

(Back-up

Serial No. 10001-10662

relay)

relay)
relay)

RELAY connector

5 pins

Serial No. 10663 and up

CN297

CN55 CN54

CN53 CN52 CN51 CN50


425F551

82-E-1

WA500-1

TROUBLESHOOTING
Failure mode:
*

MACHINE

When disconnecting

CHART

No. E-8.

DOES NOT TRAVEL

or connecting

the T-adapter

FORWARD.

(or socket adapter)

or short socket adapter, or when disconnect-

ing the connector for checking, turn the starting switch OFF to prevent accidents.
*

When connecting the T-adapter

When disconnecting

(or socket adapter), connect to the connector specified.

connectors

or connecting

T-adapters,

(CNxx

return them to the original condition

( 1)
immediately

checking, then go to the next check.

4
YES
3 Is there continuity
between CN16
(female) (1) and
chassis ground?

Is there continuity
between CN16
(male) (1) and (2)?

1) place F-R lever in


REVERSE.
2) Connect Tadapter (or
socket adapter)
to CN16.
3) Turn starting
switch OFF.
NO

1)Connect
T-adapter (or
socket adapter)
to CN16
(female).
2)Turn starting
switch OFF.

YES
1

NO

YIES

Is parking brake

chassis ground?

YES

YES

CN85 (A) (female)


and chassis ground

1 I Disconnect CN85
2) Turn starting
switch ON. (Do
not start
3) Parking brake
switch ON-OFF
(release).

engine.)

Troubleshooting
tools

8220

T-adapter or socket adapter


(for Econoseal)

ES

1) Place F-R lever in


FORWARD.
2) Disconnect
CN85.
3) Turn starting
switch OFF.

I
YES

Is problem
removed when
relay is replaced?
1
1) Interchange
neutralizer relay
(CN53) and backup lamp relay
(CN54).
2) start engjne.
3) Parkmg brake
switch ON - OFF
(released).

removed when
short socket

11 Connect short
socket adapter to
CN21 (female).
2) Start engine.
3) Parking brake
switch ON -OFF
(release).

Short socket adapter

Tester

WASOO- 1

after

Cause

Disconnection in wiring
harness, or defective contact
between CN16 (2) (female)
- CN75 (5) - CN85 0) CN85 (A) (female)

After inspection,
repairorreplace

Defective

Replace

F-R switch

Disconnection in wiring
harness, or defective contact
between CN16 (8) (male)
and chassis ground

WA500-1

Defective

forward

Defective

neutralizer

After inspection,
repair or replace

solenoid

relay

Replace

Defective transmission
cut-off switch

Replace

Disconnection in wiring
betweenmain breaker CN59
(8) - CN53 (3) orCN53
(5)
- CN21 (1 j, (2) - CN75 (8)
- CN85 (AL

After inspection,
repair or replace

CNll (Parking brake switch)


N-SLC connector 3 pins

CN16 (Speed lever, directional lever)


ECONOSEAL connector 12 pins

CN21 (Transmission cut-off switch)


ECONOSEAL connector 2 pins

CN85 (For transmission control valve)


BENDIX connector 14 pins

82-$
-

WASOO-1

Serial

CN53

(Neutralizer

CN54

(Back-up

No. lOOOl--10662

relay)
relay)

RELAY connector

5 pins

Semi

No. 10663

and LID

CN297

CN55CN5k

CNj3

&52

dN51 bN50
425F551

WA500-1

82-E
-2

TROUBLESHOOTING
Failure mode:
*

MACHINE

When disconnecting
ing the connector

CHART

No. E-9.

DOES NOT TRAVEL

or connecting

the T-adapter

REVERSE.

(or socket adapter)

or short socket adapter, or when disconnect-

for checking, turn the starting switch OFF to prevent accidents.

When connecting the T-adapter

When disconnecting

(or socket adapter),

connectors

or connecting

connect to the connector specified.

T-adapters,

(CNxx

return them to the original condition

( ))
immediately

checking, then go to the next check.

YES
-

(rIO

Refer to E-5

CN18

chassis

ground?

II
I

(1)

Jconnect

T-adapter
(or
socket adapter)
toCN16
(femaleI.
2lTurn starting
switch OFF.

Is there continuity
between CN85 (Cl
(female) and
chassis ground?

YES

between

Is there continuity
between CN16
(male) (1) and (3)?

1) Place F-R never I


REVERSE.
2) Connect Tadapter (or
socket adaoter)
to 0416 (fdmaie).
3) Turn starting
switch OFF.
rJO

ND

1) Place F-R lever in


REVERSE.
2)Turn starting
switch OFF.

'ES

voltage

Is
between
CN85 IA) Ifemale)
and chassis ground
3OV?

i zo-

1) Disconnect
CN85.
2) Turn starting
switch ON. (Do
not start engine.)
3) Parking brake
switch ON-OFF
Irelease).

2) Start engine.
3) Parking brake
switch ON -OFF
(release).

Troubleshooting
tools

8222

T-adapter
or socket
(for Econoseal)

Tester
Short

socket adapter to
CN21 (female).
2) Start engine.
3) Parking brake
switch ON - OFF
(release).

socket

adapter

adapter

WA500- 1

after

Cause

Remedy

Disconnection in wiring
harness, or defective contact
between CN16 (female) (3)
- CN75 (6) - CN85 (C) CN85 (A) (male)

After inspection.
repair or replace

Defective

Replace

F-R switch

Disconnection in wiring
harness, or defective contact
between CN16 (male) (1)and
chassis ground.

After inspectIOn.
repair or replace

Defective

reverse solenoid

ReplaCe

Defective

neutralizer

Replace

relay

Defective transmission
cut-off switch

Disconnection
in wiring harness
between main breaker CN59
(8) - CN53 (31 or CN53 (5)
- CN21 (1). (2) - CN75 (8)
- CN85 (Al.

WA500-1

Replace

After insPection.
repair or replace

CNll

(Parking

N-SLC

brake switch)

connector

3 pins

B
CN16

(Speed

ECONOSEAL

CN21

lever, directional
connector

(Transmission

ECONOSEAL

CN85

cut-off

connector

(For transmission

BENDIX

connector

82-33-l
0

lever)

12 pins

switch)

2 pins

control

valve)

14 pins

WA500-1

Serial No. 10001 -

10662

CN53 (Neutraliter relay)


CN54 (Back-up relay)
RELAY connector 5 pins

3
Serial No. 10663 and up

CN55kkh

CNk3 Cd!52 dN51 bN50


425F551

WA500-1

82-33-2
/;\

TROUBLESHOOTING
Failure mode:
*

CHART

TRANSMISSION

When disconnecting
ing the connector

No. E-l 0.

DOES NOT