Wa350 1

SEBM04230107
KOMATSU
WA3504
MACHINE MODEL SERIAL No.
WA350- 1 10001 and up
l 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.
l WA350-1 mount the S6Dll O-l engine.

For details of the engine, see the 110 Series Engine Shop Manual.
oo-1
05-90(03)03561
a
CONTENTS
No. of page
10 ENGINE
11 STRUCTURE AND FUNCTION .. . . .. . . . ... .. . . ........ ... 1 l-l
12 TESTING AND ADJUSTING ................................................. 12-1
13 DISASSEMBLY AND ASSEMBLY.. . .. . . . ..... . . .. . . . 13-1
20 POWER TRAIN
21 STRUCTURE AND FUNCTION ............................................... 21-1
22 TESTING AND ADJUSTING ................................................. 22-l
23 DISASSEMBLY AND ASSEMBLY ............................................. 23-l
24 MAINTENANCE STANDARD ................................................. 24-l
40 STEERING SYSTEM
50 BRAKE AND AIR SYSTEM

60 WORK EQUIPMENT SYSTEM

80 ELECTRIC AND ELECTRONIC SYSTEM

90 OTHERS
97 GEAR PUMP ................................................................ 97-l
00-2 WA350-1
0
The affected pages are indicated by the use of the
following marks. It is requested that necessary actions Mark Indication Action required
must be taken to these pages according to the list below.
0 Page to be newly added Add
0 Page to be replaced Replace
( 1 Page to be deleted Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

lark dark Page Aark Page dark Page
Mark Page Page number number number
number number
oo- 1 @ l3- 6 @ 13-47 21-40 @ 23- 8 @
oo- 2 0 13-8 @ 21- 1 21-41 @ 23- 9 @
00- 2-l @ 13-g @ 21- 2 21-42 @ 23-10 @
oo- 2-2 @ 13-10 @ 2l- 3 21-43 @ 23-11 @
00- 2-3 @ 13-11 @ 21- 4 21-44 23-12 @
00- 2-4 @ 13-12 @ 21- 5 21-45 @ 23-13 @
oo- 3 13-13 @ 21- 6 21-46 @ 23-14 @
oo- 4 13-14 @ 21- 7 21-47 @ 23-15 @

13-15 @ 21- 8 21-48 23-16 @
00. 5
21- 9 21-49 23-17 @
00- 6 13-16 @
21-10 22- 1 @ 23-18 @
oo- 7 13-17 0
21-11 22- 2 @ 23-19 0
00- 8 13-18 @
21-!2 22- 3 0 23-20 @
oo- 9 13-19 @
21-13 22- 4 @ 23-21 @
oo- 10 13-20 @
21-14 22- 5 @ 23-22 @
00-11 0 13-21 @
21-15 22- 6 @ 23-23 0
00-12 @ 13-22 @
21-16 22- 7 @ 23-24 @
II- 1 13-23 @
21-17 22- 8 @ 23-25 @I
II- 2 13-24 @
21-18 22- 8-l @ 23-26 @
11- 3 13-25 @
21-19 22- 8-2 @ 23-27 @
II- 4 13-26 @
21-20 22- 9 @ 23-28 @
II- 5 13-27 @
21-21 22-11 @ 23-29 0
12- 1 13-28 @
21-22 22-12 0 23-30 @
12-2 0 13-29 0
21-23 22-13 @ 23-31 @
12-3 @ 13-30 0
21-24 22-14 @ 23-32 @
12-4 @ 13-31 0
21-25 22-15 @ 23-33 @
12-5 @ 13-32 @
21-26 22-16 @ 23-34 @
12-6 @ 13-33 0
21-27 22-17 @ 23-35 @
12-7 @ 13-34 @
21-28 22-18 8 23-36 @
12-8 @ 13-35 0
21-29 22-19 @ 23-37 @
12-9 0 13-36 @
21-30 22-20 @ 23-38 @
12-10 0 13-37 0
21-31 22-21 @ 23-39 0
12-11 0 13-38 @I
21-32 22-22 0 23-40 @
12-12 0 13-39 0
0 21-33 23-l @ 23-41 @
12-13 @ 13-40
0 21-34 23- 2 @ 23-42 @
12-14 @ 13-41
@ 21-35 23- 3 @ 23-43 @
13- 1 0 13-42
0 21-36 23- 4 @ 23-44 @
13-2 @ 13-43
13-44 0 21-37 23- 5 @ 23-46 @
13-3 0
13-45 0 21-38 23- 6 @ 23-47 @
13-4 0
0 13-46 @ 23- 7 @ 23-48 @
13-5
WA350-1 00-2 -1
0
Revision Revision Revision Revision Revision
Mark Page /lark Page Aark Page Aark Page lark Page
number number number number number
23- 49 @ 23-105 @ 41-21 44- 2 52-20

23- 50 @ 23-106 @I 41-22 44- 3 53- I
23- 51 @ 23-107 @I 41-23 44- 4 53- 2
23- 52 @ 23-108 @ 41-24 44- 6 53- 3
23- 53 @ 23-109 0 41-25 44- 7 53- 4
23- 54 @ 23-110 @ 42- 1 44- 8 53- 5
23- 55 @ 23-111 @ 42- 2 44- 9 53- 6
23- 56 @ 23-112 @ 42- 3 44-10 53- 7
23- 57 @ 23-113 @ 42- 4 44-11 53- 8
23- 58 @ 23-114 @ 42- 5 44-12 53- 9
23- 59 @ 23-Cl5 @ 0 42- 6 44-13 53-10
23- 60 @ 23-116 @ 0 42- 7 44-14 53-11
23- 61 @-- 23-117 @ 42- 8 44-15 53-12
23- 62 @ 23-118 @ 42- 9 51- I 53-13
23- 63 @ 23-119 0 42-10 51- 2 53-14
23- 64 @ 24- 1 42-11 51- 3 53-15
23- 65 @ 24- 2 @ 42-12 51- 5 53-16
23- 66 -0 24- 3 43- I 51- 6 53-17
23- 67 @ 24- 4 43- 2 51- 7 53-18
23- 68 @ 24- 5 43- 3 51- 8 53-19
23- 69 @ 24- 6 43- 4 51- 9 53-20
23- 70 @ 24- 7 @ 43- 5 51-10 53-21
23- 72 @ 24- 8 43- 6 51-11 53-22
23- 73 @ 24- 9 @ 43- 7 51-12 53-23
23- 74 @ 24- IO 43- 8 51-13 53-24
23- 75 @ 24- 11 @ 43- 9 51-14 53-25
23- 76 @ 24- 12 @ 43-10 51-15 53-26
23- 77 @ 24- 14 43-11 51-16 53-27
23- 78 @ 24- 15 43-12 51-17 53-28
23- 79 @ 24- 16 @ 43-13 51-19 53-29
23- 80 @ 24- 17 @ 43-14 51-20 53-30
23- 81 @ 24- 18 @ 43-15 51-21 53-31
23- 82 @ 24- 19 43-16 51-22 53-32
23- 83 @I 24- 20 @ 43-17 51-23 53-33
23- 84 @ 24- 21 @I 43-18 51-24 53-34
23- 85 @ 41-1 0 43-19 51-25 53-35
23- 86 @ 41-2 @ 43-20 52- I 53-36
23- 87 @ 41- 3 0 43-22 52- 2 53-37
23- 88 @ 41- 4 0 43-23 52- 3 53-38
23- 89 @ 41-5 8 43-24 52- 4 53-39
23- 90 @ 41- 6 @ 43-25 52- 5 53-40
23- 91 @ 41- 7 0 43-26 52- 6 53-41
23- 92 @ 41- 8 @ 43-27 52- 7 53-42
23- 93 @I 41- 9 0 43-28 52- 8 53-43
23- 94 @ 41- 10 43-29 52- 9 53-44
23- 95 @ 41- II 0 43-30 52-10 53-45
23- 96 @ 41- 12 0 43-31 52-11 53-46
23- 97 @ 41- 13 0 43-32 52-12 53-47
23- 98 @ 41- 14 0 43-33 52-13 53-48
23- 99 @ 41- 15 43-34 52-14 54- 1
23-100 @ 41- 16 43-35 52-15 54- 2
23-101 @ 41- 17 0 43-36 52-16 54- 3
23-102 @ 41- 18 @ 43-37 52-17 54- 4
23-103 @ 41- 19 0 43-38 52-18 54- 5
23-104 @ 41- 20 @ 44- I 52-19 54- 6 @
00-2 -2 WA350-1
0
Revision Revision Revision Revision Rewsion
Mark Page /lark Page Jlark Page lark Page lark Page
54- 7 @ 63- 5 81-10 82-27 82- 86 @

54- 8 63- 6 81-11 82-28 82- 87 @I
54- 9 0 63- 7 81-12 82-29 82- 88 @I
61- I @ 63- 8 81-13 82-32 82- 89 0
61- 2 63- 9 81-14 82-33 82- 90 @
61- 3 63-10 81-15 82-34 82- 91 Cj)
61- 4 @ 63-11 81-16 82-35 82- 92 0
61- 5 @ 63-12 81-17 82-36 82- 93 @
0 6l- 5-l 0 63-13 81-18 82-37 82- 94 @
6l- 5-2 @ 63-14 81-19 82-38 82- 95 @
6l- 6 @ 63-15 81-20 82-39 82- 96 @
6l- 7 63-16 81-21 82-40 82- 97 @
6l- 8 -. 63-17 81-22 82-41 82- 98 0
6l- 9 63-18 81-23 82-42 82- 99 @
61-10 63-19 81-24 82-43 82-100 @
61-11 63-20 81-25 82-44 82-102 @
61-12 @ 63-21 81-26 82-45 82-103 @
61-14 @ 63-22 81-27 82-46 82-104 @
61-15 63-23 81-28 82-47 82-105 @
61-15-I @ 63-24 81-29 82-48 82-106 @
61-15-2 @ 63-25 81-30 82-49 82-107 @
61-16 63-26 81-31 82-50 82-108 @
61-17 63-27 81-32 82-51 82-109 @
61-18 @ 63-28 81-33 82-52 82-110 @
61-19 63-29 81-34 82-54 82-111 @
61-20 63-30 81-35 82-55 82-112 @
61-21 @ 63-31 81-36 82-56 82-113 @
61-22 63-32 81-37 82-57 82-114 @
61-23 63-33 81-38 82-59 82-115 @
61-24 63-34 81-39 82-60 83- I @
61-25 63-35 81-40 82-61 83- 2 @
61-26 @ 63-36 81-41 82-62 9l- I @
62- 1 @ 63-37 82- I 82-63 91- 2
62- 2 @ 63-38 82- 2 82-64 9l- 3 @
62- 3 @ 64- 1 82- 5 82-65 9l- 4 @
62- 4 @ l 64- 2 82- 6 82-66 9l- 5
62- 5 @ 64- 3 82- 8 82-67 91- 6
62- 6 @ 64- 3-l 82- 9 82-68 9l- 7
62- 7 @ 64- 3-2 82-10 82-69 93- I @
62- 8 @ 64- 4 82-11 82-70 93- 2 @
62- 9 @ 64- 5 82-12 82-71 93- 3 @
62-10 @ 64- 6 82-13 82-72 93- 4 @
62-11 @ 64- 7 82-14 82-73 93- 5 @
62-13 @ 64- 8 82-15 82-74 93- 6 @
62-14 @ 64- 9 82-16 82-75 93- 7 @
62-15 @ 64-10 82-17 82-76 93- 8 @
62-16 @I 8l- I 82-18 82-77 93- 9 0
62-17 @ 8l- 2 82-19 82-78 93- IO @
62-18 @ 8l- 3 82-20 82-79 97- 1 @
62-19 @ 8l- 5 82-21 82-80 97-001 @
62-20 @ 8l- 5-2 82-22 82-81 97-002 @
63- I @ 8l- 6 82-23 82-82 97-003 @
63- 2 @ 8l- 7 82-24 82-83 97-004 @
63- 3 @ 8l- 8 82-25 82-84 97-005 @
63- 4 @ 81- 9 82-26 82-85 97-006 @
WA350-1 00-2 -3
a
Revisior Revision Revision Revfsion Revision
Mark Page Aark Page dark Page Aark Page Mark Page
97407
97-008
97-101
97-102
97-103
97-104
97-105
97-106
97-107
97-108
97-109
97-110
97-111
97-112
97-113
97-114
97-115
97-116
97-117
00-2 -4 WA350-1
a
A IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu and described in this
manual are both effective and safe methods of operation. Some of these operations re-
quire the use of tools specially designed by Komatsu for the purpose.
*& are
To prevent injury to workers, the symbols A and
4
used to mark safety pre-
cautions in this manual. The cautions accompanying these symbols should always be
followed carefully. If any dangerous situation arises or may possibly arise, first consider
safety, and take the necessary actions to deal with the situation.
A SAFETY
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for
1. Before carrying out any greasing or repairs,
smoking. Never smoke while working.
read all the precautions given on the
decals which are fixed to the machine.
2.When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when
8. Before starting work, lower blade, ripper,
grinding parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, equipment from falling. In addition, be sure
always wear welding gloves, apron, glasses, to lock all the control levers and hang
cap and other clothes suited for welding warning signs on them.
work. 9. When disassembling or assembling, sup-

port the machine with blocks, jacks or
4.When carrying out any operation with two
stands before starting work.
or more workers, always agree on the op-
erating procedure before starting. Always 10. Remove all mud and oil from the steps or
inform your fellow workers before starting other places used to get on and off the
any step of the operation. Before starting machine. Always use the handrails, ladders
or steps when getting on or off the
work, hang UNDER REPAIR signs on the
machine. Never jump on or off the machine.
controls in the operators compartment.
If it is impossible to use the handrails,
5. Keep all tools in good condition and learn ladders or steps, use a stand to provide safe
the correct way to use them. footing.
00-3
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, l When installing hoses and wires, be
loosen them slowly to prevent the oil from sure that they will not be damaged by
spurting out. contact with other parts when the ma-
Before disconnecting or removing compo- chine is being operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
circuit. sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot
ful when installing tubes for high pressure
when the engine is stopped, so be careful
circuits. Also, check that connecting parts
not to get burned.
are correctly installed.
Wait for the oil and water to cool before car-
rying out any work on the oil or water 21. When assembling or installing parts, always
circuits. use the specified tightening torques. When
13. Before starting work, remove the leads from installing protective parts such as guards, or
the battery. Always remove the lead from parts which vibrate violently or rotate at
the negative (-1 terminal first. high speed, be particularly careful to check
that they are installed correctly.
14. When raising heavy components, use a
hoist or crane. 22. When aligning two holes, never insert your
Check that the wire rope, chains and hooks fingers or hand. Be careful not to get your
are free from damage. fingers caught in a hole.
Always use lifting equipment which has
ample capacity. 23. When measuring hydraulic pressure, check
Install the lifting equipment at the correct that the measuring tool is correctly assem-
places. Use a hoist or crane and operate bled before taking any measurements.
slowly to prevent the component from hit-
24. Take care when removing or installing the
ting any other part. Do not work with any
tracks of track-type machines.
part still raised by the hoist or crane.
When removing the track, the track sepa-
15. When removing covers which are under in- rates suddenly, so never let anyone stand at
ternal pressure or under pressure from a
either end of the track.
spring, always leave two bolts in position on
opposite sides. Slowly release the pressure,
then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil

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

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

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

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

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Contact your KOMATSU distributor for the
latest information.
00-5
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK (@)a@ -.-- )
Shop manuals are issued as a guide to carry- When a manual is revised, an edition mark is
ing out repairs. They are divided as follows: recorded on the bottom outside corner of the
pages.
Chassis volume: Issued for every machine
model
Engine volume: Issued for each engine series
Each issued as
Electrical volume REVISIONS
one volume to
Attachments volume
cover all models Revised pages are shown at the LIST OF
REVISED PAGES on the between the title page
and SAFETY page.
These various volumes are designed to avoid
duplicating the same information. Therefore to
deal with all repairs for any model, it is neces-
sary that chassis, engine, electrical and attach-
ment volumes are ready. SYMBOLS
So that the shop manual can be of ample

DISTRIBUTION AND UPDATING
practical use, important places for safety and
Any additions, amendments or other quality are marked with the following symbols.
changes will be sent to KOMATSU distributers.
Get the most up-to-date information before
you start any work.
Symbol Item Remarks
FILING METHOD
Special safety precautions are
1. See the page number on the bottom of the A necessary when performing
work.
the
page. File the pages in correct order. Safety

2. Following examples shows how to read the Extra special safety precautions
page number. *& are necessary when performing
Example 1 (Chassis volume): * the work because it is under
internal pressure.
IO-3
Special technical precautions or
other precautions for
Item number (IO. Structure * Caution preserving standards are
and Function) necessary when performing the
% Consecutive page number for work.
each item.
Weight of parts or systems.
Example 2 (Engine volume): Caution necessary when
Weight selecting hoisting wire, or when
12-410 working posture is important,
etc.
Unit number (I. Engine)
Item number (2. Testing and Places that require special
Tighten-
Adjusting) attention for the tightening
ig torque ?
torque during assembly.
Group No. (4. Fuel system)
F Consecutive page No. (Page
Places to be coated with
10 of Group 4) Coat
adhesives and lubricants etc.
3. Additional pages: Additional pages are in- Places where oil, water or fuel
dicated by a hyphen (-1 and number after the Xl, water must be added, and the
page number. File as in the example. capacity.
Example:
Places where oil or water must
1 o-4 12-203 Drain be drained, and quantity to be
drained.
1 o-5 12-204
00-6
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
Slinging near the edge of the hook may

Heavy parts (25 kg or more) must be
cause the rope to slip off the hook during
lifted with a hoist etc. In the Disassembly
hoisting, and a serious accident can result.
Hooks have maximum strength at the
middle portion.
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
100% 88% 79% 71% 41%
the part to the relative parts.
FSO064
. Check for existence of another part
causing interference with the part to be 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
rem-oved.
symmetrically wound on to the load.
2. Wire ropes
A Slinging
turning
with one rope may cause
of the load during hoisting,
untwisting of the rope, or slipping of
I) Use adequate ropes depending on the
the rope from its original winding
weight of parts to be hoisted, referring to
position on the load, which can result
the table below:
in a dangerous accident.
4) Do not sling a heavy load with ropes

Wire ropes
forming a wide hanging angle from the
(Standard Z or S twist ropes
hook.
without galvanizing)
When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter (mm) Allowable load (tons)
will increase with the hanging angles. The
table below shows the variation of
10 1 .o
allowable load (kg) when hoisting is made
11.2 1.4 with two ropes, each of which is allowed
12.5 1.6 to sling up to 1000 kg vertically, at various
hanging angles.
14 2.2
When two ropes sling a load vertically, up
16 2.8 to 2000 kg of total weight can be
ia 3.6 suspended. This weight becomes 1000 kg
when two ropes make a 120 hanging
20 4.4
angle. On the other hand, two ropes are
22.4 5.6 subjected to an excessive force as large as
30 10.0 4000 kg if they sling a 2000 kg load at a
lifting angle of 150.
40 I a.0
50 28.0
60 40.0
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 from the middle portion

30 60 go* 120 150
of the hook.
Lifting angle : 01
FSO065
00-7
STANDARD TIGHTENING TORQUE
m STANDARD TIGHTENING TORQUE

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in
sections of Disassembly and Assembly.
Thread diameter Width

of bolt across flat
(mm) (mm)
I km I Nm
.. 10 1.35kO.15 13.2* 1.4

6
8 13 3.2kO.3 31.4k2.9
10 17 6.7 f 0.7 65.7k6.8
12 19 11.5*1.0 112t9.8
14 - 22 18.0t2.0 177*19
16 24 28.5*3 279&29
18 27 3924 383?39
20 30 56*6 549*58
22 32 76+8 745278
24 36 94.5* 10 927*98
27 41 135+15 1320+ 140

30 46 175220 1720-r 190
33 50 225&25 221 Ok240
36 55 28Ok30 27502290
39 60 335t35 3280&340
This torque table does not apply to the bolts with which nylon packings or other non-
ferrous metal washers are to be used, or which require tightening to otherwise specified
torque.
Sr Nm (newton meter): 1 Nm + 0.1 kgm
2.TlGHTENlNG TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
Thread: gtl,eter Width Tightening torque

across flats
(mm) (mm) kgm Nm
10 14 6.7kO.7 65.7 k6.8

12 17 II.521 112t9.8
16 22 28.5t3 279t29
00-8
STANDARD TIGHTENING TORQUE
Sealing surface
3.TlGHTENlNG TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter
of nut part
Width across flats
of nut part
r Tightening torque
(mm) (mm) km Nm
14 19 2.5kO.5 24.5 k4.9
18. 24 522 49* 19.6
22 27 822 78.5 f 19.6
24 32 1423 137.3k29.4
30 36 1823 176.5229.4
33 41 20*5 196.1 &49
36 46 2525 245.2+49
42 55 30&5 294.2*49
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Nomenclature Komatsu code Applications
LT-1 A Used to apply rubber pads, rubber gaskets, and cork plugs.
Used to apply resin, rubber, metallic and

LT-18
Adhesives non-metallic parts when a fast, strong seal is needed.
LT-2 Preventing bolts, nuts and plugs from loosening and leaking oil.
Provides an airtight, electrically insulating seal.

LT-3
Used for aluminum surfaces.
LG-1 Used with gaskets and packings to increase sealing effect.
Heat-resistant gasket for precombustion chambers

LG-3
and exhaust piping.
Gasket sealant
Used by itself on mounting surfaces on the final drive and trans-
LG-4
mission cases. (Thickness after tightening: 0.07 - 0.08 mm)
Used by itself to seal grease fittings, tapered screw
LG-5 fittings and tapered screw fittings in hydraulic circuits
of less than 50 mm in diameter.
Antif riction com-
pound (Lubricant Applied to bearings and taper shafts to facilitate press-fitting and to
LM-P
including molybde- prevent sticking, burning or rusting.
num disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust
G2-LI
(Lithium grease) prevention and facilitation of assembling work.
Vaseline - Used for protecting battery electrode terminals from corrosion.
lLT-2 is also called LOCTITE in the shop manuals.
00-9
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal _ Cable O.D.
Applicable circuit
number Number Dia. TF;ands Cross section (mm)
str_ands (mm2)
0.85 1 11 1 0.32 1 0.88 1 2.4 1 12 1 Starting, lighting, signal etc.
2 1 26 1 0.32 / 2.09 I 3.1 I 20 1 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 1 1.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
ity
Class+ ChTng / GrTd Signal Other
fication
\
G I L
1
White Black
Code WR -
2
Color White & Red -
Code WB
3
&xi_ Or White & Black -
liary
WL
t Code
4
Color White&Blue -
Code
5
t- Color
/ Code (GLI 1 -
6
Color (Green & Blue) 1 -
00-l 0
GENERAL WEIGHT TABLE
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
(Unit: kg)
11118
3Yl7 and up
Engine assembly 700 700
Radiator assembly 105 105
Torque converter assembly 160 160
Lift cylinder (I piece)
Dump cylinder 185 185
Engine hood 134 134
Rear drive shaft 12 12 Front frame 1,250 1,308

I I
Front axle assembly ) 1,129 1 1,129 Rear frame 1,040 1,021

I
Rear axle assembly 1,109 1,109 Bucket link 52 52
Front differential assembly 191 191 Tilt lever 248 248
)
Rear differential assembly 176 176
P~;t&rr~carrier assembly 68 1 68
II !
Planetary hub assembly 73 ( 73

(I piece) I
Axle pivot Front/Rear 1 61183 ( 61183 Fuel tank 204 204
Wheel (1 piece) 1 100 1 100 Battery (1 piece) 44 44
Tire (I piece) 210 210 Operators seat 37 37
Steering valve 32 32 Floor plate 75 75
Steering cylinder (1 piece) 27 27 CAB 310 310
Brake (1 piece) 111 111
l : with teeth.
l * : with bolt on cutting edge.
WA350-1 00-l 1
0
GENERAL TABLE OF OIL AND COOLANT QUANTITIES
TABLE 0 : OIL AND COOLANT QUANTITIES
RESERVOIR
Engine oil pan
Brake
Transmission case
Hydraulic system
Axle See NOTE (4) each 45 each 45

(Front and rear)
oiese, fue, LASTPAD975 No. 1

Fuel tank
Cooling system Water Add antifreeze 52 -
NOTE:
(1) When fuel sulphur content is less than 0.5%. (2) When starting the engine in an atmospherric tem-
change oil in the oil pan every periodic mainte- perature of lower then 0C. be sure to use engine
nance hours described in this manual. oil of SAEIOW, SAEIOW-30 and SAEI 5W-40,
Change oil according to the following table if fuel even though an atmospheric temperature goes up
sulphur content is above 0.5%. 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 in-
terval to half.
(4) For axle oil, use only recommended oil as follows.
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
Above 1.0% l/4 of regular interval
I TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL
* It is possible to substitute engine oil CLASS-CD
SAEBO for axle oil.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
00-12 WA350- 1
0
ENGINE
11 STRUCTURE AND FUNCTION
Engine mount .............................. 11-2

Radiator .................................. 11-3
Fueltankandpiping ........................ 11-4
Engine control ............................. 1 1-5
WA350-1 11-1
STRUCTURE AND FUNCTION ENGINE MOUNT
ENGINE MOUNT
423FOO5
. The engine, torque converter, transmission, and

transfer are each joined together.
. There are rubber mounts at the engine end and
transfer end.
1. Transmission mount
2. Engine mount
View 2
11-2 WA350-1
STRUCTURE AND FUNCTION RADIATOR
RADIATOR
Section X-X
423FOO6
I. Radiator Specifications
2. Coolant level sensor Core type: G6 type
3. Fan guard Total heat dissipating area: 52.57 m2
4. Hydraulic oil cooler Cross-sectional area of water tubes: 138 cm2
5. Torque converter oil cooler
A. Coolant inlet port
6. Coolant outlet port
WA350- 1 11-3
STRUCTURE AND FUNCTION FUEL TANK AND PIPING
FUEL TANK AND PIPING

The fuel level sensor is installed in the fuel tank.
__
F4230001
1. Connector
2. Fuel level sensor
3. Injection pump
4. Drain cock
5. Fuel filler port
11-4 WA350- 1
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
F4230002
1. Accelerator pedal
2. Injection pump
WA350-1 11-5
ENGINE
12 TESTING AND ADJUSTING
Standard value table . .. . . _. . . 12- 2

Tool list for testing and adjusting . 12- 3
Adjusting valve clearance . . . . . 12- 4
Measuring compression pressure . . . . 12- 5
Testing and adjusting fuel injection timing .. 12- 6
Measuring engine oil pressure
and temperature . . 12- 8
Measuring blow-by pressure .. . . . 12- 9
Testing and adjusting fan belt tension . 12-l 0
Measuring exhaust gas color .. .. .... 12-l 1
Measuring accelerator pedal operating force
and operating angle . .. . .. 12-l 2
Adjusting fuel cut solenoid . . .. .. .. 12-l 4
* The following precautions are necessary when using the Standard Value Tables to make judgements during
troubleshooting 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 value tables must not be used for standard values when judging claims. In addition, do not
use these values alone to make simple judgements.
WA350-1
%
TESTING AND ADJUSTING STANDARD VALUE TABLE
STANDARD VALUE TABLE
Cate
Engine
r Standard
Komatsu S6Dll O-l
Permissible
Item Condition Unit
gory value value
High idling speed 2,350 - 2,450 -

rpm
2,430 - 2,530: -
Engine speed
Low idling speed rpm 650-750
(680-780) -
Necessary starting 0C vm Min. 150 Min. 150

speed . - 20C (using starting aid) rpm Min. 100 Min. 100
Intake resistance All speed mmH,O Max. 300 Max. 635
Exhaust pressure All speed mmHg Max. 50 Max. 75
Exhaust temperature All speed (intake air temp. 20C) C Max. 650 Max. 650
At abrupt acceleration Bosch index Max. 5.0 6.5

(Max. 6.5) (8.5)
Exhaust gas color
At high idling Bosch index Max. 1 .O 2.0
(Max. 2.5) (3.5)
Valve clearance Intake valve mm 0.25 0.25

(When engine is cold) Exhaust valve mm 0.45 0.45
Oil temperature 40 - 60C kg/cm2 Min. 30

Compression pressure
u [engine speed1 [rpml [300 - 3501 13002-43501
moBlow-by pressure
At high idling,
mmH,O Max. 150 300
oil temoerature min. 60C
Oil pressure At high idling kg/cm2 3.5-5.5 2.5
(SAE30 oil temperature:
min. 8dC) At low idlino ko/cm2 Min. 1.5 1 .o
Whole speed range
Oil temperature C 80-I 10 120
(inside oil pan) I
Oil consumption ration

At continuous rated horsepowe
(oroportion to fuel consumption) 1 % Max. 0.5 1 .o
Fuel injection pressure Nozzle tester kg/cm2 250 200
Fuel injection timing Before top dead center degree 16 16+1
Whole speed range

Coolant temperature OC 70-90 100
(at engine outlet) I
Valve cracking temperature C 74.5 - 78.5 74.5 - 78.5
Thermostat function Temperature when fully open C 90 90
Lift when fully open mm 9.5-10.5 9.5 - 10.5
Fan belt tension Deflection when pushing

mm 7.5 5-10
(Alternator-Fan pulley) with finger force approx. 6 kg
Operating force kg 4-7 Max. 10.5
Operating angle cy degree CYI45 cY,33 -
Operating travel L mm 42
Stopper height L, mm 15-25
Stopper height Lz mm 15-25
Rod length X mm 136-146
( 1: Serial No. 1 1 1 18 and up

12-2 WA350-1
0
TESTING AND ADJUSTING TOOL LIST FOR TESTING AND ADJUSTING
TOOL LIST FOR TESTING AND ADJUSTING
I No. Testing and measuring item Tool Part No. Remarks
7~ 1 Engine speed Tachometer 799-203-8000 Digital display 60-I 9,999 rpm
2 Battery specific gravity 1.100 - 1.300

Battery coolant tester 795-500-1000
3 Coolant freezing temperature -5 - -50C
4 Water temperature, oil temper-

790-500-I 300 0 - 200C
ature, intake temperature Thermistor
or
temperature gauge
799-l 01-6000
5 Exhaust temperature 0 - 1,oooc
6 Lubricating oil pressure 0 - 10 kg/cm2
7 Fuel pressure 0 - 20 kg/cm2
Intake pressure, Engine presssure

8 799-203-2002 0 - 1,500 mmHg
exhaust pressure measuring kit
-
9 Blow-by pressure 0 - 1,000 mmH,O
10 Intake resistance - 1,000 - 0 mmH,O

~ I_
11 Compression pressure Compression gauge 795-502-I 204 0 - 70 kg/cm2
12 Blow-by pressure Blow-by checker 799-201-I 503 0 - 500 mmH,O

-
13 Valve clearance Feeler gauge 795-l 25-l 330 0.25,0.45 mm
Commercially Discoloration 0 to 70% standard color

14 Exhaust gas color Smoke meter
available (Discoloration %x l/l O=Bosch index)
15 Water content 0.1%. 0.2%

Fuel on water mixed in oil Engine oil checker 799-201-6000
in standard sample
16 Coolant quality Water quality tester 799-202-7001 PH. nitrous acid ion concentration
17 Leakage from cooling system Cap tester 799-202-9001 0 - 2 kg/cm2
18 Fuel injection pressure Commercially

Nozzle tester 0 - 300 kg/cm2
Nozzle injection condition available
Commercially
19 Electrical circuit Tester Current, voltage, resistance
available
20 Accelerator pedal force Push-pull scale 7AO-262-0020 Commercially available 0 - 25 kg
m When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, insert the safety
pins and block the tracks.
A When working in groups, use agreed signals and do not allow unauthorized persons near the machine.
A When checking the water level in the radiator wait for the water to cool. Do not remove the radiator cap
while the water is hot. Boiling water may spurt out.
A Be careful not to get caught in rotating parts.
WA350 1 12-3
al
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

* Condition: Engine is cold.
* Adjust clearance between valve and rocker lever
as follows.
Unit: mm
Intake valve Exhaust valve

I
Cold 0.25 0.45
Special tool --
Part number Part name Qty

A 1 795-125-1330 1 Feelergauge I 1
1. Remove air cleaner assembly and intake

connector, then remove cylinder head cover (I ).
2. Rotate the crankshaft in the normal direction to
align pointer (2) with the 1.6 TOP mark on crank-
shaft pulley. When rotating, check the movement
of the valves. When the pointer is in line with the
1.6 TOP mark, No.1 cylinder should be at com-
pression top dead center.
3. When No. 1 cylinder is at compression top dead
center, adjust the valve marked l .
When No.6 cylinder is at compression top dead
center, adjust the valves marked 0.
4. To adjust, insert tool A between rocker lever (3)

and valve stem (4) and turn adjustment screw (5)
until clearance is a sliding fit. Then tighten lock
nut (6) to hold adjustment screw in position.
m Lock nut: 3.2 * 0.3 kgm
5. Next, rotate crankshaft one turn in the normal di-

rection and adjust the valve clearance of the re-
maining valves marked o.
t After adjusting No.1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 120 each time and adjust the valve
clearance of each cylinder according to the
firing order.
l Firing order: l-5-3-6-2-4
Zr After tightening the lock nut, check the clear-
ance again.
r I
423F301
12-4 WA350-1
a
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

* Measurement condition
l Coolant temperature: Inside operating range.
l Engine valve clearance: Standard value.
l Engine speed: 360 to 380 rpm
Unit: kg/cm2
Standard Permissible
Item
value value
Compression
Min. 28 Min. 19.5
pressure
Special tools
1 Part number 1 Part name IQty

Al--- 795 502-I 204 1Compression gauge I
B 799-203-8000 Tachometer 1
* If performance tests or troubleshooting shows

that the piston, piston ring or cylinder liner may be
worn, measure the compression pressure.
m When
careful
measuring
not to touch
the compression
the exhaust
pressure,
manifold
be
or
muffler, or to get caught in rotating parts.
1. Adjust valve clearance.

t For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Warm up engine (oil temperature 40C)
3. Remove nozzle holder assembly.
4. Install adapter A in mount of nozzle holder

assembly, and connect pressure gauge.
5. Set engine tachometer B in position.
6. Disconnect fuel CUT-OFF solenoid valve

connector.
Crank engine with starting motor and measure
compression pressure.
Zr Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
* When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
* Installing the nozzle holder assembly after measur-
ing the compression pressure.
WA350-1 12-5
@
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

Unit: degree
Item
value value
m-~ B.T.D.C. 16 ( 16+ 1
TESTING FUEL INJECTION TIMING
1. Disconnect fuel injection pipe (1) of No. 1 cylinder.
2. Remove delivery valve holder (2). then remove

delivery valve (3) and spring (4). and install delivery
valve holder (2) again.
3. Place fuel control lever at FULL position.
4. Operate priming pump and rotate crankshaft

slowly in normal direction. Check point where fuel
stops flowing from delivery valve holder (2).
5. Check that 16 I.J. line on crankshaft pulley (5)

and pointer 16) are aligned at point where fuel
stops flowing.
* BEYOND injection timing line:
Timing RETARDED
Sr BEFORE injection timing line:
Timing ADVANCED
* If the test shows that the fuel injection timing is

incorrect, adjust as follows.
/j&v
423F302
12-6 WA350-1
0
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
ADJUSTING FUEL INJECTION TIMING

BY DELIVERY CHECK
1. Turn crankshaft back 30 - 40 from top dead

center.
2. Rotate cankshaft to align 16 I.J. line on crank-

shaft pulley and pointer correctly.
3. Loosen nut (7) on the injection pump mounting

flange bolt, and rotate the flange on the pump side
little by little by operating the priming pump (9)
until no fuel flows out of the delivery valve holder.
4. Tighten nut (7) in oblong hole of mountijng flange

of fuel injection pump.
+ After-tightening the bolt, check again that the
fuel stops flowing from the delivery valve
holder at the point where the pointer is aligned
with the line on the crankshaft pulley.
5. Remove delivery valve holder (2). assemble deliv-
ery valve (3) and spring (41, then install delivery
valve holder (2) again.
w Delivery holder: 3.3 -C 0.2 kgm
6. Connect fuel injection pipe (I).
m Sleeve nut: 2.4 + 0.1 kgm
WA350-1 12-7
0
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE AND TEMPERATURE
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE

1. Measuring engine oil pressure.
t Measurement condition
Unit: kg/cm*
~~
Special tool

Engine pressure
A 799-203-2002 1
measuring kit
A When measuring, be careful not to get caught

in rotating parts.
A Install and remove the plug and oil pressure
gauge with the engine stopped.
t Measure the engine oil pressure when the oil tem-
perature is at the specified temperature.
1) Remove plug (I 1.
2) Install oil pressure gauge A (25 kg/cm?
* Install the oil pressure gauge so that it is af-
fected as little as possible by the engine
vibration.
3) Start engine and measure oil pressure.
2. Measuring oil temperature.

Item
value value
Oil temperature 190- 110C I 120C
12-8 WA350-1
0
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

. Coolant temperature: inside operating range.
. Engine valve clearance: Standard valve
Unit: mm H,O
Item
value I value
Blow-by
Max. 150 300
pressure
Special tool
~ r P&t number 1 Part name
A 1 799-201-1503 1 Blow-by checker 1 1
2. Precautions when measuring blow-by

It Blow-by may vary greatly according to the con-
dition of the engine, so if there is any abnormali-
ty in the reading, check for any problem related
to defective blow-by, such as excessive oil
consumption, defective exhaut gas color, or
early deterioration or contamination of the oil.
WA350-1 12-9
0
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION
Testing fan belt tension

Check the amount the fan belt deflects when pushed Fan pulley
with a force of approx. 6 kg at a point midway

between the fan pulley and the alternator pulley.
Alternator pulley
Unit: mm
423F303
Measuring procedure
1. Push the V-belt with a force of 6 kg, at a point
midway between the pulley and the alternator.
2. Use a scale to measure the amount the V-belt
deflects.
Adjustment procedure
1. Loosen mounting bolt (1) of the alternator
assembly, and the mounting bolt of adjustment
plate (2).
2. Insert a stick or bar between the alternator
mounting bolt and the cylinder block, then raise
the alternator to the outside.
Qf If the alternator is moved to the inside with the

hands, there is danger of catching and insuring
the fingers.
3. Adjust the belt (3) tension and temporarily tighten

mounting bolt.
4. Check that the belt tension is correct then tighten
all mounting bolts fully.
12-10 WA350-1
0
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

l Valve clearance: Standard value.
Unit: Bosch index
Special tool

Commercially
A Smoke meter 1
available
* When measuring the exhaust color; be careful

not to touche the exhaust pipe.
1. Insert probe @ in outlet of exhaust pipe (I) and

secure to exhaust pipe with clip.
2. Connect probe hose, connector hose @of accel-

erator switch and air hose to smoke meter A.
* The pressure of the air supply should be under
15 kg/cm2.
3. Connect power cord to AC1 OOV socket.

Sr Check that the power switch is OFF before con-
necting the cord.
4. Loosen cap nut of suction pump and insert filter

paper.
5. Turn power switch ON
6. Accelerate engine suddenly. At the same time,

depress accelerator pedal, operate relief valve and
catch exhaust gas color on filter paper.
7. Lay filter paper used to catch exhaust gas color on

top of unused filter papers (10 sheets or more)
inside filter paper holder, and read indicated value.
WA3561
MEASURING ACCELERATOR PEDAL OPERATING
TESTING AND ADJUSTING FORCE AND OPERATING ANGLE
MEASURING ACCELERATOR PEDAL OPERATING FORCE

AND OPERATING ANGLE
Unit: kg a
Item
value value
Operating force of
4-7 Max. 10.5
accelerator oedal
Special tool _-
423 F304
A 7AO-262;0020 Push-pull scale 1
OPERATING FORCE
1. Measuring procedure
I) Put push-pull scale A in contact with the accel-
erator pedal at point 150 mm from pedal ful-
crum a.
* The center of push-pull scale A must be in
contact with a point 150 mm from the pedal
fulcrum.
2) Start the engine, push the pedal in the direction
of operation and measure the maximum value
when pushing from idling to the end of the
pedal travel (high idling).
2. Testing and adjusting

I) Stop the engine.
2) Disconnect the cable at the bottom of the ac-
celerator pedal, and check that the linkage and
ball joint at the bottom of the pedal move
smoothly.
3) Connect the cable at the bottom of the pedal,
then disconnect at the connection for the injec-
tion pump, and check that the cable moves
smoothly.
* When carrying out this inspection, adjust or
replace parts as necessary. Measure the
operating force again and check that it is
within the standard range.
12-12 WA350-1
0
MEASURING ACCELERATOR PEDAL OPERATING
TESTING AND ADJUSTING FORCE AND OPERATING ANGLE
OPERATING ANGLE OF ACCELERATOR

PEDAL
Unit: mm
Operating travel
I
L
I
42
w
423 F305
Installed height of
accelerator pedal stopper
Installed length
136-146 -
X of rod I
1. Measuring procedure
1) Stop the engine.
2) Measure the operating angle cyl, cxz, put the
angle gauge in contact with the accelerator
pedal it is operated from low-idling and high
idling.
2. Adjusting procedure
1) Remove the cover under the cab, open the
engine hood and fit the safety lock.
2) Loosen nut (I) and adjust installed length X of
rod (2) until it is 160 f 5 mm.
3) Release the accelerator pedal, loosen nut (5)
and adjust the height L, of the stopper bolt (6)
until it is 18 +- 5 mm.
4) Depress the accelerator pedal, loosen nut (3)
and adjust the height Lz of the stopper bolt (4)
until it is 17 +- 5 mm.
5) Depress the accelerator pedal, loosen lock nut
(7) and adjust the length of cable so that the in-
jection pump governor lever contacts the high
idle stopper.
t After making the above adjustments, take all
measurements again and check that they
are within the standard value.
WA350-1 12-13
TESTING AND ADJUSTING ADJUSTING FUEL CUT SOLENOID
ADJUSTING FUEL CUT SOLENOID
1. Confirm that stop lever (2) of the fuel injection

pump (I 1 is at the STOP position.
(Usually, the return spring holds the stop lever at
the STOP position.)
2. Adjust rod so that the solenoid has a maximum

stroke.
Adjust rod so clearance b is 0.4 * 0.1 mm
between injection pump stopper lever (2) and
stopper (3).
Stroke-a = 12 mm
3. Turn on the engine starting key and confirm that

the solenoid stroke a is the standard dimension.
4. Tighten nuts (5) and (6) of rod (4).
423F338
12-14 WA350-1
0
ENGINE
13 DISASSEMBLY AND ASSEMBLY
..
STARTING MOTOR ASSEMBLY RADIATOR ASSEMBLY
Removal .......................... 13- 2 Removal . . . . 13-24
Installation . . 13- 2 Installation .. ,. , . , _, . . . . . . . . 13-27
ALTERNATOR ASSEMBLY OIL COOLER ASSEMBLY
Removal . . . . . . . . .._........_....__ 13- 3 Removal ..__..__..._........._........ 13-29
Installation . .. .. . 13- 3 Installation . . . . .. . . . 13-29
FUEL INJECTION PUMP ASSEMBLY ENGINE ASSEMBLY

Removal . . . ..__..._.........._.... 13- 4 Removal .............................. 13-30
Installation . . . . . 13- 4 Installation . . .. . . . 13-37
WATER PUMP ASSEMBLY FUEL TANK ASSEMBLY
Removal . . . . . . _.........__..,_.... 13- 5 Removal . . . . 13-44
Installation . . . . . 13- 5 Installation . . . .. . 13-46
NOZZLE HOLDER ASSEMBLY

Removal .......................... 13- 6
Installation . . . .. . . 13- 6
CYLINDER HEAD ASSEMBLY

Removal _....__...__..._...__..... 13- 8
Installation . .. 13-14
TURBOCHARGER ASSEMBLY
Removal . .._........._. 13-22
Installation . . . . .. . 13-22
COMPRESSOR ASSEMBLY
Removal .. .. . . 13-23
Installation ... . . , . 13-23
Sr Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling
cylinders, pumps and pipings.
1. Start engine, keep idling.
2. Operate hydraulic cylinder 4 - 5 cycles, but do not exceed beyond 100 mm of stroke end.
3. Continued to operate cylinder 3 - 4 cycles until stroke end.
4. After finishing above steps, keep normal engine speed.
NOTE: After long storage, same procedure is required.
WA350-1 13-I
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING MOTOR ASSEMBLY
A Disconnect
terminal
the cable
of the battery.
from the negative (-1
1. Remove catch, then open hood.

2. Disconnect wire (I) and connector (2).
3. Remove ground connection (3). then remove start-
ing motor assembly (4).
__
INSTALLATION OF START-
ING MOTOR ASSEMBLY
1. Fit O-ring and install starting motor assembly (41,

then tighten together with ground connection (3).
2. Connect connector (2) and wire (1).
3. Close hood, then lock with catch.
4. Connect cable to negative (-1 terminal of battery.
13-2 WA350-1
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR ASSEMBLY
n Disconnect the cable from the negative (-1

terminal of the battery.

2. Disconnect wires (I), (2) and (3).
3. Remove bolt (4) of adjustment plate, then loosen
mounting bolt and nut (5).
4. Move alternator assembly towards cylinder block
to loosen belt tension, then remove belt (6).
5. Remove mounting bolt and nut, then remove alter-
nator assembly (7).
INSTALLATION OF
ALTERNATOR ASSEMBLY
1. Install alternator assembly (71, then partially tight-

en mounting bolt and nut (5).
2. Fit belt (6) in pulley groove and install.
3. Partially tighten bolt (4) of adjustment plate.
4. Insert a bar between alternator assembly and cylin-
der block, raise alternator assembly and adjust ten-
sion of belt.
* The belt should deflect about IO mm when
pushed with a finger pressure of 6 kg at a point
midway between the alternator and the fan
pulley.
5. Tighten bolt of adjustment plate, mounting bolt
and nut (5).
6. Connect wires (31, (2) and (I ).
8. Connect cable to negative (-1 terminal of battery.
WA350-1 13-3
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY

2. Disconnect control rods (I 1and (2).
3. Disconnect boost compensator hose (3).
4. Disconnect fuel hoses (4) and (5).
5. Disconnect fuel supply hose (6).
6. Remove lubrication tubes (7) and (8).
7. Disconnect 6 fuel injection tubes (9).
8. Remove coupling bolt (10).
9. Remove 4 mounting bolts, then pull out fuel injec-
tion pump assembly (I 1) to rear to remove.
INSTALLATION OF FUEL IN-

JECTION PUMP ASSEMBLY
1. Place fuel injection pump assembly (1 I) on

bracket, and set in position. Partially tighten 4
mounting bolts, then tighten coupling bolt (IO).
2. Rotate crankshaft and align pointer (13) with line
on crankshaft pulley (I 2).
t If the timer line is not at the front, rotate the
crankshaft one more turn.
3. Align line A on fuel injection pump with line B on
timer side, then tighten mounting bolts of pump
uniformly in turn.
4. Connect 6 fuel injection tubes (9). and tighten
nuts.
w Sleevenut: 2.4kO.l kgm
5. Fit gaskets and install lubrication tubes (8) and (7).

6. Fit gasket and connect fuel supply hose (6).
7. Fit gaskets and connect fuel hoses (51 and (4).
8. Connect boost compensator hose (3).
9. Connect control rods (2) and (I ).
IO. Close hood, then lock with catch.
13-4 WA350-1
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP AS SEMBLY

1. Remove catch, then open hood. Loosen drain
valve (I) and drain cooling water.
* If the coolant contains antifreeze, dispose of it
correctly.
2. Remove fan guard (2). then remove fan (3).
3. Loosen adjustment bolt (41, mounting bolt and nut
(5), move alternator assembly (6) towards cylinder
block, then remove belt (7).
4. Disconnect radiator outlet hose (8) and bypass
hose (9).
5. Remove bracket (IO) and plate (I 1). then remove
water pump assembly (I 2).
INSTALLATION OF WATER
PUMP ASSEMBLY
1. Fit gasket and install water pump assembly (I 2).

2. Install plate (I I).
3. Install bracket (10).
4. Connect bypass hose (9) and radiator outlet hose
(8).
5. Fit belt (7). insert a bar between alternator assem-
bly (6) and cylinder block, raise alternator assem-
bly and adjust tension of belt. Tighten adjustment
bolt (4). and mounting bolt and nut (5).
* For details of adjusting tension of belt, see 12
TESTING AND ADJUSTING.
6. Install fan (3).
7. Install fan guard (2).
8. Tighten drain valve (1) and add water through
water filler to the specified level.
It Run the engine to circulate the water through
the system. Then check the water level again.
WA350- 1
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE HOLDER ASSEMBLY

2. Loosen hose clamp (I), remove bracket bolt (2)
and band, then remove air cleaner assembly (3).
3. Remove drain tube (41, then remove muffler as-
sembly (5).
4. Remove spill pipe (6).
5. Disconnect fuel injection tube (7) at nozzle holder
end.
6. Remove nozzle holder assembly (8).
* When removing the nozzle holder, clean
around the no.zzle holder and fit a blind plug to
prevent dust or dirt from entering.
Sr Mark the nozzle holders with tags showing the
cylinder No. and keep in a safe place. If there is
no abnormality in the nozzle holder, install in
the same position when assembling.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
1. Install nozzle holder assembly (8).
w Mounting bolt: 1.7 +0.2 kgm
* Tighten the nozzle holder mounting bolts

uniformly.
2. Connect fuel injection tube (7).
B Sleeve nut: 2.3kO.2 kgm
3. Fit gasket and install spill pipe (6).

4. Install muffler assembly (51, then install drain tube
(4).
5. install air cleaner assembly (3). then tighten brack-
et bolt (2).
6. Tighten hose clamp (I), then secure with band.
13-6 WA350-1
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD ASSEMBLY
Intake Coector.
3WA350-1
Wheel loader
-I Hood
FIGI iniertinn
11
12
intake heater
13-8 WA350-1
0
1. Hood
Remove catch, then open hood.
2. Draining water
1) Loosen radiator drain plug (I ) and drain cooling
water.
2) Loosen drain plug (2) of engine cylinder block
and drain cooling water from cylinder block.
* If the coolant contains antifreeze, dispose of
it correctly.
..
3. Muffler, fuel filter

1) Remove muffler drain tube (3).
2) Remove bracket of muffler (4) together with
fuel filter (5), then move it to outside.
3) Disconnect connector (6) of coolant tem-
perature sensor.
4. Air cleaner assembly

1) Disconnect inlet hose (7) of turbocharger, then
remove 2 bracket bolts (8).
2) Remove band (9), then remove air cleaner

assembly (IO).
13-10 WA350-1
0
5. Bracket, ground connection

1) Remove bracket (I I).
2) Remove ground connection (I 2).
6. Turbocharger piping
Remove turbocharger oil supply tube (I 3). then
remove drain tube (14).
7. Intake connector, electrical air intake heater

1) Disconnect boost compensator hose (I 5). then
remove suction hose (I 6) of compressor.
2) Disconnect wire (171, then remove intake
connector (18) together with electrical air
intake heater (I 9).
8. Turbocharger, exhaust manifold assembly

Remove turbocharger (20) together with exhaust
manifold (2 I).
9. Corrosion resistor assembly

Remove bracket (22) together with corrosion
resistor assembly (231, and move it to outside.
WA350-1
10. Oil filter

I) Disconnect connector (241, then remove mount-
ing bolt (25) of tube.
2) Remove oil filter (26) together with tube (27)
and bracket (28).
11. Fuel injection tube

Remove 6 fuel injection tubes (29).
12. Electrical air intake heater switch

Remove wiring clamps (30) and (31). then remove
electrical air intake heater switch (32) and move it
to outside.
13. Bracket, hoses

1) Disconnect aeration hose (33). then disconnect
thermostat outlet hose (34).
2) Disconnect bypass hose (35).
3) Remove bracket (36).
14. Spill pipe

Remove spill pipe (37).
15. Nozzle holder assembly

Remove nozzle holder assembly (38).
* When removing the nozzle holder, clean
around the nozzle holder and fit a blind plug to
prevent dust or dirt from entering.
k Mark the nozzle holders with tags showing the
cylinder No. and keep in a safe place. If there is
no abnormality in the nozzle holder, install in
the same position when assembling.
13-12 WA350-1
0
16. Cylinder head cover

Remove cylinder head cover (39).
17. Rocker arm assembly

1) Loos& lock nut (40), then loosen adjustment
screw (41) 2 to 3 turns.
2) Remove rocker arm assembly (42).
18. Push rod

Remove push rod (43).
19. Cylinder head assembly

1) Remove mounting bolts of cylinder head.
2) Remove cylinder head assembly (44).
Cylinder head assembly: 57 kg
WA350-1
INSTALLATION OF CYLINDER HEAD ASSEMBLY
WA350-1
Wheel loader
13-14 WA350-1
0
15
-L
11
Oil filter
1I9
I
Refilling
water
witt
423F402
13-15
0
Special tool
Part number Part name IQ%

I I I *
A 795-l 25-l 330 Feeler gauge 1
1. Cylinder head assembly

Check that there is no dirt or foreign material on
the cylinder head mounting face, or inside the
cylinder.
I) Set gasket (45) on cylinder block.
2) Raise cylinder head assembly (44), use 4
mounting bolts as guides and set on cylinder
block.
3) Tighten mounting bolts (46).
* Coat the threads of the mounting bolts with
antifriction compound or engine oil.
* Tighten the mounting bolts in the order
shown and to the following tightening
torques.
a Mounting bolt:
Antifriction compound (LM-P)
m Cylinder head mounting bolt
Antifriction compound Engine oil
Order Target Range Target Range

(kgm) (kgm) (kgm) (kgm)
Center
Front Rear
142F212
2. Push rod
Assemble push rod (43).
* The push rods for the intake and exhaust
valves are both the same part.
* Check that the push rod is fitted completely
into the tappet.
13-16
0
3. Rocker arm assembly

Install rocker arm assembly (42).
* Check that the ball of the adjustment screw is
fitted properly into the socket of the push rod.
* If the tension of the valve spring pushes against
the rocker arm, turn the adjustment screw back
to prevent strain on the push rod.
4. Adjusting valve clearance

* Adjustclearance between valve and rocker arm
lever as follows.
Intake valve Exhaust valve
Valve clearance 0,25 mm

0.45 mm
(cold)
Firing order: 1 - 5 - 3 - 6 - 2 - 4
I) Rotate the crankshaft in the normal direction to
align pointer (49) with the 1.6 TOP mark on
crankshaft pulley (50). When rotating, check
the movement of the valves.
* When No. 1 cylinder is at compression top
dead center, adjust the valves marked l
* When No. 6 cylinder is at compression top
dead center, adjust the valves marked o
2) To adjust, insert feeler gauge A between rocker

arm (47) and valve stem (48) and turn adjust-
ment screw (41) until clearance is a sliding fit.
3) Then tighten lock nut (40) to hold adjustment
screw in position.
m Lock nut: 3.2kO.3 kgm
4) Next, rotate crankshaft one turn in the normal

direction and adjust the valve clearance of the
remaining valves marked o
* After tightening the lock nut, check the
clearance again.
WA350- 1
CYLINDER HEAD
5. Cylinder head cover

Fit O-ring and install cylinder head cover (39).
t Put adhesive on the O-ring of the cylinder head
cover to prevent it from slipping out of position
when assembling.
m Mounting nut of cylinder head cover:

0.9 fO.l kgm
6. Nozzle holder assembly

Install nozzle holder assembly (38).
* Check that there is no dirt inside the holder
sleeve or on the nozzle holder contact face.
* Coat the threads of the mounting bolts of the
nozzle holder with engine oil.
* Tighten the nozzle holder mounting bolts
uniformly.
w Mounting bolt: 1.720.2 kgm
7. Spill pipe
Install breather hose (37).
8. Bracket and hose
I) Install bracket (36).
2) Connect bypass hose (35).
3) Connect thermostat outlet hose (34).
4) Connect aeration hose (33).
9. Electrical air intake heater switch

1) Install electrical air intake heater switch (32).
2) Install electrical air intake heater wiring clamp
(30), (31).
10. Fuel injection pipe

Install fuel injection pipe (29).
13-18 WA350-1
0
1 1. Oil filter
1) Fit O-ring to tube and install oil filter (26)
together with tube (27) and bracket (28). then
tighten bolt (25).
2) Connect connector (24).
12. Corrosion resistor assembly

Install coirosion resistor assembly (23) together
with bracket (22).
13. Turbocharger, exhaust manifold

Fit gasket and install turbocharger (20) together
with exhaust manifold (21).
14. In1take connector, electrical air intake heater

I) Fit gasket and install electrical air intake heater
(19) together with intake connector (181, then
connect wire (I 7).
2) Connect boost compensator hose (151, then
install suction hose (16) of compressor.
WA350-1
15. Turbocharger piping

1) Fit gasket and install drain tube (I 4).
2) Fit O-ring and istall turbocharger oil supply tube
(13).
16. Bracket, ground connection

1) Install ground connection (12)
2) Install air cleaner bracket (I I).
17. Air cleaner assembly

1) Fit air cleaner, then connect inlet hose (7) of
turbocharger.
2) Tighten bracket bolts (8).
3) Secure air cleaner assembly (IO) with band (9).
18. Muffler, filter

1) Connect connector (6) of water temperature
sensor.
2) Fit gasket and install muffler (4) together with
bracket and fuel filter (5).
3) Install muffler drain tube (3).
* Fit the gasket with the TOP mark facing up.
13-20 WA350-1
0
19. Refilling with water

I) Tighten drain plug (2) of engine block.
2) Tighten drain plug (I ) of radiator, then install in-
spection cover.
3) Add water through water filler (5 I) to the speci-

fied revel.
* Run the engine to circulate the water
through the system.
Then check the water level again.
WA350- 1 13-21
0
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF TURBOCHARGER ASSEMBLY

2. Remove bolts (I). then disconnect connector (2)
and turbocharger.
3. Disconnect hose (3), remove bracket bolts (4).
then loosen air cleaner band and move air cleaner
assembly (5) to side.
4. Disconnect connector hose (6).
5. Disconnect oil supply tube (7).
6. Remove drain tube (8).
7. Remove turbocharger assembly (9).
INSTALLATION OF TURBO-
CHARGER ASSEMBLY
1. Fit gasket and install turbocharger assembly (9).
+ Fit the gasket with the TOP mark facing up.
2. Fit gasket and install drain tube (8).
3. Fit O-ring and install oil supply tube (7).
4. Connect connector hose (6).
5. Fit air cleaner assembly (51, tighten bracket bolts
(4). then connect hose (31, and secure air cleaner
assembly with band.
6. Connect exhaust connector (21, then tighten with
2 bolts (I 1.
13-22 WA350-1
0
DISASSEMBLY AND ASSEMBLY COMPRESSOR
REMOVAL OF COMPRESSOR ASSEMBLY

2. Remove fuel injection pump assembly.
For details, see 13-4 REMOVAL OF FUEL INJEC-
TION PUMP ASSEMBLY.
3. Disconnect suction hose (I) of compressor.
4. Disconnect unloader tubes (2) and (3).
5. Disconnect air outlet tube (4).
6. Disconnect lubrication tube (5).
7. Remove air governor (6).
8. Remove mounting bolts (7). then remove com-
pressor assembly (8).
INSTALLATION OF COM-
PRESSQR ASSEMBLY
1. Fit gasket, align 0 mark of spline and install
compressor assembly (8).
* Remove the cover of the meter pick-up port to
check the 0 match mark.
2. Coat 4 mounting bolts (7) with gasket sealant,
then tighten.
3. Install air governor 16).
4. Install lubrication tube (5).
5. Connect air outlet tube (4).
6. Connect unloader tubes (3) and (2).
7. Connect suction hose (I ).
8. Install fuel injection pump assembly.
For details, see 13-4 INSTALLATION OF FUEL IN-
JECTION PUMP ASSEMBLY.
WA350-1 13-23
0
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR ASSEMBLY
A Stop
the safety
the machine on level ground
bar on the frame. Lower
and install
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.
Q! Loosen
pressure
the oil filler cap slowly
inside the hydraulic
to release
tank. Then operate
the
the control levers several times to release the

remaining pressure in the hydraulic piping.
Loosen plug (I) at the top of the hydraulic tank
filter, and plug (2) of the pump piping to prevent
the oil inside the tank from flowing out.
+ Disconnect the cable from the negative (-1
Draining water
Loosen drain valve (3) and drain cooling water.
Sr If the coolant contains antifreeze, dispose of it
correctly.
- : Cooling water: 52 II
2. Radiator grille
1) Remove radiator grille (5) from engine hood (4).
2) Open engine hood and fit lock.
3. Wiring
I) Disconnect connector (6) of wiring of coolant
level sensor.
2) Disconnect connector (7) of working lamp
wiring.
13-24
0
4. Engine hood
1) Close engine hood (41, and install safety bolts
(8).
2) Remove mounting bolts (9) of engine hood,

and baffle seat.
3) Raise engine hood (4) about 300 mm, remove

mounting bolts (IO) of left and right safety
wires (I I). then lift off engine hood (4).
Engine hood: 134 kg
5. Radiator hoses
1) Disconnect radiator upper hoses (I 2) and (I 3)
at engine end.
2) Disconnect radiator lower hoses (14) at engine
end.
Sr Loosen the hose clamps at the connections
with the radiator.
3) Remove clamp of radiator cooling water drain
hose.
WA350-1 13-25
6. Hydraulic piping
Disconnect oil cooler hoses (I 51, (161, (I 7) and
(18) from tube connector at bottom of radiator.
* Cover to prevent dirt or water from entering.
Hose nut: 36 mm
7. Support
Sling radiator, then remove mounting bolts at
radiator side of radiator support (I 9).
8. Fan guard, engine fan

I) Remove hose clamp (20). then remove fan
guard (2 I).
2) Remove engine fan (22).
t Be careful not to damage the radiator fins
when removing.
9. Radiator
Remove mounting bolts, then lift off radiator (23).
& Radiator: 105 kg
13-26 WA350-1
0
INSTALLATION OF RADIATOR ASSEMBLY

1. Radiator
Raise radiator (23). set in mc )unt ing position and
install mounting bolts.
+ Tighten the mounting bolts partially, then tight-
en them fully after installing the engine hood.

1) Install-engine fan (22).
t Be careful not to damage the radiator fins
when installing.
w Mounting bolt of engine fan: 6.5 kgm
2) Install fan guard (21) to radiator, then install

hose clamp (20).
t Install so that the clearances between the
fan and fan guard at the left and right, and
top and bottom are the same.
3. Support
Install radiator support (19) to radiator.
Sr Tighten the mounting bolts partially, then tight-
4. Hydraulic piping
Connect oil cooler hoses (I 5), (I 61, (17) and (18)
to tube at bottom of radiator.
Sr Fit the O-rings securely in the grooves, and
make sure that they are not caught when
installing.
Hose nut: 36 mm
WA350-1 13-27
0
5. Radiator hoses
1) Connect radiator lower hose (I 4) at engine end.
Tighten the hose clamps at the connections
with the radiator.
2) Connect radiator upper hoses (12) and (I 3) at
engine end.
3) Install clamp of radiator cooling water drain
hose.
* Install the hose without twisting or interference.
6. Engine hood
I) Raise engine hood, install left and right safety
wires (1 I), and set in mounting position, then
tighten the mounting bolt (IO).
2) Install mounting bolts (9) of engine hood, and
baffle seat.
Sr Tighten the mounting bolts of the radiator
so that the clearances between the engine
fan and shroud at the left and right, and top
and bottom are the same.
* Tighten the mounting bolts of the radiator
and support fully.
3) Remove safety bolts, open hood and fit lock.
7. Wiring
1) Connect connector (6) of wiring of coolant
level sensor.
2) Connect connector (7) of working lamp wiring.
8. Radiator grille
Close hood, lock with catch, then install radiator
grille.
9. Refilling with oil,_water

1) Tighten plug and add engine oil through oil filler
(24) to the specified level.
2) Tighten drain valve and add water through

water filler (25) to the specified level.
/
tiz Coolant: 52 Q
Sr Run the engine to circulate the oil and water

through the system.
Then, check the oil and water levels again.
13-28 WA350-1
0
DISASSEMBLY AND ASSEMBLY OIL COOLER
REMOVAL OF OIL COOLER ASSEMBLY

2. Loosen drain valves (I) and (21, and drain cooling
water.
* If the coolant contains antifreeze, dispose of it
correctly.
3. Remove fuel injection pump assembly.
For details, see 13-4 REMOVAL OF FUEL INJEC-
TION PUMP ASSEMBLY.
4. Disconnect corrosion resistor hose (3).
5. Remove oil tubes (4) and (5).
6. Remove oil cooler assembly (6).
INSTALLATION OF OIL
COOLER ASSEMBLY
1. Fit gasket and install oil cooler assembly (6).
2. Fit O-rings and install oil tubes (4) and (5).
3. Connect corrosion resistor hose (3).
4. Install fuel injection pump assembly.
For details, see 13-4 INSTALLATION OF FUEL IN-
JECTION PUMP ASSEMBLY.
5. Tighten drain valves (2) and (I), close hood, then
lock with catch.
6. Add water through water filler to the specified
level.
* Run the engine to circulate the water through
the system. Then check the coolant level again.
WA350-1 13-29
0
DISASSEMBLY AND ASSEMBLY ENGINE
A Stop the machine on level ground and install

the safety bar on the frame. bucket to Lower
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
z3i pressure inside the hydraulic tank. Then
operate the control levers several times to
release the remaining pressure in the hydraulic
piping.
l Loosen plug (3) at the top of the hydraulic tank
filter, and the plug (2) of the pump piping to
prevent the oil inside the tank from flowing out.
+ Disconnect the cable from the negative (-1
1. Draining water
Loosen drain valve (3) and drain cooling water.
+r If the coolant contains antifreeze, dispose of it
correctly.
*
A Coolant: 52 !=?
2. Radiator grille
1) Remove radiator grille (5) from engine hood (4).
2) Open engine hood and fit lock.
3. Wiring
1) Disconnect connector (6) of wiring of coolant
level sensor.
2) Disconnect connector (7) of working lamp
wiring.
WA350-1
4. Engine hood
1) Close engine hood (4). then remove safety
bolts (8)
2) Remove mounting bolts (9) of engine hood,

and baffleseat.
3) Raise engine hood (4) about 300 mm, remove

mounting bolts (IO) of left and right safety
wires (1 I), then lift off engine hood (4).
Engine hood: 134 kg
5. Radiator hoses
1) Disconnect radiator upper hoses (12) and (I 3)
at engine end.
2) Disconnect radiator lower hoses (14) at engine
end.
Sr Loosen the hose clamps at the connections
with the radiator.
3) Remove clamp of radiator cooling water drain
hose.
13-32 WA350-1
0
6. Hydraulic piping
Disconnect oil cooler hoses (15). (161, (17) and
(18) from tube connector at bottom of radiator.
* Cover to prevent dirt or water from entering.
Hose nut: 36 mm
7. Support
Sling radiator, then remove mounting bolts at
radiator side of radiator support (I 9).

1) Remove hose clamp (ZO), then remove fan
guard (2 I).
2) Remove engine fan (22).
* Be careful not to damage the radiator fins
when removing.
9. Radiator
Remove mounting bolts, then lift off radiator (23).
Radiator: 105 kg
WA350- 1
10. Electric wiring

1) Disconnect wiring (24) between battery and
starting motor at starting motor end.
2) Disconnect cable (25) between starting motor
and ground at frame end.
3) Remove switch (27) from switch box (26).
4) Disconnect connectors (28) and (29).
5) Remove clamps.
Sr After removing the connectors, mark with a
tag to distinguish when installing.
11. Fuel hoses

1) Disconnect hose (30) between fuel tank and
fuel filter at fuel tank end.
2) Disconnect fuel return hose (31) at fuel tank
end.
12. Air tubes

Disconnect air tubes (32) and (33) at governor
and compressor end.
13. Hydraulic piping

I) Remove bracket (34) of tube between torque
converter charging pump and transmission,
transfer.
13-34 WA350-1
0
2) Disconnect tube (35) between oil cooler and

torque converter at torque converter end.
3) Disconnect tube (36) between oil cooler and
transmission at transmission end.
4) Remove tube clamp (37).
5) Disconnect tube (38) between torque con-

verter charging pump and torque converter
filter from torque converter charging pump
(39). then remove U-clamp (40).
14. Fuel control cable

I) Disconnect fuel control cable (41) from ball
joint (42).
2) Remove fuel control cable (41) from bracket
(43).
15. Brake hose

Disconnect hose (44) between slack adjuster and
brake chamber from slack adjuster.
WA350-1
16. Transmission stand

Put stand under transmission (45).
Sr Use a stand with adjustable height, and fix it so
that it cannot slip out of position.
17. Engine assembly

I) Remove muffler (46).
* When removing the muffler, be careful not
to damage the gasket.
Muffler: 23 kg
2) Remove bracket (47) for engine oil drain valve

from fuel tank (48).
3) Sling engine (49). then remove mounting bolts
(50) of engine and torque converter.
4) Remove engine mounting bolts (511, then lift

off engine assembly.
* Note how the cushions and spacers are
installed, and use for reference when
installing.
Sr The ring g-ear of the engine flywheel is
meshed with the ring gear of the torque con-
verter and the shaft, so when raising the
engine, keep the assembly horizontal when
removing.
* When removing the engine, be careful not to
damage the suction tube of the fuel tank.
Engine assembly: 700 kg
Mounting bolt: 36 mm
13-36 WA350-1
0
INSTALLATION OF ENGINE ASSEMBLY
Wheel loader
8
Electric
wiring
\ToB
I7
Refilling wth
B--t
oil, water
423F405
WA350-1 13-37
0
1. Engine assembly
I) Raise engine (49). set in mounting position, and
tighten mounting bolts of engine and torque
converter uniformly.
* Install the engine horizontally. Be careful to
mesh the flywheel ring gear and torque con-
verter ring gear, and to fit the torque conver-
ter shaft correctly.
a O-ring at contact face of engine and

torque converter: Grease (G2-LI)
2) install engine mounting bolts (5 1).

* Be careful to assemble the cushions and spa-
cers facing in the correct direction.
B Mounting bolt: 94.5f 10.5 kgm
Mounting bolt: 36 mm
3) Install bracket (47) for engine oil drain valve to

fuel tank (48).
4) Set muffler (46) in mounting position, then in-

stall mounting bolts.
13-38 WA350-1
0
2. Transmission stand
Remove stand from under transmission (49)
3. Brake hose
Connect hose (44) between slack adjuster and
brake chamber to slack adjuster.

I) Install fuel control cable (41) to bracket (43).
2) Connect fuel control cable (41) to ball joint (42).
5. Hydraulic piping
I) Connect tube (38) between torque converter
charging pump and torque converter filter to
torque converter charging pump (39). then in-
stall U-clamp (40).
WA350-1
2) Connect tube (36) between oil cooler and trans-

mission to transmission.
3) Connect tube (35) between oil cooler and
torque converter to torque converter.
4) Install tube clamp (37).
5) Install bracket (34) of tube between torque con-

verter charging pump and transmission transfer.
6. Air tubes
Connect tubes (32) and (33) at governor and com-
pressor end.
7. Fuel hoses
1) Connect fuel return hose (31) at fuel tank end.
2) Connect hose (30) between fuel tank and fuel
filter at fuel tank end.
13-40 WA350-1
0
8. Electric wiring
1) Install clamps.
2) Connect connectors (28) and (29).
3) Install switch (27) to switch box (26).
4) Connect cable (25) between starting motor and
ground at frame end.
5) Connect wiring (24) between battery and start-
ing motor at starting motor end.
9. Radiator
Raise radiator (23). set in mounting position and
* Tighten the mounting bolts partially, then tight-

1) Install engine fan (22).
* Be careful not to damage the radiator fins
when installing.
B Mounting bolt of engine fan: 6.5 kgm
2) Install fan guard (2 1) to radiator, then install

hose clamp (20).
* Install so that the clearances between the
fan and fan guard at the left and right, and
top and bottom are the same.
11. Support
Install radiator support (I 9) to radiator.
* Tighten the mounting bolts partially, then tight-

Connect oil cooler hoses (I 51, (16). (I 7) and (18)
to tube at bottom of radiator.
t Fit the O-rings securely in the grooves, and
installing.
Hose nut: 36 mm
13. Radiator hoses

1) Connect radiator lower hose (I 4) at engine end.
Tighten the hose clamps at the connections
with the radiator.
2) Connect radiator upper hoses (121 and (13) at
engine end.
3) Install clamp of radiator cooling water drain
hose.
Sr Install the hose without twisting or interference.
14. Engine hood

1) Raise engine hood, install left and right safety
wires (I I), and set in mounting position, then
tighten the mounting bolt (I 0)
2) Install mounting bolts (9) of engine hood, and
baffle seat.
t Tighten the mounting bolts of the radiator
so that the clearances between the engine
fan and shroud at the left and right, and top
and bottom are the same.
* Tighten the mounting bolts of the radiator
and support fully.
3) Remove safety bolts, open hood and fit lock.
13-42 WA350-1
0
16. Radiator grille

Close hood, lock with catch, then install radiator
grille (5).
17. Refilling with oil, water

1) Tighten plug and add engine oil through oil filler
2) Tighten drain valve and add water through
water filler (53) to the specified level.
a Coolant: 52 II
* Run the engine to circulate the oil and water

through the system.
Then check the oil and water levels again.
WA350-1
13-43
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK ASSEMBLY
a Stop the
the safety
machine on level ground
and install
the bucket
r the parking brake and put blocks under the
1. Radiator grille
Remove radiator grille (I ).
V Open hood (2) and fit lock (3).

Q
2. Draining fuel
Loosen drain valve (4) and drain fuel.
3. Drain valve
Remove engine oil drain valve (5) from fuel tank.
4. Fuel tubes, wiring, clamp

I) Disconnect fuel tubes (6) and (7) from fuel tank.
2) Disconnect wiring (8) for fuel unit from
connector.
3) Remove clamp (9) of cooling water drain hose.
13-44 WA350-1
0
5. Fuel tank
1) Sling fuel tank (IO), remove mounting bolts,
then lift off fuel tank.
* Lay a pallet below the fuel tank, keep the
tank balanced and lower slowly.
Fuel tank: 198 kg
2) Pull fuel tank (10) out from under machine.

* Be careful not to let the breather tube hit the
machine body.
WA350-1 13-45
0
INSTALLATION OF FUEL TANK ASSEMBLY

1. Fuel tank
I) Set fuel tank (I 0) on pallet, then pus1 i in to
below mounting position.
* Be careful not to let the breather tube hit the
machine body.
2) Raise fuel tank (101, set in mounting position,

then tighten mounting bolts.
* Tighten the mounting bolts in the following
order: Left - rear + right.
w Mounting bolt: 94.52 10.5 kgm
Sr When raising the tank, keep it horizontal and

set in the mounting position.
2. Fuel tubes, wiring, clamp

1) Connect wiring (8) for fuel unit to connector.
2) Connect fuel tubes (6) and (7) to fuel tank.
3) Install clamp (9) of cooling water drain hose.
3. Drain valve
Install engine oil drain valve (5) to fuel tank.
13-46 WA350-1
0
4. Hood
Release lock (3) and close hood (2)
5. Radiator grille
Install radiator grille (1)
6. Refilling with fuel

Tighten drain valve (4) and add fuel through fuel
filler (1 1).
WA350-1 13-47
0
POWER TRAIN
General . . . . .. 21- 2
. Hydrauliccircuit for power train . 21- 4
Hydraulic circuit diagram for power train . 21- 5
yorque converter and transmission piping . 21- 6
Torque converter charging pump . 21- 7
Torque converter . .. .. 2 I- 8
Torque converter oil filter . 21-I 1
Torque converter oil cooler . . . . 21-I 2
Torque converter relief valve . 21-I 3
Transmission . . . 21-l 4
Transmission control valve . . 21-22
. Upper valve . .. 21-24
. Lower valve . ... . 21-25
. Transmission solenoid valve . . 21-26
. Emergency manual spool . .. 21-27
. Priority valve . . 2 I-30
. Modulating valve and quick return valve 21-31
. Accumulator valve . 2 1-34
. Pilot reducing valve. . 21-36
Transmission pilot filter . 2 1-37
Transfer . 21-38
Drive shaft . . . . 2 I-39
Axle mount . _. . 21-40
Axle and differential. .. 21-42
Torque proportioning differential 21-47
;inal drive . . . 21-48
Tire and wheel . . 21-49
WA350-1 21-1
STRUCTURE AND FUNCTION GENERAL
GENERAL
423FOO3
OUTLINE
The motive force from engine (1) passes from the . The output shaft of transmission (5) transmits
flywheel through the ring gear and is transmitted motive force through the gear of the tranfer to the
to torque converter (2). The torque converter transfer output shaft. The motive force from the
uses oil to convert the transmitted torque to corre- transfer output shaft is then sent to the front and
spond to changes in the load. It transmits the rear axle.
motive force to the transmission input shaft. In The power for the front axle passe through center
addition, the motive force from the engine passes drive shaft (15) and front drive shaft (I 3) and is
through the pump drive gear of the torque conver- transmitted to front axle !I 0); the power for the
ter and is sent to the hydraulic and steering pump rear axle passes through rear drive shaft (I 6) and
(4). and torque converter charging pump (3) to is sent to rear axle (21).
drive these pumps. . The motive force transmitted to front axle (IO)
Transmission (5) has six clutches which are ac- and rear axle (21) is reduced by the pinion gear
tuated hydraulically by operating the solenoid and ring gear of differential (1 1),(20). It then
valve to move the directional spool and range passes from the differential to the sun gear shaft
spool of the control valve. The transmission has a (axle shaft) of final drive (8),(18).
speed selection of four FORWARD and four
REVERSE speeds. The speeds are selected
manually.
21-2 WA350- 1
@
1. Engine (S6DllO-I) 423 FOO4A

8. Final drive (Front) 15. Center drive shaft
2. Torque converter 9. Brake (Front)
16. Rear drive shaft
3. Torque convertercharging pump 10. Front axle
17. Rear wheel
4 Hydraulic pump and steering pump 1 1 Differential (Front) 18. Final drive (Rear)
5. Transmission 12. Parking brake
19. Brake (Rear)
6. Transfer 13. Front drive shaft
20. Differential (Rear)
7. Front wheel 14. Flanged bearing
2 1. Rear axle
WA350-1
21-3
@
HYDRAULIC CIRCUIT FOR POWER TRAIN
21 19 18 17 16 15
;::
;.j
.j
;;: j
j;
:
::
,:
23
\
r.,
w
m
E 7-r Ej
.:
WI
::
,,
PI
2
!
j
:
:
:: :
;: :
8
423 F050A
21-4 WA350-1
@
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN

-15
14k&
Cl-f
I
I
I
I 19
I
, r_~-_--,
r----i
3 kg/cm I
I
I 20
r---7
2A 150 Mesh I
I 1
1
1. Transmission case 13. Transmission lubrication relief valve
2. Strainer 14. Transmission lubrication
3. Torque converter charging pump 15. Reverse clutch
4. Oil filter 16. Forward clutch
5. Priority valve 17. 4th clutch
6. Modulating valve 18. 3rd clutch
7. Quick return valve 19. 2nd clutch
8. Pilot oil filter 20. Accumulator valve
9. Pilot reduction valve 2 1. 1 st clutch
10. Torque converter relief valve 22. Reduction spool, F-R spool
II. Torque converter 23. Emergency spool
12. Oil cooler 24. Solenoid valve
WA350-1 21-5
0
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER AND TRANSMISSION PIPING
423F007A
1. Transmission pilot filter 5. Torque converter charging pump

2. Transmission 6. Radiator
3. Transmission control valve 7. Torque converter oil cooler
4. Torque converter 8. Torque converter oil filter
21-6 WA350-1
0
STRUCTURE AND FUNCTION TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER CHARGING PUMP

. The torque converter charging pump is installed to . The torque converter charging pump sucks in oil
the torque converter case. It is driven by the from the bottom of the transfer case through a st-
motive force from the engine and supplies oil to rainer and sends oil to the oil filter.
the torque converter and transmission system.
423FOO8
Sect-on A-A
5
Specifications:
1. Front cover Model: SAL(3)-056
2. Drive gear (Teeth 12) Theoretical discharge: 56 cclrev
3. Gear case Max. pressure: 2 10 kg/cm2
4. Rear cover Max. pump speed: 2,500 rpm
5. Driven gear (Teeth 12)
WA350-1 21-7
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
423FO12
Specifications
Model: TCA34-2A
Type: 3-element. single stage, single phase
Stall torque ratio: 3.10
I. Mount of torque converter charging pump

2. Housing
3. Mount for hydraulic and steering pump
Section A-A
21-8 WA350-1
@
TORQUE CONVERTER
Section B-B 423F013A
8. Idler gear (PTO gear driven) A. Inlet port

4, Pilot
9. PTO gear (drive) B. Output port
5. Drive case
6. Turbine 10. Stator
7. Pump 1 1. Transmission input shaft
21-9
WA350-1
%
STRUCTURE AND FUNCTION TORQUE CONVERTER
Flow of motive force

The torque converter is installed between the
engine and transmission. The motive force from
the engine passes from the flywheel and enters
drive case (5). Drive case (51, pump (8) and PTO
gear (drive) (9) are fixed with bolts. They are rotat-
ed directly by the rotation of the engine.
The motive force of pump (8) uses oil to rotate tur-
bine (6). This transmits motive force to transmis-
sion input shaft (10).
The motive force of drive case (5) passes through
PTO gear (driverIg) and is also used as the motive
force to drive the gear pump.
10
4A
Flow of oil
l The oil pressure is adjusted by the torque conver-
ter relief valve.and then enters inlet port A, passes
through the oil passage in housing (2) and flows
to pump (8). In pump (8) centrifugal force is
applied. The oil enters turbine (6) and the energy
of the oil is transmitted to the turbine.
Turbine (6) is fixed to transmission input shaft
(IO), so the motive force is transmitted to the
transmission input shaft (I 0).
The oil from turbine (6) is sent to stator (9) and
again enters the pump. However, part of the oil
passes from the stator through outlet port B and
is sent to the cooler.
u
423FO15
21-10 WA350-1
0
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER
1. Relief valve
2. Element
3. Center bolt
4. Drain plug
Filtration area: 8,900 cm2

Relief pressure: 3.25 kg/cm
To transmission
,
LLlJ control valve
423FOO9
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 (2) is clogged with dirt, or the oil

temperature is low, the pressure at the inlet port A
rises. When this happens, the oil from the inlet
port A opens relief valve (I) and flows directly to
the outlet port B. This prevents damage to the
pump or filter element (2).
2
423FOll
WA350-1 21-11
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL COOLER
TORQUE CONVERTER OIL COOLER

OUTLINE
. The oil which comes out from the torque
converter outlet port is at a high temperature
because of the energy used in transmitting the
motive force. This torque converter oil passes
through oil cooler port A and enters the oil cooler.
Here it is cooled by the engine cooling water. The
oil then flows out from oil outlet port B, lubricates
the transmission and returns to the transfer case.
423FO49
1. Radiator A. Torque converter oil inlet port

2. Hydraulic oil cooler B. Torque converter oil outlet port
3. Torque converter oil cooler C. Hydraulic oil inlet port
D. Hydraulic oil outlet port
21-12 WA350-1
STRUCTURE AND FUNCTION TORQUE CONVERTER RELIEF VALVE
TORQUE CONVERTER RELIEF VALVE

FUNCTION To each transmission spool
. The torque converter relief valve acts to maintain
the pressure of the oil entering the torque conver-
ter at a constant pressure. It drains the oil if it
goes above the specified pressure.
OPERATION
. The oil from the pump passes through priority
valve (1) and actuates modulating valve (2). It
then enters
-. port A and flows to the torque
converter.
To tranimission From pump

lubrication
423FO42
. If the oil at port A goes above the specified To each transmission spool
pressure, it passes through orifice a of torque .>:.:.:

;;;;_...........,.,.............
.,.,.
i:.:.:.:.:
........:::::
relief valve (3) and enters port B. It then
_..
..
.:.:
converter ii;; j:j:
:;:: _...
..:.:
moves torque converter relief valve (3) to the left. j:j;
:j::
//
As a result, the oil from port A is drained, and the
oil flowing to the torque converter is maintained at
the specified pressure.
To tranimission From pump

lubrication
423FO43
WA350-1 21-13
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
/ Section B-B
423FO16
1 Oil filler
2. Transmission input shaft
3. Transmission
4. Transfer
5. Transfer output coupling
6. Transmission control valve
7. Pilot filter
View Z
8. Strainer
21-14 WA350-1
9. No. 1 sun gear (Teeth 25)
10. No. 1 planetary gear (Teeth 23)
1 1. No. 1 ring gear (Teeth 76)
12. No. 1 clutch
13. No. 1 idler ring gear (Teeth 7 1)
14. No. 2 sun gear (Teeth 3 7)
16. No. 2 clutch
17. No. 2 ring gear (Teeth 75)
20. No. 3 clutch
2 1. No. 3 ring gear (Teeth 76)
23. No. 4 clutch
27. No. 5 clutch
29. No. 6 clutch
3 1. No. 6 gear (Teeth 75)
32. Output shaft
REVERSE FORWARD 4th 3rd 2nd 1 st
33. No. 1 carrier
423FO17A 34. No. 2, 3,4 carrier
35. No. 5 carrier
Section A-A
WA350-1
21-15
0
Speed range Clutch combination

OUTLINE
The transmission consists of a 4-FORWARD, 4- Fl No. 2, No. 6
I
REVERSE speed planetary gear transmission,
transfer, and transmission
In the transmission,
control valve.
the motive force of the input
I No. 2, No. 5
shaft is changed by the combination of No. 1 or F3 No. 2, No. 4

I
NO. 2 clutch with No. 3, 4, 5 or 6 clutch to give
FORWARD 1 - 4 or REVERSE 1 - 4 speed, and F4 No. 2, No. 3
I
is transmitted to the output shaft.
RI I No. 1, No. 6
R2 No. 1, No. 5
I
R3 No. 1, No. 4
I
R4 No. 1, No. 3
I
OPERATION OF CLUTCH
. Engaged
The oil sent from the transmission control valve
passes through the oil passage inside the
transmission. When it reaches the rear 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 stopped.
423FO 118
. Disengaged
When the supply of oil from the transmission con-
trol valve is shut off, the pressure of the oil acting
on the rear of piston (2) is reduced. The piston is
then pushed back to the right by return spring (3).
and disc (4) and plate (5) are separated. Ring gear
(6) then rotates freely, and no motive force is
transmitted.
423FO19
21-16 WA350-1
FORWARD 1 ST
E423F020
. In 1 st FORWARD, No. 2 clutch and No. 6 clutch . The motive force the torque converter is transmit-
are engaged. The motive force transmitted from ted to the input shaft (2). The rotation of the input
the torque converter by input shaft (2) is transmit- shaft (2) is transmitted to planetary gear (15)
ted to output shaft (32). through sun gear (I 4).
. No. 2 clutch is actuated by the hydraulic pressure . Ring gear (17) is held in position by No. 2 clutch,
applied to the clutch piston, and it locks ring gear so the rotation of planetary gear (15) rotates car-
(17) in position. No. 6 clutch is actuated by the hy- rier (341, which is on the inside of ring gear (I 7).
draulic pressure applied to the clutch piston, and This carrier is connected to No. 5 carrier (35)
holds gear (3 I) in position. through No. 4 ring gear (241, so when No. 6 clutch
is actuated, the rotation of carrier (35) is transmit-
ted to gear (31) and rotates output shaft (321.
WA350-1 21-17
@
FORWARD 2ND
E423F021
. In 2nd FORWARD, No. 2 clutch and No. 5 clutch . Ring gear (1 7) is held in position by No. 2 clutch,
are engaged. The motive force transmitted from so the rotation of planetary gear (I 6) rotates car-
the torque converter by input shaft (2) is transmit- rier (34), which is on the inside of ring gear (I 7).
ted to output shaft (32). The rotation of carrier (34) is transmitted through
No. 2 clutch and No. 5 clutch are actuated by the ring gear (24) to carrier (35).
hydraulic pressure applied to the clutch piston, Ring gear (26) is held in position by No. 5 clutch,
and they hold ring gears (I 7) and (26) in position. so the rotation of carrier (35) rotates planetary
The motive force from the torque converter is gear (28). The planetary gear rotates on the inside
transmitted to the input shaft (2). The rotation of of ring gear (261, and rotates sun gear (30). The
the input shaft is transmitted to planetary gear sun gear rotates output shaft (32).
(15) through sun gear (I 4).
21-18 WA350-1
Go
FORWARD 3RD
/J I
i il I I
E423F022
l In 3rd FORWARD, No. 2 clutch and No. 4 clutch . Ring gear (17) is held in position by No. 2 clutch,
the torque converter by input shaft (2) is transmit- rier (341,which is on the inside of ring gear (I 7).
ted to output shaft (32). . Ring gear (24) is held in position by No. 4 clutch,
l No. 2 clutch and No. 4 clutch are actuated by the so the rotation of carrier (34) is transmitted to
hydraulic pressure applied to the clutch piston, planetary gear (I 5). The planetary gear rotates on
and they hold ring gears (1 7) and (24) in position. the inside of ring gear (24), and rotates sun gear
l The motive force from the torque converter is (25). The sun gear rotates output shaft (32).
transmitted to the input shaft (2). The rotation of
the input shaft is transmitted to planetary gear
(I 5) through sun gear (I 4).
WA350-1 21-19
0
FORWARD 4TH
2 14 15 16 21 19 18
E423F023
. In 4th FORWARD, No. 2 clutch and No. 3 clutch . Ring gear (I 6) is held in position by No. 2 clutch,
the torque converter by input shaft (2) is transmit- rier (34). which is on the inside of ring gear (I 5).
ted to output shaft (32). . Ring gear (1 6) is held in position by No. 3 clutch,
l No. 2 clutch and No. 3 clutch are actuated by the so the rotation of carrier (34) is transmitted to
hydraulic pressure applied to the clutch piston, planetary gear (19). The planetary gear rotates on
and they hold ring gears (I 6) and (2 I) in position. the inside of ring gear (21). and rotates sun gear
. The motive force from the torque converter is (18). which forms one unit with output shaft (32).
(15) through sun gear (I 4).
21-20 WA350-1
Go
REVERSE 1 ST
r_
CL
E423F024
. In 1 st REVERSE, No. 1 clutch and No. 6 clutch are l Carrier (33) is held in position by No. 1 clutch, so
engaged. The motive force transmitted from the the rotation of planetary gear rotates the ring
torque converter by input shaft (2) is transmitted gear. Ring gear (13) rotates in the opposite direc-
to output shaft (32). tion from the input shaft. Ring gear (I 3) rotates
. No. 1 clutch is actuated by the hydraulic pressure carrier (34). and the rotation of carrier (34) rotates
applied to the clutch piston, and it locks carrier ring gear (231, which then rotates carrier (3.5).
(33) in position. No. 6 clutch is actuated by the hy- Carrier (35) rotates No. 6 clutch. When No. 6
draulic pressure applied to the clutch piston and clutch is actuated, the rotation of carrier (35) is
holds ring gear (3 1) in position. transmitted to gear (31) and rotates output shaft
. The motive force from the torque converter is (32).
(I 2) through sun gear (9).
WA350-1 21-21
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
ii \ \
1 2 3 8
Serial No. 10001 - 11117
Serial No. 11118 and up
423F025B
1. Lower valve 6. Priority pressure pick-up

2. Pilot reducing pick-up 7. Modulating pressure pick-up
3. Upper valve 8. Accumulator pressure pick-up
4. Transmission lubricating pressure pick-up 9. Transmission solenoid valve
5. Torque converter relief pressure pick-up 10. Connector
27-22 WA350-1
0
Reverse
Forward
4th
3rd
2nd
i
Section A-A
423FO26
8 7
I \ \
6 5 4 3
Actuation table
for solenoid valve and clutch
1. Connector 6. FORWARD solenoid valve

2. 1 st solenoid valve 7. REVERSE solenoid valve
3. 2nd solenoid valve 8. Body
4. 3rd solenoid valve 9. Emergency manual spool
5. 4th solenoid valve
STRUCUTRE
. The transmission solenoid valve is installed to the
transmission together with the transmission
valve. When the directional lever or speed control
lever are operated, the solenoid valve is actuated
and moves the spool inside the transmission valve.
WA350-1 21-23
@
STURUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
UPPER VALVE
OUTLINE
The oil from the torque converter charging pump The other oil line flows to the modulating valve
enters port A, and passes through the priority and quick return valve. The action of the modulat-
valve. It is then divided into two lines: one to the ing valve and quick return valve raises the clutch
clutch pistons, and the other to the pilot reducing pressure smoothly. This reduces the shock when
valve. The priority valve acts to control the two actuating the FORWARD, REVERSE and 1 st, 2nd,
lines so that the pilot reducing valve is the priority 3rd, and 4th speed clutches to change gear.
circuit. The accumulator valve controls the oil flow at the
The oil flowing to the pilot reducing valve controls 2nd clutch and reduces the filling time when shift-
the pilot pressure used to actuate the directional ing from 2nd to 1 st or 3rd gear.
and speed spools. The oil regulated by the pilot The lubrication valve controls the lubrication oil
reducing valve passes through the orifice in each inside the transmission.
spool and fills the spool.
21-24 WA350-1
LOWER VALUE
10
Section B-B
I, Torque converter relief Vak? 8. 4th spool

2. Quick return valve 9. Pilot reducing valve
3. Modulating valve 10. FORWARD spool
4. Priority valve 1 1 Lubrication valve
5. Housing 12. Reverse spool
6. 1 st spool 13. 3rd spool
7. 2nd spool 14. Accumulator
WA350- 1 21-25
TRANSMISSION SOLENOID VALVE
Function
l There is one solenoid valve installed for each
directional and speed spool in the transmission
valve.
When the directional lever and speed control
levers in the operators compartment are
operated, the solenoid valve is actuated, and oil is
drained to actuate the directional and speed
spools.
..
Operation
1) Solenoid valve OFF
The oil of spool (I 1 enters port A. However, valve
(2) shuts off the oil, so directional and speed spool
(I) does not move.
2) Solenoid valve ON
When the directional and gear shift lever are From quick return val
operated, the solenoid valve is pulled up.
The oil from directional and speed spool (I)
enters port A and flows from port B to the drain
circuit. Therefore, port A becomes the low pres-
sure circuit, and directional and speed spool (I) is
actuated.
423FO32
21-26 WA350- 1
EMERGENCY MANUAL SPOOL
Function
. If there is any failure in the electrical circuit of the
transmission control system, and the solenoid
valve does not work, the emergency manual spool
is used. This spool is attached to each directional
and speed spool and is used to operate the trans-
mission valve mechanically. (It is used to drive the
machine to a place where it can be repaired.)
* Particular attention must be paid for when
using this spool.
Operation_
. Normal position
When the solenoid valve is working normally, the
spool is maintained in this position.
Oil from directional and speed spool (1) enters
port A, but it is shut off by solenoid valve (2).
reducing valve 423FO44
. Clutch OFF
Emergency manual spool (3) is pushed to the left,
and the oil at port A is shut off regardless of the
action of solenoid valve (2). The oil cannot flow to
port B, so the clutch is not actuated.
reducing valve
423FO45
From quick
. Clutch ON
When emergency manual spool (3) is pulled to the
right, the oil at port A is drained to port B regard-
less of the operation of solenoid valve (2). As a
result, the clutch is actuated.
reducing valve 423 F046
WA350-1 21-27
FORWARD 1 ST
1st 2nd F R
T/C: Torque converter
I. Solenoid valve
2. Solenoid valve
3. Oil filter
4. Priority valve
423 FO47A 5. 1 st spool
6. FORWARD spool
7. Spring
8. Spring
9. Piston
10. Quick return valve
1 I. Pilot reducing valve
21-28 WA350- 1
0
Operation
When the directional and speed control levers are l The other oil line flows from priority valve (4) to
moved to FORWARD 1 st, solenoid valves (I) and quick return valve (IO). It then flows through ori-
(2) are opened. fice a, and directional and speed spools (5) and
The oil from the pump passes through filter (3) (6). and flows to the FORWARD clutch and 1st
and enters priority valve (4). clutch. When it starts to flow to the clutch, it
The oil from the pump is divided into 2 circuits: passes through orifice a and creates a difference
one goes to pilot reducing valve (I I), and the in pressure between port C and port D. Quick
other goes to the clutches. However, when the return valve (I 0) moves to the right, and the oil at
gear is shifted, priority is given to the oil flowing to the rear of modulating valve piston (9) flows to
the clutches. drain circuit E. When each clutch is filled with oil,
One of the two oil lines flows from the pilot reduc- the difference in pressure between port C and
ing valve through the orifice of each speed spool port D disappears. The valve is pushed back to
to the solenoid valve. However, solenoid valves the left by the difference in area of the valves, and
(1) and 12) of FORWARD spool (6) and 1st spool drain circuit E is closed.
(5) are gpen, so the oil passing through the orifice At this point, each clutch is filled with oil, but the
flows to the drain circuit. As a result, a difference oil has not reached the specified pressure. The oil
in pressure is created between port A and port B, at port D flows through orifice b and reaches
and this overcomes the force of springs (7) and the back of modulating piston (9). The piston
(8). The port to the clutch is then connected. 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
engaged.
WA350-1 21-29
0
PRIORITY VALVE
Function
. The priority valve controls the minimum pressure
of the pilot reducing valve. In addition, the priority
valve gives the oil flow to the pilot reducing valve
priority over the other circuit.
To modulating valve To each transmission spool

Operation
. The oil from the pump flows to port A of priority
valve (I) and port-B of.pilot reducing valve Ci).
& 423FO33
To modulating valve To each transmission spool
. The oil entering port A flows from orifice a of

priority valve (1) to port D. The hydraulic 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 Cto the clutch spool. Pilot
oillfilter
423FO34
21-30 WA350-1
MODULATING VALVE AND QUICK RETURN VALVE
Function
. The modulating valve and quick return valve act (kg/cm )
together to raise the transmission clutch pressure
40 - Shifting gear
slowly. In this way, they reduce the shock when
shifting gear, and prevent the generation of peak
30 -
torque in the power train. As a result, operator E
fatigue is reduced, and at the same time, 2
operator P
comfort and the durability of the power train h 20-
are
=
increased. __ 0
Time (Secl
1) Immediately after shifting gear (Point A on Fig. 423FO35) 423 F035A
valve
@j&q
423FO36
To torque converter
Operation
. The oil sent from the pump flows from priority and port C. The quick return valve moves to
valve (I) through port A, passes through the right and the oil flows to clutch (5). In
modulating valve (2). and enters port B of quick addition, when quick return valve (3) moves to
return valve (3). The oil passes through orifice the right, drain port D is opened, and the
a of quick return valve (3) and flows to the pressurized oil at the rear of piston (4) flows to
clutch piston, which has been actuated. How- the drain circuit.
ever when it passes through orifice a it cre-
ates a difference in pressure between port B
WA350- 1 21-31
0
2) Clutch pressure rising (Point B on Fig.423FO35)
pIlot
luclng ralve
I
To torque converter
423FO37
ODeration
. As the pressure at the clutch piston rises, the At the same time, pressurized oil also passes
pressure at port C also rises. Quick return valve through the orifice and enters poppet (7) of
(3) is pushed back to the left and drain port D is modulating valve (2). It moves modulating
closed. The oil from the pump flows from port valve (2) to the left and some of the oil at port
C to the clutch piston, and at the same time it A flows to port G.
flows from orifice b through quick return
valve (3) and enters port E.
The oil at port E acts on the modulating piston.
It pushes back spring (6) and moves piston (4)
to the right.
21-32 WA350-1
3) Completion of rise in clutch pressure (Point C on Fig. 423FO35)
pllot reducing
Ive
To toraue converter 423FO38
Operation
. The oil entering port E continues to push piston
(4). When the piston reaches the end of its
stroke, the rise in pressure stops. When this
happens, the pressure reaches the set pressure
of the modulating valve. In addition, port F and
port G are closed by piston (4). so the oil at port
A passes through port G and flows to the
torque converter.
WA350-1 21-33
ACCUMULATOR VALVE
Function
. The accumulator valve acts to reduce the filling
time when shifting gear by allowing the oil at the
2nd clutch piston to escape slowly when shifting
from 2nd to 1 st. This allows the clutch to be en-
gaged smoothly when shifting from 2nd to 1 st.
1. Shifting to 2nd
. When shifting to 2nd gear, the oil from the
pump passes through the quick return valve
and enters port A of the transmission spool (2).
When the 2nd transmission 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 quick return valve
423 F039
21-34 WA350-1
. As the pressure of the oil entering port D rises,

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

423 FO40
2. Shifting from 2nd to 1 st
. The oil from the clutch piston of 2nd clutch (4)
enters port D and acts on the rear of the check
valve (2). The oil from port D passes through
orifice a and flows to the drain circuit. In this
way the shock when shifting gears can be
reduced.
From pilot reducing valve

423FO41
WA350-1 21-35
PILOT REDUCING VALVE
Function
. The pilot reducing valve acts to control the pres-
sure needed to actuate the transmission spools.
Operation
l The oil from the pump passes through the pilot
filter and enters port A of pilot reducing valve (I ).
The oil passes through port B and enters through
the orifice of transmission spool (2) to fill the
inside of port C. __
e To priority valve
423FO30
. When the pressure inside port C rises, pressurized

oil flows from orifice a of pilot reducing valve
(1) and goes to port D.
As a result, pilot reducing valve (I) moves to the
right, and port A and B are shut off, so the pressu-
rized oil at port C is maintained at the same
pressure.
valve
423FO29
21-36 WA350-1
STRUCTURE AND FUNCTION TRANSMISSION PILOT FILTER
TRANSMISSION PILOT FILTER
II- 0
----_-_
-----_-_
1 I
I
423 F048
1. Oil filter head

2. Element
3. Case
Specification:
Filtration area: 370 cm2
21-37
STRUCTURE AND FUNCTION TRANSFER
TRANSFER
Outline
. The transfer is installed at the power output end
of the transmission and is secured to the transmis-
sion case by bolts.
Transmission path
l Output shaft (I) of the transmission is coupled to
transfer input gear (2) by a spline. The motive
force is transmitted to output gear (6) through
idler gear (4) and output shaft (7).
Part of the power-transmitted to the output shaft
is transmitted to the front axle through the center 1. Transmission output shaft
drive shaft and front drive shaft. The rest of the 2. Transfer input gear (teeth 50)
power is transmitted to the rear axle through the 3. Rotating pick-up sensor
rear drive shaft. 4. Transfer idler gear (teeth 64)
5. Housing
6. Output gear (teeth 7 1)
7. Output shaft
8. Front coupling
9. Rear coupling
423F052A
423FO53
WA350-1
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
Outline
The motive force from the engine passes through When the body is articulated, or when there is
the torque converter, transmission and transfer. shock from the road surface during traveling, or
Part of this motiveforce passes through rear drive when there is shock during operations, the axles in
shaft (4) and goes to the rear axle; the rest of the front and behind the engine and transmission
motive force passes through center drive shaft change position.
(3). flanged bearing (2) and front drive shaft (1) To allow the motive force to be transmitted with-
and is sent to the front axle. out damage to parts of the machine when there is
In addition to transmitting the motive force, the shock or when the components move position,
drive shafts have the following purposes. the drive shafts have a universal joint and a sliding
joint.This allows them to handle changes in angle
and length.
\ 1. Front drive shaft

2. Flanged bearing
.\
3. Center drive shaft E423F054
4. Rear drive shaft
WA350-1 21-39
@
STRUCTURE AND FUNCTION AXLE MOUNT
AXLE MOUNT
?rial No. Serial No.

boo1 - 11117 11118anduD
1
ai
*_

L _
0
,-
c
Y
t
=JaJ
0 4
\
U42301001
423FO68
Section A-A Section B-B
21-40 WA350-1
0
STRUCTURE AND FUNCTION AXLE MOUNT
View i!
Serial No. 10001 - 11117
View Y
423FO69
Serial No. 11118andup 6
View Y U42301002
1. Front axle Front axle

2. Rear axle . The front axle (I) receives the force directly
3. Front frame during operations, so it is fixed directly to the front
4. Rear frame frame (3) by axle mounting bolts (5).
5. Axle mounting bolt
6. Pivot Rear axle
l 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.
WA350-1 21-41
0
STRUCTURE AND FUNCTION AXLE AND DIFFERENTIAL
AXLE AND DIFFERENTIAL

. The motive force from the engine passes through . Inside the axles, the motive force passes from the
the torque converter, transmission, transfer, and bevel pinion to the bevel gear and is sent at right
drive shafts, and is then sent to the front and rear angles. At the same time, the speed is reduced
axles. and passes through the front differential (I) to the
axle shaft. The motive force of the axle shaft is
further reduced by a planetary-gear-type final
drive (5) and is sent to the wheels.
Front
E423F055
1. Front differential
View 2 2. Parking brake
3. Housing
4. Brake (See page 5 l-l 9)
5. Final drive (See page 21-48)
6. Drain plug
21-42 WA350-1
@
Section A-A
E423F056A
Section B-B
7. Side gear (Differentialjtteeth 12)

8. Bevel pinion (teeth 9)
9. Pinion (Differentialjtteeth 9)
10. Shaft
1I Bevel gear (teeth 40)
nA350-1
Rear
,
4
423FO57
I. Rear differential
2. Housing
3. Brake (See page 5 l-l 9)
4. Final drive (See page 2 I-48)
5. Drain plug
21-44 WA350-1
Section A-A
Section B-B E423F058
6. Bevel gear (teeth 40)

7. Side gear (DifferentiaDkeeth 12)
8. Pinion (Differentialjkeeth 9)
9. Shaft
10. Bevel pinion (teeth 9)
21-45
0
Outline
l The motive force from the drive shaft passes
through bevel pinion (I) and is transmitted to the
bevel gear (5). The bevel gear changes the direc-
tion of the motive force by 90, and at the same
time reduces the speed. It then transmits the
motive force through the differential (4) to the sun
gear shaft (2).
423 F059A
When driving straight forward

l When the machine is driven straight forward, the
rotating speed of the left and right wheels is the
same, so the pinion gear (4) inside the differential
assembly does not rotate. The motive force of the
carrier (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).
423 F060A
When turning
l When turning, the rotating speed of the left and
right wheels is different, so the pinion gear (4) and
side gear (3) inside the differential assembly
rotate in accordance with the difference between
the rotating speed of the left and right wheels.
The motive force of the carrier (6) is then transmit-
ted to the sun gear shafts (21.
423F061A
21-46 WA350-1
0
TORQUE PROPORTIONING DIFFERENTIAL
Function
Because of the nature of their work, 4-wheel-drive
loaders have to work in places where the road sur-
face is bad. In such places, if the tires slip, the abil-
ity to work as a loader is reduced, and also the life
of the tire is reduced. The torque proportioning
differential is installed to overcome this problem.
In structure it resembles the differential of an
automobile, but the differential pinion gear (4) has
an odd number of teeth. Because of the difference
in the resistance from the road surface, the posi-
tion of meshing of the pinion gear (4) and side
gear (3A). (38) changes, and this changes the
traction of the left and right tires.
Operation
When traveling straight (equal resistance from 3A 30
road surface to left and right tires)
If the resistance from the road surface to the left
and right wheels is the same, the distance be-
tween the pinion gear and the meshing point a
of the left side gear is the same as the distance be-
tween the pinion gear and meshing point b of
423FO63
right side gear (3B).
Therefore the left side traction TL and the right
side traction TR are balanced.
Direction of spider rotation
When traveling on soft ground (resistance from

road surface to left and right tires is different)
On soft ground, if the tire on one side slips, the
side gear of the tire on the side which has least
resistance from the road surface tries to rotate
forward. Because of this rotation, the meshing of
the pinion gear and side gear changes. -
If left side gear (3A) rotates slightly forward, the
distance between the pinion gear and the meshing
point a of the left side gear becomes longer
than the distance between the pinion gear and the
meshing port b of the right side gear. The posi-
tion is balanced as follows.
Direction of spider rotation
axTL=bxTR
The ratio between the distances to a and b

can change to 1: 1.38.
Therefore when the ratio of the distances to a
and b is less than 1 :1.38 (that is, the difference
between the resistance from the road surface to
the left and right tires is less than 38%). the pinion
gear will not rotate freely, so drive force will be
given to both side gears, and the tires will not slip.
Because of this effect, the tire life can be increased
by 20 - 30%. and at the same the operating effi-
ciency is also increased.
WA350-1 21-47
0
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
To gain a large drive force, the final drive uses a
planetary gear system to reduce the speed and
send drive force to the tires.
The motive force transmitted from the differential
through axle shaft (I) to sun gear (6) is transmit-
ted to planetary gear (2). The planetary gear ro-
tates around the inside of a fixed ring gear (3) and
in this way transmits rotation at a reduced speed
to the planetary carrier (4). This motive force is
then sent to the wheels (5) which are installed to
the carriers.
i
6 5 423FO66
1. Axle shaft
2. Planetary gear (Teeth 27)
3. Ring gear (Teeth 72)
4. Planetary carrier
5. Wheel
6. Sun gear (Teeth 18)
21-48 WA350-1
STRUCTURE AND FUNCTION TIRE AND WHEEL
TIRE AND WHEEL

. The tire acts to absorb the shock from the ground
surface to the machine, and at the same time they
must rotate in contact with the ground to gain the
power which drives the machine.
. Various types of tires are available to suit the
purpose. Therefore it is very important to select
the correct tires for the type of work and bucket
capacity.
E423F070
I. Tire
2. Side ring
3. Lock ring
4. Rim
5. Air valve
WA350-1 21-49
POWER TRAIN
Standard value table . .. ... 22- 2

Tool list for testing and adjusting . 22- 3
Measuring engine stall speed . . 22- 4
Measuring oil pressure of torque
converter and transmission .. . 22- 6
Measuring shift lever . . .. . . . 22- 8
Method for operation of emergency
manual spool . . . . . . . 22-8-l
Tire and wheel .. . .. .. . . 22- 9
Troubleshooting ... . _. . .. 22-l 1
they should be used as reference in combination with repair and, operating records when making judgements.
WA350-1 22-1
0
Testing and measuring item Measurement condition Unit Standard value Permissible value
Shift lever operating force l Torque converter oil

and stroke temperature: 60 - 80C
l Directional lever operating force l Engine speed: Low idling
N-F kg 0.3 -0.9 Max. 1.4
N-R 0.3 -0.9 Max. 1.4
l Speed lever operating force
1 st--2nd 0.3 -0.9 Max. 1.4
~_ 2nd-3rd kg 0.3 -0.9 Max. 1.4
3rd-4th 0.3 -0.9 Max. 1.4
l Directional lever travel

N-F mm 32-42 27 -47
N-R 32-42 27 -47
l Speed lever
lst-2nd-3rd-4th mm 32-42 27 -47
Engine stall speed Coolant temperature:

Inside operating range -
l Low idling 650-750
(680-780) -
l High idling 2,350 - 2,450 -
Hydraulic temperature:
45 - 55C 2,430 - 2.5301 -
l Torque converter stall 2,170-2,370 2,070 - 2,470
rpm
2,190 - 2.3901 (2,090 - 2,490)
l Hydraulic stall 2,100 - 2,300 2,000 - 2,400
Engine speed: High idling.
2,050 -2,250I (I ,950 - 2,350)
l Full stall 1,580 - 1,780 1,480 - 1,880
1,575 - I,7751 (I ,475 - 1,875)
Oil pressure of torque converter Engine speed: High idling

and transmission
Coolant temperature:
l Pilot reducing pressure Inside operating range. 10.8 * 1 .O IO.821.0
Torque converter oil
l Modulating pressure
temperature: 60 - 80C kg/cm2
Low idling 32.52 1.5 32.5+- 1.5
High idling 34.5 + 1.5 34.5? 1.5
l Torque converter relief pressurt 6.0* 1 .O 6.0+ 1 .O
l Lubrication oil pressure 1 .I to.4 1.1*0.4
Tire and wheel Tire inflation pressure:
Fitting of wheel lock ring (A) Specified pressure -

l Max. 2.5
mm
(B) Max. 4.0 -
l Clearance of wheel lockr ing (Cl 2-10 -
423F309
( 1: SerialNo.11118andup
22-2 WA350-1
0
No. besting and measuring item1 Tool Part number Remark

I I
1 1 Enginespeed Tachometer 799-203-8000 Digital display 60 - 20,000 rpm

I
2 1 Oil temperature Thermistor kit 799-l 01-6000 1 o-1,oooc
O-25 kg/cm2
3 Oil pressure Hydraulic tester 799-l 01-5000
0 - 50 kg/cm2
4 Pedal and lever
Push-pull gauge 7AO-262-0020 O-25 kg
operatino force
5 Measuring clearance
A 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.
A Do not allow unauthorized persons near the machine.
A When measuring the engine speed, one worker should measure the engine speed while the other sits in the
operators seat to operate the controls. Always check that the operation is safe, and use agreed signals.
WA350- 1 22-3
0
TESTING AND ADJUSTING MEASURING ENGINE STALL SPEED
MEASURING ENGINE STALL SPEED

l Coolant temperature: Inside operating range
l Hydraulic temperature: 45 - 55C
l Torque converter oil temperature: 60 - 80C
Unit: rpm
Item
value value
650 - 750
Low idling
(680 - 780) 1
2.350-2.450 -
-0 High idling
(2,430 - 2,530) -
I
j; 2.170-2,370 2.070-2.470
Torque converter stall
.-z_ (2,190 - 2,390) (2,090 - 2,490)
I I
P
u 2,100- 2.300 2,000 - 2.400
Hydraulic stall
(2.050-2.250) (1.950-22.350)
1.580-1.780 1.480-1.880
Full stall
(1,575-1,775) (1.475-1.875)
( ): Serial No. 11 1 18 and up
Special tools
I Part number Part name IQ-v
A 1 799-203-8000 1 Tachometer I
799-l 01-6000 Thermistor kit 1
-
Check that the low idling and high idling speeds

are the standard value.
Before measuring the stall speeds, install ta-
chometer A to engine speed pick up (I) on the
engine block.
Check that the engine speeds are the standard
value. If any item is outside the permitted range,
check for any looseness for play in the linkage.
A Apply the parking brake and block the tires.
1. Measuring torque converter stall

1) Start engine and run at low idling.
2) Put the directional lever in FORWARD or
REVERSE, and speed control lever in the high-
est speed range.
3) Using the brake, stop the machine and measure
the engine speed when the engine reaches high
idling.
t Turn the transmission cut-off valve switch
to OFF, and use the left brake. (Check that
the pilot lamp is OFF.)
* Do not run at stall speed for more than 20
seconds, and do not let the torque converter
oil temperature rise above 120C
22-4 WA350-1
0
TESTING AND ADJUSTING MEASURING ENGINE STALL SPEED
2. Measuring hydraulic stall

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

Measure the engine speed when torque converter
stall and hydraulic stall are reached at the same
time.
* Measure full stall when both the torque conver-
ter -and hydraulic stall speeds are normal. If
either stall speed isabnormal, remove the ab-
normality and measure the stall speed again.
WA350- 1 22-5
a
MEASURING OIL PRESSURE OF
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION
MEASURING OIL PRESSURE OF TORQUE CONVERTER

AND TRANSMISSION
* Measurement conditions
l Torque converter oil temperature: 60 - 80C
l Engine speed: High idling
Unit: kg/cm
Item value
I value I
Pilot radusing 10.8i 1.o 10.8il.O
pressure ._
I I
Special tool
A_ 799-101-5000 1 Hydraulic tester 1 1
A ,, Block the tires.
Measuring procedure
* The following preparatory work is necessary
before measuring any oil pressure.
Remove the covers on both sides under the cab.
Turn the transmission cut-off valve switch to
OFF and use the left brake. (Check that the
pilot lamp is OFF.)
Remove the plug from the measuring port of
the transmission valve. erial No. 10001 - l
Install hydraulic tester A to the measuring

port, pull the gauge to the operators
compartment, then start the engine and mea-
sure the pressure.
t Check that there is no leakage of oil from any
joints.
IF-J-W 1
1. Measuring pilot reducing pressure
P5+T1/8)
I) Measuring port (P5).
Serial No. l -
2) Put the F-R lever in neutral, and measure the
pressure when the speed control lever is
operated.
22-6
; -1 423F306A
WA350-1
0
MEASURING OIL PRESSURE OF
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION
2. Measuring modulating pressure

I) Measuring port (P I).
2) Put the F-R lever in neutral, and measure the
pressure when the speed control lever is
operated.
3. Torque converter inlet port oil pressure

1) Measuring port (P8).
2) Start the engine and measure the pressure at
high idling.
._
4. Measuring lubrication valve pressure

I) Measuring port (P9).
2) Start _the engine and measure the pressure at
high idling.
PS(PTl/S) PS(PTl/S) PI (PTl /8)
Serial No. l -
423F307A
P5 (PTl/S)
WA350- 1 22-7
al
TESTING AND ADJUSTING MEASURING SHIFT LEVER
MEASURING SHIFT LEVER

Measuring conditions
l Engine speed: Stop
Unit: kg
item
value value
Neutral-Forward 0.3-0.9 Max. 1.4

Directional
lever
Neutral-Reverse 0.3-0.9 Max. 1.4
Ist-2nd 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
c
Neutral-Foward 32-42 mm 27-47 mm
Directional
lever
x Neutral-Reverse 32-42 mm 27-47 mm
5
C
In each range
Speed
from 1 st three 32-42 mm 27-47 mm
lever
4th speeds
Special tools
A 1 7AO-262-0020 1 Push-pullscale 1 1
799-l 01-6000 Thermistor kit 1
A Be sure to set chocks firmly against the tires.
1. Measuring the lever operating effort

1) Attach push-pull scale A or a spring balancer to
the lever knob at the center and measure the
operating effort required to pull it in the operat-
ing direction.
t The measurement should be made in each
speed range.
2. Measuring the lever travel

I) Put mark 1 on the center on the control lever
knob and measure the travel when the lever is
moved in the operating direction.
WA350-1
**g8
METHOD FOR OPERATION OF
TESTING AND ADJUSTING EMERGENCY MANUAL SPOOL
METHOD FOR OPERATION OF EMERGENCY MANUAL

SPOOL
OUTLINE
l The transmission valve is controlled electrically.
Therefore, 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.
A The emergency manual spool is for use when

failure in the transmission control prevents the
machine from being moved. It allows the ma-
chine to-be moved from a dangerous place to a
place where repairs can be carried out safely.
The emergency manual spool must never be
used except when the transmission control has
broken down.
A When operating the emergency manual spool,

follow the correct order of operation exactly,
and pay full attention to safety when moving
the machine.
A To prevent the machine from moving, lower

the bucket to the ground, apply the parking
brake, and block the wheels. Check that the
pressure inside the air tank is above the speci-
fied pressure.
1. Remove R.H. machine panel.
Always stop the engine before operating the

LY 1
spool.
2. Remove lock plate (I) of the emergency manual

spool of the transmission valve.
t Simply loosen the mounting bolts to remove
the lock plate.
3. Decide the direction to move the machine

(forward or in reverse), then move the emergency /ii\ \\
REVERSi FORtiARD 4th 3rd 2nd spool I St
manual spool to the operating position. spool kpool spool spool spool
FORWARD: Rotate FORWARD clutch spool and
423 F339
1 st spool counterclockwise, and
pull out approx. 10 mm to the ON
position.
REVERSE: Rotate REVERSE clutch spool and

1 st spool counterclockwise, and
pull out approx. 10 mm to the ON
position.
4. Check that the area around the machine is safe,

then remove the blocks from under the wheeis.
423F340
J\IA35C-1 22-z- 1
w
METHOD FOR OPERATION OF
TESTING AND ADJUSTING EMERGENCY MANUAL SPOOL
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.
A When the engine is started, the transmission

is engaged and the machine will start.
Therefore, before starting the engine,
always check that the direction 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,
and screw in approx. 10 mm to the OFF
position.
7. After 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.
22-8-2 WA350-1
0
TESTING AND ADJUSTING TIRE AND WHEEL
TIRE AND WHEEL
Unit: kg/cm2
Tire
Item No.
value value
Fitting of wheel
lock ring
Clearance of -
C 2-10
wheel lock ring I I
L
v
__
Wheel
Measuring procedure O-ring i-

F42301008
1. Fitting of wheel lock ring
Measuie dimentions A and B with a feeler gauge
2. Clearance of wheel lock ring

Measure dimension C.
423F309
WA350-1 22-9
0
TROUBLESHOOTING
Precautions when troubleshooting. 22-l 2

Method of reading troubleshooting table 22-14
Preventing recurrence of trouble 22-l 6
Method of locating main problem points when
troubleshooting transmission system 22-l 7
Troubleshooting table . . 22-l 8
1. Machone does not move 22-l 8
2. Machine lacks power or speed 22-20
3. Excessive time lag when starting machine
or shifting gear.. 22-22
4. Torque converter oil temperature
toohigh 22-23
WA350-1 22-11
a
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
PRECAUTIONS WHEN TROUBLESHOOTING

1. SAFETY
l Stop the machine on level ground, and check that the safety pins and parking brake are correctly applied,
/I
and that the tires are blocked.
l When working in groups, use agreed signals and do not allow unauthorized persons near the machine.
l Be careful not to get burned by hot parts or to get caught in rotating parts.
l Always disconnect the cable from the negative (-) terminal of the battery before disconnecting any
wiring.
l 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 FOP TROUBLESHOOTING

* Just because a failure occurs, do not immediately start to disassemble the machine.
If the machine is disassembled before making the proper checks,
l 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, -
l The customer and operator will lose confidence in you.
l Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.
To avoid these problems, use the following procedure when troubleshooting.
1. Ask the customer and operator the following questions about the breakdown.
a. Have there been any other problems apart from the one reported?
b. Was there anything unusual before the machine broke down?
c. Did the breakdown occur suddenly, or had there been signs of trouble before?
d. What was the machine doing when the breakdown occurred?
e. Had the machine been repaired before the breakdown? If so, who carried out the repair, and when?
f. Had the same kind of failure occurred before?
2. Check the following items which can be checked simply by visual checks etc.
a. 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.
3. Reenact the failure and check the condition of the machine (particular conditions at the time of failure)
a. Ask the user or operator if the decision about the failure was made based on measured values, or by
comparison, or by feeling.
b. Compare extent of failure with standard values.
l Check safety before carrying out any check.
l Did not make any check or measurement that will make the condition 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 trans-
mission electric control.
In particular, when trouble occurs in the transmission system, the probable location of the failure can be
divided as follows.
l Transmission itself, or transmission control valve
l Transmission electric control
To decide which of these two is the location of the failure, go to page 22-l 7.
22-12 WA350-1
0
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
Carry out troubleshooting using the troubleshooting charts.

There are the following two types of troubleshooting charts.
1. TROUBLESHOOTING TABLE.. _. 22 POWER TRAIN,
42 STEERING SYSTEM,
52 BRAKE AND AIR SYSTEM,
62 WORK EQUIPMENT SYSTEM
2. TROUBLESHOOTING FLOW CHART.. 82 ELECTRIC AND ELECTRONIC SYSTEM
The troubleshooting charts consist of:
1) Items which can be checked easily
2) Items which are likely to be the cause of such failures.
Follow these charts to carry out troubleshooting.
At the same time, do not forget the following points.
l Check related items.
l Check that there are no other failures or breakdowns.
For details of troubleshooting tables, see page 22-l 4.
6. Investigate causes of breakdown
. Even if the breakdown is repaired, if the original cause of the problem is not removed, the same breakdown
will occur again. To,investigate and remove the original cause, see Actions to take to prevent failures from
occurring again.
3. PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING

PARTS DURING TROUBLESHOOTING
If it is necessary to remove, install, disassemble or assemble parts for troubleshooting, remember the follow-
ing 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 a 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.
WA350-1 22-13
0
TROUBLESHOOTING METHOD OF READING TROUBLESHOOTING TABLE
METHOD OF READING TROUBLESHOOTING TABLE

DESCRIPTION OF SYMBOLS USED IN TROUBLESHOOTING TABLE
The following symbols are used in the Remedy

column to indicate the method of eliminating the
cause of a fault.
X : Replace; A: Repair
A: Adjusting; C: Clean
METHOD OF READING TROUBLESHOOT-

ING TABLE
The symbol 0 in the table is inserted only for

causes which can be diagnosed. If a cause cannot
be diagnosed, the corresponding box is left blank.
If the result of problem 1 using the troubleshooting

table shown at right is abnormal, the cause of the
trouble can be assumed to lie between a and
d. Because it is not possible to make a problem
regarding e, it is necessary to perform the next
problem (owing to the possibility of a multiple
fault).
If the result of problem 1 is normal, the cause of
the fault does not lie between a and d. In
such a case, before diagnosing the cause as e,
however, carry out a check by means of problem
2 or 5.
If now the result of problem 1 is abnormal and the
result of problem 2 normal, the cause is one of
a, b or d. In addition, if the result of problem
3 is abnormal, the cause will be narrowed down to
one of b or d. To determine which of b or
d is the actual cause, perform problem 4.
If the result of problem is abnormal, blacken out
the corresponding o in the table and then perform
the next problem on these causes in order to
narrow the likely causes.
Unnecessary
problem
Example 1:
Problem 1 + Abnormal From the table of
Problem 2 + Normal example 1, the
Problem 3 -Abnormal cause of the fault
Problem 4 + Normal i is b.
Example 2:
From the table of
Problem 1 + Normal
example 2, the
Problem 2 + Abnormal
cause of the fault
I is e.
Unnecessary
* In example 2, it is evident that the cause is
problem
e without carrying out problem 2, however
problem 2 is performed by way of an addi-
tional check.
22-14 WA350-1
0
TROUBLESHOOTING METHOD OF READING TROUBLESHOOTING TABLE
Example 3:
Problem 1 + Abnormal From the table of
Problem 2 4 Abnormal example 3, the cause
Problem 3 + Normal is one of a, c
I I
I and e.
I
,
I
1
I
I
I
Continuk problems
I
I
From the table of
Problkm 4 1, Normal
example 3 - 1, the
Problem 5 - Normal
cause is c. Example 3-1
Example 4:
From the table of
I
Problem 1 + Abnormal
example 4, the
Problem 2 -+ Normal
1 cause is one of
Continue problems
1
Problem 3 L Abnormal From the table of

Problem 4 + Abnormal example 4 - 1, the Example 4-l
Problem 5 + Normal cause is a or d.
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 l marks there are in the column corresponding
to that cause, it will cause to be an actual cause if
there is even one o mark in the same column.
WA350-1
TROUBLESHOOTING PREVENTING RECURRENCE OF TROUBLE
PREVENTING RECURRENCE OF TROUBLE

The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of
equipment. It is not able to establish the root cause of the damage or failure, however.
Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not
mention what action should be taken to prevent a recurrence of the root cause.
In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause
while referring to the following items.
Regarding the method of checking and adjusting each part or piece of equipment, refer to Testing and adjust-
ing in the Shop Manual.
HYDRAULIC EQUIPMENT
1. Oil checks 3) Oil cleaning and replacement

l The fundamental cause of almost all faults occur- l If a large amount of metal particles or other for-
ring in hydraulic equipment is the inclusion of eign matter is discovered in the oil, either wash
water, air or other foreign matter in the oil. the oil using an oil refresher or replace it.
Accordingly, it is necessary to check the oil to see Sr If the oil is contaminated by water, it is not
whether or not it contains any of the above possible to remove the water by means of
substances, and then take appropriate action. an oil refresher.
I) Oil checks + When washing the oil, also wash or replace
l Check for water ingress the strainer and replace the filter.
Check the oil for possible water ingress by
means of a diesel engine oil checker or a hot
plate.
l Check for ingress of other foreign matter
Remove the drain plug and filter, then check 2. Cleaning fragments of damaged parts
the bottom of the tank and also the filter to see . If a part becomes damaged, fragments may pass
if any foreign matter has collected there. into the oil line. It is thus necessary to wash the oil.
Check the degree of contamination by means . In addition, disassemble and wash such parts as
of a contamination checker. valves and cylinders which are liable to collect
l Viscosity check metal fragments and other foreign matter, thus
Check the viscosity of the oil using a viscometer helping to prevent a recurrence of faults due to
in order to confirm whether or not the oil is such fragments becoming lodged in various parts
satisfactory. of the engine or hydraulic equipment.
2) Check of ingress point

If, as a result of the above checks, it is discov-
ered that the oil is contaminated by water or
other foreign matter, 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.
Sand: Oil replenishing or replacing meth-
od, etc.
Rubber: Cylinder packing, etc.
Metal: Wear or damage to hydraulic equip-
ment such as pump and motor, as
well as transmission and torque
converter, etc.
22-16 WA350-1
a
METHOD OF LOCATING MAIN PROBLEM POINTS WHEN
TROUBLESHOOTING TROUBLESHOOTING TRANSMISSION SYSTEM
METHOD OF LOCATING MAIN PROBLEM POINTS WHEN

TROUBLESHOOTING TRANSMISSION SYSTEM
The problem points in the transmission system can be broadly divided into the following two areas.
1. Transmission itself and transmission control valve.
2. Transmission electric control.
Use the following method to decide which of the two areas has the problems.
Problem: Machine will not start.

Machine will only travel in one direction (FORWARD or REVERSE)
2 YES
Replace transmission control
z
Does machtne move valve
If screw of
YE
emergency spool for -
ForRandlstis
pushed in7 Go to Troubleshooting for
transmission
resistance of F or R (See page 22-l 8 - 22-23)
solenoid correct?
11 Voltage 20 - 3ov.
2) Resistance approx.
60fi.
GO to Troubleshooting for
electrical system of
transm1ss10n
fSee page 82-46 - 82-52)
Problem: Machine will not move in certain speed ranges
Replace transmkon control

valve
GO to Troubleshooting for
Is voltage
and
transmission
resstance of
(See page 22-18 - 22.231
solenoid for problem
speed range correct?
I) Voltage 20 - 3ov.
2) Resistance approx.
Go toTroubleshooting for
600.
electrical system of
transmission
ISee page 82-46 - 82-52)
WA350-1 22-17
0
TROUBLESHOOTING TROUBLESHOOTING TABLE
TROUBLESHOOTING TABLE
1. Machine does not move
Ask the operator the following points.

l Did the machine suddenly stop moving?
Yes = Component seized or damaged.
l Was there any abnormal noise when the ma-
chine stopped moving?
Yes = Component broken.
Checks before troubleshooting

0 Is oil level in transmission case correct?
l Is voltage of solenoid valve correct?
l Is monitor display normal?
l Is drive shaft broken?
Transmission
8 Pilot reducing pressure defective

I I I I I I
Note 1: If the solenoid valve and hydraulic pressure

are normal, the I in the Causes column indi-
cates that the valve spool does not work.
Note 2: If the transmission clutch pressure is low,
but the cause cannot be found in the above
table, a possible cause is cracks in the valve
or transmission.
22-18 WA350-1
0
The following symbols are used to indicate the action

to be taken when a cause of failure is located.
X: Replace A: Repair
A: Adjust C: Clean
-
WA350-1
22-19
0
2. Machine lacks power or speed

l Is oil,level in transmission case correct?
l Is there any leakage of oil from joints of piping
or valves?
l Is parking brake or brake locked?
l Is operation of electric circuit correct?
Checking for abnormalities

Engine high idlcng speed
Toque converter stall speed
Machine travel speed
Transmission clutch pressure
Pressure at outlet port of pump
Pilot reducing pressure
Tire inflation pressure

22-20 WA350-1
0
3. Excessive time lag when starting machine

or shifting gear

0 Is oil level in transmission case correct?
. Is there any leakage of oil from joints of piping
or valves?
0 Is operation of control valve normal?

l Check STANDARD VALUE TABLE to confirm
that time lag is actually excessive
3 Machine moves normally in certain speed ranges 0 0 0
4 Transmission modulating pressure too low

in every speed range 0 0 0 0
5 As in item 4; indicator fluctuates violently 0

Torque converter oil temperature is above operating
6 0 0
range.

A: Adjust C: Clean
WA350-1 22-21
0
4. Torque converter oil temperature too high
Ask the operator the following points.

l Does the torque coverter oil temperature go up
during torque converter stall, and down when
the torque converter is not stalled?
Yes = Normal (Incorrect selection of gear
speed)

l Is oil level in transmission and steering case
correct? _-
l Is filter clogged?

l Check STANDARD VALUE TABLE to confirm
that torque converter oil temperature is actually
high.
* If the oil temperature is normal but the
temperature gauge is outside the operat
range, the oil temperature gauge is defecti
4 Transmission modulating pressure too low

A: Adjust C: Clean
22-22
0
POWER TRAIN
..
TORQUE CONVERTER CHARGING PUMP FRONT DIFFERENTIAL

Removal ........... ,.................. 23- 2 Removal ............... . 23- 78
Installation ......... ,.................. 23- 3 Installation ............. . 23- 81
TORQUE -CONVERTER, TRANSMISSION, TRANS- REAR DIFFERENTIAL

FER ASSEMBLY Removal ............... .. 23- 84
Removal .............................. 23- 4 Installation ............. . 23- 85
Installation ............................ 23-l 3
DIFFERENTIAL
TORQUE CONVERTER ASSEMBLY Disassembly ............ . . 23- 86
Disassembly ........................... 23-21 Assembly .............. . 23- 89
Assembly ............................. 23-26
FRONT AXLE
TRANSMISSION ASSEMBLY Removal ............... . 23- 97
Disassembly ........................... 23-32 Installation ............. . 23- 99
Assembly ............................. 23-46
REAR AXLE
TRANSFER ASSEMBLY Removal ............... . 23-101
Disassembly ........................... 23-61 Installation ............. 23-l 05
Assembly ............................. 23-64
DRIVE SHAFT
TRANSMISSION CONTROL VALVE Disassembly ............ 23-l 09
Removal .............................. 23-72 Assembly .............. . 23-l 11
Installation ............................ 23-73
FINAL DRIVE
LOWER VALVE Disassembly ............ 23-l 13
Disassembly 23-74 Assembly .............. . 23-l 16
Assembly ........................... 23-74
UPPER VALVE
Disassembly ........................ 23-76
Assembly ........................... 23-76
* For details of disassembly and assembly of the gear pump, see SECTION 97.
* Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling
3. Continue to operate cylinder 3 - 4 cycles until stroke end.
WA350-1 23-l
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
REMOVAL OF TORQUE CONVERTER CHARGING PUMP
a Stop the
the safety
and install
the bucket
A Open hood (1) and fit lock (2).
1. Engine oil filter

Remove oil filter (3).
2. Hydraulic piping
1) Disconnect tube (4) between torque converter
charging pump and torque converter filter at
torque converter charging pump end.
* Remove the U-clamp holding the tube.
2) Disconnect tube (5) between torque converter
charging pump and transfer at torque converter
charging pump end.
3. Torque converter charging pump

Remove mounting bolts, then remove torque con-
verter charging pump (6).
f There is little space, so be careful not to injure
your hands or fingers.
23-2 WA350-1
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
INSTALLATION OF TORQUE CONVERTER CHARGING PUMP

1. Torque converter charging pump
Set torque converter charging pump (6) in mount-
ing position, then tighten mounting bolts.
* Fit the O-ring securely in the groove, and make
sure that it is not caught when installing.
2. Hydraulic piping
1) Connect tube (5) between torque converter
charging pump and transfer to torque converter
charging pump.
charging pump and torque converter filter to
torque converter charging pump.
Sr Fit the O-ring securely in the groove, and
make sure that it is not caught when
installing.
Sr Secure the tube with a U-clamp.
3. Engine oil filter

Install engine oil filter (3).
* Close the hood and fit the catch.
WA350-1 23-3
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION, TRANSFER
REMOVAL OF TORQUE CONVERTER, TRANSMISSION,

TRANSFER ASSEMBLY
A
--Ladder
4
Hydraulic
tank piping
Wheel loader
\\\ Brakevalve H &asier
Drive shaft
423F406
23-4 WA35071
0
A Stop
the safety
the machine
bar on the frame.
on level ground
Lower
and install
the bucket
Q! Loosen
pressure
operate
the oil filler
inside
the control
the
cap slowly
hydraulic
levers
to release
several
tank.
times
the
Then
to
release the remaining pressure in the hydraulic
piping.
t Disconnect the cable from the negative (-)
. Loosen plug (1) at the top of the hydraulic tank
filter, and the plug (2) of the pump piping to
prevent the oil inside the tank from flowing out.
1. Draining air
Loosen drain valve (5) and drain air from air tank.
2. Ladder
Sling ladder (6). remove mounting bolts, then
remove ladder.
* Remove the ladders on both the left and right
sides.
Ladder: 65 kg
WA350-1 23-5
0
3. Hood
1) Remove clamps of wiring and vinyl tube for
window washer, then remove window washer
tank (7) from hood.
2) Sling hood (81, remove mounting bolts, then lift
off hood.
t Be careful not to hit the rear window of the
cab when lifting off the hood.
Hood: 62 kg
4. Hydraulic tank piping

1) Disconnect hose (9) between hydraulic tank
and work equipment circuit at work equipment
circuit block end.
2) Loosen clamp of hose (IO) between hydraulic

tank and steering and hydraulic pump, then
disconnect hose at hydraulic tank end.
5. Brake oil tank

1) Disconnect connector (1 1) of wiring for brake
oil tank.
2) Disconnect hoses (I 2) and (I 3) between brake
oil tank and brake chamber at brake chamber
end.
23-6 WA350-1
0
6. Main control valve piping

1) Disconnect lift cylinder hoses (1 6) and (I 7).
2) Disconnect dump cylinder hoses !I 4) and (I 5).
3) Disconnect steering valve hose (I 8).
4) Disconnect hose (19) for work equipment
circuit.
5) Disconnect bucket control linkage (20) at main

control valve end.
7. Support
Sling support (21). remove mounting bolts, then
lift off support.
* Remove the bracket of the block for the work
equipment circuit.
* Be careful not to hit the rear window of the cab
when lifting off the support.
8, , Electric wiring
I) Disconnect connectors (23). (241, (25). (26),
(271, (281, (29) and (30) at bracket of floor
frame (22).
* After removing the wiring, mark with a tag
to distinguish when installing.
2) Disconnect ground connection and connector.
3) Disconnect connector of wiring for brake sole-
noid valve.
WA350- 1 23-7
0
9. Brake valve
1) Disconnect hoses (3 I) and (32) between brake
valve and brake chamber at brake vlave end.

1) Disconnect fuel control cable (35) from ball
joint (36).
(37).
Sr Remove the strap properly.
11. Floor frame, cab assembly

I) Remove lever lock plate (38) of work equipment
control lever box inside cab.
23-8 WA350-1
0
2) Remove floor surface plate (39) of work equip-

ment control lever box.
* Remove the plate with the boot attached.
3) Sling floor frame and cab assembly (40),

remove mounting bolts, then lift off assembly.
t After lifting off the floor frame and cab
assembly, remove the steering shaft from
the gear box.
* If shims are inserted, check numbers of
shims.
6 kg Floor frame, cab assembly: 250 kg
WA350-1 23-9
@
3) Disconnect tube (45) between brake chamber

and brake valve from brake chamber.
4) Remove air tank tube (46).
5) Sling brake chamber (47). remove mounting
bolts, then lift off.
14. Torque converter oil filter

I) Disconnecttube (48) between torque converter
charging pump and torque converter oil filter
from torque converter oil filter.
2) Disconnect hose (49) between torque converter
oil filter and transmission from torque converter
oil filter.
3) Disconnect hoses (50) and (51) between trans-
mission valve oil filter and transmission from
filter.
4) Remove mounting bolts of bracket, then
remove torque converter oil filter (52) together
with bracket.

1) Remove tube clamp and U-bolt, then remove
bracket (53).
2) Disconnect tube (54) between transmission
and oil cooler from transmission.
3) Disconnect tube (55) between transfer and oil
cooler from transmission.
16. Drive shaft

Disconnect center drive shaft (56) and rear drive
shaft (57) from transfer.
23-10 WA350-1
0
17. Torque converter, transmission, transfer as-

sembly
1) Disconnect clamp and connector of wiring (58)
for torque converter and transmission solenoid
valve.
2) Put block @between rear axle and bottom of

engine to support engine.
t When inserting the block, be careful not to
damage the brake tube.
3) Rotate transfer mount (59) of oil supply tube,

move towards inside of machine body, then
secure with 1 bolt.
* Be careful not to let the mount come out of
the transfer, and tighten the bolts immedi-
ately after rotating the mount.
* Before moving to the inside of the rear
frame, remove the oil filler cap.
4) Sling torque converter, transmission and trans-

fer assembly (60). then remove connecting
bolts (61) of torque converter and engine.
WA350-1 23-11
0
5) Remove left and right mounting bolts (621,

then remove spacer (63) and cushion (64).
Sr Measure all the clearances of the positioning
bolts.
t Make match marks on the mount of the
mounting bracket and rear frame, and mea-
sure the protrusion of the positioning bolts
to give a guide when installing.
6) Raise torque converter, transmission and trans-

fer assembly (60) 20 to 30 mm, move to front
to disconnect, then remove left and right brack-
ets (65).
* When raising the assembly, be careful of the
meshing of the engine and torque converter
ring gear shaft, and lift off the assembly.
7) Lift off torque converter, transmission and

transfer assembly (60). Be careful not hit rear
frame.
Torque converter, transmission, trans-

E?Ikg
fer assembly: 710 kg
23-12 WA350-1
0
INSTALLATION CIF TORQUE CONVERTER, TRANSMISSION,

TRANSFER ASSE MBLY
2
Drive shaft - ToA
-To 6
= ToC
Torque converte
WA350-1
transfer assembl
Wheel loader
Brake oil tank

A-
16
Ladder
17 18
I
423 F408
WA350-1 23-13
0
1. Torque converter, transmission, transfer as-

sembly
I) Raise torque converter, transmission and trans-
fer assembly (60) and set in mounting position.
Align ring gear and shaft, then connect and par-
tially tighten mounting bolts.
* Raise the assembly horizontally and be care-
ful of the ring gear and shaft when installing.
* Use a new O-ring and fit it securely in the
groove.
E??YE O-ring-at contact face of engine and

torque converter: Soapy water
2) Install left and right brackets (65) to

transmission, fit cushions and spacers behind
brackets, then tighten mounting bolts (62).
* Assemble the cushions so that the cham-
fered face is on the spacer side.
* Never use oil or soap when assembling the
cushions.
+ Partially tighten the mounting bolts, then set
in position and tighten the bolts fully.
m Mounting bolt of bracket:

18.Ok2.0 kgm
w Mounting bolt: 94.5 + 10.5 kgm
3) Install connecting bolts (61) of torque con-

verter and engine, then tighten fully.
4) To position the transmission, adjust with ad-

justment screw (66) so that clearance a is
the specified value, then tighten the mounting
bolts fully.
Clearance a: 1 - 2 mm
w Mounting bolt: 28&3 kgm
Clearance a 424F114
23-14 WA3561
8
5) Rotate transfer mount (59) of oil supply tube,

then pull to outside of machine.
Sr Be careful not to let the mount come out of
the transfer, and tighten the bolts im-
mediately after rotating the mount.
Sr When pulling to outside of the rear frame,
first remove the oil filler cap, then tilt over.
6) Remove block @ from between rear axle and

bottom of engine.
7) Connect clamp and connector of wiring (58)

for torque converter and transmission solenoid
valve.
2. Drive shaft
Connect rear drive shaft (57) and center drive
shaft (56) to transfer.
m Mounting bolt: 11.5* 1 .O kgm
WA350- 1 23-15
0
3. Hydraulic piping
I) Connect tube (55) between transfer and oil
cooler to transmission.
2) Connect tube (54) between transmission and
oil cooler to transmission.
3) Install bracket (531, then install tube clamp and
U-bolt.
4. Torque converter oil filter

I) Set torque converter oil filter (52) in mounting
position, then tighten mounting bolts.
2) Connect hoses (50) and (51) between trans-
mission valve oil filter and transmission to filter.
3) Connect hose (49) between torque converter
oil filter and transmission to torque converter
oil filter.
charging pump and filter to torque converter oil
filter.
5. Brake chamber
I) Raise brake chamber (47). set in mounting
position, and install.
2) Install air tank tube (46).
3) Connect tube (45) between brake chamber and
brake valve to brake chamber.
4) Connect hoses (43) and (44) between brake

chamber and slack adjuster to brake chamber.
5) Connect connector of brake chamber wiring.
23-16 WA350-1
0
6. Steering valve piping

1) Install hose (42) between steering valve and
main control valve.
2) Install hose (41) between steering valve and
steering pump.
t Fit the O-ring securely in the groove, and
installing.

1) Raise floor frame and cab assembly (40). set in
mounting position, then tighten mounting bolts.
* Insert the steering shaft correctly into the
spline of the steering column, and secure
with wire so that it does not come out.
423 F484 423F485

68
2) Select number of shims matching clearance

a and I( b,
3) Loosen mounting bolts, and after inserting

shim (671, retighten mounting bolts.
* Install shims. The lower rubber mounts (68)
should not bulge after tightening mounting
bolts.
* There should not be any clearance at in-
stalled portion of shim. Move shim by hand
if there is clearance.
4) Install lever lock plate (38) of work equipment

lever box.
5) Install floor surface plate (39) of work equip-
ment lever box inside cab.
Sr Coat the outside circumference of the lever
with soap, then assemble the boot to the
plate first.
WA350-1 23-17

1) Install fuel control cable (35) to bracket (37).
2) Connect fuel control cable (35) at ball joint (36).
9. Brake valve
I) Connect hoses (33) and (34) between brake
valve and air tank at brake valve end.
valve and brake chamber at brake valve end.
10. Electric wiring

I)
11. Support
I) Raise support (211, set in mounting position
and install.
2) Install bracket of block for work equipment
circuit.
t Be careful not to hit the rear window of the
cab when installing the support.
23-18 WA350-1
0
12. Main control valve piping

1) Connect work equipment control linkage (20)
to main control valve.
2) Connect hose (19) for work equipment circuit.

3) Connect steering valve hose (I 8).
4) Connect dump cylinder hoses (I 4) and (I 5).
5) Connect lift cylinder hoses (I 6) and (I 7).
13. Brake oil tank

1) Connect hoses (I 2) and (I 3) between brake oil
tank and brake chamber at brake chamber end.
2) Connect connector of wiring for brake oil tank
(I I).
14. Hydraulic tank piping

I) Install hose (I 0) between hydraulic tank and
steering and hydraulic pump at tank end, then
tighten clamp.
WA350- 1 23-19
0
2) Connect hose (9) between hydraulic tank and

work equipment circuit at work equipment cir-
cuit block end.
15. Hood
1) Raise hood-(8). set in mounting position, then
tighten mounting bolts.
2) Install window washer tank (7) to hood, then in-
stall vinyl tube for window washer and clamps
of wiring.
16. Ladder
Raise ladder (6). set in mounting position, then
It Install the ladders on both the left and right
sides.
17. Refilling with oil

1) Tighten plug (I) at top of hydraulic tank filter,
and plug (2) of pump piping, then add hydraulic
oil through oil filler (66) to the specified level.
* Run the engine to circulate the oil through
the system.
Then check the oil level again.
2) Add transmission oil to the specified level.
@ Transmission oil: 53 Q
* Run the engine to circulate the transmission

oil through the system. Stop the engine and
wait for 15 minutes, then check the oil level
again.
18 . Bleeding air, checking

Bleed air from brakes, then check operation.
For details of bleeding air, see 52 TESTING AND
ADJUSTING.
? Close hood, then lock with catch.

/I
2 3-20 WA3561
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY
1 2 3 4 5
t ToA
assembly
I\
Special tools
Part No. Part Name IQty

A 790-501-5000 Unit repair stand 1
AI 790-901-21 10 Bracket 1
A, 793-310-2140 Plate 1
B 790-I 01-2501 Push-puller (kit) 1
BI 790-I 01-2102 Puller 1
B2 790-101-1102 Pump 1
Preparatory work
Remove torque converter assembly (2) from torque
converter, transmission and transfer assembly (I 1.
For detailes, see 23-4 REMOVAL OF TORQUE
CONVERTOR, TRANSMISSION, TRANSFER
ASSEMBLY.
WA350- 1 23-21
0
1. Turbine, case assembly

1) Set torque converter assembly (2) in tool A
2) Remove mounting bolts (3) of case, then

remove turbine and case assembly (4).
t When removing the mounting bolts, leave 2
mounting bolts on opposite sides, then turn
over the assembly (pilot side at the top) and
remove the remaining 2 mounting bolts.
3) Disassemble turbine and case assembly as

follows.
i) Remove pilot (5).
ii) Remove snap ring (6), then remove spacer
(7).
iii) Using 2 forcing screws @ (Thread dia. =
IO mm, pitch = 1.5 mm), remove turbine
(8) from case (9).
* Pull out from bearing inner race side.
423F410
23-22 WA350-1
Q
2. Stator
Remove snap ring (13). then remove stator (I 4).
3. Pump
Remove pump (I 5).
4. Case
Remove 12 bolts, then remove case (16).
WA350-1 23-23
0
2) Using tool B, remove gear (19) and bearing

(20).
6. Stator shaft
Remove 8 mounting bolts, then remove stator
shaft (23).
t Tap the end of the shaft with a copper hammer
to remove.
7. Pump drive gear assembly

Screw in forcing screw and remove pump drive
gear assembly (25).
8. Idler gear shaft

Using 2 forcing screws @ (Thread dia. = 10
mm, pitch = 1.5 mm), remove shaft (38).
t Check the number and thickness of the shims,
and keep in a safe place.
23-24 WA350-1
0
9. Idler gear, bearing

Remove gear (39) and bearing (40).
WA350-1 23-25
0
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
1 2 4 5
t ToA
7 9 9
A
423F411
Special tools
A2 793-310-2140 1 Plate I
1. Idler gear, bearing

1) Set torque converter case in tool A.
2) Install outer race (41) (O.D.: 1 10 mm) on gear
(39).
23-26
0
3) Assemble bearings (40) on both sides of gear

(391, then set in case.
..
2. Idler gear shaft

1) Fit-o-ring, align with inner race of bearing and
install shaft (38).
2) Press fit shaft fully, then measure clearance

between case and shaft (38) with feeler gauge
0.
3) Select shims so that measured clearance is 0 to
0.005 mm (+I.
4) Insert selected shims, then tighten mounting
bolts.
3. Pump drive gear assembly

I) Assemble gear assembly as follows.
i) Install bearing (35) (O.D.: 100 mm) in cage
(36).
ii) Install snap ring (42).
WA350-1 23-27
iii) Push inner race (I.D.: 55 mm) side of

bearing, and install cage (36) on shaft (34).
iv) Install snap ring (33).
v) Install inner race (31) (I.D.: 50 mm) on gear

(32). -
vi) Install snap ring (30).
vii) Install gear (29)on shaft.
m Mounting bolt: 7kO.5 kgm
2) Install bearing (27) (O.D.: 90 mm) in case (28).

31 Install snap ring (26).
23-28 WA350-1
0
4) Fit O-ring and install pump drive gear assembly

(25).
4. Stator shaft
1) Using guide bolt @ (Thread dia. = 10 mm,
pitch = 1.5 mm), install stator shaft (23).
2) Install seal ring (24) on shaft (23).

* Coat the seal ring with grease and make the
protrusion from the shaft uniform.
5. Gear, bearing
1) Install bearing (21) (O.D.: 180 mm) on gear
(I 9).
2) Push inner race end and install bearing (21) on
shaft together with gear.
WA350-1 23-29
0
6. Case
Install case (I 6)
m Mounting bolt: 3.220.2 kgm
7. Pump
Align bolt holes and install pump (I 5).
8. Stator
1) Install stator (I 4).
2) Install snap ring (I 3)
9. Turbine, case assembly

I) Assemble turbine and case assembly as
follows.
i) Assemble snap ring to bearing (I 0).
ii) Install bearing (I 0) (O.D.: 1 10 mm) in case
(9).
23-30 WA350-1
0
iii) Support turbine (8), push inner race (I.D.:

70 mm) of bearing, and install case (9) on
turbine (8).
iv) Assemble spacer (7) and install snap ring
(6).
VI Install pilot (5).
m Mounting bolt: 720.5 kgm
i 423F412
2) Align bolt holes, then install turbine and case

assembly (4).
3) Install 24 mounting bolts (3) of case.
w Mounting bolt: 3.2kO.3 kgm
. Torque converter assembly

Fit O-ring, align spline of transmission input shaft
with boss of turbine, then install torque converter
assembly (2) on transmission assembly (I 1.
WA350-1 23-31
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY OF TRANSMISSION ASSEMBLY
7
Checking
Transmission
Transmission operation of
assembly piston
Special tools
23-32 WA350-1
0
14 15
t ToA
- ToB
24 25
No. 5 sun
gear
423F413
WA350-1
23-33
0
1. Torque converter assembly

Raise torque converter assembly (2) and remove
from transmission assembly (I ).
2. Filter assembly
Remove filter assembly (3).
3. Control valve assembly

Remove control valve assemblies (4) and (5)
4. Sleeve
Using eye bolts @ (Thread dia. = 16 mm, pitch
= 2 mm), remove 5 sleeves (6).
5. Transfer assembly
1) Set transfer assembly at bottom.
2) Remove 2 tie bolts (8).
* Remove the two bolts on opposite sides
where there are bulging oil holes on the top
surface of the plate.
These are holes for eye bolts.
3) Remove mounting bolts of transmission case
and transfer.
4) Screw in forcing screw, raise transmission
assembly (9) and disconnect from transfer
assembly (7).
23-34 WA350-1
0
6. Transmission case
1) Remove mounting bolts (IO) of case, and lower
to ground.
2) Remove 2 housing lock bolts (I I) each on left
and right.
3) Using 2 eye bolts @ (Thread dia. = 16 mm,

pitch G 2 mm), remove transmission assembly
(12) from case.
7. Checking operation of piston

I) Set transmission assembly (12) on tool A.
2) Using tool B, check operation of piston before
disassembling.
8. Input shaft, No. 1 carrier assembly

1) Remove tie bolt (8).
2) Lift off input shaft and No. 1 carrier assembly
(14).
WA350-1 23-35
0
9. No. 1 clutch ring gear, spring

Remove ring gear (I 5) and spring (I 6).
10. No. 1 clutch disc, plate

Remove discs (17) and plates (I 8).
t There are 4 discs and 3 plates.
11. No. 1 housing

Remove No. T housing (20).
* Tap with a copper hammer to disconnect
dowel pin, then remove.
12. Guide pin, spring

Remove guide pin (I 9) and No. 2 clutch spring
(21).
13. No. 2 clutch disc, plate

Remove discs (22) and plates (23).
* There are 4 discs and 3 plates.
23-36 WA350-1
0
14. No. 1 idler ring gear

1) Remove snap ring (251, then remove ring gear
(26).
2) Remove plate (27).
15. Ring gear of No. 2 clutch

Remove ring gear (28).
16. No. 2 housing

Remove No. 2 housing (30).
+I Tap with a copper hammer to disconnect
dowel Pin, then remove.
17. No. 3 clutch disc, plate, spring

Remove springs (33). discs (34) and plates (35).
WA350-1
18. Bearing, cover

Remove snap ring (37). then remove cover (38).
19. No. 2,3,4 carrier assembly

I) Remove snap ring (40) at shaft end.
2) Using puller @, remove No. 2, 3 and 4 carrier
assembly (41).
* No. 3 clutch ring gear will come off at the
same time.
20. No. 3 housing

Remove housing (42).
* Tap with a copper hammer to disconnect
dowel pin, then remove.

Remove springs (441, discs (45) and plates (46).
t There are 2 discs and 1 plate.
23-38 WA350-1
0
22. Ring gear for No. 4 clutch

1) Remove snap ring (471, then remove ring gear
(48).
2) Remove plate (49).
23. No. 4,5 housing assembly

Remoie No. 4 and 5 housing assembly (50).
24. Spacer, No. 4 sun gear

1) Remove snap ring (51), then remove spacer
(52) and No. 4 sun gear (53).
2) Remove snap ring (54).
25. No. 5 sun gear

Remove snap ring (55). then remove No. 5 sun
gear (56).
WA350-1 23-39
0
26. No. 5 carrier assembly

I) Remove mounting bolts.
2) Tap with copper hammer to disconnect dowel
pin, remove No. 5 carrier assembly (57).
* When disassembling the planet gear, see
DISASSEMBLY OF INPUT SHAFT, NO. 1
CARRIER ASSEMBLY, Step 7 for details.
27. Hub, spring

I) Remove hub (58).
2) Remove spring (59).

Remove discs (60) and plates (61).
29. Output shaft

I) Remove output shaft assembly from tool A.
2) Support collar end, and push shaft (63) with
press to remove.
23-40 WA350-1
0
30. Cage
I) Remove snap ring (64).
2) Support No. 6 housing (631, and push cage
(65) with press to remove.
DISASSEMBLY OF INPUT SHAFT, NO. 1

CARRIER ASSEMBLY
1. No. 2 sun gear

Remove snap ring (75). then remove No. 2 sun
gear (76).
2. No. 1 sun gear

I) Remove snap rings (77) and (78)
2) Remove No. 1 sun gear (79).
3. Spacer
Remove spacer (80)
4. Input shaft
Support housing (811, and push shaft (82) with
press to remove.

1) Remove snap ring (85).
Sr On inner race side.
2) Support housing (86). and push carrier
assembly (87) with press to remove.
WA350-1 23-41
0
6. Spacer
Remove spacer (88).
7. Planet gear
1) Remove shaft (89).
Sr Be careful not to lose ball (90).
2) Remove planet gear (91). bearing (92) and

thrust washer (93).
DISASSEMBLY OF NO. 2,3,4 CARRIER

ASSEMBLY
1. No. 3 ring gear

Remove No. 3 ring gear (I 00)
423P f 390

Remove No. 4 carrier assembly (102) from No. 2
and 3 carrier assembly (103).
t Remove the mounting bolts, tap with a copper
hammer to disconnect dowel pin, then remove
assembly.
423P139f
23-42 WA350-1
0
3. No. 4 carrier, planet gear

t When disassembling the planet gear, see DIS-
ASSEMBLY OF INPUT SHAFT AND NO. 1 CAR-
RIER ASSEMBLY, step 7 for detailes.
4. No. 2,3 carrier, planet gear

1) Using tool C, remove shaft (I 04).
t Be careful not to lose ball (I 05)
2) Remove gear (106). bearing (I 07) and thrust

washer !I 08).
DISASSEMBLY OF NO. 4,5 HOUSING

ASSEMBLY
1. No. 4 housing
Remove No. 4 housing (I IO).
* Lever up where the dowel pin is located. Be
careful not to damage the housing.
2. Discs, plates, springs

Remove springs (1 131, discs (I 14) and plates
(1 15).
WA350-1 23-43
0
3. No. 5 clutch ring gear

Remove ring gear (I 16)
23-44 WA350-1
0
ASSEMBLY OF TRANSMISSION ASSEMBLY
No. 6 clutch
housmg
6
No. 5 sun
gear
20
No. 1.2 carrier
ring gear
Special tools
A 790-501-5000 Unit repair stand 1
A, 790-901-2110 Bracket 1
A, 793-31 o-21 40 Plate 1
A, 1 793-310-2150 ( Plate I I
B ( 799-301-I 500 1 Leak tester I I
23-46 WA350-1
0
.
8
To B
1 \, ToC
30
423F419
WA350-1 23-47
0
ASSEMBLY OF NO. 4,5 HOUSING

ASSEMBLY

Set ring gear (I 16) on No. 5 housing.
2. Discs, plates, springs

Install discs (I 14), plates (I 15) and springs (1 13).
3. No. 4 housing
I) Assemble seal ring (I 12) on piston (1 1 1).
2) Assemble seal ring on.housing (I 10).
* The seal ring must be installed facing in the
correct direction. Install with the side
receiving the pressure facing the groove.
3) Install piston (I 1 I) in housing (I 10).
Housing
423F420
4) Align dowel pin and install No. 4 housing (I IO).

+r Tap the position of the dowel pin with a
copper or plastic hammer.
42!3Pl3$4
23-48 WA350-1
0
ASSEMBLY OF NO. 2,3 CARRIER

ASSEMBLY
1. No. 2,3 carrier, planet gear

I) Assemble bearing (I 07) on planet gear (1061,
then fit thrust washers (108) on both sides and
set in carrier.
t Align the center of all parts with the shaft hole.
2) Tap shaft (I 04) with a plastic hammer to install.

Assemble ball (I 05) and knock in completely.
t Check that the gear and thrust washer
rotate smoothly.
3) Caulk tip of shaft at one point.
No. 4 carrier, planet gear

Sr Install in the same way as for the NO. 2. 3
carrier, planet gear.

Align dowel pin and install No. 4 carrier assembly
(102). then tighten bolts (I 02A).
6~ Mounting bolt: Adhesive (LT-2)
m Mounting bolt: 10 - 12.5 kgm
+ Tap the position of the dowel pin with a copper

or plastic hammer.
4. Seal ring
Install seal ring (I 01).
5. No. 3 ring gear

Install No. 3 ring gear (100).
* Install with the internal teeth facing the No. 4
carrier.
WA350-1
ASSEMBLY OF INPUT SHAFT, NO. 1

CARRIER ASSEMBLY
1. Planet gear
* For details, see ASSEMBLY OF NO. 2, 3, 4
CARRIER ASSEMBLY.
2. Bearing
I) Install bearing (98) (O.D.: 90 mm) to No. 1
carrier (99).
2) Install snap ring_(97).

I) Install bearing (95) (O.D.: 125 mm) to housing
(96).
2) Install snap ring (94).
4) Install housing (86) on carrier assembly (87).

* Press fit the inner race of the housing to the
carrier.
23-50
0
4. Input shaft
I) Install snap ring (84) on shaft (82).
2) Install shaft (82) in carrier (83).
5. Spacer
lnstalf spacer (80)
6. No. 1 sun gear

1) Install No. 1 sun gear (7%.
2) Install snap rings (78) and (77).
7. No. 2 sun gear

Install sun gear (761, then install snap ring (75)
(ASSEMBLY OF TRANSMISSION)
1. Cage
1) Install bearing (73) (O.D.: 1 f55 mm) and
bushing (72) to No. 6 housing (63).
2) Install snap ring (7 I).
WA350-1 23-51
0
3) Install bearing (69) (O.D.: 95 mm) in cage (65).

5) Install seal ring (67).
6) Install cage (65) in housing (63).

+ Press ftt the housing inner race.
8) Install piston (65) and guide pin (66) in housing

(63).
* For details of installing the piston seal ring,
see ASSEMBLY OF NO. 4, 5 HOUSING
ASSEMBLY.
2. Output shaft
Fit seal ring, then install output shaft (62) in No. 6
housing assembly (63).
* Press fit the inner race of housing to the shaft.
23-52 WA350-1
Q
3. Hub
1) Set No. 6 housing assembly (62) in tool A.
2) Install hub (58).
4. No. 6 clutch discs, plates, springs

Install discs (60). plates (61) and springs (59).

1) Align with dowel pin, and install No. 5 carrier as-
sembly (57).
2) Tighten mounting bolts.
w Mounting bolt: 11 .O+ 1 kgm
* When assembling the planet gear, see AS-

SEMBLY OF NO. 2,3,4 CARRIER for details.
6. No. 5 sun gear

1) Install sun gear (56).
WA350-1 23-53
0
7. No. 4,5 housing assembly

Align No. 5 clutch ring gear with planet gear and
install No. 4 and 5 housing assembly (501.
8. No. 4 sun gear

2) Install No. 4 sun gear (53).

1) Install plate (49).
2) Install ring gear (48).
* Pull the ring gear to check that the snap ring
is correctly fitted.
10. No. 4 clutch discs, Plates. Springs

Install discs (451, plates (46) and springs (44).
23-54 WA3561
0
11. No. 3 housing

I) Install piston (43) in housing.
* For details of assembling the piston, see AS-
SEMBLY OF NO. 4,5 HOUSING.
2) Install housing (42).
* Tap with a copper or plastic hammer to in-
stall the dowel pin.
12. Spacer
I) Install spacer (52)
2) Install snap ring (5 I).
13. No. 2,3,4 carrier assembly

Align planet gear with sun gear, then install No. 2,
3 and 4 carrier assembly (41).
14. Bearing, cover

I) Install bearing (39) to carrier and shaft at the
same time.
WA350-1 23-55
0
3) Install cover (38). then install snap ring (37)

Install discs (34), plates (35) and springs (33).
16. No. 2 housing

1) Install piston (3 1) in housing.
2) Assemble sleeve inside housing.
+ Tap with a copper or plastic hammer to in-

Install ring gear (28).
t Install with the side with no internal teeth
facing up.
23-56 WA350-1
0

Install discs (221, plates (23) and springs (2 I).
k There are 4 discs and 3 plates.
19. No. 1 housing

1) Install piston (24) in housing.
t Tap with a copper or plastic hammer to in-
20. No. I,2 carrier ring gear

I) Install plate (27).
2) Install ring gear (26).
* Pull the ring gear to check that it is correctly
installed.
21 No. 1 clutch ring gear

Install ring gear (I 5).
* Install with the side with internal teeth facing
up.
WA350-1 23-57
0
22. No. 1 clutch discs, plates

Install discs (I 7) and plates (I 8).
t There are 4 discs and 3 plates.
23. Guide pin, spring

Install guide pin (19) and spring (I 6).
24. Input shaft, No. 1 carrier assembly

1) Align meshing of sun gear and planet gear
teeth, then install input shaft and No. 1 carrier
assembly (14).
2) Tighten tie bolts (8).
* Do not install in the holes for eye bolts.
m Tie bolt: 11 .O+l kgm
25. Checking operation of piston

Using tool B, check operation and stroke of piston.
* Air pressure: 3 - 5 kg/cm2
+ Piston stroke: Clutch No. Stroke (mm)
No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
26. Clutch case

1) Using eye bolts @ (Thread dia. = 16 mm,
pitch = 2 mm), raise transmission assembly
and install to case (12).
Sr Align the dowel pin of the collar with the pin
hole in the case.
23-58 WA350-1
0
2) Install housing mounting bolts (I I) and mount-

ing bolts (IO) of case.
k??k Both faces of housing mounting bolt:

Gasket sealant (LG-I)
27. Transfer assembly

I) Fit b-ring on case side.
2) Align output shaft with spline of transfer input
gear, then raise transmission (9) and install to
transfer assembly (7).
3) Install 2 tie bolts (8).
m Tie bolt: 1 1 .0&l kgm
28. Sleeve
Fit O-rings and install 5 sleeves (6).
WA350-1 23-59
0
29. Control valve assembly

Fit gaskets and install control valve assemblies (5)
and (4).
w Mounting bolt: 6.5+ 1 kgm
30. Filter assembly

Fit O-ring on tube, then install filter assembly (3).
31. Torque converter assembly

Fit O-ring, align spline of transmission input shaft
with spline of turbine, then install torque converter
assembly (2) to transmission assembly (1).
23-60 WA350-1
0
DISASSEMBLY AND ASSEMBLY TRANSFER
DISASSEMBLY OF TRANSFER ASSEMBLY
Transfer
assembly
423F414
1. Speedometer gear assembly

Remove speedometer gear assembly.
2. Cover
Remove cover (2)
WA350-1 23-61
0
3. Cage (transfer input)

Screw in forcing screw and remove cage (3).
* Check the number and thickness of the shims,
4. Gear assembly (transfer input)

Remove gear assembly (5).
5. Idler gear cage

Screw in forcing screw and remove cage (I 6).
t Check the number and thickness of the shims,
6. Idler gear assembly

Remove idler gear assembly (I 8).
7. Coupling (rear)
Remove coupling (21).
8. Cage (rear)
9. Coupling (front)
1) Remove bolt (221, then remove holder (23).
2) Remove coupling (24).
10. Cage (front)

* Check the number and thickness of the shims,
23-62 WA350-1
0
11. Output shaft

Using tool D, remove output shaft (33).
12. Gear, cpllar

Remove collar (3 1) and gear (32).
WA350-1 23-63
0
ASSEMBLY OF TRANSFER ASSEMBLY
14
t ToA
* ToB
t ToC
10 11 12
B
C
423F415
23-64 WA350-1
0
1. Gear assembly (transfer side)

1) install outer race (13) (O.D.: 140 mm) on case.
9
2) Install worm gear (9) and pin (8) to gear (I 0).
3) Install cover (71, then install snap ring (6). /
16
4) Install bearing (I I) (I.D.: 80 mm) on gear (I 0).

5) Install gear assembly (5).
2. Cage (transfer side)

1) Install outer race (4) (O.D.: 140 mm) to cage (3).
2) Install shims which were removed, fit O-ring
and install cage (3).
3) Rotate shaft with torque wrench @ and

measure preload of bearing.
t Preload of bearing (rotating torque).
i) Alone: 0.01 - 0.1 kgm
ii) Combined with idler gear:
0.04 - 0.18 kgm
* Adjust with shims to obtain the above

rotating torque.
WA350-1 23-65
0
3. Idler gear assembly

1) Install outer race (20) (O.D.: 150 mm) on case.
2) Install bearing (19) (I.D.: 85 mm) on idler gear
assembly (18).
3) Install idler gear assembly (I 8).
4. Idler gear cage

1) Install outer race (17) (O.D.: 150 mm) to cage
(I 6).
2) Install shims which were removed, fit O-ring
and install cage (16).
3) Rotate shaft (IO) with torque wrench 0 and

measure preload of bearing.
* Preload of bearing (rotating torque) ,. ,,, ,. ,, :
i) Combined with input shaft:
0.04 - 0.18 kgm
ii) Alone: 0.01 - 0.1 kgm
* Adjust with shims to obtain the above
rotating torque.
23-66 WA350-1
0
5. Gear
1) Install outer race (40) (O.D.: 125 mm) to case.
2) Set gear (32) in position.
6. Output shaft
1) Install inner race (38) (I.D.: 65 mm) to shaft
(33).
2) Align spline with gear (321, then install shaft
(33).
7. Cage (rear)
1) Install bearing (36) (O.D.: 120 mm) to cage
(26).
3) Install oil seal (35) (O.D.: 1 10 mm).

* Be careful not to damage or deform the seal.
#?I& Lip of oil seal: Grease (G2-LI)
4) Install cover (34).
& Mounting bolt: Thread tightener

(LT-2)
WA350-1 23-67
0
5) Fit O-ring and install cage (26).
8. Collar, bearing
1) Turn over tiansfer case.
2) Using hydraulic jack 0, hold output shaft in
mounting position.
3) Install collar (31).
4) Install bearing (29) (I.D.: 70 mm)

5) Install spacer (30).
6) Install bearing (29) (I.D.: 70 mm).

7) Install outer race (28) (O.D.: 125 mm).
23-68 WA350-1
Q
9. Cage (front)
1) Install oil seal (42) (O.D.: 1 10 mm) to cage (27).
It Be careful not to damage or deform the seal.
a Lip of oil seal: Grease (GZ-LI)
2) Fit O-ring and temporarily install cage (27)
10. Coupling
1) Installcoupling (24). then assemble O-ring (25).
2) Install holder (23), then install mounting bolts
(221.
m Mounting bolt: 3923 kgm
11. Adjustment, cage

Adjust the preload of the bearing as follows.
1) Tap cage (27) with a plastic hammer to install.
2) Hold cage (27) down and measure clearance
between cage and case.
t If using bolts to hold down the cage, be
careful not to screw in the cage.
It Measure at 2 or 3 places and take the
average.
3) Select shims of following value:
Measured value - (0 - 0.05)
4) Fit shim and tighten cage (27).
12. Coupling (rear)

Install coupling (21).
t Install the coupling so that the difference
between the positions of the front and rear
couplings is within 8.
WA350-1 23-69
13. Cover
Fit O-ring and install cover (2).
14. Speedometer gear assembly

Install speedoineter gear assembly.
23-70 WA350-1
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION CONTROL VALVE
A Stop the machine

the safety
on level ground
and install
the bucket
Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then oper-
ate the control levers several times to release
the remaining pressure in the hydraulic piping.
Hydraulic tank
Remove hydraulic tank.
For details, see 63 REMOVAL OF HYDRAULIC
TANK.
Transmission control valve

I) Remove tube (2) between hydraulic tank and
pump (I 1.
2) Disconnect connector of wiring (3) for solenoid

valve, then disconnect wiring at top of valve.
3) Remove mounting bolts (5) of transmission

control valve (4). then lift off valve.
* When removing, the careful not to damage
or deform the thread of the connector case.
Transmission control valve: 53 kg
23-72
0
INSTALLATION OF TRANSMISSION CONTROL VALVE
1. Transmission control valve

1) Raise transmission control valve (4). set in
mounting position, then tighten mounting bolts
(5).
t To prevent the valve from twisting, tighten
the mounting bolts in diametrically opposite
positions.
Repeat this procedure two or three times.
* Fit the O-ring securely in the groove.
2) Connect connector of wiring (3) for solenoid

valve, then secure wiring at top of valve with
clamp.
* Be careful not to mistake the direction of the
connector.
3) Install tube (2) between hydraulic tank and

pump (I 1.
2. Hydraulic tank
Install hydraulic tank.
For details, see 63 INSTALLATION OF HYDRAU-
LIC TANK.
WA350-1 23-73
0
DISASSEMBLY OF LOWER VALVE
1. Remove solenoid valve assembly (1).

2. Remove stopper (2), spring (3) and valve (41.
3. Remove valves (5) and (6). and shim (7).
4. Remove spring (81, then remove shim (91, valves
(1 I), (12) and (I 31, and spring (I 4) as a set.
5. Remove covers (I 5) and (I 6).
6. Remove stopper (2). spring (3) and valve (4).
7. Remove valve (I 7).
8. Remove spring (I 8) and valve (19).
9. Remove plug (201, then remove collar (21) and
spring (22).
ASSEMBLY OF LOWER VALVE
1. Assemble spring (22) to collar (21). install body

(231, then fit O-ring and install plug (20).
2. Assemble spring (I 8) in valve (I 91, then install.
3. Install valve (17).
4. Install valve (4). spring (3) and stopper (2).
5. Fit gasket and install covers (I 6) and (I 5).
6. Assemble valve (I I), spring (I 31, valve (121, shim
(9) and spring (8) in valve (I 0). then install in body.
7. Assemble shim (7) in valve (61, then install in body.
8. Install valve (5).
9. Install valve (41, spring (3) and stepper(2).
10. Fit gasket and install solenoid valve assembly (1).
23-74 WA350-1
0
CONTROL VALVE
__
7
21
0
P
20
423F421
WA350-1
23-75
0
DISASSEMBLY OF UPPER VALVE
1. Remove covers (I ) and (2).

2. Remove guide (3). then remove spring (4). shim
(51, valves (6), (7) and (91, and spring (8) as a set.
3. Remove valves (IO), (I 2) and (131, and spring
(I I).
4. Remove stopper (14). then remove quick return
valve (I 5).
5. Remove spacer (I 6).
6. Remove snap ring (17). then remove guide (I 8).
7. Remove snap ring (I 91, shim (201, valves (21).
(22) and (24). and spring (23) as a set.
8. Remove cover (25). valve (261, shim (271, and spr-
ings (28) and (29) as a set.
9. Remove cover (30).
10. Remove plug (3 I), then remove spacer (32).
ASSEMBLY OF UPPER VALVE
1. Assemble spacer (32) in body (331, fit O-ring and

install plug (3 I).
2. Install cover (30).
3. Assemble shim (27). and springs (28) and (29) in
valve (261, then assemble in body, fit O-ring and
install cover (25).
4. Assemble valves (22) and (24). spring (23). shim
(20) and spring (19) in valve (21). then assemble
in body (33).
5. install guide (I 81, then install snap ring (I 7).
6. Install spacer (I 6).
7. Assemble valve (I 5). fit O-ring and install stopper
(I 4).
8. Assemble valves (I 2) and (1 O), and spring (1 1) in
valve (I 3). then install in body (33).
9. Assemble valves (9) and (71, spring (8). shim (5)

and spring (4) in valve (61, then install guide (3).
10. Fit gaskets and install covers (2) and (1).
WA350-1
23-76
0
14
% 16
423F422
WA350-1
23-77
0
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
REMOVAL OF FRONT DIFFERENTIAL
Special tools
A 793-520-2420 Bracket 1
B 793-520-25 10 Bracket 1
Q? Stop the
the safety
and install
the bucket
wheels to-prevent the machine from moving.
1. Draining oil
Remove drain plug (I) and drain oil from axle
assembly.
- : Axle assembly: Approx. 45 L
2. Tire, wheel
I) Using lift arm, raise front axle, then put stand
under left housing and put block @ under
front frame.
2) Sling left tire and wheel (2). remove mounting
bolts, then lift off.
4kg Tire, wheel: 310 kg
,,, ,,,,\,,,,,
,, ,,,,,,,,,,
3. Covers
Remove left and right covers (3).
23-78 WA350-1
0
4. Axle shaft
Using forcing screw, pull out axle shaft (4) and
sun gear (5) about 200 mm.
5. Drive shaft
1) Disconnect grease tube (6).
2) Disconnect front drive shaft (7) at differential
and at center.
3) Remove flange bearing (81, then move front
drive shaft towards rear frame.
6. Parking brake
1) Release parking brake, then disconnect lever
(9) of linkage.
2) Remove parking brake caliper (I 0).
7. Hydraulic piping
Remove lift cylinder tube (1 1) from brackets (I 2)
on left and right of front frame, and bracket (13)
inside front frame, then move it towards rear
frame.
WA350- 1 23-79
0
8. Differential
1) Remove 2 mounting bolts of differential (14),
then install guide bolts (Thread dia = 14 mm,
pitch = 2 mm, length = 50 mm).
* Screw the thread of the guide bolts in fully.
t After screwing in the guide bolts, remove
the remaining mounting bolts.
2) Fit lifting tool @ to differential case (I 5).
3) Install forcing screw, and pull out differential

(14) along guide bolts about 20 mm from axle
housing (I 6).
* Be careful not to damage the differential
O-ring.
4) Install tools A and B to garage jack, then insert
between differential and axle housing, and
install tool A to differential.
5) Adjust height of lifting tool and garage jack,

and remove differential (I 4) carefully.
el kg Differential: 191 kg
6) Operate garage jack and pull differential out

from under machine body.
7) Remove O-ring (17).
t To remove the rear differential, first remove

the axle assembly, then remove the
differential from the axle.
23-80 WA350-1
0
INSTALLATION OF FRONT DIFFEF SENTIAL
1. Differential
I) Install tools A and B to garage jack, then ins tall
differential (14) in tool A.
2) Operate garage jack and pull differential in
under machine body.
3) Install guide bolts (Thread dia. = 14 mm, pi tch

= 2 mm, length = 50 mm) in axle housing.
4) Fit lifting tool to differential case (I 5).
5) Fit O-ring (17) to differential, adjust height of

lifting tool and garage jack, and assemble dif-
ferential along guide bolts.
* Fit the O-ring securely in the groove and
installing.
6) When clearance between axle housing (16)

and differential (14) is about 20 mm, remove
tool A and tighten mounting bolts uniformly.
7) Remove guide bolts (I 8) and install mounting
bolts.
D Mounting bolt: 18.Ok2.0 kgm
WA350-1 23-81
0
2. Hydraulic piping
Install lift cylinder tube (1 I) to brackets (12) on
left and right of front frame, and bracket (13)
inside front frame.
3. Parking brake
1) Install parkiing brake caliper (IO).
2) Connect parking brake linkage to lever (9), then
apply parking brake.
4. Drive shaft
1) Temporarily install flange bearing (8).
2) Connect front drive shaft (7) at differential and
at center.
3) Connect grease tube (6).
4) Tighten flange bearing fully.
Sr When connecting the drive shaft, clean the
contact surfaces of the spider and coupling,
and mesh the pilot correctly to install.
m Mounting bolt: 28.5*3 kgm
5. Axle shaft
Push in axle shaft (4) together with sun gear (5)
23-82 WA350-1
0
6. Cover
Fit O-rings (18) in grooves of covers (3) and install
on left and right sides.
t Fit the O-ring securely in the groove make
sure that it is not caught when installir
7. Tire, wheel
1) Raise tire and wheel (2). set in mounting
position, then install mounting nuts.
m Mounting nut: 48*6 kgm
2) Remove stand.

Tighten level plug and add oil through oil fillers
(I 8) and (I 9) to the specified level.
* Set the machine so that the drain plug of the
final drive is at the bottom when refilling with
oil.
G Axle assembly: 45 II
WA350-1 23-83
@
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
REMOVAL OF REAR DIFFERENTIAL
a Stop
the safety
the machine on level
bar on the frame.
ground
Lower
and install
the bucket
1. Rear axle
Remove rear axle.
For details, see 23. REMOVAL OF REAR AXLE.
2. Draining oil
Remove drain plug (1) and drain oil from axle
assemblv.
- : Axleassembly: 45Q
3. Axle shaft
I) Remove cover (2).
2) Using forcing screw, pull out axle shaft (3) and
sun gear (4) about 200 mm.
4. Differential assembly
Using forcing screw, remove differential (5).
Differential: 176 kg
23-84 WA3501
0
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
INSTALLATION OF REAR DIFFERENTIAL
1 Differential
Raise differential (51, set in mounting position,
* Check that there is an O-ring fitted to the
mounting face of the differential.
w Mounting bolt: 18*2 kgm
2. Axle shaft
1) Pushin axle shaft (3) together with sun gear (4).
* If the axle shaft cannot be inserted, rotate
the differential coupling lightly. Never try to
force the shaft in.
2) Fit O-ring (6) on cover (2) and install cover.

Sr Check that there is an O-ring fitted to the
mounting surface of the cover.
t Make sure that the O-ring is not caught
when installing.
3. Rear axle
Install rear axle.
For details, see 23 INSTALLATION OF REAR
AXLE.

Tighten drain plug and add oil through oil fillers (7)
and (8) to the specified level.
* Set the machine so that the level plug of the
oil.
/ Axle assembly: 45 Q
%
WA350-1 23-85
0
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DISASSEMBLY OF DIFFERENTIAL
1. Differential gear
1) Remove ring gear stopper bolt.
2) Loosen adjustment ring lock bolt, then remove
lock plate (I 1.
+ Rotate the adjustment ring and disconnect
the differential gear from the pinion gear.
3) Remove bearing cap (2).

Zr Make match marks on the left and right
bearing caps.
4) Remove adjustment ring (3) and bearing cup

(4).
5) Remove differential gear (5) from carrier.

* The pilot bearing will hit the carrier, SO tilt it
slightly to the right when raising.
Differential gear assembly: 75 kg
23-86 WA350-1
0
2. Case
I) Remove bearing (6).
2) Remove case (7).
* Make match marks before removing.
3) Rempve side gear (81, spider (91, thrust washer

(IO) and pinion gear (I I).
3. Ring gear, flange half

I) Remove bearing (12).
2) Remove mounting bolts, then remove ring gear
(I 3) and flange half (I 4).
4. Turning over differential gear

Turn over differential gear.
WA350-1 23-87
0
5. Pinion gear
1) Loosen mounting bolts of yoke (I 5).
* Leave the yoke temporarily fitted.
2) Remove pinion gear (I 7) from differential case
(16).
* There are shims installed, so check the
number and thickness of the shims, and
keep in safe place.
6. Pinion shaft
1) Using press, remove pinion shaft (I 8).
2) Remove bearing cups (20) and (2 I) from cage
(19).
3) Remove pilot bearing (22) and bearing (23)

from pinion shaft (I 8).
* Do not remove pilot bearing (22) and bearing
(23) if not necessary.
423 F424
20 19
22 29 423F426 423 F425
23-88 WA3561
0
ASSEMBLY OF DIFFERENTIAL
Special tool
A 1 793-520-2620 ( Plate I 1
* If the pinion or ring gear are replaced, always

replace them both together as a set. Never mix old
and new parts.
Replace the flange half and the case also as a set.
1. Pinion shaft
1) Press fit pilot bearing (22) on pinion shaft (I 8).
2) Press fit bearing (23) on pinion shaft (I 8).
t Press-fitting force for bearing (23) and pilot
bearing (22): 5 ton
423F427
3) Press fit bearing cups (20) and (21) on cage

(I 9).
t Press-fitting force for bearing cap: 5ton
Inside circumference of cage,

a outside circumference of cup:
Axle oil (See page 01-l 0)
4) Assemble cage (19) to pinion shaft (I 8) and in-

stall spacer (25).
423F425
2. Adjusting preload
1) Press fit bearing (24) on pinion shaft (I 8)
WA3561 23-89
0
25
3) If the measurement is not within the standard
range, replace bearings (23) and (24). and
spacer (25) with new parts and measure again.
4) Check the end play must also be within the
standard range when if the measurement is
within the standard range.
* End play: Max. 0.152 mm
23
423F428
3. Pinion gear
I) Press fit oil seal (27) on cage (261, and
temporarily install coupling (15).
* Use a new oil seal.
e Lip of oil seal: Grease (G2-LI)
w Mounting bolt of coupling:

28.5*3 kgm
423F429
2) Assemble pinion gear (I 7) in differential case

(I 6) without fitting shims.
423F430A
23-90 WA3561
@
3) To adjust the backlash between the bevel gear

and pinion gear, calculate the thickness of shim
to insert between the differential case and
cage, then adjust the shim.
* This calculation is to calculate the initial
thickness of the shim. The thickness of the
shim is adjusted finally according to inspec-
tion of the tooth contact between the bevel
gear and pinion gear.
* If the bearing, pinion gear, or bevel gear are
replaced, follow this procedure to adjust the
shim.
i) Install tool A to differential case (I 6), then
measure distance L from tool A to the end
face of the pinion gear, and calculate dimen-
sion c from the center line of the bevel
gear to the end face of the pinion gear. Cal-
culate as follows.
C = L - Thickness of tool A
ii) Using dimension A and dimension 6 shown
on the end face of the pinion gear, calculate
standard value D. Calculate as follows.
D = MDA - MDB
F423C1060
= (204 +s, - (101 +c)
* Be careful to calculate the + and -

values correctly for the displayed values.
t The displayed values for dimension A and
dimension B are 100 times the actual Dimension B
value for the dimension.
3
iii) Next, calculate shim thickness T from
above Steps i) and ii). Calculate as follows.
-.
T=D-C
* Select the minimum number of shims.
MoA
\
Thickness of shim (T) Pinion gear F42301001
F42301002
4) Assemble shim and install pinion gear (17) to

differential case (I 6).
6 Mounting bolt: Adhesive (LT-2)
m Mounting bolt: 18&2 kgm
WA350-1 23-91
8
4. Bevel gear
1) Press fit bearing (I 2) in flange half (14).
2) Knock pin (27) into bevel gear (13).

3) Install flange half (14) on bevel gear (13).
4) Tighten mounting bolts.
& Mounting bolt: Adhesive (LT-2)
w Mounting bolt: 1822 kgm
5. Side gear
Install washer (28). then install side gear (8)
6. Pinion gear
Assemble pinion gear (1 1) and thrust washer (10)
on spider (9).
23-92 WA350-1
@
7. Side gear
1) Assemble side gear (8) and washer (28).
2) Press fit bearing (6) on case (7).
3) Install case (7).

* Align the match marks and install.
m Mounting bolt: 18t2 kgm
8. Differential gear
1) Raise gear (51, assemble bearing cup (4) on
bearing, then install in case.
2) Align with thread of differential case (I 6) and

install adjustment ring (3).
3) Align match marks and install bearing cap (2).
Sr Be careful not to damage thread of the cap.
w Mounting bolt: g4.5? 10.5 kgm

(Width across flats: 36 mm)
WA350- 1
9. Adjusting preload of bearing

Turn adjustment ring with a bar until bevel gear
contacts pinion gear, and adjust until there is no
backlash.
Rotate the bearing well so that it is properly
in contact with all other parts, and tap the
bevel gear with a copper hammer.
Coat the bearing well with oil.
If the adjustment ring on one side is
loosened by one turn, tighten the ring on the
other side bK one turn.
Install spring balance to bevel gear and measure

the rolling resistance torque.
B Rolling resistance torque: 1.4 - 2 kg
* Target: 2 kg
10. Adjusting tooth contact, backlash

Adjust the backlash as follows.
1) Use adjustment ring to adjust bevel gear.
t Always turn the adjustment rings at both
ends the same amount in the same direction.
2) Put dial gauge in contact with tooth face at out-

side tip of bevel gear, and turn adjustment ring
to adjust.
t Measure at 3 or 4 places, and keep the
pinion gear fixed when measuring.
* Backlash: 0.25 - 0.33 mm
Adjust the tooth contact as follows.

1) Mix red lead with oil and coat face of 7 or 8
teeth of pinion gear lightly with red lead
(miniurn).
2) Rotate the pinion gear forward and backward
and inspect the pattern left of the teeth.
23-94 WA350-1
@
11. Adjusting tooth contact

Coat face of 7 or teeth of bevel pinion lightly with red lead (miniurn). 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.
Tooth contact Cause Procedure for adjustment
The tooth contact pattern Adjust the pinion gear by adjusting the shims at
should start from about the cage. Adjust the bevel gear in the same way as
5 mm from the toe of when adjusting backlash.
the bevel gear and cover
about 50% of the length
of the tooth. It should
be in the center of
2OBF514 the tooth height.
Bevel pinion gear is too 1. Reduce shims at pinion gear to bring closer
far from bevel gear. to bevel gear.
2. Move bevel gear further away from pinion 2
gear and adjust backlash correctly. *
? a
2OBF515 2OBF519
Bevel pinion gear is too 1. Increase shims at pinion gear to move away
close to bevel gear. from bevel gear.
2. Move bevel gear closer to pinion gear and 2
adjust backlash correctly. c
? J
20BF516 20BF520
Bevel gear is too close to 1. Reduce shims at pinion gear to bring closer
pinion gear. to bevel gear.
2. Move bevel gear further away from pinion
gear and adjust backlash correctly. 1
;a
2OBF517 2OBF519
Bevel gear is too far from I. Increase shims at pinion gear to move away
pinion gear. from bevel gear.
2. Move bevel gear closer to pinion gear and 2
adjust backlash correctly. c
? d
20BF518 20BF520
* When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the
left and right. Always keep the same total thickness of shims.
WA350-1 23-95
0
12. Lock plate

After adjusting tooth contact, wipe off red lead
and install lock plate (I 1.
13. Adjustment bolt

After adjusting, tighten bolt (29) until it contacts
rear face of ring gear, then loosen l/2 turns and
tighten lock nut (30).
& Adjustment bolt:

Thread tightener (LG-51
m Adjustment bolt: 22.552.5 kgm
423F431
23-96 WA350-1
Go
DISASSEMBLY AND ASSEMBLY FRONT AXLE
REMOVAL OF FRONT AXLE
Stop the machine on level ground and install

the safety bar on the frame. Lower the bucket
Put blocks under the rear wheels to prevent the

machine from moving, and apply the parking
brake securely.
Insert block @between frame (2) and the top sur-
face of rear axle housing (I).
Jack up the machine, and put blocks @under the

front frame on the left and right sides.
Tire, wheel
Sling left and right wheels (3). remove mounting
nuts, then lift off.
Tire, wheel: 310 kg
2. Drive shaft
Disconnect drive shaft (4) at differential end.
WA350- 1 23-97
0
3. Brake tube
Disconnect brake tube (5) from slack adjuster (6).
* After disconnecting the piping, cover to prevent
dust or dirt from entering.
4. Parking brake
Release parkiing brake, then disconnect from lever
(7) of linkage.
5. Front axle
1) Sling front axle housing (8) on one side, and fit
garage jack under other side.
2) Fit garage jack under bottom of differential
case.
* Be careful not to damage the side face of
the parking brake disc.
Sr When installing the lifting tool, be careful
not to crush the brake tube.
3) Remove mounting bolts (9) of front axle.

4) Put block under front axle, then using hoist and
garage jack to maintain balance, lower front
axle.
Front axle: 1130 kg
5) Pull out front axle assembly from machine.
23-98 WA3561
0
INSTALLATION OF FRONT AXLE
1. Front axle
1) Pull front axle under machine body.
2) Fit lifting tool to front axle (10). set garage jack
under parking brake disc and maintain balance
while setting in mounting position.
3) Install mounting bolts (9) of front axle with
engine oil.
m Mounting bolt: 1052 10 kgm
6 Founting bolt:
Engine oil and washer
2. Parking brake
Release parking brake, then connect lever (7) Of
linkage.
A Apply the parking brake.
3. Brake tube
Connect brake tube (5) to slack adjuster (6).
t Wipe the connection with a clean cloth.
4. Drive shaft
Connect front drive shaft (4) at differential end.
m Mounting bolt: 11.5 f: 1 .O kgm
WA350-1 23-99
0
5. Til re, wheel

I) Set left and right wheels (3) in mounting
position, then install mounting nuts.
w Mounting nut: 48*5 kgm
2) Jack up machine, then remove block @ from

under front frame.
3) Remove block 0 from between frame and top
surface of rear axle housing.
6. Bleeding air from brakes

It For details of bleeding air, see 52 TESTING
AND ADJUSTING.
23-100 WA350-1
Gc
DISASSEMBLY AND ASSEMBLY REAR AXLE
REMOVAL OF REAR AXLE
a Stop the
the safety
and install
the bucket
Put blocks under the front wheels to prevent the

machine from moving, and apply the parking
brake securely.
Jack up the machine, put block @under the rear
frame, and put a stand under the counterweight.
Tire, wheel
Sling left and right wheels (I), remove mounting
nuts, then lift off.
6 kg Tire, wheel: 310 kg
2. Drive shaft
Disconnect rear drive shaft (2) from rear axle.
3. Brake hose
Disconnect hose (3) between brake chamber and
slack adjuster.
WA350-1 23-101
0
4. Grease tubes
Disconnect grease tubes (4) and (5) from rear axle
support.
5. Engine oil drain valve

Remove bracket (6) of engine oil drain valve from
fuel tank (7).
6. Rear axle, support assembly

1) Secure axle support (8) and rear axle (9) with
chains.
* Fit the chains on the right side where there is
no grease tube.
2) Sling rear axle and support assembly (IO) on

one side, and fit garage jack under axle housing.
t When installing the lifting tool, be careful
23-102 WA350-1
0
REAR AXLE
3) Remove mounting bolts (1 I) of axle support,

then using hoist and garage jack to maintain
balance, lower rear axle.
& Rear axle, support assembly: 1260 kg
4) Pull out rear axle and support assembly from

machine.
7. Rear axle
1) Remove front support (I 2) from rear axle (9).
* Be careful not to damage the O-ring.
Front support: 61 kg
2) Remove retainer (I 3) from front support.

3) Remove O-ring (14) from retainer.
4) Remove O-rings (15) and (161, and bushing
(17) from front support.
423F432
WA350-1
23-103
0
5) Raise rear support (I 8) and remove cover (19)
Rear support: 83 kg
6) Remove thrust washer (20), thrust plate (21)

and thrust washer (22) from rear axle.
7) Remove rear support (18).
8) Remove O-ring (23) and bushing (24) from rear
support.
423F433
23-104 WA350-1
0
INSTALLATION OF REAR AXLE
1. Rear axle
1) Install bushing (24) and O-ring (23) on rear sup-
port (18).
Zr Assemble the bushing with the chamfered
edge on the axle housing side.
Zr Fit the O-ring securely in the groove, and
installing.
t Check that the O-ring is on the axle housing
side_.
2) Raise rear support, and set in position on rear

axle mount.
3) Install thrust washer (22). thrust plate (21) and
thrust washer (20).
4) Install cover (I 9).
5) Install bushing (17) and O-ring (I 6) on front

support (I 2).
Sr Assemble the bushing with the chamfered
edge on the axle housing side.
6) Assemble O-rings (14) and (15) on retainer
(I 3).
7) Install retainer on front support.
t Fit the O-ring securely in the groove, and
installing.
423F432 17 12 16
13
8) Raise front support (I 2) and insert on rear axle

mount.
* Be careful not to damage the seal with the
coupling.
WA350-1 23- 105

Q
2. Rear axle, support assembly

1) Secure rear axle (9) and axle support (8) with
chains.
Sr Fit the chains on the right side where there is
no grease tube.
2) Raise rear axle and support assembly (IO) on

one side, ahd fit garage jack under axle housing.
Sr When installing the lifting tool, be careful
3) Pull rear axle and support assembly (IO) under

machine.
4) Using hoist and garage jack to maintain
balance, set in mounting position, and install
mounting bolts of axle support.
* Tighten the mounting bolts of the front sup-
port on opposite sides in turn.
* Coat engine oil on the mounting bolts and
washers, then tighten.
& Bolt and washer: Engine oil
m Mounting bolt: 105* 10 kgm
3. Engine oil drain valve

Install bracket (6) of engine oil drain valve to fuel
tank (7).
23-106 WA35071
@
4. Grease tubes
Connect grease tubes (4) and (5) to rear axle
support.
5. Brake hose
Install hose (3) between brake chamber and slack
adjuster.
6. Drive shaft
Connect rear drive shaft (2) at rear axle end.
Sr When connecting the drive shaft, wipe the con-
tact surface of the spider and coupling, and
mesh the pilot correctly when installing.
w Mounting bolt: 11.5f 1 .O kgm
7. Tire, wheel
1) Set left and right wheels (I) in mounting
position, then tighten mounting nuts.
w Mounting nut: 4825 kgm
2) Remove block @ from under rear frame, and

stand from under counterweight, then lower
machine to ground.
WA350-1 23-107
@
8. Bleeding air from brakes

* For details of bleeding air, see 52 TESTING
AND ADJUSTING.
23-108 WA350- 1
0
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DISASSEMBLY OF DRIVE SHAFT
1. Front drive shaft

1) Remove coupling and tube (I).
* Make match marks a before removing so
that the direction of the coupling does not
change.
2) Loosen bolt (21, then remove coupling (3) and

retain&-.
* Make match marks before removing so that
direction of the coupling does not change.
3) Using a press, remove flange bearing (4).
2. Center drive shaft, rear drive shaft

* Follow the procedure in 1. Front drive shaft
Step I).
WA350-1 23-109
0
DRIVE SHAFT
3. Spider, bearing
I) Remove seal and bearing caps (5).
2) Remove ring (7) of spider (6) and bearing, then

tap with plastic hammer to remove spider and
bearing.
* Repeat the same procedure for the front,
center and rear drive shafts.
423 F434
WA350-1
23-110
0
ASSEMBLY OF DRIVE SHAFT
1. Spider, bearing
1) Set spider (6) and bearing in mounting position,
assemble ring (7). then install.
* Assemble so that the grease nipples face in
the same direction.
* Repeat the same procedure for the front,
center and rear drive shafts.
423F434
2) Install seal and bearing cap (5).

* Check that there is a bearing and Derling
washer inside the bearing cap.
6 Bearing cap: Grease (G2-LI)
* If the spider and bearing cap are worn, re-

place the spider and bearing.
* Heat will damage the bearing, so do not weld
strap (8) of the cap.
2. Front drive shaft

I) Press fit flange bearing (4).
Zr Do not hit the flange bearing directly with a
hammer.
2) Align match marks, install coupling (3) and re-

tainer (9). then tighten mounting bolt (2).
* Tighten the bolts to the specified tightening
torque after installing on the machine.
e:: Spline: Grease (G2-LI)
B Mounting bolt: 94.5&l 0.5 kgm
WA350- 1 23-l 11
@
3) Align match marks and install coupling and

tube (1).
* Check that the couplings are facing in the
same direction.
* If the spline is worn, replace the whole drive
shaft assembly.
/ic1, Spline: Grease (G2-LI)
3. Center drive shaft, rear drive shaft

* Follow the- procedure in 2. Front drive shaft
Step I) to 3).
23-112 WA350-1
0
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL DRIVE
a Stop the machine on level ground and install

Special tool
Part number Part name IQV

A 793-520-2320 Fixture 1
1. Tire, wheel
Jack up axle, insert stand under axle, then lift off
tire and wheel (I I.
* After removing the tire and wheel, put a stand
under the axle.
Tire, wheel: 310 kg
2. Draining oil
assembly.
* Set the drain plug at the bottom.
,
& Axle assembly: 45 II
3. Cover
Remove cover (3). then remove O-ring (4)
WA350-1 23-113
0
4. Axle shaft assembly

Remove axle shaft assembly (5) from axle.
5. Planet carrier assembly

Remove 3 mounting bolts (61, then lift off planet
carrier assembly (7).
Sr Make match marks to act as a guide when
installing.
Zr Be careful of the center of gravity, and lower
slowly.
Planet carrier assembly: 68 kg
6. Ring gear assembly

1) Using tool A, hold wheel hub (8) and brake as-
sembly (9) in position.
Sr Install tool A to points on opposite sides, and
use washers to adjust clearance.
2) Remove mounting bolts of retainer (IO). then

remove ring gear assembly (I I).
t There are shims between the retainer and
axle housing, so check the number and thick-
ness of the shims, and use for reference
when installing.
kg
tIYz?z Ring gear assembly: 29 kg
23-114 WA350-1
0
7. Disassembly of planet carrier

I) Using a press, pull out shaft (12) and remove
pinion gear (I 3).
* There is a lock ball (14) on the shaft, so be
careful not to lose the ball.
Sr Write a number on the case and keep all the
removed parts separately in sets.
2) Remove bearing cups (I 5) and (I 6). cone (I 71,

spacer (18) and snap ring (19) from pinion gear
(I 3).
Sr The bearings and other parts have settled in
together, so mark the parts and keep them in
sets.
8. Disassembly of ring gear

I) Remove lock plates (21) from ring gear hub
(201, then remove ring gear (22).
2) Screw in forcing screws (Thread dia. = 12

mm, pitch = 1.75, length 70 mm) from ring
gear hub (20). and remove bearing (23).
WA350-1 23-115
0
ASSEMBLY OF FINAL DRIVE
Special tool
A 793-520-2320 Fixture 2
1. Assembly of ring gear

1) Press fit bearing (23) on ring gear hub (20).
t After press fitting the bearing, check that
there is no clearance between the rib and
bearing.
2) Set ring gear hub (20) on ring gear (22), then
install lock plates (2 1).
t Install the lock plates with the wider ones on
the inside.
Sr Remove all grease and oil from the bolt.
fil, Hub mounting bolt:

Thread tightener (LT-2)
2. Assembly of planet carrier

I) Install snap ring (19) and spacer (18) on pinion
gear (I 3), then press fit bearing cups (I 5) and
(16).
* Do not raise the press-fitting force for the
bearing cups too high as this will damage
the snap ring.
* Press fit bearing cup (I 5) first.
6 Inside circumference of press-fitting

portion of bearing cup: Oil (SAESO)
15/ 423F436
2) Assemble bearing cone (17) on pinion gear

(I 31, then using lifting bar 0, set in position
on carrier mount.
+ insert all three pinion gears in the carrier.
/
423F437
23-116 WA350-1
0
3) Align holes of carrier and gear, then press fit

cooled shaft (12).
? Do not touch the cooled shaft directly by hand.
Q
t Press fit so that the hole for the lock ball is
on the outside circumference, then stop
with the hole at the front and align the holes.
t Cool the shaft at - 30C for 20 minutes.
4) Assemble lock ball (I 4) on shaft, then press fit

shaft again.
* After press fitting the shaft, check that the
gear rotates smoothly.
3. Ring gear assembly 423F438
1) Raise ring gear assembly (I I), set in mounting

position, and insert in axle housing.
* Align the spline groove and insert the
assembly slowly.
2) Tighten retainer (IO) temporarily with 3 bolts,

then remove tool A.
* Remove all grease and oil from the bolt hole
of the retainer mount.
* Do not insert shims in the retainer when
tightening temporarily.
* Rotate the wheel hub to settle the bearing,
then tighten to a uniform torque.
m Mounting bolt of retainer: 3.0 kgm
3) Insert a depth micrometer through measuring

hole of retainer (I 0). and measure clearance
a between end face of housing and end face
of retainer.
* Measure at 2 places and take the average.
WA350-1 23-117
4) Shim thickness is clearance a + 0.2 mm.

* Use the smallest number of shims which
gives the required thickness. Be careful that
the total shim thickness is no less than a
+ 0.2 mm.
* Shim thickness: 1 .O mm, 0.3 mm, 0.2 mm
5) Install tool A to brake assemblv and wheel hub,

and remove retainer (IO). Install required
thickness of shims, then install retainer (IO)
again.
* Always install tool A before assembling the
shims.
* Rotate the wheel hub and tighten the
mounting bolts uniformly to the specified
tightening torque.
a Mounting bolt:
m Mounting bolt: 11.5+ 1 .O kgm
4. Planet carrier
Fit O-ring (24) to wheel hub (81, raise planet
carrier (71, set in mounting position, then install.
* Align mounting holes and install carefully so
that the O-ring does not slip out of place.
5. Axle shaft
Install axle shaft (5).
* If the position of the sun gear does not match,
rotate the wheel hub to align.
23-118 WA350-1
0
-
6. Cover
Fit O-ring (4) in groove in cover, then install cover
(3).
@El Mounting bolt: 7.OkO.5 kgm

Tighten drain plug and add oil through level plug
Oil.
Q Axle assembly: 45 Q
8. Tire, wheel
Install tire and wheel (I 1, then remove stand.
m Mounting nut: 48k5 kgm
WA350-1 23-119
@
POWER TRAIN
ti MAINTENANCE STANDARD
Transmission and engine mount 24- 2

Torque converter charging pump 24- 3
Torque converter 24- 4
TORQFLOW transmission . 24- 6
I. Transmission . . 24- 6
2. Transmission control valve 24- 8
3. Solenoid valve . .. 24-l 2
Transfer . . . ... . 24-14
Differential . 24-16
Final drive . . 24-l 8
Drive shaft . .,. 24-19
Axle mount . 24-20
WA350-1 24- 1
MAINTENANCE STANDARD TRANSMISSION AND ENGINE MOUNT
TRANSMISSION AND ENGINE MOUNT
h h
423F205
View Z
Unit: mm
No. Check item Criteria Remedy
1 Clearance between transmission bracket and l-2 Adjust

adjustment bolt
2 Tightening torque of mounting bolt 94.5& 10.5 kgm
Tightening torque of bracket mounting 11.5?1.0kgm

3
bolt
4 Tightening torque of bracket mounting 18.02 2.0 kgm Retighten

bolt
5 Tightening torque of mounting bolt 94.52 10.5 kgm
6 Tightening torque of clearance adjustment

28.0 _ 3.0 kgm
bolt
2i2 WA350-1
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER CHARGING PUMP

. Model SAL (3) -56
Section A-A
\
2/
423F206
Unit: mm
Standard clearance Clearance limit

Clearance between gear case and side plate,
0.06 - 0.15
0.9510.25 kgm
Oil: EOl O-CD

Temperature: 45 - 55C
WA350-1 24-3
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
10
12
\
24-4 WA350-1
MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm
Standard size
Width and thickness of seal ring
0.192 - 0.485
7 Tightening torque of bolt 6.8 ir 0.7 kgm

I I
8 Tightening torque of bolt 3.2t 0.3 kgm
9 Tightening torque of bolt 3.220.3 kgm
10 Tightening torque of bolt 6.8i0.7 kgm Retighten
11 Tightening torque of bolt 6.8t0.7 kgm
12 Tightening torque of bolt 11.3?1.2kgm
WA350-1 24-5
MAINTENANCE STANDARD TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION
1. TRANSMISSION
423F208
Unit: mm
Backlash between No.1 sun gear and planet 0.13 - 0.33

1
gear
Backlash between No.1 planet gear and 0.12 - 0.33

2
ring gear
Backlash between No.2 sun gear and planet 0.1 1 - 0.28 Replace
3
gear

4
ring gear
Backlash between No.3 sun gear and planet 0.1 1 - 0.28

5
gear
24-6 WA350-1
Unit: mm
Backlash between No.3 planet gear and

6 0.12 - 0.33
ring gear
Backlash between No.4 sun gear and planet

7 0.11 - 0.28
gear
Backlash between No.4 planet gear and

8 0.12 - 0.32
ring gear
Backlash between No.5 sun gear and planet

9 0.16 - 0.25
gear

10
ring gear
Standard size Repair limit
Free Installation Installation Free Installation

length length load length load
11 No.1 clutch springs
59 46.8 12.2 kg 57 10.2 kg
12 No.2 clutch springs 59 48.8 10.2 kg 57.5 8.3 kg
13 No.6 clutch springs 41.5 31.8 15.5 kg 40 13.1 kg

I
14 No.3 and No.4 clutch spring 51.8 40.8 11.7 kg 50 9.8 kg
15 No.5 clutch spring 38.4 31.3 IOkg 37.5 8.7 kg

Reolace
16
Thickness of assembled 4 discs and 3 plates 35 +0.26 31.1
for No.1 clutch I -0.26 I
Thickness of assembled 4 discs and 3 plates +0.26 31.1
I?
for No.2 clutch 35 -0.26
18
Thickness of assembled 3 discs and 2 plates 25+o.22 22.2
for No.3 and No.4 clutches -0.22
Thickness
for of assembled
No.5 clutch 2 discs and 1 plate ,5+o.17
-0.17 13.3
19
Thickness of assembled
for No.6 clutch 3 discs and 2 plates 26 f0.22
-0.22 22.2
20
21 Thickness of 1 disc 5+0.1 4.4

-0.1
22 Thickness of 1 plate 6+0.1 4.5

-0.1
75+o.013
23 Outside diameter of input shaft bearing 75.018
I - 0.006 I
24 Outside diameter of output shaft bearing 72+o.ol 3 72.018

-0.006
25 Outside diameter of output shaft bearing g5+0.016 95.022

- 0.006
Wear of seal ring for input shaft Width 3$8$ 2.6

26
Thickness 2.1 r$: 1.8
3-o.01
Wear of seal ring for output shaft Width -0.03 2.6
27
Thickness 2.1 $:I 1.8
WA350-1 24-7
0
MAINTENANCE TORQFLOW TRANSMISSION
STANDARD
2. TRANSMISSION CONTROL VALVE
. UPPER VALVE
_------lo
-5
\ 2
i2 423F210
24-8 WA350-1
Unit: mm
Clearance between torque converter

1
valve spool and body
I 25 - 0.045
-0.035 +0.013
0 0.035
0.058- 0.08
Clearance between priority valve spool -0.035 +0.013 0.035 -

2 and body 25 -0.045 0 0.058 0.08
-
Clearance between quick return valve spool - 0.035 +0.011 0.035 -
3 and body 12 -0.045 0 0.056 0.08
Clearance between modulating valve spool - 0.035 +0.013 0.035 -

4 and body 25 -0.045 0 0.058 0.08
Replace

5 Priority valve spring
62 37.7 22.1 kg 59.6 19.9 kg
6 Torque converter relief valve spring 62 48 12.8 kg 60.6 11.5 kg
7 To;zx converter relief valve spring 26 19 0.58 kg 25.3 0.52 kg
W&lating valve spring

8 118 106.5 22.5 kg 117 20.5 kg
9 Mc&$ting valve spring 145.7 141.5 4.14 kg 145.3 3.7 kg
10 Thickness of shim for accumulator 1 mm (pressure per 1 piece: 0.19 kg/cm21
11 Thickness of shim for modulation valve 4 mm (pressure per 1 piece: 0.55 kg/cm2)
Adjust
12 Thickness of shim for priority valve 2 mm (pressure per 1 piece: 0.26 kg/cm?
-
13 Thickness of shim for torque converter valve 2 mm (pressure per 1 piece: 0.26 kg/cm*)
Tightening torque of modulation locknut 4.3 * 0.7 kgm Retig hten
WA350- 1 24-9
0
. LOWER VALVE
8 9
4 5
8 8
8 8
1 13
423F211
7
24-10 WA350-1
Unit: mm
C
Tolerance
Standard Standard Clearance
Clearance between FORWARD-REVERSE size clearance limit
Shaft Hole
spool and body
22 -0.035 +0.013 0.035 - 0.08

- 0.045 0 0.058
Clearance between 1st speed spool and body 22 -0.035 +0.013 0.035 - 0.08
-0.045 0 0.058
3 Clearance between 2nd speed spool and body 22 -0.035 +0.013 0.035 - 0.08 Replace
-0.045 0 0.058
- 0.035
4 Clearance between 3rd speed spool and body 22 +0.013 0.035 - 0.08
- 0.045 0 0.058
-
5 Clearance between 4th speed spool and body 22 -0.035 +0.013 0.035 - 0.08
-0.045 0 0.058
-
Clearance between pilot reducing valve 22 0.035 -
6 -0.035 +0.013 0.08
and body -0.045 0 0.058
Clearance between lubrication valve plunger

7
and body
22 -0.035
-0.045
+0.013
0
0.035 -
0.058
0.08
I / I I

FORWARD-REVERSE, No.1, No.2, No.3 length length load length load
8 and No.4 speed spring
78 48 10.5 kg 75 9.5 kg
Reolace
9 Accumulator spring 162 125.6 40 kg 158 36 kg
-
Fo;;;ducing valve spring
10 62 43.7 16.7 kg 60.1 15kg

-
F?l$educing valve spring
11 26 19 0.58 kg 25.3 0.52 kg
12 Lubrication valve spring 39.4 37 6.2 kg 39.2 5.6 kg
13 Thickness of shim for pilot reducing valve 3 mm (pressure per 1 piece: 0.26 kg/cm) Adjust
WA350-1 24-11
@
3. SOLENOID VALVE
Section A-A
423F212A
Tightening torque of solenoid valve mounting 0.17 f 0.01 kgm
2 Tightening torque of solenoid valve terminal 0.17 t 0.01 kgm

screw
6 Tightening torque of solenoid valve terminal 0.075 f 0.005 kgm

screw Retighten
4 Tightening torque of solenoid valve connector 0.07 % 0.01 kgm

mounting screw
6 Tightening torque of terminal mounting 0.07 2 0.01 kgm

screw
6 Tightening torque of solenoid valve assy 6.7 t 0.7 kgm

mounting bolt
WA350-1
MAINTENANCE STANDARD TRANSFER
TRANSFER
i 423F209
24-14 WA350-1
MAINTENANCE STANDARD TRANSFER
Unit: mm
-
-
Standard size Tolerance Repair limit
311seal sliding surface of output shaft coupling
1
[Rear)
85 84.82
-:.087
~;ss;l sliding surface of output shaft coupling

2 a5 84.82
I - g.087 I I
1 Sta$wd 1 shafolerrHo,e 1 S$ann;;; 1 Cle;;;ce 1
Clearance between Input shaft bearing

3 and housing
I
I
140
-:.015
I
-00.035
I
-00.035
I
0
I
1 Replace
Clearance between idler shaft, beanng
4 150 0
and housina I -:.018 -:.035 - g.035 I
-
Clearance between output shaft, bearing
5 and housing (Rear) 0
125 -oO.oTa -00.035 -EC35
Clearance between output shaft and bearing 70 +0.051 -:.015 0.032 -

6 0
- 0.032 0.066
+0.039 0.020 -
7 Clearance between output shaft and bearing 65 -0.020 Jo13 0.052 -0.02
-
8 ;;Z;;,nce between Idler shaft and bearing 85 i-0.023

+0.045 -:.020 0.023
0.065 - -0.02
-
;l;;wrvce between idler shaft and beanng f0.045 0.023 -
9 a5 +0.023 -:.020 0.065 -0.02
Standard size Repalr limit

10 Clearance between input cover and case
2 Preload 0.01 - 0.1 kgm
Adjust
11 llearance between output cover and case 2 Less than 2.05
12 Clearance between Idler cover and case 2 Preload 0.01 - 0.1 kgm
13 3acklash of input gear 0.1 a - 0.49

-
Replace
14 Backlash of output gear 0.21 - 0.52
-
15 Tightening torque of coupling mounting bolt 38.5k3.5 kgm Retighten
WA350-1 24-15
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
15
423F214A
Unit: mm
Tolerance
size clearance limit
Shaft Hole
1 Clearance of side bearing of differential Outer race 0 +0.054 0.014 -

gear assembly 150 -0.018 +0.014 0.072 -
Inner race +0.073 -0.051 - Replace

100 +0.051 -:.020 -0.093 -
Outer race 0 -0.020 -0.002 -

130 -0.018 - 0.045 -0.045 -
2 Clearance of pinion shaft of bearing
Inner race i-o.033 0 -0.020 -
60 +0.020 -0.015 -0.048 -
24-16 WA350- 1
0
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
No
Clearance of pilot bearing
Backlash of gear 0.25 -0.33
End play of pinion gear Less than 0.152
13 Thickness of side gear washer
14
-
15
-
16
17
18
-
19 Tightening torque of mounting bolt 18.0 & 2.0 kgm Retighten
20 Tightening torque of mounting bolt 11.5 ? 1 .O kgm
21 Tightening torque of mounting bolt 18.0 * 2.0 kgm
22 Tightening torque of mounting bolt 94.5 f 10.5 kgm
23 Tightening torque of mounting bolt 28.5 f 3.0 kgm
24 Tightening torque of adjustment lock nut 22.5 * 2.5 kgm
WA350-1 24-17
0
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
I C(
<y
10 9 423F215
Unit: mm
No Check item Criteria Remedy

I
Clearance between planetary shaft

1
and bearing
40 +0.013 JOI 0.002 - -

+0.002 2 0.025
-
165.1 +0.064 +0.025 0.013 - _
2 Clearance between ring gear hub and bearing
-IO.038 0 0.064
-
3 Thickness of retainer at ring gear hub mount
4 Backlash between planet gear and sun gear

-
5 Backlash between planet gear and ring gear 0.21 - 0.58

I
6 Thickness of standard shim for wheel hub
7 Tightening torque of mounting bolt 11.5t- l.Okgm

-
a Tightening torque of mounting bolt 7.0 f 0.5 kgm
Retighten
9 Tightening torque of nut 48 f 5 kgm
1c Tightening torque of mounting bolt 3.2 f 0.3 kgm
24-18 WA350-1
@
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
,,,,, \ 423F213
-i\
\ Unit: kgm
1 Tightening torque of mounting bolt 11.5+ 1.0
2 Tightening torque of mounting bolt 28.5 3.0
3 Tightening torque of mounting bolt 94.52 10.5
4 Tightening torque of mounting bolt 11.5* 1 .o Retighten

I
5 Tightening torque of mounting bolt 11.5-11.0
I I I
6 Tightening torque of mounting bolt 11.5irl.O
7 Tightening torque of mounting bolt 11.55 1 .o
WA350- 1 24-19
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
Serial No. Serial No.

10001 - 11117 11118andup
U42301003
Section A-A
u
2
E423F216
Section B-B
24-20 WA350-1
0
MAINTENANCE STANDARD AXLE MOUNT
View 2
423FO69
Unit: mm
-
Standard size Tolerance Repair limit

1 Thickness of thrust plate
20 -
-:.I5
2 Thickness of wear plate 5 -

-00.1
-
Tolerance
Replace
Clearance of shaft and hole Shaft Hole
3
Front support side
- 0.056 +0.439 0.079 -
Dia. 260
-0.137 +0.023 0.576
-
Clearance of shaft and hole - 0.043 +0.455 0.070 -
4
Rear support side Dia. 170 -0.106 f- 0.027 0.561
-
5 Tightening torque of mounting bolt 28.5 & 3.0 kgm
6 Tightening torque of mounting bolt 26.5 * 3.0 kgm Retighten

. (~$Y engine
7 Tightening torque of mounting bolt 105 ? 10 kgm (Coat engine oil)
-
8 Tightening torque of axle mounting bolt (F) 105 f 10 kgm (Coat engine oil)
-
WA350-1 24 -21
0
General .................................. 41- 2

Hydraulic circuit for steering ............... 41- 4
l Hydraulic circuit diagram for steering ..... 41- 5
l Operations of steering valve ............. 41- 6
Steering control system ................... 41- 8
l Steering valve ......................... 41- 8
l Steering relief valve .................... 41-I 0
l Safety valve (Differential type) ........... 41-I 1
l Operation of demand spool ............. 41-l 2
l Two-way restrictor valve ............... 41-I 4
Steering cylinder .......................... 41-I 5
Steering column and gear box .............. 4 1- 16
Center hinge pin .......................... 41-I 7
Steering linkage .......................... 41-I 8
Emergency steering pump (if equipped) ..... 41-I 9
Diverter valve (if equipped) ................. 41-20
Security valve (if equipped) ................ 41-23
WA350-1 41-l
63
GENERAL
OUTLINE
l The oil from hydraulic tank (I) is sent to steering . When steering valve (3) is actuated, oil flows to
valve (3) by hydraulic and steering pump (2). steering cylinder (4) and the steering is actuated.
l When steering wheel (7) is operated, the move- . When steering wheel (7) is not being operated, all
ment is transmitted by steering column (61, univer- the oil which enters steering valve (3) flows to
sal joint, gear box (5), drag link, and link, and actu- main control valve.
ates steering valve (3).
F4230003
41-2 WA350-1
@
F4230004
/ \
I. Hydraulic tank c Turn right
2. Hydraulic and steering pump (See page 61-I 2) Turn left

@
3. Steering valve
4. Steering cylinder
5. Gear box
6. Steering column
7, Steering wheel
WA350-1 41-3
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT FOR STEERING
HYDRAULIC CIRCUIT FOR STEERING
Engine running, steering wheel is not being operated.
-8
e Main control L
Steering Hydraulic
pump I v-v 423FO866
. The steering wheel is not being operated, so the . The merged oil passes throuoh orifice b and
steering spool (6) does not move. flows to steering spool (6). However, it is at
. The oil from the steering pump enters port A. At neutral, so the oil does not flow to the cylinder. It
the same time, the circuit for the oil from the hy- pushes open check valve (8) and all the oil flows
draulic pump is closed, so the pressure rises. It to the hydraulic circuit.
pushes check valve (4) open, so the oil enters port
A and merges with the oil from the steering pump.
41-4 WA350-1
0
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING
To main control valve -
1 -I
F423C1009A
I. Hydraulic tank 7. Steering relief valve

2. Hydraulic and steering pump 8. Check valve
3. Steering valve 9. Safety valve (with suction)
4. Check valve 10. Steering cylinder
5. Demand spool 1 1. Two-way restrictor valve
6. Steering spool 12. Two-way restrictor valve
WA350-1
41-5
8
OPERATIONS OF STEERING VALVE
Turning right
.A.
::j
,
i:i
..i
....
::::
::::
::::
jjjj
::::
....
:.: .,.,._.,._.,.,.,.,.
...................
. . . . . . . . . . . . . . . . . . . . . . . . . . ..A.. ,\..................
j:j:
12
11
,6
-5
e Main control valve
-----&-
. When the steering wheel is turned to the right, the valve (I I1, and flows to the bottom end of the left
control linkage is actuated and steering spool (6) cylinder and rod end of the right cylinder to turn
moves to the right. the machine to the right.
The oil from the pumps enters port A passes The oil from the left and right cylinders passes
through demand spool (5) and flows to steering through two-way restrictor valve (I 2). and is
spool (6). The oil passes through port B of the drained through port C of the steering spool.
spool, pushes the poppet of two-way restrictor
41-6 WA350-1
0
Turning left
control valve
423F088B
. When the steering wheel is turned to the left, the bottom end of the right cylinder to turn the ma-
control linkage is actuated and steering spool (6) chine to the left.
moves to the left. The oil from the left and right cylinders passes
The oil from the pumps enters port A, passes through two-way restrictor valve (1 I), and is
through the demand spool and flows to steering drained through port B of the steering spool.
spool (6). The oil from port C of the spool pushes
the poppet of two-way restrictor valve (121, and
oil flows to the rod end of the left cylinder and
WA350-1 41-7
0
STRUCTURE AND FUNCTION STEERING CONTROL SYSTEM
STEERING CONTROL SYSTEM

STEERING VALVE
A. To steering cylinder
B. To hydraulic circuit
C. To steering cylinder
D. From hydraulic pump
E. To steering pump
F. To hydraulic tank
41-8 WA350-1
0
Section Y-Y
Section X-X
Section Z-Z
E423F075B
1. Lever 6. Steering spool

2. Valve body 7. Steering relief valve
3. Check valve 8. Safety valve (with suction)
4. Demand spool
5. Check valve
WA350- 1 41-9
0
STEERING RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
5608 F069
Function
. The steering- relief valve is inside the steering
valve. When the steering cylinder reaches the end
of its stroke and abnormal pressure is generated,
the oil sent from the pump is relieved through this
valve. This prevents damage to the pump or
circuit.
(The relief valve sets the maximum pressure of 560BF070
the circuit.)
Operation
l Port A is connected to the pump circuit, and port
C is connected to the drain circuit. The oil passes
through the orifice in main valve (1) and fills port
B. Pilot poppet (3) is in contact with valve seat (2).
56OBFO71
When the pressure inside port A and B reaches

the pressure set by the poppet spring (set
pressure), pilot poppet (3) opens and the hydraulic
pressure at port B escapes from port D to port C.
This lowers the pressure at port B.
When the pressure at port B drops, the orifice of
main valve (1) generates a difference in pressure
between port A and port B. Main valve (I) is
opened by the pressure at port A and the oil at
port A is relieved.
41-10 WA350-1
SAFETY VALVE (with suction valve) Function

l The safety valve (with suction valve) is in the main
valve. If shock causes any abnormally high pres-
sure in the cylinder when the main valve is at
neutral, the safety valve (with suction valve)
releases the abnormal pressure and protects the
cylinder from damage.
I. Suction valve 4. Pilot piston

2. Main valve 5. Suction valve spring
3. Main valve spring 6. Valve body
421 F045
Operation
As a safety valve
Port A is the cylinder circuit and port B is the drain
circuit.
The pressure oil in port A flows to port D through
a hole in the pilot piston. It also flows to port C
through an orifice consisting of the main valve (2)
and the pilot piston (4).
The pilot piston is secured to the safety valve by a
lock nut. The diameter of the cross section
(cross-sectional area) gives a relationship of d2 >
dl > d3 > d4.
If abnormally high oil pressure occurs in port A, 421 F046
the suction valve (I) is not actuated because of
the relationship d2 > dl.
However, because of the relationship d3 > d4 in
port A and C, the hydraulic pressure on the main
valve (2) is equivalent to the area difference be-
tween ds and da. If this pressure goes up to the
poppet spring force (set pressure), the poppet is
actuated, and the oil in port A flows into port B.
As a suction valve
If negative pressure is generated in port A, port D
also has negative pressure, because port D and A
are connected with each other. The tank pressure 421 F047
in port B is applied to port E.
Hydraulic pressure a equivalent to the area dif-
ference between d2 and dl is applied to the safety
valve because of the tank pressure in port E.
Therefore, hydraulic pressure e acts to open the
valve and hydraulic pressure a acts to close the
suction valve (I 1.
If the pressure in port A drops, (approaching nega-
tive pressure) hydraulic pressure a becomes
smaller than oil pressure e.
When oil pressure e becomes larger than oil
pressure a + valve spring (5) force, the suction
valve (1) opens, causing the oil to flow from port
B into port A. This prevents negative pressure 421 F048
from building up in port A.
WA350-1 41-11
0
OPERATION OF DEMAND SPOOL

To steering cylinder From steering cylinder
Q 8
Engine at low speed
. The oil from the steering pump enters port A. At
the same time the circuit for the oil from the hy-
draulic pump is closed by demand spool (2), so
the oil pushes check valve (I) open and enters
port A to merge with the oil from the steering
pump.
. The merged oil passes through orifice a of
demand spool (2) and enters port B. However, the
oil flow is small, so the pressure at port B does not
rise and the spool does not move.
. Therefore, all the oil flows from steering valve
spool (4) to the steering cylinder.
423FO83B
P,: Steering pump
PI: Hydraulic pump

Engine at midrange speed
+ w
. The oil from the steering pump enters port A. At
the same time, the circuit for the oil from the hy-
draulic pump is closed, so the pressure rises. It
pushes back the spring of check valve (I) and
pushes the valve open, so the oil enters port A and
merges with the oil from the steering pump.
. The merged oil passes through orifice a in
demand spool (2) and enters port B. The flow of
oil is larger than when the engine is at low speed,
so the pressure at port B rises because of the ori-
fice at port C. This pressure becomes greater
than the force of spring (5). and demand spool (2)
moves to the right. +
For this reason, some of the oil from the hydraulic alve
pump passes through port D and flows to the

main control valve.
. All the oil from the steering pump and the remain-
der of the oil from the hydraulic pump flows to the d '/PI/ P2 /II@
steering cylinder.
423FO84B
P,: Steering pump
P1: Hydraulic pump
41-12 WA350-1
0
Engine at high speed

TO steering cylinder From steering cylinder
The oil from the steering pump enters port A.

Demand spool (2) is opened when the engine is at
midrange speed, so the oil from the hydraulic
pump is divided into oil which enters port D and oil
which enters port A from check valve (I).
The oil which merges at portA passes through ori-
fice a of demand spool (2) and enters port 6.
The flow of oil is larger than when the engine is at
midrange speed, so the pressure at port B rises
higher because of the orifice of port C. The pres-
sure becomes even higher than the force of spring
(51, so the demand spool is moved further to the
right. e
For this reason, all of the oil from the hydraulic alve
pump and part of the oil from steering pump

merges at port D and flows to the main control
valve. a i
423 FO85B
P,: Steerrng pump

P,: Hydraulic pump
WA350-1 41-13
0
TWO-WAY RESTRICTOR VALVE
1. Body
2. Spring
3. Poppet
423FO80
Function
. To reduce the shock caused by the inertia of the
machine when the steering is operated,
an orifice
is installed in the oil line of the return circuit from
the cylinder. This applies pressure to the returning
oil, and regulates the movement of the cylinder
piston.
Operation
. When the oil is flowing to arrow & , it pushes
spring (2) and flows through the orifice, and be-
tween poppet (3) and the poppet seat. From
pump
423F081A
. When the oil is flowing to arrow +, the oil flows

only from orifice a inside the poppet (3). SO the
flow is controlled.
423F082A
41-14 WA350-1
0
STRUCTURE AND FUNCTION STEERING CYLINDER
STEERING CYLINDER
423 F089
Specifications
1. Head Cylinder bore: 80 mm
2. Rod Rod diameter: 45 mm
3. Cylinder Stroke: 442 mm
4. Piston Cylinder max. length: 1,209 mm
5. Piston nut Cylinder min. length: 767 mm
Width across flats of piston nut: 50 mm
WA350-1 41-15
STRUCTURE AND FUNCTION STEERING COLUMN AND GEAR BOX
STEERING COLUMN AND GEAR BOX

Outline
. The steering gear is a recirculating ball type gear. . Balls (6) move in the nut groove of the shaft
In this type of gear there is a round-bottomed together with the rotating of the steering wheel.
thread cut in the steering shaft. There are several They pass from the end of the nut through the
balls (6) between the nuts which slide in this passage on the outside, and return to the nut to be
thread. Ball nut (5) moves up and down in recirculated
accordance with the rotation of the steering shaft,
and turns the center shaft.
9-
n
I I
Section D-D
Section B-B Section C-C

423FO72
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
41-16 WA350-1
STRUCTURE AND FUNCTION CENTER HINGE PIN
CENTER HINGE PIN
Outline
. The front frame (3) and rear frame (4) are I. Front axle
connected through a bearing by the center hinge 2. Rear axle
pin (5), (6). The steering cylinders are connected 3. Front frame
to the left and right front and rear frames, so 4. Rear frame
when the cylinders are operated, the frame bends 5. Upper hinge pin
at the middle to give the desired angle, that is the 6. Lower hinge pin
desired turning radius.
Serial No. Serial No.

10001 - 11117 11118andup
U42301004
Serial No. 10001 - 11117 Serial No. 11118 and UD
Section A-A section A-A

Section B-B Section B-B
U42401008
E423FlS4
WA350-1 41-17
0
STRUCTURE AND FUNCTION STEERING LINKAGE
STEERING LINKAGE
SerialNo. 10001 - 10186
Section A-A
Section A-A
423FO73A
1. dear box
2. Pitman arm
3. Steering column
4. Link
5. Steering valve
41-18 WA350-1
@
STRUCTURE AND FUNCTION EMERGENCY STEERING PUMP
EMERGENCY STEERING PUMP (If equipped)
Section A-A
419F479
View Z
1. Drive gear (Teeth 12)

2. Front cover
3. Gear case
4. Rear cover
5. Driven gear (Teeth 12)
Specifications
l Model: SAM(2)-040
l Direction of revolution: Possible to rotate both direction
. Theoretical delivery: 50.8 cc/rev.
l Max. delivery pressure: 210 kg/cm2
41-19
WA350-1
co
STRUCTURE AND FUNCTION DIVERTER VALVE
DIVERTER VALVE (If equipped)
\ Section X-X
Section Y-Y D
419F480
1. Diverter valve A. From steering pump

2. Valve body B. To steering valve
3. Check valve C. To hydraulic tank
4. Check valve D. Sensor mounting port
E. Emergency pump port
F. Emergency pump port
G. From hydraulic pupm
FUNCTION
l If the engine stops or the pump seizes during ma-
chine traveling, and it becomes impossible to
steer, the rotation of the transmission is used to
turn the emergency steering pump to make steer-
ing possible.
41-20 WA350-1
@
OPERATION
l Pump and engine are working normally.

@
_....
::::
::
:::
::::
::
:::
:::
:::
:::
...
i$$
.:..
ii;;
....I
it :::
:jj :; ..:.
11
.A.
.A.
.A.
:!:
::: ::
:.,
j:j
::::
::: :i:
:::
::: i;; .A.
.A.
: :!: .A.
:::
::: i:; :::
.A.
.A.
.A.
.A.
.A.
.:. :j: :i: _ .A.

.A.
Hydraulic tank
423F501
. When the steering pump and engine are working

To steering cylind,er From steering cylinder
normally, the hydraulic pump, steering pump, and
switch pump are rotated by the engine. Therefore,
oil is sent to the steering valve, and the machine
can be steered.
In addition, the emergency steering pump is rotat-
ed by the transmission, so oil from port A of the
diverter valve pushes open check valve (2) and
enters port 6.
Pressure oil from the steering pump is flowing to
port D, so it pushes spool (3) in the direction of
the arrow.
As a result, the oil from port B flows to port C and
0
Steering pump
is drained to the hydraulic tank. 423F502
WA350-1 41-21
@
l Failure in pump or engine when machine is traveling.

$J
:::
:::
:::
Q 3
0 main T
.C
Hydraulic pum
Steering pump
Hydraulic tank
423F503
l If there is a failure in the pump or engine when the

machine is traveling, the rotation of the wheels is
transmitted through the transfer to rotate the Emergency steering pump
emergency steering pump. \P--
The steering pump is not rotating, so no pressure
oil is formed at port D. As a result, spool (3) is
pushed in the direction of the arrow by spring (4).
The oil from the emergency steering pump passes
from port A through port B and flows to the steer-
ing valve to make steering possible.
* The emergency steering pump is designed so
that it can rotate both directions.
426FO65
41-22 WA350-1
@
STRUCTURE AND FUNCTION SECURITY VALVE
SECURITY VALVE (If equipped)
Section A-A
419F4S4
FUNCTION
1. Valve body l If hoses between security valve (including work
2. Spool equipment control valve) and each cylinder are
3. Spring broken, security valve prevents oil flowing out.
When lower oil level until float valve actuating
point, security valve actuates to return all oil flows
to work equipment control valve to hydraulic tank.
WA350-1 41-23
@
OPERATION
1) When work equipment circuit is normal. (Hydraulic tank oil level is correct.)
To main
Hydraulic circuit
l Oil from steering pump enters port a, and it To steering cylinder From steering cylinder
pushes spool (I) in the direction of arrow, and

also it reaches to float valve (2) chamber A.
l Oil from steering valve flows to work equipment

control valve through port b.
423F505
41-24 WA350-1
@
2) When work equipment circuit is abnormal. (Hydraulic tank oil level is to low.)

@
iii
:i:
:::
::jj I
.:.
:::
:::
:::
1
iteering pump
423F506
Hydraulic circuit
l When oil in the hydraulic tank is decreased, float

TO steering cylinder From steering cylinder
(3) goes down and oil from the pump circuit flows
to the hydraulic tank. The pressure of port a
I
goes down and spool (1) moves to + direction,
then oil from steering valve flows to tank circuit to
prevent the leak from the damaged part.
423F507
WA350-1 41-25
Go
STEERING SYSTEM
Standard value table ... . . . 42-2

Tool list for testing and adjusting . . 42-2
Measuring steering wheel play .. . 42-3
Measuring operating force of
steering wheel . . . 42-4
Operating time of steering wheel lock to lock. 42-5
Testing steering linkage . 42-6
Adjusting steering linkage .. . . 42-7
Steering oil pressure . ... . . .. .. 42-8
Troubshooting __.__.,..................... 42-9
Sr The following precautions are necessary when using the Standard Value Tables to make judgements during
WA350-1 42-l
0
Testing and measuring item Measurement condition Unit standard value Permissible value
Steering wheel Road surface: Flat,

horizontal, dry, pavet surface
Steering wheel play mm 20-70 20-100
l Hydraulic temperature:
Steering wheel operating force kg 1.5-2.2 Max. 3.3
45 - 55C
Operating time of steering l Machine posture:

wheel (Low idling) Facing straight 3.2 -4.2 Max. 5.0
Sec.
(High idling) 2.2-3.2 Max. 5.0
Steering linkage Tire inflation pressure:

Specified pressure
l Clearance between front frame
mm 20 - 30 -
and rear frame
Steering oil pressure Hydraulic temperature:

45 - 55C
l Main relief oil pressure kg/cm2 210 -2 2 lo+_;
No. Testing and measuring item Tool Part number Remark
1 Steering wheel operating force Push-pull scale 7AO-262-0020 O-25 kg

I
2 Steering oil pressure Hydraulic tester 799-l 01-5000 0 - 400 kg/cm2
3 Steering wheel operating time Stop watch 7AO-262-0550 l/IO second

I I I I
4 Clearance between front frame

Convex scale Commercially available -
and rear frame
A When carrying
bar on the frame,
out testing,
lower
adjusting
the bucket
or troubleshooting,
to the ground,
stop
and stop the engine.
the machine on level ground, install the safety
A When installing or removing gauges, loosen the oil filler cap slowly to release the pressure inside the hydrau-
lic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic
piping.
A When taking measurements, do not allow unauthorized persons near the machine.
A The oil in the circuit is hot, so be careful not to get burnt.
42-2 WA350-1
CJ
TESTING AND ADJUSTING MEASURING STEERING WHEEL PLAY
HOW TO MEASURE
1. Turn the steering wheel lightly clockwise and
counterclockwise two or three times and confirm
the neutral position of the steering mechanism.
Put mark 1 on the outer frame of the vehicle
419F302
monitor.
2. Turn the steering wheel clockwise. Align the posi-

tion where the tires begin to move with mark I,
then put mark 2 on the steering wheel.
3. Turn the steering wheel counterclockwise. Align

the position where the tires begin to move with
mark 1 , then put mark 3 on the steering
wheel. Measure the distance of a straight line be-
tween mark 3 and mark 2.

* Inspect the steering linkage for looseness and free
play. If any, adjust the linkage.
1. Loosen lock nuts (4) on the steering gear box.
2. Then, adjust by turning adjustment screw (5) in or

out.
t To decrease the free play, turn the adjustment

screw in, to increase the free play, turn the screw
out.
-~
-_ ____
423F311
WA350-1 42-3
0
TESTING AND ADJUSTING MEASURING OPERATING FORCE OF STEERING WHEEL
MEASURING OPERATING FORCE OF STEERING WHEEL
Condition
Road surface: Flat, horizontal, dry, paved surface.
Coolant temp: Inside operating range
Hydraulic oil temp: 45 - 55C
Tire inflation pressure: Specified pressure
Engine speed: Low idling (bucket unload)
Unit: kg
Item
stZi::rd
Force of steering wheel 1.5-2.2 Max. 3.3
Special tool -
-(Partnumber 1 Part name IQty
~0-262-0020 1 Push-pull scale I 1
Measuring procedure
1. Hock push-pull scale A to the knob of the steer-
ing wheel.
2. Start the engine.

* After starting the engine, raise the bucket
about 400 mm and remove the safety bar.
3. Pull push-pull scale A at a tangent, and read the

value when the steering wheel is moving smoothly.
Do not read the valve at the time, the steering
wheel starts to move.
42-4 WA350-1
0
TESTING AND ADJUSTING OPERATING TIME OF STEERING WHEEL LOCK TO LOCK
OPERATING TI ME OF STEERING WHEEL LOCK TO LOCK
Measurement condition
Road surface: Flat, horizmontal, dry, paved surface
Coolant temp: Inside operating range
Hydraulic oil temp: 45 - 55C
Tire inflation pressure: Specified pressure.
Engine speed: Low idling and high idling
Unit: set
Item
value value
Special tool
7AO-262-0550 Stop watch 1
Measuring procedure
1. Start the engine.
* After starting the engine, raise the bucket
about 400 mm and remvoe 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.
t Measure at low idling and high idling, and when
turning to the right and to the left.
WA350-1 42-5
0
TESTING AND ADJUSTING TESTING STEERING LINKAGE
TESTING STEERING LINKAGE
Hydraulic temperature: 45 - 55C
Road surface: Flat, horizontal, dry, paved surface
Engine speed: 1200 rpm
Center lever: square with the machine center line
Pitman arm: Prependicular to the machine rear frame
Unit: set
Serial No. 10001 - 10186 Serial No. 10187 and up
Measuring procedure
1. Start the engine and operate the steering wheel to
set the front and rear frames in a straight line.
2. Check looseness of mounting bolts and nut (I) of

linkage and play of ball joint (2). rod (3) and center
lever bearing (4).
423F3 I2
3. Check that the center lever is at right angles to the

center line of the machine.
* The steering spool should be at neutral.
4. Check that the pitman arm is perpendicular.
5. Start the engine and turn the steering wheel to the

left and right to the full lock position. Check that
clearance a between the front frame and rear
frame stoppers is the standard value.
* When measuring the clearance to the right, ad-
Clearance 423F313
justment screw (5) should be in contact with
the pitman arm.
* When measuring the clearance to the left, ad-
justment screw (7) should be in contact with
the pitman arm.
* Conform that adjustment screws (6) and (8) do
not in contact with the valve lever respectively.
I
423F314
42-6 WA350-1
0
TESTING AND ADJUSTING ADJUSTING STEERING LINKAGE
ADJUSTING STEERING LINKAGE
. Hydraulic temperature: 45 - 50C
. Road surface: Flat, horizontal, dry, paved surface.
. Tire inflation pressure: Specified pressure.
A Install the safety bar and stop the engine.
Adjustment procedure
1. Set the machine facing directly to the front and in-
stall the safety bar.
2. Disconnect steering linkage (I ).
3. Adjust steering linkage (2) so that center lever (8)
is at 90 to the center line of the chassis when
steering valve lever (9) is at neutral.
4. In the condition in Step 3, move the steering valve
lever to the end of its travel so that the valve lever
contacts stopper bolts (5) and (6).
Then turn it back l/2 turn, and lock in position
with the nut.
5. Set pitman arm (7) perpendicular to the front
frame, adjust the length of steering linkage (I),
then connect steering linkage (1) and pitman arm
(7).
6. Remove the safety bar.
7. Start the engine, turn the steering wheel fully to
the left and right, and adjust so that the pitman
arm contacts stopper bolts (3) and (4) when clear-
ance a between the front frame and rear frame
stopper is 20 - 30 mm, then lock in position with
the nut.
* After completing the above adjustments, in-
spect again to check that the measurements
are within the standard value.
423F3 I3 A
WA350-1 42-7
a
TESTING AND ADJUSTING STEERING OIL PRESSURE
STEERING OIL PRESSURE
l Hydraulic temperature: 45 - 55C
Unit: kg/cm2
Special tool
A 799-l 01-5000 Hydraulic tester 1
Procedure for measuring main relief pressure
a Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank. Then oper-
ate the steering wheel several times to release
the remaining pressure in the hydraulic piping.
1. Fit safety bar (1) on the frame, then remove cover

(2).
2. Remove plug (3) for measuring the right turn
steering circuit.
3. Install hydraulic tester A to the measuring port.
4. Start the engine and run at high idling. Turn the
steering wheel to the right and measure the
pressure when the relief valve is actuated.
* When removing the plug for the left turn
steering circuit, turn the steering wheel to the
left and measure.
Testing and adjusting
n Always stop the engine before adjusting the

hydraulic 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.
t Amount of adjustment for 1 turn of adjustment
screw.
1 turn: Approx. 24.8 kg/cm2
Sr Adjust the set pressure as follows.
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw. I
* If the relief pressure cannot be measured

6
accurately, do not try to adjust the pressure. 423F315
42-8 WA350-1
0
TROUBLESHOOTING
Troubleshooting table . . . 42-10

1. Steering wheel does not turn . .. 42-10
2. Steering wheel is sluggish . . 42-11
3. Steering wheel moves unsteadily or
is subjected to large shock . 42-12
4. Machine tends to turn naturally in one
particular direction when traveling 42-12
5. Left and right turning radii are different 42-12
* Before carrying out the troubleshooting in this section, read PRECAUTIONS WHEN TROUBLESHOOTING
page 22-l 2, METHOD OF READING TROUBLESHOOTING TABLE page 22-l 4 and PREVENTING RECUR-
RENCE OF TROUBLE page 22-l 6.
WA350-1 42-9
0
1. Steering wheel does not turn.
Ask the operator the following questions.

l Did the steering wheel suddenly cease to turn?
- Damage to equipment in steering circuit.
l Did steering wheel show signs of being sluggish
for some time? - Worn parts in steering circuit
or faulty seal.

l Is oil level inhydraulic tank and type of oil
satisfactory?
l Is there any damage to the steering gear box or
the steering linkage?
l Has the safety bar been removed from the
frame? _
l Is the steering linkage properly adjusted?
* Because the steering circuit and the work equip-

ment circuit are intimately related to each other,
check the operation of the work equipment if the
steering behaves abnormally.

to be taken when a cause of failure IS located.
42-10 WA350-1
0
2. Steering wheel is sluggish.

l Did the steering wheel suddenly become
sluggish?
Damage to equipment in steering circuit.
l Did the steering wheel show signs of being
sluggish for some time? --*Worn parts in steer-
ing circuit or faulty seal.

Is oil level in hydraulic tank and type oil sat-
isfactory?
Is there any abnormality in the steering gear
box mounting part, steering column or linkage?
Is the adjust of the steering valve control lever
correct?
Is there any oil leakage from the oil pressure
hose, valves, cylinders, etc?
Is there any seizure between the pin, pin bearing
and bushing of the center hinge and the steer-
ing cylinder pin and bushing?
Check tire pressure.
Fault check
. Measure the operating force of the steer-
ing wheel and also the time required to
turn the machine when the steering is
operated, then check the results
against the judgement criterion
table to see whether or not
there is any abnormality.
Problems
1 Steering wheel is sluggish in both left and right directlons. 0 0 0 0 0
2 Steering wheel IS sluggish in one of left and right directions. 0 0
3 Steering wheel is particularly sluggish at low engine speed. 0 0

Boom lifting speed is insufficient when engine is at full
4 0
throttle.
5 Steering wheel is sluggish and jerky. 0
6 1 Hydraul IC oil overheats.

I lIIIllol I
7 Steering circuit pressure is low. 0 0 0 0
Oil pressure In return side piping of steertng cylinder
8 rises. 0 0
The followlng symbols are used to indicate the action

X: Replace D: Repair
A: Adjust C: Clean
WA350- 1 42-11
0
3. Steering wheel moves unsteadily or is

subjected to large shock.

Is oil level in hydraulic tank and also oil type
satisfactory?
Is there any damage to the steering gear box
mounting part, steering column or linkage?
is there any play in the center pin hinge bearing
or steering cylinder pin bushing?
Does tire inflation pressure fluctuate?
Steering wheel play
Fault check
Operate the wheel loader in a safe place and
check the conditions under which the steering
wheel becomes unsteady.
wheel is sluggish.
No.
1 Machine body is unsteady when traveling on bumpy

road surface.
Steering wheel becomes unsteady if suddenly turned
2 0 0
when working or traveling.
Machine body becomes unsteady when traveling at high
3 0 0 0
speed.
4 Machine body becomes unsteady during engine starting.
4. Machine tends to turn naturally in one par- to be taken when a cause of failure IS located.
titular direction when traveling.
Cause: Faulty steering valve

0 Incorrect positioning of Spool.
l Faulty safety valve.
l Oil leakage in steering cylinder.
l Does tire pressure fluctuate?
5. Left and right turning radii are different.
Cause: Incorrectly adjusted steering linkage

Left and right steering balance, lock posi-
tion of stopper.
(Valve relief noise can be heard upon com-
pletion of turning.)
42-12 WA350-1
0
STEERING SYSTEM
STEERING GEAR
Removal . 43- 2
Installation 43- 3
Disassembly 43- 4
Assembly ______ 43- 5
STEERING VALVE
Removal 43- 8
Installation . 43-l 0
Disassembly 43-l 2
Assembly .._ 43-l 2
STEERING CYLINDER
Removal . . .._._____._._._..__......... 43-14
Installation . . . . . _. . . 43-l 5
Disassembly........................... 43-16
Assembly . .. .. .. . . .. . . . . 43-18
CENTER HINGE PIN

Removal . . .. .. .. . . . . . . . 43-22
Installation . .. .. .. .. .. 43-30

WA350-1 43-l
0
DISASSEMBLY AND ASSEMBLY STEERING GEAR
REMOVAL OF STEERING GEAR

* After stopping the engine, turn the steering wheel

several times to the left and right to set the
steering valve in NEUTRAL.
.
1. Pitman arm
I) Disconnect connector of wiring (I), then
remove mounting nuts (3) of pitman arm (2).
Sr Before removing, check that the pitman arm
is horizontal.
2) Disconnect sector shaft (4) of steering gear
and pitman arm (2).
* Before removing, make match marks on the
sector shaft of the steering gear and pitman
arm.
2. Steering column
Loosen lock bolt (5). and increase clearance a of
column joint (6).
* Make match marks on the column joint and
steering gear.
3. Steering gear
Remove mounting bolts (71, then remove steering
gear (8).
43-2 WA350-1
0
INSTALLATION OF STEERING GEAR
1 Steering gear
Align match marks of column joint (6) and
steering gear (8);and insert joint. Set steering gear
in mounting position, then install mounting bolts
(7).
w Mounting bolt: 11.53~ 1 .O kgm
2. Steering column
Tighten lock bolt (5) of column joint (6).
w Lock bolt: 5.720.7 kgm
3. Pitman arm
Align match marks of pitman arm (2) and sector
shaft (4). install pitman arm, then tighten
mounting nuts and connect connector of wiring
(I).
B Mounting nut: 1923 kgm
4. Checking steering linkage

After completion of assembly, check the linkage
and adjust if necessary.
t For details, see 52 TESTING AND ADJUST-
ING.
WA350-1 43-3
@I
DISASSEMBLY OF STEERING GEAR
1. Side cover
1) Loosen lock nut (3) of adjustment screw (21,
then remove mounting bolts (4) of cover.
2) Hold side cover so that it cannot rotate, and

tighten adjustment screw to remove side cover
(1).
2. Sector shaft
Turn steering gear shaft (6) so that sector shaft is
in vertical position, and remove sector shaft (5).
t Be careful not to damage the bushing or thread
of the sector gear.
3. Rear cover, shaft, ball nut assembly

Remove rear cover (7). then remove shaft and ball
nut assembly (8).
43-4 WA350-1
@
ASSEMBLY OF STEERING GEAR
1. Bearing outer race

I) Press fit bearing outer race (10) on gear box (9)
and rear cover (7).
2) Press fit oil seals (I I), (12) on gear box and

rear cover.
* If bushing (13) of the gear box is badly
worn, replace the gear box.
& Lip of oil seal: Grease (G2-LI)
2. Shaft, ball nut assembly, rear cover

Assemble shaft and ball nut assembly (8) in gear
box, then install rear cover (7).
RCZL Shaft, ball nut assembly, bearing (I 4):

Grease (G2-LI)
* If there is any problem with shaft (I 6) or ball

nut (I 5) of the shaft and ball nut assembly, re-
place the whole shaft and ball nut assembly.
WA350-1 43-5
@
3. Adjusting shim
Select shim thickness so that starting torque of
shaft is within standard range.
* First assemble a larger thickness than
necessary, then reduce the thickness to adjust.
* Measure the starting torque with torque
wrench A.
* Standard range for starting torque:
3.5 - 6.5 kgcm
w Mounting bolt (16) of rear cover:

-.
4.5 f 1 kgm
4. Sector shaft, side cover

Assemble so that sector gear is meshed at center
of ball nut.
t If bushing (3) of the gear box is badly worn, re-
place the gear box.
w Mounting bolt: 4.5+-l kgm
5. Adjusting adjustment screw

1) Temporarily install pitman arm (I 7). move arm
lightly and tighten adjustment screw (2) so that
backlash is 0.
2) Turn adjustment screw so that starting torque

of shaft is within standard range, then tighten
lock nut.
t Standard range for starting torque:
3.5 - 7.0 kgcm
w Lock nut: 2.5kO.5 kgm
43-6 WA350-1
0
WA350-1 43-7
0
DISASSEMBLY AND ASSEMBLY STEERING VALVE
REMOVAL OF STEERING VAL
A Stop the
the safety
bar on the frame.
and install
Lower the bucket
Q! Loosen
pressure
to release
tank. Then operate
the
the steering wheel several times to the left and

right to release the remaining pressure in the
hydraulic piping.
l Loosen plug (I) at the top of the hydraulic tank
* Disconnect the cable from the negative (-1

1. Steering linkage, cover

1) Remove floor cover (3) of floor frame.
2) Remove mounting nut of steering linkage (4).
2. Hydraulic piping
I) Disconnect tube (5) between steering valve and
steering pump at steering valve end.
2) Disconnect tube (6) between steering valve and
hydraulic pump at steering valve end.
3) Disconnect hose (7) between steering valve
and main control valve at steering valve end.
steering cylinder (bottom end) at steering valve
end.
43-8 WA35071
0

hydraulic tank at steering valve end.
6) Disconnect tube (IO) between steering valve
and steering cylinder (rod end) at steering valve
end.
* After disconnecting each hose or tube,
cover the port to prevent dirt or water from
entering.
3. Steering valve
Remove mounting bolts, then remove steering
valve (1 I).
+ If the valve is stuck to the mounting surface,
tap with a plastic hammer. Do not use a steel
hammer.
* The valve body is covered in oil and is very
slippery, so be careful when removing.
+ Be careful not to damage the tubes, and pull
the valve out to the right.
Steering valve: 32 kg
WA350-1 43-9
0
INSTALLATION OF STEERING VALVE
1. Steering valve
Raise steering valve (1 I), set in mounting position,
Sr Tighten the mounting bolts partially, and tighten
fully after installing the hoses and tubes.
* Be careful not to damage the mounting sur-
faces of the tubes and hoses when installing.
2. Hydraulic piping
I) Connect tube (IO) between steering valve and
steering cylinder (rod end) at steering valve end.
2) Connect tube (9) between steering valve and
hydraulic tank at steering valve end.
steering cylinder (bottom end) at steering valve
end.
4) Connect hose (7) between steering valve and
main control valve at steering valve end.
hydraulic pump at steering valve end.
steering pump at steering valve end.
* Fit the O-ring securely in the groove, and
installing.
3. Steering linkage, cover

1) Tighten mounting nut of steering linkage (4).
m Mounting nut: 28.5k3.0 kgm
43-10 WA3561
0
2) Install floor cover (3) of floor frame.
..

Tighten-plug (I 1 at top of hydraulic tank filter, and
plug (2) of pump piping, and add hydraulic oil
through oil filler to the specified level.
Sr Run the engine to circulate the oil through the
system. Then check the oil level again.
WA350-1 43-11
0
DISASSEMBLY OF STEERING VALVE
1. Remove tubes (I) and (2).

2. Remove main relief valve assembly (3) and safety
valve assembly (4).
3. Case assembly
I) Remove case assembly (51, then remove collar
(6).
2) Remove covers (26) and (27).
3) Remove dust seal (28).
4) Loosen bolt (30) of lever (29). then remove
shaft (31). --
5) Remove oil seal (32) and bearings (33) and
(34).
4. Spool assembly
1) Remove case (7). then remove spool assembly
(8). -
2) Remove bolt (91, then remove retainer (I 0).
spring (1 1) and retainer (I 0) from spool (I 2).
t When loosening the bolt, loosen with the
spool assembled in the body.
5. Remove plate (I 3). then remove valve (I 4).
6. Remove plate (I 31, then remove seat (I 5). spring
(I 6) and valve (I 7).
7. Remove valve (I 81, then remove boss (I 91, spring
(201, washer (21) and spool (22).
8. Remove plate (I 3). then remove seat (231, spring 423F441
(24) and poppet (25).
ASSEMBLY OF STEERING VALVE
1. Assemble poppet (25) and spring (24). fit O-ring 4 6. Case assembly
and back-up ring, install seat (23). then install 1) Install bearings (33) and (34). and oil seal (32)
plate (I 3).
e Lip of oil seal: Grease (G2-LII
2. Assemble spool (221, washer (21). spring (20)
and boss (191, then fit O-ring and install cover 2) Assemble key, then install shaft (31) to lever
(I 8). (29) and tighten bolt (30).
3. Assemble valve (I 7) and spring (I 61, fit O-ring 3) Install dust seal (28).
and back-up ring, install seat (15). then install 4) Fit O-rings and install covers (27) and (26).
plate (I 3). 5) Assemble collar (6), then fit O-ring and install
4. Fit O-ring and back-up ring, install valve (I 41, then case assembly (5).
install plate (I 3). 7. Fit O-rings and install safety valve assembly (4)
5. Spool assembly and main relief valve assembly (3).
1) Assemble retainer (I 01, spring (I I) and retainer
m Safety valve assembly: 4.5f0.5 kgm
(IO) to spool (I 2). then tighten bolt (9).
+ When tightening the bolt, tighten with the D Main relief valve assembly:
spool assembled in the body. 8.5 +- 1.5 kgm
2) Assemble spool assembly (8) in body (351,
8. Fit O-rings and install tubes (2) and (I ).
then fit O-ring and install case (7).
43-12 WA350-1
0
4
\ \
423F440
WA350-1 43-13
0
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
REMOVAL OF STEERING CYLINDER
A Stop
the safety
and install
the bucket
Q! Loosen
pressure
several
to release
tank. Then operate
times to the left and
the
the steering wheel

right to release the remaining pressure in the
hydraulic piping.
.

1. Hydraulic piping
I) Remove mounting bolt of tube support (3).
2) Disconnect hose (4) from cylinder.
* Cover the disconnected parts.
3) Disconnect tube (5) from cylinder.
I) Remove lock bolt at rod end, then remove pin
(6).
* If there are any shims inserted, check the
keep in a safe place.
2) Sling steering cylinder, remove lock bolt at

bottom end, then remove pin (7).
Sr If there are any shims inserted, check the
3) Remove steering cylinder (8).

* Be careful not to damage the cylinder rod.
Steering cylinder: 27 kg
43-14 WA350-1
0
INSTALLATION OF STEERING CYLINDER
1) Raise steering cylinder (8) and set in mounting
position.
2) Install pin (7) at bottom end, then install lock
bolt.
3) Install pin (6) at rod end, then install lock bolt.
Use a bar to align the pin holes. Never use

A
your fingers.
+ Adjust clearance between cylinder and
frame to become 0 to 0.5 mm with shim.
2. Hydraulic piping
1) Connect hose (4) to cylinder.
Zr Install the hose without twisting or
interference.
m Hose: 8*2 kgm
2) Connect tube (5) to cylinder.

* Tighten partially, then tighten fully after in-
stalling the tube support.
m Tube: g.5+1 kgm
3) Install tube support (3) to cylinder.
3. Greasing
Grease cylinder pins well.
* Wipe off any grease which comes out.
WA350-1 43-15
@
DISASSEMBLY OF STEERING CYLINDER

Special tools
Part number Part name IQtv
A 1 790-502-l 000 1 Cylinder repair stand/ 1
B 796-l 00-l 200 Wrench 1
1. Set cylinder assembly (I) on tool A.
2. Straighten lock tab of cylinder head (2). then

using tool B, remove cylinder head (2) from
cylinder.
3. Pull cylinder head and piston rod assembly (3)

from cylinderJ4) and lift off.
* Oil will come out when the piston rod assembly
is removed from the cylinder, so have a
contrainer ready.
4. Remove cylinder (4) from tool A.
5. Set cylinder head and piston rod assembly on tool

A. and loosen nut (5) with power wrench @and
socket 0.
* Power wrench: 16 times
* Width across flats of socket @ : 50 mm
6. Remove nut (51, then remove piston assembly (6)

and cylinder head assembly (7) from rod (8).
43-16 WA350-1
0
7. Disassemble piston assembly as follows:

1) Remove wear ring (9).
2) Remove piston ring (I 0) from piston (I 1).
,
...l(_.._) J .
125P387A ,_ 125P388A
8. Disassemble cylinder head assembly as follows:

1) Remove snap ring (I 6), then remove dust seal
(17).
2) Remove rod packing (18). retainer (141, snap
ring (15).
3) Remove bushing (I 9) from cylinder head (20).
4) Remove O-ring (21) and back-up ring (22).
__ .._ xl~-.l,.l
125P3SOA
WA350-1 43-17
0
ASSEMBLY OF STEERING CYLINDER
Special tools
Part number Part name IQ'W
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
packing, dust seals or O-rings when installing.
Assemble cylinder head assembly as follows:

I) Using a push tool, press fit bushing (19) on
cylinder head (20).
* Take particular care not to deform the
bushing when press fitting.
2) Assemble rod packing (18). retainer (I 41, snap
ring (15).
t Be careful to install the rod packing facing in
the correct direction.
Rod packing
20
125P389A 125P388A
2OXF130
3) Using a push tool, install dust seal (I 7) on head

(20).
4) Install snap ring (I 6).
5) Install back-up ring (22) and O-ring (21).
* Do not force back-up ring. Heat in hot water
(50 - SOC) before inserting.
_ .,
125P390A
43-18 WA350-1
0
2. Assemble piston assembly as follows:

I) Using tool C, expand piston ring (I 0).
* After setting the piston ring in tool C, rotate
the handle 8 to 10 times to expand.
2) Remove piston ring (10) from tool C and
assemble on piston (I 1).
.,
-. .
.
3) Fit tool D on piston ring and compress piston

: j
ring with clamp 0.
* Parts No. of clamp @
07281-00909
4) Assemble wear ring (9).
;._. ._ i...
3. Set piston rod (8) in tool A.

4. Assemble cylinder head assembly (7) and piston
assembly (6) on rod, then install nut (5).
5. Using power wrench 0 and socket 0, tighten

nut (5) to the following specified torque:
t Power wrench: 16 times
* Width across flats of nut (5): 50 mm
t Tightening torque: 11 O+ 11 kgm
WA350-1
6. Remove piston rod and cylinder head assembly

from tool A.
7. Set cylinder (4) in tool A.
8. Sling piston rod and cylinder head assembly (3)

and install in cylinder (4).
9. Using tool B, tighten cylinder head nut (2).
m Cylinder head nut: 60?6 kgm
10. Bend lock into notch on cylinder.
11. Remove cylinder assembly from tool A.
43-20 WA350-1
0
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
REMOVAL OF CENTER HINGE PIN
2
Ladder
43-22 WA350- 1
0
* Before starting the operation, remove the bucket.

For details, see 63 REMOVAL OF WORK
EQUIPMENT.
A Stop
the safety
and install
the bucket
0! Loosen
pressure
to release
tank. Then operate
the
the steering wheel and control levers several

times to release the remaining pressure in the
hydraulic piping.
the oit inside the tank from flowing out.
* Disconnect the cable from the negative (-1
Open hood (3) and fit lock (4).
a
1. Draining air
2. Ladder
Sling ladder (61, remove mounting bolts, then lift
off.
* Remove the ladders on both the left and right
sides.
Ladder: 65 kg
3. Vinyl tube for window washer

Disconnect vinyl tube (7) for window washer.
WA350-1 43-23
0
DISASSEMBLY AND ASSEMBLY CENTER HiNGE PIN
4. Electric wiring
1) Disconnect connectors (91, (10). (I 1). (12).
(13), (14), (15) and (16) at mounting plate for
floor frame (8).
* After removing the wiring, mark with tag to
distinguish when installing.
2) Disconnect ground connection and connector.
3) Disconnect connector of wiring for brake sole-
noid valve.
5. Brake valve
1) Disconnect hoses (17) and (18) between brake
valve and brake chamber at connection of hose
and tube.
2) Disconnect hoses (I 9) and (20) between brake
valve and air tank at connection of hose and
tube.

1) Disconnect fuel control cable (21) from ball
joint (22).
(23).
* Remove the strap correctly.

I) Remove control lever lock plate (24) of work
equipment control lever box inside cab.
43-24 WA350-1
0
2) Remove plate (25) of work equipment control

lever box.
Sr Remove the plate with the boot attached.
3) Sling floor frame and cab assembly (261,

After lifting off the floor frame and cab
assembly, make match marks on the steering
shaft and remove it from the gear box.
When lifting off the floor frame and cab
assembly, raise about 20 mm, then stop to
check that everything has been properly
disconnected. If everything is correct, lift off
the assembly.
If shims are installed, check numbers of
shims.
2
fi kg Floor frame and cab assembly: 250 kg
Remove left and right pins (27) at steering
cylinder rod end.
* If there are any shims, check the number and
thickness of the shims, and keep in a safe place.
9. Drive shaft
Remove center drive shaft (28).
WA350-1 43-25
0
10. Electric wiring, piping

1) Remove clamp of wiring (29) for front frame.
2) Disconnect air hoses (301, (3 I) and (32).
t Release the parking brake and disconnect
the lever of the linkage.
3) Disconnect hose (33) between brake chamber
and slack adjuster.

1) Disconnecf dump cylinder hoses (34) and (35)
at rear frame end.
2) Disconnect lift cylinder hoses (36) and (37) at
rear frame connection.
12. Steering linkage

Disconnect steering linkage at ball joints (38) and
(39).
13. Support
I) Disconnect work equipment control lever con-
trol linkages (40) and (41) at main control valve
end.
2) Remove work equipment control lever and
steering gear support (42).
43-26 WA350-1
0
14. Disconnecting frame

1) Adjust height of rear frame (43) and insert
stand.
t Insert stands under the frame on both left
and right sides.
2) Adjust height of front frame (44) and insert

stand.
Sr insert stands under the frame on both left
and right sides.
Sr Be extremely careful when adjusting the
height of the frame.
3) Insert stand @under counterweight (45).

Sr Block both the left and right rear tires
securely.
* Use a stand with adjustable height.
4) Remove safety bar.
5) Remove mounting bolts of lower hinge pin,

then remove pin (46) from top.
* Adjust the height of the front and rear
frames enough so that the pins can be
removed without forcing.
6) Remove mounting bolts of upper hinge pin,

then remove pin (47) from bottom.
* Be careful not to drop the pin.
WA3561 43-27
0
7) Remove mounting bolts, then remove retainer

(48) at rear frame end.
8) Remove spacer (49).
9) Jack up front differential and pull out front

frame to front.
* Taking care not to let the spacer at the
bottom of the upper hinge bite into the rear
frame, disconnect the frame and then
remove the spacer.
* Be careful to maintain parts in balance when
carrying out the operation.
15. Lower hinge

1) Remove dust seals (50) at top and bottom.
2) Remove snap rings (51) and (52). then remove

bearing (53).
l52
423F465
43-28 WA350-1
0
16. Upper hinge

1) Remove mounting bolts, then remove retainer
(54).
Remove dust seal (55) from retainer.
Sr There are shims between the retainer and
front frame, so check the number and
thickness of the shims, and keep in a safe
place.
2) Reinove spacer (56) and seal (57) from bottom

of front frame.
3) Remove bearing (58).
423F467 423 F466
WA350-1 43-29
0
INSTALLATION OF CENTER HINGE PIN
IWA350-1 Connecting
3
ToA
wheel loader
] Y Lowerhinge r V
1n IA Brakevalve 1 I//
17
Bleeding air,
checking 423 F468
43-30 WA350-1
0
Special tools
D 793-520-2370 Push tool 1
D, 793-520-2350 Push tool 1
D2 793-520-2540 Guide 1
D, 793-520-2360 Bar 2
E 793-840-I 310 Push tool 1
F 792-l 03-0400 Grip 1
1. Upper hinge 58
Ii /stall tools A, B, C, D1, D2, and D3 to top of 58
upper hinge of front frame. Set bearing (58) in
tool D, set from above in press-fitting position,
then press fit.
When press fitting, use tool D2 as a gude.
423F469
Make sure that the bearing is installed
straight.
Fill inside of bearing (58) with grease.
When assembling the bearing, do not forget
to install the spacer.
The clearance of bearing (58) is adjusted, so
do not change the combination with spacer
(59). When replacing the bearing, replace as
a set.
2) Press fit dust seal (55) on retainer (54).

* Replace the dust seal with a new part, and
press fit so that the lip face is on the outside. 423F470
a Lip of dust seal: Grease (G2-LII
3) Tighten retainer (54) with 3 mounting bolts,

then insert shims so that maximum clearance
between retainer and hinge is less than 0.1 mm.
w Mounting bolt (when adjusting shim):

2.020.2 kgm
w Mounting bolt: 11.5+ 1 .O kgm
WA350-1
4) Install dust seal (57) and spacer (56) from

under front frame.
a Lip of dust seal: Grease (G2-LI)
JC& Inside circumference of spacer:

Grease (G2-LI)
$r Replace the dust seal with a new part, and

press fit so that the lip face is on the outside.
* Assemble the spacer (56) from below so
that the large chamfered side is on the
bearing side.
2. Lower hinge
1) Assemble snap rings (51) and (52) at lower
hinge of front frame, then using tools E and F,
press fit bearing, (53) then secure with snap
ring.
* When press fitting, press fit so that the sur-
face is level with snap ring (52).
423F471
2) After installing snap ring (511, press fit dust

seals at top and bottom hinge.
+ Replace the dust seal with a new part, and
press fit so that the lip face is on the outside.
PC?% Lip of dust seal: Grease (G2-LI)
423F472
52
423F465
WA350- 1
3. Connecting frame
I) Jack up front differential, move front frame
towards rear frame and align pin holes.
* Be careful not to let the lower spacer of the
upper hinge hit the rear frame.
* Align the pin holes correctly.
Use a bar to align the pin holes. Never use

your fingers.
2) Assemble spacer (49) to upper hinge (60).
* Assemble the spacer (49) from below so
that the large chamfered side is on the
bearing side.
* Be careful not to damage the lip of the dust
seal.
a Outer circumference of hinge pin:

Grease (G2-LI)
KI& Inner circumference of spacer:

Grease (G2-LI)
3) Assemble upper hinge pin (47) from below.

4) Tighten retainer (48) to upper hinge pin with 3
mounting bolts (621, then assemble shims so
that clearance b between hinge and retainer
is less than 0.2 mm.
w Mounting bolt of pin (when adjusting 423F473

shim): 2.020.2 kgm
* When tightening mounting bolt (61). leave a

clearance of about 5 mm from the face of re-
tainer (48).
5) After adjusting shim, tighten mounting bolts
(61) of retainer to the specified tightening
torque, then tighten mounting bolts (62) of pin
fully.
m Mounting bolt of pin:

28.5e3.0 kgm (10001 - 10514)
21.O*l.Okgm (10515andup)
QF Mounting bolt of retainer:

11.5?1.0 kgm
48
\
=I
Clearance b
423F474
WA350-1
6) Insert lower hinge pin (46). then secure with

lock bolt.
& Outside circumference of hinge pin:

Grease (G2-LI)
7) Remove stands from front and rear frames, and

from counterweight.
8) Install safety bar.
4. Support
I) Install work equipment control lever and
steering gear support (42).
2) Connect work equipment control lever control
linkages (40) and (41) at main control valve
end.
5. Steering linkage
Connect steering linkage at ball joints (38) and
(39).
6. Hydraulic piping
1) Connect lift cylinder hoses (36) and (37) at rear
frame connection.
2) Connect dump cylinder hoses (34) and (35) at
rear frame connection.
43-34 WA350-1
0
7. Electric wiring, piping

I) Connect hose (33) between brake chamber
and slack adjuster, then connect parking brake
linkage to lever.
2) Connect air hoses (30). (31) and (32).
3) Install clamp (29) of wiring for front frame.
8. Drive shaft
Install center drive shaft (28).
B Drive shaft: 11.5* 1 .O kgm
Install left and right pins (27) at steering cylinder
rod end.
Sr Do not forget to install the shims.
* Adjust clearance between cylinder and frame
to become 0 to 0.5 mm with shim.
WA350-1

I) Raise floor frame and cab assembly (26), set in
* Align the match marks of the steering shaft,
insert in the spline of the steering column,
then secure with wire to prevent it from
coming out.
68
67
423 F484
6s 423F485
2) Select number of shims matching clearance

Ua and b.
3) Loosen mounting bolts, and after inserting

shim (67). retighten mounting bolts.
* Install shims. The lower rubber mounts (68)
should not bulge after tightening mounting
bolts.
t There should not be any clearance at in-
stalled portion of shim. Move shim by hand
if there is clearance.
4) Install lever lock plate (24) of work equipment

lever box.
5) Install floor surface plate (25) of work equip-
ment lever box inside cab.
* Coat the outside circumference of the lever
with soap, then assemble the boot to the
plate first.

1) Install fuel control cable (2 I) to bracket (23)
2) Connect fuel control cable (21) to ball joint (22).

* Secure with the strao.
WA350-1
12. Brake valve

valve and air tank at brake valve end.
valve and brake chamber at brake valve end.
13. Electric wiring

1) Connect connector of brake solenoid valve
wiring.
2) Connect ground connection and connector.
3) Connect connectors (91, (I 01, (I I), (I 21, (I 31,
(141, (15) and (16) at mounting plate for floor
frame (8).
Sr Fit the O-rings of the connectors securely in
the grooves.
14. Vinyl tube for window washer

Connect vinyl tube (7) for window washer.
15. Ladder
Raise ladder (61, set in mounting position, then
* Install the ladders on both the left and right
sides.
WA350-1

Tighten plug (63) at top of hydraulic tank filter,
and plug (64) of pump piping, and add hydraulic
oil through oil filler (65) to the specified level.
* Run the engine to circulate the oil through the
17. Bleeding air, checking

Sr For details of bleeding air, see 52 TESTING
AND ADJUSTING.
A Close hood, then lock with catch.
43-38 WA350-1
0
STEERING SYSTEM
44 MAINTENANCE STANDARD
Steering linkage ...................... . . 44- 2

Steering column and gear box .......... . . 44- 4
Steering valve ........................ . 44- 6
Steering cylinder mount ............... 44- 8
Steering cylinder ...................... . . 44- 9
Center hinge pin ...................... . 44-l 0
Diverter valve (if equipped) ............. 44-l 2
Emergency steering pump (if equipped) . . 44-14
Security valve (if equipped) ............ . . 44-l 5
WA350-1 44-l
@
MAINTENANCE STANDARD STEERING LINKAGE
STEERING LINKAGE
Serial No. 10001 - 10186
5,
0
h
\
0
Serial No. 10187 -
Section A-A
articulate stopper
423F218~
44-2 WA350-1
0
MAINTENANCE STANDARD STEERING LINKAGE
Unit: mm
No.
I Check item Criteria Remedy
StanIciysize 1 ;;;; 1 Repaymit 1 Replace

Interference of press-fitting part of center
1
level bearing
Clearance of articulation stopper 25.0 -C 2.0 (at engine speed 1,200 rpm)
19.5 ? 2.5 kgm
Tightening torque of lock nut 11.25? 1.25 kgm
5 Tightening torque of mounting nut 28.25 2 3.25 kgm
6 Tightening torque of lock nut 7.25 I? 1.75 kgm Retighten
7 Tightening torque of lock nut 7.25 +- 1.75 kgm
8 Tightening torque of mounting nut 18.0 t 2.0 kgm

I I
9 Tightening torque of mounting bolt 3.15 t 0.35 kgm
10 Tightening torque of lock nut 11.25 ? 1.25 kgm
WA350-1 44-3
0
MAINTENANCE STANDARD STEERING COLUMN AND GEAR BOX
STEERING COLUMN AND GEAR BOX
Saction D-D
423F217A
Section B-B 1 Unit: mm

I
1 Clearance between sector shaft and bushing
-
35 -0.034
-0.009 +0.025
0 0.009
0.059 -
- Replace
30 -0.007 +0.021 0.007 - - bushing
2 Clearance between sector shaft and bushing
-0.028 0 0.049
-
Clearance between steering shaft and column
3
bushing
4 Tightening torque of mounting nut
5 Tightening torque of mounting bolt
44-4 WA350-1
0
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
10
8
\
423F219A
WA350-1
MAINTENANCE STANDARD STEERING VALVE
Unit: mm
Clearance
limit
Clearance between steering spool and
valve bodv
Replace
- 0.006 +0.015 0.017 - assembly
19
-0.012 -ho.007 0.023
Clearance between demand spool and - 0.006 +0.015 0.017 -

2 19
valve body -0.012 i-o.007 0.023
Free Installation installation Free Installation

3 Steering spool return spring
93.5 53.5 24 kg - 22.6 kg

IReolace
4 Demand spool return spring

-
5 Check valve return spring

-
6 Check valve return spring
7 Trghtening torque of main relief valve 8.5? 1.5 kgm
8 Tightening torque of safety valve with suction 4.520.5 kgm

- IRetighten
9 Tightening torque of plug 7.0% 1 .O kgm
10 Tightening torque of plug 3.7t0.3 kgm

L
WA350-1 44-7
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
Serial No. 10001 - 11117
=Ea-- 0
Section B-B U42301008
423F220
Unit: mm
Tolerance
Clearance between mounting pin and bushing Shaft Hole
1 at connection of steering cylinder rod
and frame
+0.20 0.100 -
50
-:.025 +0.10 0.225 -
Clearance between mounting pin and bushing
50 +0.150 0.050 -
2 at connection of steering cylinder bottom
and frame -:.025 +0.050 0.175 -
Width of boss Standard Clearance

Width of hinge
(Clearance a + b)
3 Connection of steering cylinder and front frame
80+0.8 63+2.0 After adjusting with
0 -2.0 shim: Less than 0.5
4 Connection of steering cylinder and rear frame 80+0.8 83+2.o Atter adjusting with
I I 0 I -2.0 shim: Less than 0.5
44-8 WA350-1
0
MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
423F221
Unit: mm
No Check item Criteria

1
Clearance
limit
1 Clearance between rod and bushing
0.594
- Replace
bushing
Clearance between piston rod mounting pin -
2
snd diameter of hole
Clearance between cylinder bottom mounting +0.142 0.080 -

3 50
oin and bushing -:.025 +0.080 0.167
- +0.3 -
4 Cylinder bore 80
0
-
5 Tightening torque of cylrnder head 602 6 kgm

Retighten
6 Tightening torque of piston nut 110-t 11 kgm (Width across the flats 50 mm)
WA350-1 44-9
0
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
-..-. _
Serial No. 10001 - 11117

U42301005
18 7
Section A-A
11 Section B-B
E423F232
Section B-B I Section A-A
U42401010
WA350-1
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm
No Check item Criteria
Clearance between upper hinge pin and

rear frame
Clearance between upper hinge pin and

2
spacer (small)
Clearance between upper hinge pin and - 0.030 0.015 -

3 80
bearing - 0.049 -EL015 0.049 - I
-
Clearance between upper hinge pin and - -
4
spacer (large) 80 -0.049
0.030 +
+0.030
0.060 0.060
0.030 -
Clearance between rear frame and spacer - -

5
(large) 95 -0.071
0.036 +0.071
-10.036 0.072
0.142 -
I
Clearance between front frame and upper -0.048 0.023 -

6 130
hinge bearing -;.025 -0.080 0.088 -
-
-0.036 +0.054 0.036 -
82.55
0.112 -
Clearance between lower hinge pin and
7
rear frame
(80.00) Replace
I I I
-0.036 +0.061 0.066 -

82.55
-0.058 +0.030 0.119 -
Clearance between lower hinge pin and
8 bearing
(80.00) -
-
+0.035 0.013 -
107.95
- E.020 -0.013 0.055 -
Clearance between front frame and lower
9
hinge bearing
(130.00) -
~ Gi.025) / (%:i:) 1-,,,3,; 1
-
-
82.55 -0.071
0.036 +0.054
0 0.036
0.125- -
Clearance at press-fitted part of seal of
10
lower hinge pin
(105.00) (+;:A;;) (+;.054) --;,&y -
11 Height of upper hinge spacer (small) 24% 1
12 Height of upper hinge spacer (large) 561 1

-
Shim thickness for upper hinge - -
1: 3.0 0.05 0.1
and retainer
-
1L
Shim thickness
and retainer
for upper hinge
1 .o - I - 1 0.1 ]-02-l
When adjusting with shim: 2.0 t 0.2 kgm
Tightening torque of upper hinge
I
15
retainer mounting bolt
Final value: 1 1.5 ? 1 .O kgm
When adjusting with shim: 2.0 & 0.2 kgm

Tightening torque of upper hinge Retighten
1t
retainer mounting bolt
Final value: 28.5 +- 3.0 kgm
-
Tightening torque of upper hinge pin
1; 11.5 ? 1.0 kgm
mounting bolt
-
28.5 * 3.0 kgm I
Tightening torque of lower hinge pin
It
mounting bolt (11.5 2 1 .O kgm)
-
): Serial No. 11 118 and up

44-11
(
WA350-1
MAINTENANCE STANDARD DIVERTER VALVE
DIVERTER VALVE (If equipped)
I-- A
I- A
Section A-A
Section B-S
419F493
44-12 WA350-1
@
MAINTENANCE STANDARD DIVERTER VALVE
Unit: mm
Tolerance
Shaft Hole
1 Clearance between body and spool
- +0.015 0.017 -
26 0.027 -
+0.009
-
Reolace
2 Spool spring
3 Check valve spring

-

-
6 Tightening torque of mounting bolt 2.5 ? 1 .O kgm Retig hten
7 Tightening torque of plug ll.O? 1.5kgm
a Tightening torque of plug 21.5 f 3.0 kgm

-
WA350-1 44-13
@
MAINTENANCE STANDARD EMERGENCY STEERING PUMP
EMERGENCY STEERING PUMP (If equipped)

l Model SAM(2)-40
Section A -A
419F492
Unit: mm
NO. Check item Criteria Remedy
Standard clearance Clearance limit

, Clearance between gear case and
side plate, gear
0.10 - 0.15 0.19
- Replace
2 Clearance between inside diameter of needle 0.020 - 0.043 0.075
bearing and outside diameter of gear shaft
3 Insertion depth of pin

I l2-g.5 -1
0.3 z? 0.7 kgm -
4 Rotating torque of spline shaft
5 Tightening torque of bolt 16.5? 1.5 kgm Retighten
Standard
ReyrolutTon rr;;$iT yiTpamr;,e
Discharge P -
Oil: EOl O-CD
Temperature: 45 - 55C 3,000 210 106 64
44-14 WA350-1
@
MAINTENANCE STANDARD SECURITY VALVE
SECURITY VALVE (If equipped)
Section A-A
419F494
Unit: mm
Tolerance
Shaft Hole
1 Clearance between body and spool
- +0.015 0.017 -
26 0.027 -
+0.009
Standard size Repair limit Replace
2 Spool spring
I Free
length
I 116.7
3 Tightening torque of plug I

-
WA350-1 44-15
@I
BRAKE AND AIR SYSTEM
General .................... .. 51- 2

Air tank .................... . 51- 5
Safetyvalve ................ 51- 5
Brake valve. ................ 51- 6
l Brake actuated ........... 51- 7
. Operating in balance ...... 51- 8
. Brake released ........... . 51- 9
Air governor. ............... 51-10
Two-way valve ............. . 51-12
Brake chamber ............. . 51-13
Slack adjuster .............. 51-15
Brake ...................... 51-19
Parking brake .............. 51-21
Parking brake solenoid valve . 51-23
Spring cylinder ............. . . 51-24
Brake caliper ............... 51-25
WA350- 1 51-1
GENERAL
423F090A
Outline
. The air compressed by the air compressor (1) . When the brake valve (1 I), (I 2) are actuated, the
enters the wet tank (5) and the moisture is air in the dry tank (6). (7) flows to the brake cham-
removed. The air then enters the left and right dry ber and applies pressure to the brake oil in the
tanks (61, (7) and also flows to the parking brake master cylinder. The pressurized oil passes
valve (21). The air in the left and right dry tanks through the slack adjuster (I 71, (I 8) and pushes
(61, (7) flows to the brake valve (I I), (I 2). the wheel piston to apply the brake (I 91, (20).
l When the air produced by the air compressor (I) . The parking brake (24) is applied mechanically by
fills the circuit and the air pressure in the wet tank the spring in the spring cylinder (23). It is designed
(5) reaches the maximum set pressure of the air to be released by air pressure. Therefore, if the air
governor (2), the air governor (2) is actuated. It pressure is less than the force of the spring in the
opens the unloader valve of the compressor, so spring cylinder (231, the brake is kept applied.
the compressor (1) is put in a no-load condition When the air pressure rises and the parking brake
and no air is compressed. When the air is used release is reached, a solenoid valve is actuated to
and the air pressure inside the tank drops below supply air to the spring cylinder (23). This release
the minimum set pressure of the air governor (21, the parking brake (24).
the air governor (2) is actuated. It closes the un-
loader valve of the compressor and the compres-
sor (I) is actuated. If the air governor (2) does not
work properly, and the pressure inside the tank
reaches the set pressure, the safety valve (28)
opens and the air pressure is released to the
atmosphere. This protects the air circuit.
51-2 WA350-1
@
1. Air compressor
2. Air governor
3. Tire inflation
4. Drain cock
5. Air tank (wet)
6. Air tank (dry)
7. Air tank (dry)
8. Check valve
9. Check valve
10. Drain cock
1 1. PH. brake valve
12. L.H. brake valve
13. Two-way valve
14. Two-way valve
15. Front brake chamber
16. Rear brake chamber
17. Front slack adjuster
18. Rear slack adjuster
19. Front brake
20. Rear brake
2 1
Parking brake solenoid valve
22. Parking brake sensor
23. Spring cylinder
24. Parking brake
25. Horn valve
26. Horn
27. Brake oil tank
28. Safety valve
29. Air pressure sensor
30. Stop lamp switch
3 1 Transmission cut-off switch
rl 3 423F127
WA350-1
51-3
51-4
STRUCTURE AND FUNCTION AIR TANK, SAFETY VALVE
AIR TANK
A
WET TANK
A. To air governor
B. To air tank (dry)
C. Air pressure sensor Pick-up
D. Air pressure sensor Pick-up
E. From air compressor
F. To drain cock
G. To safety valve
H. To brake valve
I. To drain cock
J. From air tank (wet)
DRY TANK Name Capacity Maximum pressure

423FO94
Wet tank 9.4Q 9.5 kg/cm2
Dry tank (L) 20.3 II 9.5 kg/cm2
Dry tank (RI 1 20.311 1 9.5 kg/cm2
423FO95
l The air tank consists of one wet tank and two dry
tanks. The air from the compressor first enters
the wet tank and the moisture is removed. It is
then divided and sent to the left and right dry
tanks.
l A safety valve and air pressure sensor are installed
in the wet tank.
1. Adjustment nut
2. Spring cage
3. Spring
SAFETY VALVE 4. Ball
6 5. Locknut
Function
6. Relief valve
l The safety valve is installed in the wet tank, and
7. Body
acts as a safety device for the air circuit.
Operation
l If the air governor does not work properly and the
pressure inside the air tank rises above the set
pressure, ball (4) is pushed up and the air escapes
to the atmosphere. 423FO96
WA3561 51-5
0
STRUCTURE AND FUNCTION BRAKE VALVE
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 ac-
tuated in the same way as with the right pedal, but
at the same time, the transmission solenoid valve
is actuated electrically, and the transmission is put
in neutral.
6 423FO97
1. 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
51-6 WA350- 1
BRAKE ACTUATED
Upper part
l When pedal (1) is depressed, the operating force
passes through plunger (2) and rubber spring (7).
and is transmitted 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 (1 1) flows from port A to port C. This
actuates the front brake chamber (I 2).
._...
wet tank
_ --
To front slack
adjuster
Lower part
l When pedal (1) is depressed, the operating force
passes through plunger (2) and rubber spring (7). e
and is transmitted to piston (3). When piston (3) To rear slack
adjuster
moves down, inlet valve (4) is moved down, and
air from the air tank flows from port B to port D. 423FO98
This actuates the rear brake chamber.
Operation of brake when lower valve fails

l Even if there is leakage of air in the lower piping,
the upper part will operate normally.
adjuster
WA350-1
STRUCTURE AND FUNCTION BRAKE VALUE
Operation of brake when upper valve fails

l Even if there is leakage of air in the upper piping, if
the pedal (1) is depressed, piston (5) will be
pushed down mechanically and the upper part will
operate normally.
OPERATING IN BALANCE
Upper part
l When the pressure in the space below piston (3)
and the air pressure from the brake chamber
become high, the pressure pushes rubber spring
-(7). and piston (3) moves up to close inlet valve (4).
When this happens, exhaust port (9) stays
closed. The air pressure entering the brake cham- ear slack
ber is retained and the brake is kept applied. ster
423FlOO
Lower part
l 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 maintained and the brake is kept
applied.
The air pressure in the space at the upper part bal-
ances the operating force of the pedal. The pres-
sure 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
become equal to the air pressure in the tank.
on- front slack
Therefore, the braking effect can be adjusted by
the amount the brake pedal is depressed. When
the pistons move down to the end of their stroke,
the brake is applied fully.
From rear slack
423FlOl
51-8 WA350-1
0
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 cham-
ber 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 of
piston (5) and spring (13) pull the piston up. Ex-
haust port (10) opens and the air pressure in brake
slack
chamber is released to the atmosphere.
E423F102
WA350-1 51-9
0
AIR GOVERNOR
AIR GOVERNOR
1. Spring 5. Exhaust stem
2. Exhaust port 6. Inlet valve
3. Piston 7. Tank port
4. Unloader port 8. Filter
Specifications
l Cut-out pressure: 8.3 f 0.3 kg/cm2
l Cut-in pressure: 7.0 + 0.3 kg/cm2
423F091A
Function
The air governor maintains the pressure in the air cir-
cuit to the specified range.
OPERATION
Compressor working
l The air pressure in the wet tank passes from the
tank port (7) through the filter (8) and acts on the
bottom of the piston (3).
When the air pressure in the tank is below the
specified pressure (cut-out pressure) the piston
(3) is pushed down by the spring (1).
l When this happens, the air at the unloader port (4)
passes through the exhaust stem (5) to the atmo-
sphere and the compressor is actuated.
+
To dr
423 F092A
Compressor loaded
WA350-1
51-10
0
STRUCTURE AND FUNCTION AIR GOVERNOR
Compressor stopped
When the pressure in the wet tank rises, and
reaches the set pressure (cut-outthe pressure),
piston (3) is pushed up against the spring (I 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
piston (3) is pushed down by the spring (I 1.
When then pressure drops below the specified
pressure (cut-in pressure), the inlet valve (6)
closes and the exhaust stem (5) opens. The pres-
sure at the unloader port (4) passes through the
exhaust stem (5) and is released into the
atmosphere, To wet tank
so the compressor starts to work
again.
423FO93A
Compressor no-load
WA350-1 51-11
0
STRUCTURE AND FUNCTION TWO-WAY VALVE
TWO-WAY VALVE
Function
. The two-way valve is installed between the two
brake valves. It acts to prevent the air pressure
from escaping from one brake valve when the
other brake valve is depressed.
Operation
. The air circuit of the left and right brake valves is
connected so that the brakes on all four wheels
are actuated 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
to port 6. Therefore, the air pressure flows only to
1 2 3 4
port C and actuates the brake chamber (5).
423F103
1. Body 3. Plug
2. Seat 4. Cap
5. Brake chamber
51-12 WA350-1
STRUCTURE AND FUNCTION BRAKE CHAMBER
BRAKE CHAMBER
Section A-A
mm m
423F105A
Specifications
1. Air cylinder
1. Air cylinder 7. Master cylinder Cylinder bore: 180 mm
2. Air piston 8. Piston valve Stroke: 85.5 mm
3. Rod 9. Bleeder Cylinder capacity: 2380 cc
4. Spring 10. Brake chamber 2. Master cylinder
5. Body stroke sensor Cylinder bore: 68 mm
6. Piston Stroke: 84.5 mm
Delivery: 297 cc
WA350-1 51-13
a
STRUCTURE AND FUNCTION BRAKE CHAMBER
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 (3) 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.
I,
To slack
adjuster
423F106
Brake held in position

When the brake pedal is kept depressed at a constant
force, the hydraulic pressure is kept constant, so the
brake is kept applied.
e
To slack
adjuster
423F107
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 is released from the
brake valve, and the hydraulic pressure inside master
cylinder (7) drops. 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 To t,ze
force of the brake return spring. valve
423F108
51-14 WA350-1
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
Function
. The slack adjuster is installed in the brake oil line
from the brake chamber to the brake piston. It
acts to keep the clearance between the brake
piston and discs constant even when the brake
discs are worn. In this way it acts to keep a con-
stant time lag when the brake is operated.
A
423F109
1. Bleeder A. Inlet port

2. Cylinder B. Outlet port
3. Check valve
4. Piston
5. Spring
WA350- 1 51-15
OPERATION
1. Brake pedal depressed
The oil pumped out from the brake chamber (6)
flows in from port P of the slack adjuster. From
port E the oil is divided and sent to left and right
cylinders (2) and moves piston (4) a distance of S
to the right.
4 2 4
423FllO
Because of this, an amount of oil corresponding to

stroke S flows from port C to the brake cylinder
(7). When this happens, the clearance between
the brake piston and disc becomes 0, so no
braking force is generated.
423FlllA
51-16 WA350-1
0
If the oil pressure in the chamber (7) goes above a

certain specified pressure, check valve (3) opens
and the oil flows through pilot circuit D and applies
pressure to port C. This gives the braking force.
423F112A
2. Brake pedal released

When the brake is released, pressure is applied to
the back of the brake piston because of the hy-
draulic pressure of the brake. Piston (4) is moved
back stroke S and the disc clearance returns to
normal.
423F113A
WA350-1
%
STRUCTURE AND FUNCTION BRAKE
BRAKE
Function
l The brakes are wet-type multiple disc brakes, and
are fitted to all four wheels.
7 8
Detail P
423F116A
1. Guide pin 5. Inner gear (Teeth 112)

2. Return spring 6. Cylinder
3. Brake piston 7. Plate
4. Outer gear (Teeth 164) 8. Disc
WA350-1 51-19
0
STRUCTURE AND FUNCTION BRAKE
Operation
. When the brake pedal is depressed, pressure is ap-

plied to the brake oil by the master cylinder of the
brake chamber. Brake piston (4) is moved to the
right, and disc (8) is kept in close contact with
plate (7). Disc (8) rotates together with wheel, so
when it is held, the rotation is stopped and the
brakes are applied to stop the machine.
Frc,lTl
adj us
423F117
. When the brake pedal is released, the pressure on 2 4

the rear of brake piston (4) is released. The piston
is then moved to the left by the force of return
spring (2) and the brake is released.
To slack
adjuster
423F118
51-20 WA350-1
PARKING BRAKE
PARKING BRAKE
Outline
on The parking brake caliper (3) is fixed to the front
l The parking brake is a disc type and is installed l
differential case.
the front axle.
The disc is installed to the differential yoke and ro-
l The force of the spring inside the spring cylinder
it is re- tates together with the coupling.
(I 1 is used to apply the brake mechanically;
leased by air pressure.
423F122A
1. Spring cylinder
2. Rod
3. Brake caliper
WA350-1
51-21
0
STRUCTURE AND FUNCTION PARKING BRAKE
Brake operated
When the parking brake switch lever is moved to
ON, solenoid valve (6) is actuated and the air from
the air tank is shut off by valve (8). At the same
time, the air from the spring cylinder (3) is
released to the atmosphere from between valve
(7) and body (3).
Therefore, the piston (5) of spring cylinder (3) and
the rod (1) are pulled by the tension of the spring, .7
so when lever (9) is pulled, the parking brake is
applied.
E$- Exhaust
Part A is the fulcrum of the lever, which pulls the
bolt, so the left and right pads are pushed against From air tank
the disc, and the parking brake is applied.

The clearance between the pad and the disc is
different at the top and the bottom. This is
because the bottom of the caliper is the center
and it draws a circle as it moves. As a result, the
amount of movement is greater at the top, so the
clearance must also be greater at the top.
423F125A
Brake released
l When the parking brake switch is turned to OFF,
the solenoid valve (6) is actuated and valve (7)
closes the exhaust port.
At the same time, the air in the air tank enters the
top part of the piston (5) of spring cylinder (3). It
overcomes the force of the spring (4) and pushes
the piston (5). This pushes rod (I) and releases
the brake.
Therefore, air pressure is applied to the spring
cylinder and the parking brake is kept released. tank
l However, if the air pressure inside the tank drops
to a level where it cannot maintain the normal
operation of the brake, the air pressure sensor
installed to the tank sends an electric signal to the
solenoid valve. This releases the spring cylinder
circuit, and the parking brake is automatically
applied.
423 F126A
51-22 WA350-1
0
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
1. Coil 2. Body
3. Outlet port 4. Inlet valve
5. Outlet valve 6. Exhaust port
1 7. Inlet port
FUNCTION
2 5 l The parking brake solenoid valve is a valve to
switch air to the parking brake air chamber. It is
controlled and actuated by a switch in the opera-
tors compartment.
6
3
7
Spri
423F119
From wet tank
OPERATION
l Parking brake ON
When the parking brake switch in the operators
compartment is turned ON, the solenoid valve is
switched OFF, and air from the spring cylinder
enters port A. It passes around valve (51, enters
port B and is drained. In addition, air from the tank
enters port C, but it is shut off by valve (4). so the
air does not flow.
As a result, the parking brake is applied by spring
To brake valve
force in the spring cylinder.
423F120
l Parking brake OFF

From wet tank
When the parking brake switch in the operators
compartment is turned OFF, the solenoid valve is
switched ON, and valve (5) moves down. Valve
(5) is connected by a rod, so valve (5) and valve
(4) both move down. The air from the tank enters
port C, but valve (4) has moved down, so the air
passes around valve (4) and enters port A. Air is
sent to the spring cylinder and the parking brake is
released.
I$
To brake valve
423F121
WA350-1 51-23
0
STRUCTURE AND FUNCTION SPRING CYLINDER
SPRING CYLINDER
423F124
1. Rod Outline
2. Boot . The air pressure from the parking brake solenoid
3. Cylinder valve pushes the spring and compresses it to
4. Spring release the parking brake.
5. Piston Usually the parking brake is kept applied by spring
(4). so the machine is prevented from moving.
51-24 WA350-1
STRUCTURE AND FUNCTION BRAKE CALIPER
BRAKE CALIPER
423F123A
1 Pad carrier Outline

2. Pad l The parking brake caliper is fixed to the front dif-
3. Adjustment bolt ferential case.
4. Lever The disc is installed to the coupling of differential,
5. Disc and rotates together.
WA350- 1
51-25
0
Standard value table . . . ...... 52- 2

Tool list for testing and adjusting . ...... 52- 3
Measuring brake pedal . . . ...... 52- 4
Measuring air. . . . . . ...... 52- 5
Brake performance . . . . _. ...... 52- 8
Checking brake piston leakage . ...... 52- 9
Measuring wear of brake disc . . ...... 52-l 0
Air bleeding from brake line .. ...... 52-l 1
Parking brake performance . . . ...... 52-l 2
Checking and adjusting parking brake ...... 52-l 3
Troubleshooting . . . 52-l 5
I. The values in these tables are based on the values for new machines leaving the plant, so they should be
WA350-1 52-l
@
Testing and measuring item Measurement condition Unit

%trd ermissible
value
Brake pedal l Coolant temperature:

Inside operating range
l Operating force l Engine speed: Low idling kg 39-47 Max. 55
l Angle l Air pressure: Specified pressure degree 6.5 - 20.5
Air system
l Air governor cut-in pressure 7.OkO.3 7.020.3
l Air governor cut-off pressure l Air pressure: 7 kg/cm2 kg/cm2 8.3kO.3 8.320.3
l Safety valve actuating pressure 9.5kO.4 9.520.4
Warning buzzer
l Actuating starting pressure 6.0?0.1 6.0fO.l
l Air pressure: 7kg/cm2 kg/cm2
l Actuating stopping pressure 6.0+;.4 6.0+8.4
l Road surface: Flat, horizontal,

dry, paved surface
l Speed when applying brakes:
20 km/h
l Time lag when pressing
the pedal: 0.1 set
Brake performance l Air pressure: 7 kg/cm2 m Max. 5 Max. 5
l Brake pedal operating force:
38kg
l Tire inflation pressure:
Specified pressure
l Coolant temperature:
Drop in brake oil pressure Inside operating range kg/cm2 Max. 5 Max. 5
l Test pressure 53 kg/cm2 5 min.
l Coolant temperature:
Wear of brake disc mm 2.3-3.1 Max. 4.7
Inside operating range
Parking brake performance l Tire inflation pressure:

Specified pressure
Machine
l Road surface: Flat, dry, paved
stopped -
surface with l/5 (I l20)
gradient
l Machine: In operating condition
l Thickness of pad 13.7 (a,b,c)

Min. 7.0
mm 1 1.7 (d)
l Clearance between disc

0.1 -0.4 Max. 2.6
and pad
419F315
52-2 WA350-1
0
Tool Part number Remark
Push gauge 799-l 01-l 001

I O-IlOkg
Hydraulic tester 0 - 100 kg/cm2
Wear of brake disc Vernier calipers Commercially available 150mm - 200mm

I
Tape measure Commercially available 30m
Feeler gauge 1Commercially available 0.1 -3.0 mm
A When- carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
LU When taking measurements, do not allow unauthorized persons near the machine.
WA350-1 52-3
0
TESTING AND ADJUSTING MEASURING BRAKE PEDAL
MEASURING BRAKE PEDAL

l Coolant temp: Inside operating range
l Engine speed: Low idling
l Air pressure: 7 kg/cm2
Item
value I value
Operating
39-47 kg Max. 55 kg
force
Brake pedal 1 I I
Operating -
16.5 - 20.5
angle
Special tool
A 799-l 01-l 001 Push gauge 1
1. Measuring operating force of pedal

1) Fit push gauge A to the operators foot.
t Align the center of the push gauge with the
center of the pedal.
2) Start the engine and run at low idling, then dep-
ress 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 dep-
ress the pedal with an operating force of 43 kg
and measure the travel L of the pedal with an
angle meter.
3. Measuring play of pedal
1) Start the engine.
2) Push the brake pedal in lightly by hand, and use
an angle meter to measure the travel of the
pedal to the point where its starts to become
heavy.
423F316
52-4 WA350-1
0
TESTING AND ADJUSTING MEASURING AIR
MEASURING AIR
Air governor
Unit: kg/cm2
Item
value value
Cut-in pressure 7.0* 0.3 7.OkO.3
Cut-off pressure ( 8.3kO.3 ( 8.3kO.3
Warning buzzer
Unit: kg/cm2
Item
value value
Actuating starting 6.OkO.l

6.0+ 0.1
pressure
Actuating stopping 6.0+.4 6.0+.4
oressure 0 0
Safety valve Unit: kg/cm2
Special tools
D 1 790-301-1110 1 Nipple I 1
E 790-301-I 190 Nipple 1
Commercially 1
F Connector
available
+ When measuring, connect nipple B. hose C, nipple

D, E, and connector F to gauge A, then insert in
the tire inflation coupler on the machine.
1. Measuring set pressure of air governor

1) Open the drain valve and drain air from the tank.
2) 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).
WA350-1 52-5
0
3) With the engine at low idling, use the brake

pedal to lower the air pressure. Measure the
pressure at which the air compressor cuts in
(Start of operation).
Adjusting
I) Stop the engine.
2) Loosen lock nut (I), and turn adjustment screw (2)
to adjust.
* Turn the adjustment screw as follows.
To DECREASE set pressure, TIGHTEN screw.
To INCREASE set pressure, LOOSEN screw.
* Amount of adjustment for 1 turn of screw
Approx. 1.4 kg/cm2
-k After adjusting as above. measure again and

check that all values are standard.
2. Measuring cut-off pressure of air pressure

alarm buzzer
I) Start the engine and run at low idling. Use the
brake pedal to lower the air pressure, and mea-
sure the pressure at which the buzzer starts to
sound.
2) Lower the pressure further, then increase the
engine speed and measure the pressure at
which the buzzer stops sounding.
* If the pressure is not standard value, check
the switch. If necessary, replace the switch.
* After replacing the switch, measure the pres-
sures again.
425F206
52-6 WA3.50-1
@I
3. Measuring safety valve

1) Loosen the adjustment screw of the air gover-
nor and set the actuating pressure of the air
governor above the actuating pressure of the
safety valve.
2) Start the engine and measure the pressure
when air comes out of the safety valve.
* After measuring, do not forget to return the air

governor to the specified pressure.
* If the safety valve is defective, replace the valve
assembly:.
Do not try to adjust it.
* Hook the tool on part a when tightening or
removing. Never use part b when tightening.
* Install-so that the exhaust port c faces down.
423F318A
WA350-1 52-7
@
TESTING AND ADJUSTING BRAKE PERFORMANCE
BRAKE PERFORMANCE
Time lag when pressing the pedal: 0.1 sec.
Air pressure: Inside operating range
Road surface: Flat, horizontal, straight, dry, paved
surface.
Machine speed: Speed when applying brakes:
20 km/h
item
value value
Brake
Max. 5 m Max. 5 m
performance I
Special tool

Commercially
Tape measure 1
available
Conditions for measurement

I) 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, dep-
ress the left brake pedal (transmission cut-off
selector switch ON) with the specified operating
force.
* Decide the run-up road and point to apply the
brakes, then apply the brakes when the braking
point is reached.
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.
A A A
Stopping point Braking point Brake pedal operating
position
L Braking distance Runup road
423F319
52-8 WA350-1
0
TESTING AND ADJUSTING CHECKING BRAKE PISTON LEAKAGE
CHECKING BRAKE PISTON LEAKAGE

l Test pressure: 53 kg/cm2
l Air pressure: Inside operating range
Item
value value
Drop in
Max. 5.0 kg/cm2 Max. 5.0 kg/cm2
pressure
Special tool
1 Hydraulic tester ) 1
A Block the tires securely.
Measuring procedure
1. Remove bleeder screw (I), then install tool A in
bleeder screw mount.
2. Start the engine and bleed the air.
* Two workers are needed for this operation: one
depresses the pedal and the other bleeds the
air from bleeder screw (2).
* Turn the transmission cut off switch ON.
3. Depress the left brake. When the gauge reading is
53 kg/cm2, leave for 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, bleed the air from
the brake circuit again.
WA350-1 52-9
@
TESTING AND ADJUSTING MEASURING WEAR OF BRAKE DISC
MEASURING WEAR OF BRAKE
l Air pressure: Inside operating range
Unit: mm
Special tool
Commercrally
Vernier calipers 1
available
A 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 a from the end face of the hous-
ing to the spring guide.
* Keep the brake pedal depressed when mea-
suring.
4. Install a vinyl hose to bleeder (2). loosen the bleed-
er and bleed the air brake oil.
* After bleeding the brake oil, check that the
brake piston has returned to the end of its
stroke.
5. Measure depth b from the end face of the hous-
ing to the spring guide.
Calculating wear
S=a-b
S = Max. 4.7 mm
Piston stroke S
b
J q+=cZY-I II IllIll
423F320
52-10 WA350-1
@
TESTING AND ADJUSTING AIR BLEEDING FROM BRAKE LINE
AIR BLEEDING FROM BRAKE LINE
Order of operation
Remove cap (1) of the bleeder screw, insert vinyl
hose (2) into the screw and put the other end in a
container.
Start the engine.
Two workers are needed for this operation: one
depresses the pedal and the other bleeds the air
from bleeder screw.
Tighten the bleeder screw, then release the brake
pedal slowly.
* Depress the left brake pedal.
-f 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.
t To bleed the air completely, bleed the air first
from the cylinder furthest from the master
cylinder.
t When the air has been bled from all the
cylinders, confirm 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 end face a.
WA350-1 52-11
0
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE
PARKING BRAKE PERFORMANCE
Road surface: Flat, dry, paved surface with II5
(I l20) gradient.
Machine: In operating condition
423F321
Measuring procedure
1. Start the engine and drive the machine straight up
a 1 I5 gradient with the bucket unloaded.
2. Depress the brake, place the directional 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.
l The measurement must be made with the ma-
423F322
chine facing either up or down the slope.
52-12 WA350-1
0
TESTING AND ADJUSTING CHECKING. AND ADJUSTING PARKING BRAKE
CHECKING AND ADJUSTING PARKING BRAKE
. Air pressure: Maximum set pressure
Unit: mm
Item
value value
13.7 (a,b,c)
Thickness of pad 7.0
11.7 (d) 423F322A
Measuring procedure
1. Turn the main switch ON.
2. Turn the parking brake switch OFF to release the
brake.
3. Stop the engine, and measure the thickness from
the disc to the backing plate of the pad.
Be extremely careful not to turn the main
switch OFF during operation.
If the measurement is not within the standard
value, replace the two pads as one set.
For details of replacement, see DISASSEMBLY
AND ASSEMBLY.
Measuring clearance
Unit: mm
Measurement procedure
1. Turn the main switch ON.
2. Turn the parking brake switch OFF to release
brake.
3. Insert a feeler gauge between disc (I 1 and pad (21,
and measure the clearance A,B.
423F323
WA350-1
52-13
0
TESTING AND ADJUSTING CHECK AND ADJUSTING OF PARKING BRAKE
Adjusting
* Be extremely careful not to turn the main switch
OFF during operation.
* If the measurement is not within the standard
value, adjust as follows.
1. Turn the parking brake switch OFF to release the

brake.
2. Loosen nuts (2) and (3) of turnbuckle (1). remove

the cotter pin from pin (5). then remove pin (5)
and remove from caliper lever (4).
3. Adjust with adjustment bolt (6) so that clearances

A and B between the pad and disc are 0.05 - 0.2
mm.
F42301003
4. Turn turnbuckle (11, align the hole of caliper lever

(4) with the hole of pin (5). then insert pin (5) and
lock with the cotter pin.
5. Turn turnbuckle (1) until there is no more play,

then tighten nuts (2) and (3).
* Be careful not to tighten adjustment bolt (6) too
much.
* After adjusting, make sure that there is no play
in adjustment bolt (6) in the axial direction.
1
2-
F42301004
52-14 WA350-1
8
TROUBLESHOOTING
Troubleshooting table . 52-I 6

1. Air pressure does not rises at all 52-l 6
2. Air pressure does not rise to the

specified range . .. . 52-l 7
3. Brake is ineffective or not very

effective . . . . 52-18
4. Brake does not release, or drags 52-l 9
5. Parking brake does not release,

or drags . 52-20
out the troubleshooting in this section, read PRECAUTIONS WHEN TROUBLESHOOTING

* Before carrying
TROUBLESHOOTING TABLE page 22-l 4 and PREVENTING RECUR-
page 22-l 2, METHOD OF READING
RENCE OF TROUBLE page 22-16.
WA350- 1 52-15
a
1. Air pressure does not rise at all.

l Did the air pressure suddenly cease to rise?
--L Damage in air circuit or equipment.
l Was the air pressure difficult to raise for some
time? -+ Air leakage, performance drop in air
equipment.

l Damaged air hose or tube, external damage to
equipment associated with air system.
l Is the drain cock completely closed?
Fault check
l Check the-air pressure by air gauge
l If the pointer of the air gauge on the instrument
panel remains at 0 despite opening the air
pressurized, the gauge is faulty.
e circuit between the air go

A: Adjust C: Clean
52-16 WA350-1
a
2. Air pressure does not rise to the specified

range.

Check for possible air leakage from air hose,
tube and air equipment.
Is the drain cock completely closed?
Check for deformation of compressor or air
intake hose.
Fault check
l Install a pressure gauge in the air circuit and
measure the air pressure, then compare the
measured value with the judgement criterion
table to see whether or not it deviates from the
specified value.
No.
Problems
Air discharge from compressor discharge pipe is weak

1 0 0
when engine is running.
Compressor starts to build up pressure when circuit
2 0
between air governor and unloader is disconnected.
Air comes out of discharge pipe of compressor when
3 0
enaine is runnina but oressure does not build up.

A: Adjust C: Clean
WA350-1 52-17
a
3. Brake is ineffective or not very effective.

l Did the brake suddenly cease to be effective?
-) Damage in air or brake equipment.
l Did brake gradually deteriorate? - Deteriora-
tion of seal or packing, wear of lining.

Is kind of brake oil correct? (SAEI OW-CD)
Is air pressure and brake oil quantity sat-
isfactory? --
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 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 pres-
sure does not rise to the specified range. If
the measured value is normal, move on to the
following problems.
Fault check
l Check it against the valve in the judgement
criterion table to see whether or not brak-
ing performance is bad.
l The left and right wheels at both front
When the machine is raised using a 4-wheel jack,

the wheel axles placed on a stand and the brake
8 0000 0
operated with the engine in the forward 1st speed
position, however a particular turns fast.

52-18 WA350-1
0
4. Brake does not release, or drags.

l Does brake pedal return completely?
l Does parking brake completely disengage?
Fault check
l Abnormal heat generation in brake.
l Inertial travel on flat ground.
I I I I
No.
Problems
Air comes out and brake disengaged if brake chamber air O

1
input is disconnected when brake pedal is released.
Circuit pressure fails off and brake disengages if 011is
2 0 0 0
bled from air bleeder when brake pedal is released.
A particular wheel rotates sluggishly when the machine
is raised with a 4-wheel jack, the wheel axles placed on
3 000
a stand, the engine shut down and the tires rotated by
hand with the parking brake released.
The following symbols are used to Indicate

X: Replace
I A: Adjust
a: Repaw
C: Clean
WA350-1 52-19
a
5. Parking brake does not release, or drags.

(Applies to machines equipped with air
parking brake.)

l Is the pressure in the air circuit within the speci-
fied range? (if the air circuit pressure is 4.0
kg/cm2 or less, the parking brake solenoid valve
will automatically operate to engage the parking
brake.)

A: Adjust C: Clean
52-20 WA350-1
0
AIR GOVERNOR BRAKE ASSEMBLY

Disassembly..... ... 53- 2 Disassembly . . 53-22
Assembly . . .. . 53- 3 Assembly . . .. . 53-29
BRAKE VALVE SPRING CYLINDER

Removal . . . . . . . . . . . 53- 4 Removal . .. . . . . . . 53-37
Installation .. . .. .. . 53- 5 Installation ..... . . . . 53-38
Disassembly..... . 53- 6 Disassembly . . . . . . 53-39
Assembly . . . . 53- 8 Assembly . . .. .. .. 53-41
BRAKE CHAMBER PARKING BRAKE

Removal .. . . . ...... .. . 53-10 Removal . . . .. . .. . 53-43
Installation .. ...... . .. 53-l 2 Installation ... .. . 53-45
Disassembly . . . ...... 53-l 3
PARKING BRAKE PAD
Assembly . . . . . . . ...... .. . . 53-l 6
Removal . . . .. .. . 53-47
SLACK ADJUSTER Installation .. . . . .. 53-48
Removal .. . . . .. 53-l 9
Installation . . .. ...... . 53-l 9
Disassembly .. .. . . 53-20
Assembly .: . . ...... . . 53-21
WA350-1 53-l
0
DISASSEMBLY AND ASSEMBLY AIR GOVERNOR
DISASSEMBLY OF AIR GOVERNOR
1. Cover
Remove cover (I 51, then remove retaining ring
(I 4).
2. Spring seat
1) Remove spring seat assemblies (IO), (I I),
(I 21, (I 31, (I 6) and (I 7).
Sr Remove lock nut (I 6) inside the spring seat
assembly before removing the assembly.
2) Remove exhaust stem (9) and spring (8) from

top of piston (3).
3. Piston _
1) Turn body (I 1 upside down and tap to remove
piston (3) from bottom.
2) Remove spring (4) and valve (5) from piston (3).

* If the piston does not come out, blow in air
lightly from port a.
2 =
423 F442A
53-2 WA350-1
0
DISASSEMBLY AND ASSEMBLY AIR GOVERNOR
ASSEMBLY OF AIR GOVERNOR
KI& Inside surface of body, outside surface of

piston, O-ring groove, spring guide, adjust-
ment screw: Grease (G2-LI)
1. Piston assembly
1) 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 of piston (3), insert

spring -(4), fit in groove, then install on O-ring
(18) and assemble piston assembly in body (I).
2. Spring seat assembly

Assemble lower spring seat (I 1 A), spring guide
(IO), rower spring seat (I I), spring (I 2) and upper
spring seat (I 3) in order on adjustment screw
(17). Tighten lock nut (16) so that distance from
bottom face of adjustment screw to top face of
upper spring seat (I 3) is 47.6 mm.
* Check that exhaust stem (9) and spring (8) are
correctly fitted on piston (31, then insert the ad-
justment screw assembly in the body.
3. Cover
423F443
Stop cover (I 5) with retaining ring (14), then
install.
4. Filter 17 16 15
Insert filter (2).
* Install the governor on the machine and connect
the air piping. Check the air pressure when the
air compressor is increasing and decreasing
pressure. If the pressure is outside the specified
value, adjust it.
10
1 2
423 F444A
WA350-1
5%3
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
REMOVAL OF BRAKE VALVE
& Stop the machine on level ground and install

1. Draining air
Drain air from air tank, then remove cover of pedal.
2. Air piping, wiring

Disconnect air piping (I 1, (2), (3). (4), (5) and (6),
connector (7j and wire (8).
3. Pedal
Pull out cotter pin (10) of pin (9). remove pin, then
remove pedal (1 I).
4. Brake valve
Remove mounting bolt (121, disconnect valve
body (I 3) and mount flange (141, then remove
plunger (I 5).
423F445
53-4 WA350-1
Q
INSTALLATION OF BRAKE VALVE
Brake valve
Assemble plunger (I 5) on mount flange (14). then
install in valve body (I 3) with mounting bolt (I 2).
& Plunger: Brake oil (See page 01-l 0)
423F445
Pedal
Set pedal (I I) in mounting position, insert pin (91,
align stopper hole on left side of pin and assemble
on right side with cotter pin.
* Bend the cotter pin securely.
Air piping, wiring

Connect air piping (I), (21, (31, (4). (5) and (61,
wiring (7) and connector (8).
4. Air leakage check

Stand engine, check for leakage of air, and check
operation of brakes.
WA350-1
DISASSEMBLY OF BRAKE VALVE
1. Body assembly
I) Make match mark a on upper body and lower
body.
2) Loosen mounting bolts (I 1, remove upper body

(2) and lower body (31, then disconnect them.
2. Upper valve assembly

I) Hold slot-head screwdriver @ in vice 0, and
fit in slot in stem inside exhaust passage of
relay piston.
2) Loosen nut (4), then remove washer (51, plain

washer (61, spring seat (7). rubber spring (8).
upper piston (91, return spring (I 01, relay piston
spring (1 I), relay piston (I 2), and stem assem-
bly (I 3).
When loosening the nut, the piston may

fly out under the force of the return
spirng, so hold the piston by hand when
loosening the nut.
53-6 WA350-1
0
3) Remove snap ring (14), then remove primary

valve (1 5) from upper body.
4) Remove snap ring (I 6). then disassemble pri-

mary valve into washer (17). O-ring retainer
(I 8). O-rings (I 9) and (201, upper valve sping
(21). valve retainer (22). and upper valve (23).
3. Lower valve assembly

II Remove exhaust cover (241, then remove
secondary valve assembly (25).
2) Remove O-ring (26) from lower body.
3) Remove snap ring (27). then disassemble

secondary valve assembly into washer (28).
O-ring retainer (291, O-rings (30) and (31).
lower valve spring (321, valve retainer (33). and
lower valve (34).
WA3561
ASSEMBLY OF BRAKE VALV E
1. Lower valve assembly

1) Set lower valve (34) with valve seat at bottom,
assemble valve retainer (33). lower valve spring
(321, O-ring retainer (29) and washer (28). then
secure with snap ring (27).
* Assemble O-rings (30) and (31) on the
O-ring retainer first.
2) Assemble secondary valve assembly (25) in

lower body, then install exhaust cover (24).
2. Upper valve assembly

1) Set upper valve (23) with valve seat at bottom,
assemble valve retainer (22). upper valve
spring (21), O-ring retainer (I 8) and washer
(17). then secure with snap ring (16).
t Assemble O-rings (19) and (20) on the
O-ring retainer first.
2) Assemble primary valve assembly (15) in upper

body, then secure with snap ring (I 4).
53-8 WA350-1
0
3) Hold slot-head screwdriver @ in vice 0,

assemble relay piston spring (1 1). relay piston
(12) and stem assembly (13) in bottom of
upper body, then set with screwdriver.
t Do not forget to fit an O-ring on the relay
piston.
4) Assemble return spring (IO), upper Piston (91,

rubber spring (81, spring seat (71, 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

ss the return spring, so hold the piston by
hand when assembling.
m Nut: 0.55kO.15 kgm
3. Body assembly
I) Install O-ring (35) on lower body (3).
2) Align match marks on upper body (2) and lower

body (31, assemble and tighten mounting bolts
(1).
WA350-1
DISASSEMBLY AND ASSEMBLY BRAKE CHAMBER
REMOVAL OF BRAKE CHAMBER
A Stop the
the safety
and install
the bucket
A Disconnect
terminal
the cable
of the battery.
from the negative (-1
1. Draining air
2. Hydraulic piping, wiring (rear)

1) Disconnect wiring connector (2).
2) Disconnect hose (3) between slack adjuster
and brake chamber at brake chamber end.
3) Disconnect hose (4) between brake oil tank and
brake chamber at brake chamber end.
3. Air piping (rear)

Disconnect tube (5) between brake valve and
53-l 0 WA350-1
0
4. Brake chamber (rear)

Sling brake chamber (6). remove mounting bolts
(7). then lift off brake chamber.
* Be careful not to damage the hoses and tubes
when removing.
* Be careful not to damage the steering cylinder
rod when removing.
5. Brake chamber (front)

t The front brake chamber is behind the rear
brake chamber, so remove the rear brake cham-
ber first, then repeat the same procedure as in
Steps 2 - 4 to remove the front brake
chamber.
WA350-1 53-11
0
INSTALLATION OF BRAKE CHAMBER
1. Brake chamber (rear)

Set brake chamber (1) in mounting position, then
t Sling the brake chamber.
t Be careful not to damage the steering cylinder
rod.
+ Be careful not to damage the hose and tube
when assembling.
2. Hydraulic piping, wiring (rear)

1) Connect hose (4) between brake oil tank and
* Install front brake chamber hose without
bending and twisting, then install strap
securely.
2) Connect hose (3) between slack adjuster,and
3) Connect wiring connector (2).
3. Air piping (rear)

Connect tube (5) between brake valve and brake
chamber at brake chamber end.
4. Air check
I) Check for leakage of air from piping
connections.
2) Bleed air from brakes and check operation.
* For details of bleeding air, see 52 TESTING
AND ADJUSTING.
5. Brake chamber (front)

Use the same procedure as for installing the front
brake chamber.
53-12 WA350-1
@
DISASSEMBLY OF BRAKE CHAMBER
1. Accessories
Remove breather !I 1. bleeder (2) and sensor (3)
2. Cylinder
Loosen lock nut (41, then remove cylinder (5).
t There is an O-ring fitted on the thread of the
cylinder, so remove it.
3. Piston assembly
1) Move retainer (6) to right, remove pin (71, then
remove piston assembly (8).
+ Use a guide pin (Dia. 2.5 mm, length 50 mm)
to remove the pin.
423F446
2) Remove rod (91, then remove O-ring.
4. Disassembly of piston assembly

I) Remove snap ring (I 0). then remove seat (I I),
spring (I 2) and valve (I 3).
Sr Spring (12) is small, so be careful not to lose
it.
2) Remove packing (I 5) from piston (I 4).
WA350-1
5. Body
Hold body (I 6) with hand, remove mounting bolt,
then remove body.
* The tension 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 (171, then remove ring (I 8).
packing (I 91, seat (20) and packing (2 I).
423F448
2) Remove snap ring (22), then remove ring (23)

and seal (24).
53-14 WA350-1
0
2) Remove nut, then remove piston (28) and rod

(29).
3) Remove packing (30) and ring (3 I) from piston.
4) Remove O-ring (321 and washer (33) from rod
WA350-1 53-15
0
ASSEMBLY OF BRAKE CHAMBER
1. Assembly of piston assembly

1) Install washer (33) and O-ring (32) on rod (29).
Sr When fitting the O-ring, wind tape around
the threads of the rod to prevent damage to
the O-ring.
a O-ring: Brake oil (See page 01-l 0)
2) Assemble packing (30) and ring (31) on piston

(28). -
&& Packing: Grease (G2-LI)
3) Insert rod (29) in mount of piston (281, then

secure with nut.
* After tightening the nut, check that there is
no clearance between the stepped part of
the rod and the piston.
a Piston mounting hole: Grease (G2-LI)
w Nut: 14-+2 kgm
2. Assembly of body
1) Install seal (24) and ring (23) in body (I 61, 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.
& Seat: Brake oil (See page Cl-1 0)
53-16 WA350-1
0
2) Turn over body, assemble packing (21). seat

(20) and packing (19). insert ring 1181, then
secure with snap ring (I 7).
Sr Install the seal with the lip facing the outside.
Sr Check that the snap ring is fitted securely in
the groove.
a Packing: Brake oil (See page 01-I 0)
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 cylinder 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 (I 61, then install in
air cylinder.
* Push in the body by hand, install 2 mounting
bolts in diametrically opposite positions, then
tighten together with bracket (35).
B Mounting bolt: 4.4kO.6 kgm
5. Assembly of piston
I) Insert valve (131, spring (I 2) and seat (I I) in
piston (14), then secure with snap ring (I 0).
t Be careful to insert the spring facing in the
correct direction.
Sr Check that the snap ring fitted securely in
the groove.
WA350-1
2) Assemble packing (I 5) on piston.

* install the packing with the lip facing the
outside.
E??E Packing: Grease (G2-LI)
6. Piston assembly
Blow air into air cylinder and blow out rod. Set
piston assembly (8) in mounting position, 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 (51,
screw into mount, then secure with nut.
Sr Screw the cylinder in fully, then turn back until
the breather and bleeder are in a straight line.
E???E Inside surface of cylinder:

Brake oil (See page 0 I- IO)
m Nut: 14-+3 kgm
8. Sensor
Fit O-rings on rod (9) and sensor (3). then install in
mounting position.
Sr Insert the rod until it is level with the body.
m Sensor: 5.6kO.6 kgm
9. Accessories
Install breather (I ) and bleeder (2)
B Bleeder: 0.95kO.25 kgm
53-18 WA350-1
0
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
REMOVAL OF SLACK ADJUSTER
QT Stop
the safety
the machine
bar on the frame.
on level ground
Lower
and install
the bucket
1. Brake piping
1) Disconnect tube (1) between slack adjuster and
brake c.hamber at slack adjuster end.
t Hose (2) at rear.
2) Disconnect tube (3) between slack adjuster and
left and right brake pistons at slack adjuster
end.
2. Slack adjuster
Remove mounting bolts, then remove slack adjust-
er (4).
+ There is little space, so be careful when
working.
INSTALLATION OF SLACK
ADJUSTER
1. Slack adjuster
Set slack adjuster (4) in mounting position, then
Sr Tighten the mounting bolts partially, then tight-
en fully after connecting the piping
2. Brake piping
I) Connect tube (3) between slack adjuster and
left and right brake pistons at slack adjuster
end.
2) Connect tube (I) between slack adjuster and
brake chamber at slack adjuster end.
t Hose (2) at rear.
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.
* Bleed the air from the brake end and slack ad-
juster end.
WA350-1
DISASSEMBLY OF SLACK ADJUSTER
1. Bleeder
Remove bleeder (2) from body (I 1
..
2. Cylinder
Remove mounting bolts, then disconnect body (I 1
and cylinder (4) together with bracket (3).
There is spring tension inside the cylinder, so

hold the contact surfaces and be careful
when removing.
3. Piston
I) Remove spring (5) and O-ring (6).
2) Remove piston (71, 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.
4. Poppet
1) Remove cover (8) from cylinder (41, then
remove plug (9). spring (I 0) and poppet (I I).
t When removing the poppet, blow in air from
the oil hole in the cylinder.
t Hold the oil port of the cylinder by hand, and
do not pump in air suddenly.
* Do not change the combination of poppet
(I 1) and cylinder (4). If replace the poppet or
the cylinder, replace the poppet and cylinder
as a set.
2) Remove O-ring (I 2) from poppet.
53-20 WA350-1
@
ASSEMBLY OF SLACK ADJUSTER
1. Poppet
1) Fit O-ring (I 2) on poppet (I I).
2) Install poppet (I I), spring (10). plug (9) and
cover (81, then assemble cylinder (4).
2. Piston
I) Install O-ring (I 3) on piston (7).
2) Insert piston (7) in cylinder (4).
* Check that the piston moves smoothly.
3. Cylinder
1) Install O-ring (6) and spring (5) in cylinder.
t Installed load of spring: 4.4 kg
2) Install body (I) and cylinder (4) together with
bracket (3).
4. Bleeder
Install bleeder (2).
WA350-1 53-21
0
DISASSEMBLY AND ASSEMBLY BRAKE
DISASSEMBLY OF BRAKE ASSEMBLY
WA350-1
Wheel loader
7
Brake, wheel
) ToA
hub assembly
Special tool
A 793-520-2320 Fixture 2

1. Tire, wheel
Jack up axle, put stand under axle, then lift off tire
and wheel (I).
Tire, wheel: 310 kg
53-22 WA350-1
@
2. Draining oil
assembly.
+ Set with the drain plug at the bottom.
& Axle assembly: 45 II
3. Cover
Remove cover (31, then remove O-ring (4).

Remove axle shaft assembly (5) from axle.
* Attach a hook to the gear when removing the
shaft.
5. Planetary carrier assembly

Remove 3 mounting bolts (6). then lift off plane-
tary carrier (7).
* Make match marks to act as a guide when
assembling.
* Be careful of the center of gravity, and remove
slowly.
Planetary carrier: 68 kg
WA350-1 53-23

I) Using tool A, hold wheel hub (8) and brake (9)
in position.
Zr Install tool A to points on opposite sides, and
use washers to adjust clearance.
__
2) Remove mounting bolts of retainer (IO), then

remove ring gear assembly (I I).
* 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: 29 kg
7. Brake, wheel hub assembly

I) Remove brake tube (I 2).
2) Sling brake and wheel hub assembly (13).
8. Axle housing
Remove bearing (15) and retainer (16) from axle
housing (I 4).
53-24 WA350-1
0
9. Piston, cylinder
I) Set with wheel hub (17) at bottom, then
remove tool A.
2) Using forcing screw, lift off piston assembly
(I 8).
3) Remove O-rings (19) and (20) from piston
assembly.
4) Remove plug (21) from piston assembly, pull

out pin (22) and remove rod (23) and piston
return spring (24).
* The pin is small, so be careful not to lose it.
5) Pump in air through brake oil filler (25) and

push out piston (26).
* Hold one end of the piston by hand and
pump in the air slowly to prevent the piston
from flying out.
Sr Be careful not to damage the piston.
423F453
6) Remove oil seal (27) from piston (26).
WA350-1
7) Remove mounting bolts, then remove sleeve

(28).
* Be careful not to damage the cylinder.
8) Remove O-ring (29) and seal (30) from sleeve

(28). -
10. Discs, plates

Loosen stop bolt (311, then remove plates (32)
and discs (33) in order.
* When removing the discs, make match marks
on the inner gear and discs, and on the outer
gear and plates.
* The plates are made of a soft material, so be
careful not to damage them when removing.
11. Disassembly of outer gear

I) Sling outer gear (341, then remove seal ring
(35) and O-ring (36).
53-26 WA350-1
0
2) Using forcing screw, disconnect outer gear

(34) and retainer (371, then remove O-ring (38).
* Be careful not to damage the a face of the
retainer.
12. Inner gear

Remove mounting bolts, then remove inner gear
(39).
13. Wheel hub assembly

I) Remove seal ring (41) and O-ring (42) from
wheel hub assembly (40).
2) Remove retainer (431, then remove O-ring (42).
WA350-1 53-27
0
3) Remove bearing caps (45) and (46) from wheel

hub (44).
53-28 WA350-1
0
ASSEMBLY OF BRAKE ASSEMBLY
7
Brake, wheel
t TOA
hub assembly
12
Refilling with
oil
13
Tire, wheel
423 F454
Special tools
A ) 793-520-2680 1 Installer
8 1 791-580-1600 1 Push tool I

C 793-520-2320 Fixture 2
1. Wheel hub assembly

I) Press fit bearing cups (45) and (46) on wheel
hub (44).
WA350-1 53-29
0
2) Fit O-ring (47) on retainer (43)
3) Fit O-ring (42) on seal ring (41). set retainer

(43) in insertion position, then use tools A and
to insert.
Remove all white powder from the surface
of the O-ring with methyl alcohol.
Thoroughly remove all grease from the
mating surfaces of the O-rings in the seal
rings and retainers.
Tighten tool B uniformly to prevent the
O-ring from being twisted.
After press-fitting, measure height 9 at
four places around the circumference, and
confirm-that the difference in dimensions is
less than 1 mm.
423F455
Do not hit the seal ring with a hammer
J=??Y= Seal ring: Brake oil (See page 01-l 0)
4) Install retainer (43) on wheel hub (44).

t After aligning the dowel pin hole and press
fitting, check that there is no clearance at
the contact faces.
2. Inner gear
t Install inner gear (39) on wheel hub (44).
& Mounting bolt: Thread tightener (LT-2)
53-30 WA350-1
0
3. Outer gear
I) Install O-ring (38) on retainer (37).
Fit O-ring (36) on seal ring (351, set retainer
(37) in insertion position, then use tools A and
to insert.
Remove all white powder from the surface
of the O-ring with methyl alcohol.
After press-fitting, measure height t at
four places around the circumference, and
confirm that the difference in dimensions is
less than 1 mm.
Tighten tool B uniformly to prevent the
O-ring from being twisted.
Thoroughly remove all grease from the
mating surfaces of the O-rings in the seal
rings and retainers.
423F455A
Be careful not to damage the a surface of

the retainer.
2) Install outer gear (34) on wheel hub assembly

(40).
4. Discs, plates
Align match marks of outer gear (34) and plate
(321, and disc (33) and inner gear (391, and assem-
ble elates and discs in turn.
Loosen the stop bolt so that it is pulled com-
pletely free from the outer gear spline.
The final plate must be fitted securely on the
spline of the inner gear.
Soak the discs in brake oil for at least 30 mi-
nutes before assembling.
WA350-1
5. Piston, cylinder
I) Fit seal (29) and O-ring (30) on sleeve (28).
EEL Seal, O-ring:

Brake oil (See page01 -10)
2) Align match marks, install sleeve (28) in

housing (471, then partially tighten with 3
mounting bolts.
Sr Be careful not to let the cylinder O-ring come
out.
* Tighten the mounting bolts fully after press
fitting the piston.
m Mounting bolt: 18*2 kgm
3) Assemble seal (27) on piston (26).

* Fit the seal securely in the groove.
&IL Seal: Brake oil (See page 01-l 0)
4) Press fit piston (26) in housing (47).

* When press fitting the piston, hit it with a
plastic hammer. Do not use a steel or copper
hammer.
* Coat the press-fitting portion of the piston
assembly and the outside circumference of
the piston with brake oil.
&?&= Sliding surface of piston:

Brake oil (See page 01-l 0)
,,,,, ,,
53-32 WA350-1
0
5) Insert piston return spring (241 and rod (23) in

piston assembly (18). then lock with pin (22)
and install plug (21).
6) Fit O-rings (I 9) and (20) on piston assembly

(I 8), set outer gear assembly in position, then
w Mounting bolt: 18 ?2 kgm
0 Mounting bolt: Thread tightener

(LT-2)
6. Axle housing
Press fit retainer (I 6) and bearing (I 5) on axle
housing (14).
* After press fitting the retainer and housing, and
the retainer and bearing, check that there is no
clearance at any point.
7. Brake, wheel hub assembly

1) Use tool C to hold brake assembly (48) and
wheel hub (44) in position.
* As far as possible, install tool C to points at
diametrically opposite positions.
* Install tool C so that the circumference is
uniform.
WA3561
2) Raise brake and wheel hub assembly (I 3), set

in position on axle housing mount, then tighten
mounting bolts.
* Be careful of the center of gravity, and raise
horizontally.
* Do not force into position because the
O-ring will be twisted. Align the centers and
install slowly.
&& Mounting bolt:

w Mounting bolt: 56*6 kgm
3) Install brake tube (1 2).

1) Raise ring gear assembly (1 I), set in mounting
position, and insert in axle housing.
k Align the spline groove and insert the
assembly slowly.
2) Tighten retainer (IO) temporarily with 3 bolts,

then remove tool C.
* Remove all grease and oil from the bolt hole
of the retainer mount.
t Do not insert shims in the retainer when
tightening temporarily.
* Rotate the wheel hub to settle the bearing,
then tighten to a uniform torque.
m Mounting bolt of retainer: 3.0 kgm
3) Insert a depth micrometer through measuring

hole of retainer (IO), and measure clearance
a between end face of housing and end face
of retainer.
sr Measure at 2 places and take the average.
* Shim thickness is clearance a + 0.2 mm.
* Use the smallest number of shims which
gives the required thickness.
* Be careful that the total shim thickness is no
than a + 0.2 mm.
* Shim thickness: 1 .O mm, 0.3 mm, 0.2 mm
423F456
53-34 WA350-1
0
4) Install tool C to brake assembly and wheel hub,

and remove retainer. Install required thickness
of shims, then install retainer again.
+ Always install tool C before assembling the
shims.
* Rotate the wheel hub and tighten the
mounting bolts uniformly to the specified
tightening torque.
&?YS Mounting bolt:

m Mounting bolt: 11.5f 1 .O kgm
9. Planet carrier assembly

Fit O-ring (24) to wheel hub (81, raise planet
carrier assembly (71, set in mounting position,
then install.
* Align mounting holes and install carefully so
that the O-ring does not slip out of place.

Install axle shaft assembly (5).
t If the position of the sun gear does not match,
rotate the wheel hub to align.
11. Cover
Fit O-ring (4) in groove in cover, then install cover
(3).
WA350-1

Tighten drain plug and add oil through level plug
oil.
%2 Axle assembly: 45 II
13. Tire, wheel

Install tire and wheel (I 1, then remove stand.
m Mounting nut: 4825 kgm
14. Checking for leakage of brake oil

After completing all operations, check for leakage
of brake oil.
* For details, see 52 TESTING AND ADJUST-
ING.
53-36 WA350-1
Go
DISASSEMBLY AND ASSEMBLY SPRING CYLINDER
REMOVAL OF SPRING CYLINDER
Q7 Stop the
the safety
and install
the bucket
t Check again that the wheels have been blocked
properly, then turn the main switch to ON, and
release the parking brake.
1. Cover .
Remove cover (I) at front of front frame.
2. Linkage
Disconnect ball joint (2) of parking brake linkage.
+ The ball joint can not be disconnected if the
parking brake is applied.
3. Air piping
Disconnect air piping (3) of spring cylinder.
* Drain the air.
* After removing, cover to prevent dust or dirt
from entering.
4. Spring cylinder
Remove mounting nut, then remove spring
cylinder (4).
WA350-1 53-37
0
INSTALLATION OF SPRING CYLINDER
1. Spring cylinder
Set spring cylinder (4) in mounting position, and
install.
m Mounting nut: 28.5A3.0 kgm
2. Air piping
Connect air piping (3) to spring cylinder.
* Turn the main switch ON and apply the parking
brake.
3. Linkage
Connect ball joint (2) of parking brake linkage.
* For details of adjusting the linkage, see 52
TESTING AND ADJUSTING.
* Check the operation of the parking brake.
m Mounting nut: 11.5f 1 .O kgm
4. Cover
Install cover (I) at front of front frame.
53-38 WA350-1
0
DISASSEMBLY OF SPRING CYLINDER
1. Boot and retainer

Remove boot (I ), then remove retainer (2).
2. Boot
Remove boot (3).
3. Filter
Remove filter holder (4). then remove filter and
retainer.
4. Rod
Remove lock nut (5) and mounting nut (6) of boot,
then remove rod (7).
WA350-1
5. Spring and support

Using a press, remove mounting bolt of support
(81, then remove spring (9).
When the pressure of the pr ess i s released,

there is danger that the spring may fly out, so
release the press slowly.
6. Piston
1) Remove piston (1 I) from cylinder (10).
2) Remove wiper ring (I 2) and seal (I 3) from

piston.
7. Cylinder
Remove bushing (14) and seal (15) from cylinder.
53-40 WA350-1
0
ASSEMBLY OF SPRING CYLINDER
1. Cylinder
Install bushing (I 4) and seal (I 5) in cylinder (I 0).
2. Piston
1) Install wiper ring (12) and seal (13) on piston
(IIi.
SrUse a new part for the wiper ring and seal,
and soak in oil before installing.
a Wiper ring: Engine oil (See page 01-l 0)
2) Assemble piston (1 1) in cylinder (I 0).
ia Piston seal, inside of seal and bushing,

sliding surface of piston and cylinder:
Silicon grease
3. Spring, support
Using a press, assemble spring (9) and support
(81, then tighten mounting bolt.
* Align the mounting bolt holes correctly.

* Installed load of spring: 310 kg
m Mounting bolt: 1.4kO.4 kgm
Tighten the mounting bolt fully before

removing the press.
WA350-1
4. Rod
1) Install flange nuts (I 6) and (17) lock nuts (I 8)
and (19).
+ Tighten the flange nut partially.

+ Installed distance L, of lock nut: 55 mm.
m Lock nut: 5+ 1 kgm
2) Install flange nuts (I 6) and (17) to give installed

distance L2.
Sr Installed distance L, of flange nut: 100 mm
m Flange nut: 5f 1 kgm
3) Install boot to rod, then install nut (6) and lock

nut (5) to give specified clearance a.
Clearance a: 1.6 - 2.6 mm
* After installing, check that clearance a is

correct.
m Mounting nut of boot, lock nut:

5fl kgm
5. Filter
Set retainer (4) and filter (21) in mounting
position, then install filter holder (20).
6. Boot
Install boot (3).
7. Retainer, boot
Install retainer (2) and boot (1)
53-42 WA350-1
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
REMOVAL OF PARKING BRAKE
a Stop the
the safety
and install
the bucket
* Turn the starting switch ON and release the park-

ing brake. _.
1. Linkage
Disconnect parking brake lever (I) and linkage (2).
2. Drive shaft
Disconnect front drive shaft (3) from differential.
3. Caliper assembly
Remove mounting bolts (4). then remove caliper
assembly (5).
4. Disc
Remove mounting bolts (6), then remove disc (7)
from coupling.
WA350-1
DISASSEMBLY AND ASSEMBLY PARKING BRAKE.
5. Disassembly of caliper
1) Remove adjustment screw (8).
2) Extend lock plate (9) with a chisel, remove
bolts, then disconnect retraction plate (I 0) and
calipers (1 1) and (I 2).
3) Remove nut from caliper, then remove pads
(13) and (I 4).
4) Remove spring (I 6) and pin (I 5) from caliper
(I 2).
WA350-1
53-44
0
INSTALLATION OF PARKING BRAKE

1. Assembly of caliper
1) Install pin (I 5) and spring (16) on caliper (I 2).
423F457
2) Install pads (I 3) and (14) to caliper, then

secure with nut.
3) Set calipers (I 1) and (12) in mounting position,

install retraction plate (IO) and lock plate (91,
Sr Knock the tip of the retraction plate into the
caliper mount hole up to the root.
m Mounting bolt: 1.2-tO.l kgm
4) Bend lock plate with a chisel to lock bolt.

* Bend the lock plate securely.
5) Install adjustment screw (8).
WA350-1
2. Disc
I) Set disc (7) in position on mount of coupling
(I 7). then tighten mounting bolt.
m Mounting bolt: 11.5f 1 .O kgm
3. Caliper assembly
Set caliper assembly (5) in mounting position,
then tighten mounting bolt (4).
N$
Q
m Mounting bolt: 1822.0 kgm j)
4. Drive shaft
Connect front drive shaft (3) at differential end.
m Mounting bolt: 11.5* 1 .O kgm
53-46 WA350-1
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
REMOVAL OF PARKING BRAKE PAD
a Stop the machine

the safety
on level ground
and install
the bucket
t Check that the blocks are set properly under
the wheels.
Linkage
Remove lock nut (I), then disconnect parking
brake lever (2) and linkage (3).
* Before disconnecting the linkage, turn the start-
ing switch to ON and release the parking brake.
Pads
1) Extend lock plate (4) with a chisel, and remove
bolts (5).
2) Remove calipers (6) and (7).
/-
4 423F458
3) Remove nut (I 0) from calipers (6) and (7), then

remove pads (8) and (9).
WA350- 1
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
INSTALLATION OF PARKING BRAKE PAD

1. Pads
1) Set pads (8) and (9) in position on mounts of
calipers (6) and (71, then secure with nut (I 0).
..
0
2) Set calipers (6) and (7) in mounting position, in-
stall lock piate (41, then tighten bolts. - -_I
0
t Knock the tip of the lock plate into the caliper

mount hole up to the root.
4 423F458
3) Bend lock plate (4) with a chisel to lock bolt (5).

t Bend the lock plate securely.
53-48 WA350-1
0
Brake valve. . 54-2

Brake chamber 54-4
Slack adjuster 54-5
Brake 54-6
Parking brake 54-8
Spring cylinder . 54-9
WA350-1 54-l
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
13'
423F222
54-2 WA350-1
MAINTENANCE STANDARD BRAKE VALVE
Unit: mm
No.
Clearance between pedal mounting pin

1
and mount plate
2
-
4
-
etween relay piston and
5
-
6 Outside diameter of roller
7
-
8 Piston return spring
9 Primary valve spring

-
10
-
11 Outer stem spring 41.0 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 0.5520.15 kgm Retighten
WA350-1
MAINTENANCE STANDARD BRAKE CHAMBER
3
BRAKE CHAMBER r -i
Section A-A
423F223
mm m
Unit: mm
Tolerance
Shaft Hole
1 Clearance between cylinder and piston
-0.030 +0.046 0.030 -
68 0.15 Replace
-0.076 0 0.122
2 Outside diameter of oil seal 69.6 -0.5 +0.046 1.254 - 1 .O

-0.3 0 1.1
-
-
3 Air piston stroke 69.2 - 75.2 (Normal pressure: Max. 9.5 kg/cm*)
4 Tightening torque of nut 14.0& 2.0 kgm

- Retighten
5 Tightening torque of nut 4.4? 0.6 kgm
54-4 WA350-1
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
- 1
kc=
I
I
I
_&=.
-
4
423F224
Unit: mm
-
Tolerance
Shaft Hole
1 Clearance between body and piston
-
55 -0.030 +0.074 0.030.15 0.25
-0.076 0
Replace
2 Spring
3 Spring 6.8 kg

- Retighten
5 Tightening torque of plug 5.7eO.7 kgm
WA350-1 54-5
0
MAINTENANCE STANDARD BRAKE
BRAKE
CIY , 9 10 ,P
\ \ f I /
Detail P
14
11
12
423F225A
5i6 WA350-1
MAINTENANCE STANDARD BRAKE
Unit: mm
1 Return spring
-
I
2 Thickness of plate I
2.3 * 0.1 1.7
t-
3 Thickness of disc 3.8 * 0.1 3.5
4 Total thickness of plate and disc 26.7 f 0.9 23.1 Replace

-
355+0.05J
5 Wear of surface in contact with piston seal
0
3, 5+0.214
6 Wear of surface in contact with piston seal
+0.125
Deformation of friction surface of plate

7 0.30 0.50
and disc I
-
a Backlash between outer gear and plate

I
0.23 - 0.65
-
9 Backlash between inner gear and disc 0.31 - 0.74
I
10 Tightening torque of bolt 18*2kgm
11 Tightening torque of bolt 11.5* l.Okgm

-
12 Tightening torque of bolt 26.5 - 3.0 kgm 1 Retighten
-
13 Tightening torque of bolt 18?2kgm
14 Tightening torque of bolt 56 f 6 kgm

-
WA350- 1 54-7
0
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
/i
a b
I\ 423F226
Unit: mm
Wear of pad
(remaining thickness of friction material) 10.5 (a, b, c), 8.5 (d) 3.8
1
Replace
(including backing plate) 13.7 (a, b, cl, 11.7 id) 7.0
-
2 Face runout of disc 0.25 0.5

Rebuild
Thickness of plate
must be under 18 mm
3 Wear of disc
20.0
(thickness of disc plate)
Less than 18 mm Replace
4 Clearance between pad and disc 0.1 - 0.4 Adjust

-
5 Tightening torque of nut 0.2720.5 kgm
WA350-1
MAINTENANCE STANDARD SPRING CYLINDER
SPRING CYLINDER
423F2278
- Unit: mm
Tolerance
1 Clearance between cylinder and piston Shaft Hole
l&lg 59
-
158.65 Jz.35 -
Clearance between piston insert and Hole: 38.8
2 - Replace
center boss Shaft: 38 - -0q8

I I
3 Piston spring Free Installation Installation Free Installation
280 110.5 310kg -
4 Play of rod in axial direction 1.6 - 2.6
Adjust
5 Installed dimension of rod 244
6 Tightening torque of rod, lock nut 5.0 ? 1 .O kgm
7 Setting dimension of lock nut 55 - 58
8 Tightening torque of mounting bolt 1.4 & 0.4kgm
WA350-1 54-9
@
WORK EQUIPMENT SYSTEM
General .................................. 61- 2

Hydraulic circuit system ................... 61- 4
Hydraulic circuit diagram [for 2-Spool) ...... 6 I- 5
Hydraulic circuit diagram
(for 3-Spool)(if epuipped). ................ 61- 5-l
Bucket linkage ............................ 61- 5-2
Bucket positioner and boom kick-out ....... 6 1- 8
Hydraulic tank ............................ 61-I 0
l Oil filter bypass valve ................... 61-l 1
l Breather ............................... 61-11
Hydraulic and steering pumps .............. 61-l 2
Main control valve (for 2-Spool) ............ 61-I 4
Main control valve (for 3-Spool)(if equipped) . 61-I 5-l
l Relief valve ............................ 61-22
l Safety valve (with suction valve) ......... 61-23
l Suction valve .......................... 61-24
Hydraulic cylinder ......................... 61-25
WA350-1 61-1
0
GENERAL
Outline
The work equipment system consists of the hy- The maximum pressure of the hydraulic circuit is
draulic circuit and steering circuit. The hydraulic regulated by the relief valve inside the main control
circuit controls the operation of the bucket and valve. There is a safety valve (with suction valve)
attachment. in the dump cylinder circuit to protect the circuit.
The oil in hydraulic tank (1) is sent by hydraulic Hydraulic tank (1) is a pressurized, sealed type and
pump (2) to main control valve (7). When the has a breather with a relief valve. This acts to
dump and lift spools of the main control valve are pressurize the tank and at the same time prevents
at neutral, the oil passes through the drain circuit negative pressure. This protects the pump from
of the main control valve. It is then filtered by the cavitation.
filter in the hydraulic tank, and returns the tank.
When the levers-are operated, the dump spool or
lift spool in the main control valve moves, and oil
flows from the main control valve to lift cylinder
(3) or dump cylinder (4). The lift arm or bucket
then moves. -
61-2 WA350-1
F4230007
1. Hydraulic tank
2. Hydraulic and steering pump
3. Lift cylinder
4. Dump cylinder
5. Lift lever
6. Dump lever
7. Main control valve
WA350-1 61-3
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT SYSTEM
HYDRAULIC CIRCUIT SYSTEM (For S-SPOOI)
Engine low idling, hydraulic control lever in HOLD, Steering wheel at Neutral
...
.A.
.\.
.A.
:j:;
:.:.
: ::
j
:::
j,jj
0..
. ..
.I-
I
:ii
:::
::: :::
:::
:::
::: :::
:::
ii; :::
.:.
:!: :::
::. ;:I
::. ::.
Water outlet -
-Water inlet
423F152A
WA350-1
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM (For P-~~0011
---------1 )(/
_J
45
A3
83
19
SAR(3)-50
kil
;AR(3)-80 A2
-__--- 1
r-i 7
423F153B
1 Hydraulic tank 12. Two-way restrictor valve

2 Oil filter 13. Steering cylinder
3 Hydraulic pump (SAR(3)-80) 14. Relief valve
4. Steering pump (SAR(3)-50) 15. Safety valve (with suction)
(SAR(3)-40: Serial No. 1 11 18 and up) 16. Dump spool
5. Steering valve 17. Lift spool
6. Check valve 18. Suction valve
7. Demand spool 19. Lift cylinder
8. Check valve 20. Dump cylinder
9. Steering relief valve 21. Oil cooler
10. Steering spool 22. Main control valve
11. Safety valve (with suction)
WA350-1 61-5
8
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

(For 3-Spool, with emergency steering (if equipped))
Engine stopped
28 r------
(6
423F5088
1. Hydraulic tank 15. Safety valve (with suction)

2. Oil filter 16. Dump spool
3. Hydraulic pump (SAR(3)-80) 17. Lift spool
4. Steering pump (SAR(3)-50) 18. Suction valve
(SAR(3)-40: Serial No. 1 1 1 18 and up) 19. Lift cylinder
5. Steering valve 20. Dump cylinder
6. Check valve 2 1 Oil cooler
7. Demand spool 22. Main control valve
8. Check valve 23. Attachment spool
9. Steering relief valve 24. Attachment cylinder
10. Steering spool 25. Safety valve (with suction)
1 1. Safety valve (with suction) 26. Float valve
12. Two-way restrictor valve 27. Security valve
13. Steering cylinder 28. Diverter valve
14. Relief valve 29. Emergency pump
61-5-1 WA350-1
0
STRUCTURE AND FUNCTION BUCKET LINKAGE
BUCKET LINKAGE
Serial No. 10001 - 11117
423F 155
I. Tilt lever
2. Dump cylinder
3. Lift cylinder
4. Lift arm
5. Bucket link
6. Bucket
WA350-1 6 l-5-2
BUCKET LINKAGE
1. Tilt lever
2. Dump cylinder U42301006
3. Lift cylinder
4. Lift arm
5. Bucket link
6. Bucket
61-6 WA350-1
0
. Section A-A Section B-B

Section C-C
Section E-E Section F-F
Section D-D
Section G-G Section H-H

Section J-J
423F156
WA350-1 61-7
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
_--f- - -
i .1
T
423F158
Section A-A
1. Proximity switch 3. Lever 5. Proximity switch

2. Plate 4. Cylinder
61-8 WA350-1
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
Bucket positioner
The bucket positioner is electrically actuated and
is used to automatically obtain the optimum dig-
ging angle for the bucket.
When the bucket is moved from the DUMP posi-
tion to the TILT position, and it reaches the
desired angle, the dump lever is automatically
moved from the TILT position to the neutral.
Lever (3) is secured by bolts to dump cylinder rod.
A proximity switch is fixed by bolts to the cylinder.
When the bucket is moved from the DUMP posi-
tion to the TILT position, the dump cylinder rod
moves to the left. At the same time, lever (3) also
moves to the left. When it reaches the desired
position, lever (3) separates from proximity switch
(5). and the bucket lever returns to neutral.
Boom kick-out
l The boom kick-out is electrically operated and
acts to stop the lift arm. When the lift arm
reaches the desired position before the maximum
height, the lift arm lever is returned to neutral.
l Plate (2) is secured to the lift arm. A proximity
switch (1) is fixed to the frame. When the lift arm
is moved from the LOWER position to the RAISE
position, the lift arm rises. When it reaches the
desired position, the proximity switch and lever
come into contact and the lift arm lever is returned
to neutral.
WA350-1 61-9
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
Outline
. The oil from the hydraulic tank is sent from the . The oil filter (2) filters all the oil in the circuit. If the
pump through the control valve to the cylinders. oil filter (2) becomes clogged, a bypass valve (1)
In the return circuit, the oil from various parts acts to allow the oil to return directly to the tank
merges. Part of it is cooled in the oil cooler, (4). This prevents damage to the filter (2). The
passes through the oil filter (2) and returns to the bypass valve (1) is also actuated when negative
tank (4). pressure is generated in the circuit.
Section A-A
423F130
1. Bypass valve
2. Oil filter
3. Breather
4. Hydraulic tank
5. Drain valve
6. Oil level sight gauge
61-10 WA350-1
STRUCTURE AND FUNCTION HYDRAULIC TANK
OIL FILTER BYPASS VALVE
When the filter is clogged

Bypass valve (I) opens and the oil returns directly to
From main
the tank without passing through the filter. control valve
Bypass valve set pressure: 1.27 kg/cm2
When
circuit.
negative pressure is formed in the return
I 423F131
Valve (2j moves up and acts a check valve.
Check valve set pressure: 0.26 kg/cm2
To main
Control valve
423F132
BREATHER
Preventing negative pressure inside the tank

The tank is a pressurized, sealed type, so negative
pressure is formed inside the hydraulic tank when
the oil level drops during operations. When this
happens, the-difference in pressure between the tank
and the outside atmospheric pressure opens the
poppet (3). and air from the outside is let into the
tank to prevent negative pressure.
Preventing rise in pressure inside the tank

1. Body
When the hydraulic cylinders are being used, the oil
2. Filter element
level in the hydraulic circuit changes and the tem-
3. Poppet
perature rises. If the hydraulic pressure rises above
4. Sleeve
the set pressure, the breather is actuated to release
the hydraulic pressure inside the tank.
WA350-1 61-l 1
STRUCTURE AND FUNCTION HYDRAULIC AND STEERING PUMPS
HYDRAULIC AND STEERING PUMPS
I \9 \8
10
Section A-A
423F 134
Hydraulic pump Steering pump

,
I
I
SARi3)-080 SARC31-050
(SAR(3)-040)
Specifications
I, Drive gear (for hydraulic pump)(Teeth 12) Hydraulic pump
2. Front cover Model SAR(3)-080
3. Gear case Theoretical discharge 80 cc/rev
4. Rear cover Max. pressure 2 10 kg/cm
5. Front cover Max. pump speed 2,500 rpm
6. Drive gear (for steering pump)(Teeth 12)
7. Gear case Steering pump
8. Rear cover Model SAR(3)-050
9. Driven gear (Teeth 12) (SAR(3)-040)
10. Driven gear (Teeth 12) Theoretical discharge 49.8 cc/rev
(40.0 cc/rev)
Max. pressure 210 kg/cm
Max. pump speed 2,500 rpm
( ): Serial No. 1 1 1 18 and up
61-12 WA350-1
0
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE (For 2-SPOOI)
Section X-X
i-W F
Section Y-Y
423F135
1. Body 6. Lift spool return spring A. Pump port

2. Lift spool 7. Safety valve (with suction) B. To dump cylinder rod side
3. Dump spool 8. Safety valve (with suction) C. To lift cylinder rod side
4. Main relief valve 9. Suction valve D. Drain port
5. Dump spool return spring E. To lift cylinder bottom side
F. To dump cylinder bottom side
G. Drain port
H. Drain port
61-14 WA350-1
@
Section U-U
\
Section W-W 7
Section Z-Z
Section V-V
423F136
Outline
. The main control valve controls the actuation of However, the circuit gives priority to the bucket,
the attachments and the buckets in the hydraulic so when the dump spool is being operated, even if
system. It has a tandem circuit which gives priority the lift spool is operated, the lift arm will not move.
to the bucket circuit. . There are two safety valves (with suction valves)
. The oil from the pump enters port A. The maxi- (7) and (8) to protect the circuit if abnormal pres-
mum pressure is set by the relief valve. The oil sure is generated in the bucket circuit. If one of
passes through the bypass circuit of dump spool the two safety valves is acting as a relief valve, the
(3) and lift spool (2). It then flows from port B to other valve acts as a suction valve to make up any
the drain circuit, passes through.the filter and re- lack of oil.
turns to the tank. If the dump and lift spools are
actuated, the oil flows to the dump and lift
cylinders.
WA350-1 61-15
MAIN CONTROL VALVE (For 3-Spool (if equipped))
n n n
Section F-F
h 9 f
Section D-D
F424CO119
1. Check valve 6. Spool a. From steenng valve

2. Suction valve 7. Spool return spring b. To attachment cylinder
3. Main relief valve 8. Valve body C. To dump cylinder
4. Spool 9. Safety valve (with suction) d. To lift cylinder
5. Spool e. To hydraulic tank
f. To lift cylinder
g- To dump cylinder
h. To attachment cylinder
61-15-l WA350- 1
0
Section C-C
Section A-A
Section E-E Section B-B
F424CO120
Outline
l The main control valve controls the actuation of However, the circuit gives priority to the attach-
the attachments and the buckets in the hydraulic ment and the bucket, so when the dump spools
system. It has a tandem circuit which gives priority are being operated, even if the lift spool is
to the attachment and the bucket circuit. operated, the lift arm will not move. The attach-
l The oil from the pump enters port a. The maxi- ment and the dump spools can be operated at the
mum pressure is set by the relief valve. The oil same time.
passes through the bypass circuit of dump spool l There are two safety valves (with suction valves)
(5) and lift spool (6). It then flows from port e to (9) to protect the circuit if abnormal pressure is
the drain circuit, passes through the filter and re- generated in the attachment and the bucket
turns to the tank. If the attachment, dump and lift circuit. If one of the two safety valves is acting as
spools are actuated, the oil flows to the dump and a relief valve, the other valve acts as a suction
lift cylinders. valve to make up any lack of oil.
WA350-1 61-15-2
@
LIFT AND DUMP SPOOLS AT NEUTRAL POSITION
>n..:.>&+, 0
4
Steering valve
E423F144
Operation
. The oil flows from pump (1) through the steering The lift spool (3) is also at neutral, so the bypass
valve and enters port A. circuit is open. The oil from port B passes around
. Dump spool (2) is at neutral, so the bypass circuit the spool, flows from the drain circuit through the
is open and the oil from port A passes around the oil cooler and filter, and goes back to the tank.
spool and flows to port B.
61-16 WA350-1
LIFT SPOOL AT RAISE POSITION
Water
E423F145
Operation
. When lift control lever (4) is pulled, lift spool (3) is . At the same time, the oil from the cylinder rod end
pushed into the RAISE position. flows from port E to drain port F and returns
. The oil flows from pump (1) through the steering through the oil cooler to the tank. When this
valve. It then passes through the bypass circuit of happens, the lift arm goes up.
dump spool (2) and flows to the bypass circuit of
lift spool (3). The bypass circuit is closed by dump
spool (2). so the oil pushes open check valve (5).
The oil from check valve (5) flows to port D and
enters the cylinder bottom.
WA350-1 61-17
LIFT SPOOL AT LOWER POSITION
Water
E423F146A
Operation
l When lift control lever (4) is pushed, lift spool (3) The oil then flows from check valve (5) to port E
is pulled out to the LOWER position. and enters the rod end of cylinder.
l The oil flows from pump (I) through the steering l At the same time, the oil from the cylinder bottom
valve. It then passes through the bypass circuit of flows from port D and enters drain port F. It then
dump spool (2) and flows to the bypass circuit of passes through the oil cooler and return to the
lift spool (3). The bypass circuit is closed by lift tank. When this happens, the lift arm goes down.
spool (3). so the oil pushes open check valve (5).
61-18 WA350-1
@
LIFT SPOOL AT FLOAT POSITION
Water
Float e
E423F147
Operation
When lift control lever (4) is pushed down further In addition, RAISE circuit D and LOWER circuit E
from the LOWER position, lift spool (3) is pulled of the lift cylinder are connected to the drain
into the FLOAT position. circuit, so the lift arm goes down under its own
The oil flows from pump (1) through the steering weight.
valve. It then flows around the bypass circuit of When the bucket is in contact with the ground, it
dump spool (2) to the lift spool bypass circuit. can move up and down in accordance with the
The oil in the bypass circuit flows to the drain cir- shape of the ground.
cuit because of the spool, but it cannot push open
check valve (5).
WA350-1 61-19
DUMP SPOOL AT TILT BACK POSITION
E423F148
Operation
When dump lever (6) is pulled, dump spool (2) is The oil from port A flows from check valve (7)
pushed into the TILT position. through port G to the cylinder bottom.
The bypass circuit is closed by dump spool (2), so . At the same time, the oil at the cylinder rod end
oil from port A pushes open check valve (7). flows from
port H to drain port F. It then passes
through the oil cooler, and flows back to the tank.
When this happens, the bucket tilts.
61-20 WA350-1
DUMP SPOOL- AT DUMP
Dump
Steering
Pump
E423F149A
Operation
l When the dump lever (6) is pushed, dump spool . At the same time, the oil at the cylinder bottom
(2) is pushed into the DUMP position. end flows from port G to drain port F and then re-
. The bypass circuit is closed by the dump spool turns to the tank. As a result, the bucket is
(6). so the oil front port A pushes up check valve dumped.
(7). The oil from port A flows from port D into the
spool. It then flows from port H to the cylinder
rod end.
WA350-1 61-21
@
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
1 2 3
423F137
Function
l The relief valve is installed at the inlet of the main
control valve. When the oil goes above the set
pressure, the relief valve drains the oil to the tank. 5608 FO70
In this way, it sets the maximum pressure in the
hydraulic circuit and protects the circuit.
3
Operation
Port A is connected to the pump circuit and port C
is connected to the drain circuit. The oil passes
through the orifice of main valve (I) and flows to
port B. Pilot poppet (3) is in close contact with
valve seat (2).
When the hydraulic pressure in the circuit inside
port A and port B reaches the set pressure of the 56OBF071
pilot poppet spring (41, pilot poppet (3) opens, and
the pressurized oil from port B flows from port D
to port C, so the pressure at port B drops.
When the pressure at port B drops, the orifice
effect of main valve (1) generates a difference in
pressure between port A and port B. The main
valve is pushed open and the oil from port A
passes through port C and flows to the drain cir-
cuit to release the abnormal pressure.
The set pressure can be varied by changing the
tension of pilot poppet spring (4). To change the
set pressure, remove cap nut, loosen lock nut and
turn adjustment screw (5) as follows.
56OBFO72
61-22 WA350-1
STRUCTURE AND FUNCTION MAIN CONTROL VALVE,
SAFETY VALVE (with suction valve)
I. Valve body
2. Suction valve
3. Main valve
4. Main valve spring
5. Pilot piston
6. Suction valve spring
423F138
Function
. The safety valve (with suction valve) is in the
dump cylinder circuit in the main valve. If shock
causes any abnormally high pressure in the cylin-
der when the main valve is at neutral, the safety
valve (with suction valve) releases the abnormal
pressure and protects the cylinder from damage.
Operation
As a safety valve
. Port A is the cylinder circuit and port B is the drain
circuit.
The pressure oil in port A flows to port D through
a hole in the pilot piston. It also flows to port C
through an orifice consisting of the main valve (3)
and the pilot piston (5).
The pilot piston is secured to the safety valve by a
lock nut. The diameter of the cross section
(cross-sectional area) gives a relationship of d2 >
dl > d3 > da.
. If abnormally high oil pressure occurs in port A,

the suction valve (2) is not actuated because of
the relationship d2 > dl.
However, because of the relationship d3 > d4 in
port A and C, the hydraulic pressure on the main
valve (3) is equivalent to the area difference
between d3 and da. If this pressure goes up to the
poppet spring force (set pressure), the poppet is
actuated, and the oil in port A flows into port B.
423F139
WA350-1 61-23
As a suction valve
If negative pressure is generated in port A, port D

also has negative pressure, because port D and A
are connected with each other. The tank pressure
in port B is applied to port E.
Hydraulic pressure a equivalent to the area
difference between d2 and dl is applied to the
safety valve because of the tank pressure in port E.
Therefore, hydraulic pressure e acts to open the
valve and hydraulic pressure a acts to close the
suction valve (2):
If the pressure in port A drops, (approaching nega-
tive pressure) hydraulic pressure a becomes
smaller than oil pressure e.
When oil pressure e becomes larger than oil
pressure a + valve spring (6) force, the suction
valve (2) opens, causing the oil to flow from port
B into port A. This prevents negative pressure
from building up in port A.
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
: ,,,, ,,
,,, ,, ,,, 423F142
Operation
. If negative pressure is generated in port A (lift
cylinder rod end) (if the pressure is lower than in
port B in the tank circuit), the main poppet (I)
opens because of the difference in area between
dl and d2 . Oil then flows from port C at the tank
end to port A at the cylinder port end.
423F143
61-24 WA350-1
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
LIFT CYLINDER
1 2 \s 423F150
I Lift cylinder
1. Head
2. Rod Cylinder I.D. 150mm
I
3. Cylinder
4. Piston Rod dia. 90 mm
I
5. Lock ring
Cylinder max. length 2050 mm
I
Cylinder min. length 1337 mm
I
Stroke 713mm
I
WA350-1 61-25
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
DUMP CYLINDER
423F151
Dump cylinder
1. Head
2. Rod Cylinder I.D. 180mm
3. Cylinder
4. Piston Rod dia. 90 mm
5. Lock ring
Cylinder max. length 1550 mm
Cylinder min. length 1062 mm
Stroke 488 mm
I
61-26 WA350-1
@
Standard value table .. . . . 62- 2

Tool list for testing and adjusting .. 62- 3
Measuring dump and lift control levers . 62- 4
Adjusting dump and lift control levers 62- 5
Measuring hydraulic pressure . . 62- 6
Measuring lift arm and bucket . 62- 8
Measuring hydraulic drift of lift
arm and bucket .. . .. . 62- 9
Adjusting bucket positioner . .. 62-10
Adjusting boom kick-out . . 62-l 1
Troubleshooting . . . .. . 62-l 3
+ The following precautions are necessary when using the Standard Value Tables to make judgements during
The values in these tables are based on the values for new machines leaving the plant, so they should be
The standard values in these tables for judgement when troubleshooting are estimated values based on the
These standard value tables must not be used for standard values when judging claims. In addition, do not
WA350-1 62-1
0
Testing and measuring item Measurement condition Unit Standard value Permissible value
Dump lever and lift lever
l Lift lever operating force

(Hold-Raise) 1.7 -4.7 Max. 7.1
(Raise-Hold) 1.7 -4.7 Max. 7.1
(HolddLower) . Hydraulic temperature: 1.5 -4.5 Max. 6.8
(Lower-Hold) 45 - 55C 1.5 -4.5 Max. 6.8
(Lower-Float)
kg 2.8 - 5.8 Max. 8.7
(Float-Hold) 1.7 -4.7 Max. 7.1
l Dump lever operating force l Engine speed: Low idling

(Hold-Dump) 1.5 -4.5 Max. 6.8
(Hold-Tilt) 1.5 -4.5 Max. 6.8
(Tilt-Hold) 1.3 -4.3 Max. 6.5
l Lift lever travel

(Hold+Raise) 70-90 60 - 100
(HolddLower) 70-90 60 - 100
(Hold-Float) 108-128 98 - 138
mm
l Dump lever travel
(Hold-Dump) 70-90 60 - 100
(Hold-Tilt) 70-90 60 - 100
Main valve l Hydraulic temperature:

45 - 55C kg/cm2 210*5 210 f 10
l Main relief oil pressure l Engine speed: High idling
Lift arm and bucket operating Hydraulic temperature:

speed. 45 - 55C
l Lift arm lifting time Engine speed: High idling 5.4-6.0 Max. 7.2
l Lift arm lowering time Steering position:Neutral 2.7 - 3.3 Max. 4.0
l Bucket dumping time Coolant temperature: sec. 1.3 - 1.9 Max. 2.3
l Bucket tilt back time Inside operating range. 2.1 -2.7 Max. 3.2
(Full stroke) Bucket:un loaded
l Bucket tilt back time 0.9 - 1.5 Max. 1.8
(Horizontal position of bucket)
Hydraulic drift of lift arm Hydraulic temperature:

and bucket 45 - 55C
l Retraction of lift Coolant temperature: Max. 10 Max. 28
cylinder rod Inside operating range
Stop engine, lever for 5 mm
minutes, then measure
l Retraction of dump cylinder rod for next 15 minutes. Max. 10 Max. 48
Lift arm horizontal
Bucket horizontal
Unloaded
Bucket positioner Hydraulic temperature:

l Clearance of switch 45 - 55C Max. 5 -
mm
Boom kick-out
l Clearance of switch Max. 5
62-2 WA350-1
0
No. Testing and measuring item Tool Part number Remark

I
1 Hydraulic pressure Hydraulic tester
2 Oil temperature Thermistor kit
3 Engine speed Tachometer
4 Dump lever and lift

Push-pull scale 7AO-262-0020 O-25 kg
I lever operating force I
5 Measuring travel Convex scale Commercially available 0 - 2 mm
A When carrying cut testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
A Do not allow unauthorized persons near the machine.
A When measuring the engine speed, one worker should measure the engine speed while the other sits in the
operators seat to operate the controls. Always check that the operation is safe, and use agreed signals.
WA350-1 62-3
0
TESTING AND ADJUSTING MEASURING DUMP AND LIFT CONTROL LEVERS
MEASURING DUMP AND LIFT CONTROL LEVERS

l Hydraulic oil temperature: 45 - 55C
l Engine speed: Low idling
Unit: kg(mm)
Item
value value
( Hold-Raise ) 1.7-4.7 1 Max. 7.1
Float-Hold 1.7-4.7 Max. 7.1
Hold-Dump 1.5-4.5 Max. 6.8
Dump Hold-Tilt 1.5-4.5 Max. 6.8

control
lever Tilt-Hold 1.3-4.3 Max. 6.5
Hold-Raise (70-90) (60 - 100)

Lift
control Hold-Lower (70-90) (60-100)
lever Raise
Hold-Float (108-128) (98-138) #
*
Dump Hold-Dump (70-90) (60 - 100) t
control Tilt
lever Hold-Tilt (70-90) (60 - 100)
i, I
Special tool
A 7AO-262-0020 Push-pull scale 1
n
! Install the safety bar on the frame.
423F324
Measuring procedure
1. Operating force of dump and lift control levers
l Fit push-pull scale A on dump and lift control
levers and measure operating force.
* Hook the push-pull scale on the center of
the knob.
* Operate at the same speed as normal and
measure the minimum force needed to oper-
ate the knob.
2. Travel of dump and lift control levers

l Measure the travel X of the control levers at
each position.
t Mark the knob of the lever and use a scale to
measure.
62-4 WA350-1
0
TESTING AND ADJUSTING ADJUSTING DUMP AND LIFT CONTROL LEVERS
ADJUSTING DUMP AND LIFT CONTROL LEVERS

* Disconnect all the linkage before starting the ad- Lift lever raise position
justment procedure.
-
1. Put the dump control lever in the TILT position,
and the lift control lever in the RAISE position.
* Check the positions of the dump and lift lever
as shown in the diagram below.
2. Adjust the position of the magnetic switch so that

the clearance between plate (1) for connecting the
magnetic switch and lever pin (2) is the standard
value.
* Standard clearance: 0 - 2 mm 423F325
3. Put the dump and lift control levers in NEUTRAL,

adjust the length of rod (4) and connect main con-
trol valve and lever (3).
Sr Check the neutral positions of the dump and lift
control levers as shown in the diagram below.
* Check that the main control valve is in the NEU-
TRAL position.
* After making the above adjustment, measure

again and check that the measurements are the
standard value.
I
423F326
WA350-1 62-5
0
TESTING AND ADJUSTING MEASURING HYDRAULIC PRESSURE
MEASURING HYDRAULIC PRESSURE

Unit: kg/cm*
Item S tva,n,d;d Pervqimible
Main relief pressure 210*5 210 f 10
Special tool
Serial No. 10001 - 11 1 17 Serial No. 1 1 118 and UD

A 799-l 01-5000 Hydraulic tester 1
1, Measuring procedure (Main relief valve)
A Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank. Then
operate the control levers several times to
release the remaining pressure in the hydrau-
lic piping.
I) Remove plug (I) for measuring pressure of

dump cylinder circuit.
Serial No. 10001 - 11 1 17 Serial No. 1 1118 andUD
2) Install hydraulic tester A to measuring port.
* Check that there is no oil leakage from any
connection.
* Use a hose (2) which is long enough to
reach the operators compartment.
3) Start the engine, raise the lift arm 400 mm
from the ground and operate the dump control
lever (TILT). Measure the pressure when the
relief valve is actuated.
* Be careful not to apply any sudden pressure
to the pressure gauge.
A When removing the hydraulic pressure gauge,

release the pressure inside the circuit in the
same way as-when installing.
62-6 WA350-1
0
TESTING AND ADJUSTING MEASURING HYDRAULIC PRESSURE
To INCREASE pressure, TIGHTEN screw.

To DECREASE pressure, LOOSEN screw.
* If the relief pressure cannot be measured
accurately, do not try to adjust the pressure.
3 2
423F315A
WA350-1 62-7
0
TESTING AND ADJUSTING MEASURING LIFT ARM AND BUCKET
MEASURING LIFT ARM AND CKET

Lifting time of lift arm
Coolant temperature: Inside operating range
Steering position: Neutral
Bucket: Unloaded
Engine speed: High idling
Unit: set
Item
value value
Lifting time of lift arm 5.2-5.8 Max. 7.4

._
Lowering time of lift arm 2.5 -3.5 Max. 4.2
IDumping time of bucket 1.0-1.6 Max. 1.9

I
Special tool
7AO-262-0550 Stop watch 1
423F328
Dumping time of bucket
Measuring procedure
1. Lifting time of lift arm
Set the bucket near the maximum tilt back position
and at the lowest position on the ground. Raise
the bucket and measure the time taken for bucket
to reach the maximum height of the lift arm.
2. Lowering time of lift arm

Set the bucket horizontal with the lift arm at the
maximum height, lower the bucket and measure
the taken for the bucket to reach the lowest posi-
tion on the ground.
423F329
3. Dumping time of bucket
Tilt back time of bucket
Raise the lift arm to the maximum height and mea-
sure the time taken for the bucket to move from
the maximum tilt back position to the maximum
dump position.
4. 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 tilt back position.
2) Set the bucket horizontal and measure the time
taken for the bucket to move from the horizon-
tal position to the maximum tilt back position. 423F330
62-8 WA300-1
0
TESTING AND ADJUSTING MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET
MEASURING HYDRAULIC DRIFT OF LIFT ARM

AND BUCKET
Coolant temperature: Inside operating range
Stop engine, leave for 5 minutes, then measure
for next 15 minutes.
Lift arm horizontal
Bucket horizontal
Unloaded
Unit: mm
Ttem
value value
Retraction of lift cylinder rod Max. 10 Max. 28
Retraction-of dump cylinder rod Max. IO Max. 48
Special tool

Commercially
Convex scale 1
available
a. Frt the safety locks on the control levers.
A Do not go under the work equipment.
Measuring procedure
I) 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 and dump cylinder
rods retract during 15 minutes.
* Use the same orocedure to measure when the
bucket is unloaded and loaded.
* When measuring with bucket loaded, the load
423F331
may spill, so be careful.
A. Retraction of lift cylinder rod

B. Retraction of dump cylinder rod
423F332
WA350-1 62-9
@
TESTING AND ADJUSTING ADJUSTING BUCKET POSITIONER
ADJUSTING BUCKET POSITIONER

Sr Measurement conditions
Unit: mm
Item
value value
Clearance between proximity

Max. 5
switch and angle
1. Inspection procedure
I) With the engine stopped, check that the clear-
ance between switch (I) and angle (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
I) Lower the bucket to the ground and operate
the bucket to the desired digging angle. Return
the lever to the hold position and stop the
engine.
2) Adjust nut (4) of the proximity switch so that
clearance (a) between the tip of protector (3) of
proximity switch (I) and the face of the prox-
imity switch sensor is the standard value, then U42301OOg
lock in position.
* Clearance a: 0.5 - 1 .O mm
m Mut: 1.8 f 0.2 kgm
3) Use shim (5) and adjust protector (3) so that

clearance (b) between angle (2) and the tip of
protector (3) is the standard value.
Check that protector (3) and angle (2) are
not in contact.
Adjust with shims so that the clearance be-
tween angle (2) and the tip of protector (3) is
the standard value at the full stroke of the
angle, then lock in position. 2/ -Il-b
Check that the centers of the sensing sur-
face of the proximity switch and angle (2) U42301010
are in line, then lock in position.
After adjusting, operate the bucket lever and
check that the bucket positioner is actuated
at the desired position.
62-10 WA350-1
0
TESTING AND ADJUSTING ADJUSTING BOOM KICK-OUT
ADJUSTING BOOM KICK-OUT
Unit: mm
Item
value value
Clearance between proximity

Max. 5 -
switch and plate
1. Inspection procedure
I) With the engine stopped, check that the clear-
ance between switch (2) and plate (I) is the
standard value.
2) Start the engine, run at high idling and check
the act&ion position. (Measure three times
and take the average.)
2. Adjusting
1) Raise the lift arm to the desired position.
Return the lever to the hold position and stop
the engine.
A Always
trol lever.
apply the safety lock to the con-
2) Align the marking with the switch center and

adjust the plate (1) position so that the switch
(2) center and the plate lower end are in line
with each other.
3) Fix the switch so that the clearance between
the sensing surface of the switch (2) and plate 423F335
(1) is Max. 5 mm.
B Switch mounting nut: 1.8 f 0.2 kgm
* After adjusting, operate the lift lever and

check that the kick-out is actuated at the
desired position.
* Check that the sensing surface of the prox-
imity switch and plate (I ) are not in contact.
WA350-1 62-11
0
TROUBLESHOOTING
Troubleshooting table . .. . . ... .. 62-l 4

1. Lift arm does not rise . ... .. 62-l 4
2. Lift arm moves slowly or does not have
sufficient lifting power . . . .. 62-l 5
3. Lift arm movement becomes slow after it
reaches a certain height . .. .. . 62-l 6
4. Bucket cannot be held down with lift
cylinder. .... . .. . . . . 62-l 6
5. Lift arm has large hydraulic drift ... . 62-l 6
6. Lift arm movememt is unsteady
during work . . . .. .. .... 62-l 6
7. Lift arm descends momentarily
when control lever is shifted
from Hold to Raise . . . . . . . . . 62-l 6
8. Bucket does not tilt back . .. .. .. 62-l 7
9. Bucket moves slowly or has insufficient
tilt back power . . . . . . 62-l 8
10. Bucket movement becomes slow during
tilt back. . .. .. . . .. 62-l 9
11. Bucket cannot be held down by the dump
cylinder. ... .. .. .. .. . 62-l 9
12. Bucket has large hydraulic drift ... 62-l 9
13. Bucket moves unsteadily when machine travels
under load
(Main control vave in Hold) . . . . . . . . 62-l 9
14. Bucket dumps momentarily when control lever
is shifted from Hold to Roll back . 62-l 9
15. Cantrol levers of lift arm and dump
move stiffly and sluggishly . 62-20
RENCE OF TROUBLE page 22-16.
WA35071 62-13
0
1 Lift arm does not rise.

l Did the boom suddenly fail to rise? + Seizure
or damage to various units.
Was an unusual noise produced? (where dit it
emanate from?)
l Were there previous signs of the boom slowing
down. -L Wear of parts or flattening of spring.

l Is oil level in hydraulic tank correct?
l Is stroke of lift control lever and spool correct?
a b c d e f g
C A A A
No.
Problems xx xx xx
1 Bucket cannot operate and lift arm is unable to ascend. lololololol I
r The following symbols are used to

to be taken when a cause of failure
X: Replace
A: Adjust
indicate the action
is located.
A: Repair
C: Clean
62-14 WA350-1
0
2. Lift arm moves slowly or does not have

sufficient lifting power.

Is the amount of oil in the hydraulic tank and
also the type of oil correct?
Is the stroke of the lift control lever and also the
spool of the main control valve correct?
Seizure of bucket linkage bushing.
(Does emits unusual noise)
Fault check
There is a strong relationship between faults in-
volving lifting force and lifting speed. Such faults
appear initially in the form of insufficient lifting
speed._ Measure the lifting speed of the lift arm
when loaded and refer to the judgement criterion
table to determine whether or not there is a
-
No.
-
1
-
2
-
3
-
4
5
-
6
-
7
-
a
-

WA350-1 62-15
0
3. Lift arm movement becomes slow after it 6. Lift arm movement is unsteady during
reaches a certain height. work.
Check before troubleshooting During excavation or ground leveling when the lift
l Visible deformation of lift cylinder. arm control lever is in the Hold position, the
bucket and lift arm move up and down in accor-
Cause dance with the terrain.
. Swollen or internally damaged lift cylinder tube.
+ Regarding other faults occurring during lift arm Problem and cause
ascent, refer to item 2 Lift arm moves slowly Check the amount of hydraulic drift and whether
or does not have sufficient lifting power. or not the machine body can be lifted up by the lift
._
cylinder.
1. If the amount of hydraulic drift is greater than
the standard value, refer to item 5 Lift arm has
4. Bucket cannot be held down with lift arm large hydraulic drift.
cylinder. _ 2. If the machine body can be lifted up by the lift
If the relief pressure in the circuit at the bottom of cylinder, refer to tiem 4 Bucket cannot be held
the lift cylinder is insufficient, refer to item 2 Lift down with lift cylinder.
arm moves slowly or does not have sufficient lift- 3. If the amount of hydraulic drift is normal and
ing power. the machine body can be lifted up by the lift
cylinder after the lift arm is moved several
Checks before troubleshooting times to cause the lift cylinder to move through
l Is level of oil in the hydraulic tank correct? its entire stroke 4 the trouble is due to the gen-
l Is stroke of main control valve and lift spool eration of a vacuum in the cylinder.
correct? * If a vacuum is generated frequently, +
faulty suction valve on lift cylinder rod side.
Cause
l Faulty main control valve or suction valve seat
on lift cylinder rod side.
l Oil leakage from lift cylinder piston seal. 7. Lift arm descends momentarily when con-
trol lever is shifted from Hold to Raise.
The lift arm descends momentarily under its own
weight when the lift arm control lever is gradually
5. Lift arm has large hydraulic drift. shifted from the Hold position to the Raise po-
sition while the engine is at low idling. When the
Ask the operator the following questions. control lever is put completely into the Raise
l Did the hydraulic drift suddenly become large? position, the lift arm behaves normally.
+ Dirt lodged in valve or damaged parts. Cause
l Did the hydraulic drift gradually become large? l Faulty seating of main control valve or lift arm
+ Worn parts. load check valve.

l Is the type and temperature of the oil in the hy-
draulic tank correct?
l Is the lift arm spool in the neutral position? +
Seized link bushing, faulty spool detent.
Problem and cause

l When measuring hydraulic drift, internal of lift
cylinder produces oil leak noise -, Damaged
piston packing.
62il
6
WA350-1
8. Bucket does not tilt back.

l Did the bucket suddenly cease to move? -L
Seized or damaged equipment.
Was any unusual noise emitted (where dit it
emanate from)?
l Were there previous signs of the bucket slow-
ing down? + Worn parts or flattened spring.

l Is amount of oil in hydraulic tank satisfactory?
l Is the stroke of the bucket control lever and
spool correct?
a b c d e f g h
I
A A
No.
xxX xx
1 Lift arm cannot operate and bucket is unable to tilt back. 10101010101 101
The machine can be lifted up by the bucket but

2 the bucket cannot tilt back. Alternatively, the lift arm
operates but the bucket cannot tilt back. I I I I I loI loI
The bucket can tilt back under no load but cannot
3 0 0
excavate or scoop.
4 The hydraulic pump produces an unusual noise. 0 0
5 Bucket cylinder has large hydraulic drift. 000

Steering action is light and excessively fast when the
6
engine is at full throttle.
0
7 Steering action is heavy and slow when the engine is A

A: Adjust C: Clean
62-17
0
9. Bucket moves slowly or has insufficient

tilt back power.

l Is the oil quantity in the hydraulic tank and the
type of oil satisfactory?
l Is the stroke of the bucket control lever and the
main control valve spool correct?
l Seizure of bushing in bucket linkage.
(Does emits unusual noise)
Fault checks _-
l Check the amount of deficient tilt back force
by performing actual work.
l Measure the operating speed of the bucket and
check it against the judgement criterion table to
determine whether or not it is normal.
The following symbols are used to Indicate the actlon

to be taken when a cause of fatlure IS located.
62-18 WA350-1
0
10. Bucket movement becomes slow during 13. Bucket moves unsteadily when machine
tilt back. travels under load. (Main control valve in
Hold).
. External deformation of dump cylinder. Checks before troubleshooting
l Is oil level in hydraulic tank and type of oil
Cause correct?
l Swollen or internally damaged dump cylinder l Excessive play in pin and bushing of work
tube. equipment linkage.
Regarding other faults which occur when the l Was an unusual noise produced?
bucket operates, refer to item 9 Bucket moves
slowlyor has insufficient roll back power. Cause
l Faulty piston seal of dump cylinder.
11. Bucket cannot be held down by the l Faulty safety valve with suction valve for the
bucket cylinder. bottom side of dump cylinder.
Refer-to item 9 Bucket moves slowly or has insuf- If the above symproms occur together with
ficient tilt back power. other symptoms, refer to the problems items
corresponding to each fault.
Check before troubleshooting
l Is oil level in the hydraulic tank satisfactory? 14. Bucket dumps momentarily when control
l Is the stroke of the main control valve dump lever is shifted from Hold to Tilt back.
spool correct? The bucket dumps momentarily under its own
weight when the dump control lever is gradually
Cause shifted from the Hold position to the Tilt back
l Faulty seat of safety with suction valve of con- position while the engine is at low idling. When the
trol valve for the bottom side of dump cylinder. control lever is put completely into the Tilt back
l Oil leakage from seal of dump cylinder piston. position, the bucket behaves normally.
12. Bucket has large hydraulic drift, Cause

l Faulty seating of main control valve dump
Ask the operator the following questions. spool check valve.
l Did the hydraulic drift suddenly become large?
+ Dirt lodged in valve or damaged parts.
l Did the hydraulic drift gradually become large?
--L Worn parts.
Check before troubleshooting

l Is the type and temperature of the oil in the hy-
draulic tank correct?
l Is the dump spool in the neutral position? --L
Seized link bushing, faulty spool detent.
Fault check
l Use the judgement criterion table to check
whether or not the hydraulic drift of the bucket
is actually large.
l If hydraulic drift is large.
Cause: Oil leakage in dump cylinder.
l 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.
WA350-1 62-19
0
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.
The following symbols are used to indicate the actIon

X: Replace a : Repair
A: Adjust C: Clean
62-20 WA350-1
0
HYDRAULIC TANK LIFT CYLINDER

Removal . . . . . . . . . . . . . ..__... 63- 2 Removal . . . .._..............__ 63-25
Installation . . . .. 63- 4 Installation . . 63-26
HYDRAULIC FILTER HYDRAULIC CYLINDER ASSEMBLY

Removal _........__........_ 63- 6 Disassembly ._..........._____.. 63-27
Installation .. 63- 6 Assembly . . . . . . . . . . . .._........ 63-29
HYDRAULIC, STEERING PUMP WORK EQUIPMENT

Removal . . . . . . . . . . . .._..... . 63- 7 Removal . . . . . . . . . . . .._......... 63-32
Installation . . 63-10 Installation . . . .. . ... 63-35
MAIN CONTROL VALVE COUNTERWEIGHT

Removal . . . 63-13 Removal ..____...........____.. . 63-38
Installation . . . . . 63-16 Installation . . .. . 63-38
Disassembly . . . 63-18
Assembly . . . 63-20
DUMP CYLINDER
Removal . 63-22
Installation . 63-24
WA350-1 63-1
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC TANK
A Stop
the safety
and install
the bucket
pressure inside the hydraulic tank. Then operate
l Loosen plug (I)_ at the top of the hydraulic tank

Open hood (3) and fit lock (4).

A
I) Remove clamps of wiring and vinyl tube for

tank (5) from hood (6).
2) Sling hood (6). remove mounting bolts, then lift

off.
* Be careful not to hit the rear window of the
Hood: 62 kg
63-2 WA350-1
0
2. Hydraulic piping
I) Loosen clamp of hose (7) between hydraulic
tank and hydraulic pump.
and main control valve from hydraulic tank.
and work equipment circuit from hydraulic tank.
3. Brake oil tank

Remove mounting bolts of brake oil tank (IO),
then remove from hydraulic tank (I I).
t Remove the hose clamp of the brake oil tank.
4. Hydraulic tank
Sling hydraulic tank (I I), remove mounting bolts,
then lift off.
when lifting off the hydraulic tank.
* The bottom of the hydraulic tank is not flat, so
use blocks when standing it on the floor.
Hydraulic tank: 147 kg
WA350-1 63-3
0
INSTALLATION OF HYDRAULIC TANK

2. Hydraulic tank
I) Raise hydraulic tank (I I), set in mounting
position, then install mounting bolts.
t The rear window of the cab is close, so be
careful when lifting the hydraulic tank.
* Align the connections of the hoses when
setting in mounting position.
* Fit the tip of the oil drain hose in the clamp
on the rear frame.
2. Brake oil tank

Install brake oil tank (I 0) to hydraulic tank, then in-
stall hose clamp.
3. Hydraulic piping
I) Connect hose (9) between hydraulic tank and
work equipment circuit at hydraulic tank end.
installing.
* Install the hose without twisting or
interference.
main control valve at hydraulic tank end.

hydraulic pump at tube (I 2) of hydraulic tank,
then tighten clamp (I 3).
63-4 WA350-1
0

stail clamps of wiring and vinyl tube for
window washer.

Tighten plug (I) at top of hydraulic tank filter, and
plug (2) of pump piping, then add hydraulic oil
through oil filler (I 4) to the specified level.
* Run the engine to circulate the oil through the
WA350-1 63-5
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
REMOVAL OF HYDRAULIC FILTER

! Loosen the oil filler cap slowly to release the
-ss pressure inside the hydraulic tank.
1. Cover
Remove mounting bolts, then remove cover (I 1.
! The tension of the spring is pushing the

0 cover, so be careful when removing.
t Be careful not to damage the O-ring on the con-
tact faces of the cover and tank.
2. Filter
Remove spring (2) and bypass valve (31, then
remove filter (4).
INSTALLATION OF
HYDRAULIC FILTER
1. Filter
Install filter (41, then install bypass valve (3) and
spring (2).
2. Cover
Fit O-ring (5) in groove of cover, then install cover
(I 1to tank.
* 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.
63-6 WA350-1
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC, STEERING PUMP
REMOVAL OF HYDRAULIC, STEERING PUMP
A Stop
the safety
and install
the bucket
0! Loosen
pressure
to release
tank. Then operate
the

. Loosen p!ug (I) at the top of the hydraulic tank

2) Sling hood (6). remove mounting bolts, then lift

off.
* Be carerul not to hit the rear window of the
2..
m Hood: 62 kg
WA350-1
2. Hydraulic piping
I) Disconnect hose (7) between hydraulic tank
and work equipment circuit from hydraulic tank.
and main control valve from hydraulic tank.
3) Loosen clamp of tube (9) between hydraulic
tank and hydraulic pump, and disconnect from
hydraulic tank.
3. Brake oil tank

Remove mounting bolts of brake oil tank (IO),
then remove from hydraulic tank.
4. Hydraulic tank
Sling hydraulic tank (1 I), remove mounting bolts,
then lift off.
when lifting off the hydraulic tank.
k The bottom of the hydraulic tank is not flat, so
use blocks when standing it on the floor.
63-8 WA350-1
0
5. Steering, hydraulic pump

I) Disconnect hose (12) between steering pump
and steering valve at steering and hydraulic
pump end.
2) Disconnect hose (13) between hydraulic pump
and steering valve at steering and hydraulic
pump end.
3) Disconnect tube 114) between hydraulic pump
and hydraulic tank at steering and hydraulic
pump (15) end.
4) Fit sling around steering and hydraulic pump

(15), and raise. Remove mounting bolts, then
lift off.
Steering, hydraulic pump: 26 kg
WA350-1
63-9
0
INSTALLATION OF HYDRAULIC, STEERING PUMP

1. Steering, hydraulic pump
1) Raise pump (15). set in mounting position, then
..
2) Install tube (14) between hydraulic pump and

hydraulic tank at steering pump end.
3) Connect hose (I 2) between steering pump and
steering valve at steering and hydraulic pump
end.
installing.
4) Connect hose (13) between hydraulic pump
and steering valve at pump end.
2. Hydraulic tank
Raise hydraulic tank (1 I), set in mounting
position, and install mounting bolts.
* The rear window of the cab is close, so be care-
ful when lifting the hydraulic tank.
t Align the connections of the hoses when set-
ting in mounting position.
t Fit the tip of the oil drain hose in the clamp on
the rear frame.
63-10 WA350-1
0
3. Brake oil tank

1) Install brake oil tank (10) to hydraulic tank.
2) Install hose clamp of brake oil tank.
4. HI fdraulic piping
I) Tighten clamp of hose (I 6) between hydraulic
tank and hydraulic pump at hydraulic tank end.

main control valve at hydraulic tank end.
work equipment circuit at hydraulic tank end.
installing.
* Install the hose without twisting or
interference.
5. H ood
II1Raise hood (6). set in mounting position, then
WA350-1 63-11
0
2) install window washer tank (5) to hood, then in-

stall clamps of wiring and vinyl tube for
window washer.

Tighten plug 11) at top of hydraulic tank filter, and
through oil filler (17) to the specified level.
t Run the engine to circulate the oil through the
63-12 WA350-1
0
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL OF MAIN CONTROL VALVE
A Stop
the safety
and install
the bucket
-r(
! Loosen
pressure
the oil filler
cap slowly to release
tank. Then operate
the

.
l Loosen plug (1) at the top of the hydraulic tank
) Open hood (3 ;) and fit lock (4).

Q
1. Hood
I) Remove clamps of wiring and vinyl tube for
tank (5) from hood (6).
2) Sling hood (61, remove mounting bolts, then lift

off.
* Be careful not to hit the rear window of the
Hood: 62 kg
WA350-1 63-13
0
2. Brake oil tank

I) Remove hose clamp from brake oil tank (7).
2) Remove mounting bolts of brake oil tank, then
put brake oil tank on top of bracket of hydraulic
tank (8).
3. Hydraulic piping
1) Disconnect hose (9) between main control
valve and hydraulic tank at hydraulic tank end.
2) Remove clamp (I 0) of tube.
3) Remove clamp (I 1) of tube.
4) Disconnect dump cylinder tube (I 2) and hose
(13) from main control valve.
5) Disconnect lift cylinder tubes (14) and (I 5)
from main control valve.
6) Disconnect tube (I 6) between main control
valve and steering valve at main control valve
end.
7) Disconnect hose (17) between main control
valve and work equipment circuit at main con-
trol valve end.
63-14 WA350-1
0

1) Disconnect control linkage (18) from main con-
trol valve.
2) Sling main control valve (19). remove mounting

boks, then lift off.
t When using a nylon sling to lift off the main
control valve, be careful to maintain the
balance.
el kg Main control valve: 74 kg
WA350-1 63-15
INSTALLATION OF MAIN CONTR ;OL VALVE

1) Raise main control valve (19). set in mounting
* Tighten the mounting bolts fully after install-
ing the tubes and hoses.
2) Connect control linkage (18) to main control

valve. -
2. Hydraulic piping
1) Connect hose (17) between main control valve
and work equipment circuit at main control
valve end.
2) Connect tube (I 6) between main control valve
and steering valve at main control valve end.
3) Connect lift cylinder tubes (14) and (I 5) at
main control valve end.
4) Connect dump cylinder tubes (I 2) and hose
(13) at main control valve end.
5) Install clamp (I I) of tube.
6) Install clamp (IO) of tube.
7) Connect hose (9) between main control valve
and hydraulic pump at main control valve end.
t Fit the O-rings securely in the grooves, and
installing.
* Install the hoses without twisting or
interference.
63-16 WA3561
0
3. Brake oil tank

1) Install brake oil tank (7) to hydraulic tank (8).
2) Install hose clamp on brake oil tank.
4. Hood
I) Raise hood (61, set in mounting position, then

stall clamps of wiring and vinyl tube for
window washer.

Tighten plug (I) at top of hydraulic tank filter, and
through oil filler (20) to the specified level.
+ Run the engine to circulate the oil through the
WA350-1 63-17
0
DISASSEMBLY OF MAIN CONTROL VALVE

1. Case assembly
1) Remove bolt (I ), then remove case assembly
(2).
2) Remove plate (31, then loosen bolt (5) of lever
z
(4).
3) Remove shaft (6) from lever (4).
4) Remove oil seal (7) and bearings (8) and (9).
0
27---Q
.
26---B
2. Spool assembly
1) Remove case (IO), then remove spool assembly
(I I). 24
2) Remove bolt (I 2). then remove retainer (I 3).
spring (141, and retainer (I 3) from spool (I 5).
* Remove bolt (I 2) with the spool still assem-
bled in the valve body.
3. Main relief valve assembly (with suction)

1) Remove main relief valve assembly (1 7).
2) Loosen nut (I 81, then remove holder (I 9).
3) Remove poppet (201, spring (21) and retainer
(22).
4) Remove seat (23) from sleeve (251, then
remove spring (24).
t If there is any abnormality in sleeve (25).
valve (26) or plug (27). replace the whole
assembly. These parts are not available
individually.
4. Safety valve with suction valve assembly

Remove safety valve assembly (28).
5. Suction valve assembly

Remove suction valve assembly (29).
423F460
6. Check valve
Remove plug (30). then remove spring (31) and
valve (32).
63-18 WA350- 1
0
423F459
WA350-1 63-19
0
ASSEMBLY OF MAIN CONTROL VALVE

1. Check valve
Assemble valve (32) and spring (31) in body (331,
fit O-ring, then tighten plug (30).
D Plug: 47.5zb2.5 kgm
2. Suction valve assembly

Fit O-ring
valve assembly
w
and
Suction
back-up
(29).
valve:
ring, then
14f 1 kgm
install suction
z
0
27-G
264
3. Safety valve with suction valve assembly

Fit O-ring and back-up ring, then install safety
valve assembly (28).
24
Qz Safety valve: 142 1 kgm
4. Main relief valve assembly 0

1) Assemble spring (24) in sleeve (251, then install
seat (23).
2) Assemble poppet (201, spring (21) and retainer
23-g
(23) in sleeve (25).
3) Screw nut into holder (I 91, fit O-ring, install
20-il a
sleeve (25), then tighten nut (I 8).
E
4) Fit O-ring and back-up ring, then install main 21-s
relief valve (I 7).
22--z
w Main relief valve: 15.5k2.5 kgm
,*A 0
5. Spool assembly 19
1) Assemble retainer (I 31, spring (I 4) and retainer 3 0
(13) in spool (I 5), then tighten bolt (I 2).
B Bolt: 7kO.5 kgm
* When tightening bolt (121, tighten with the

spool assembled in the valve body.
2) Assemble spool assembly (I 1) in body, fit O-
ring, then install case (10).
6. Case assembly 423 F460
1) Install bearings (9) and (8). and oil seal (7) in

case.
2) Assemble lever (4) inside case, fit key, then in-
stall shaft (6) to lever (4) inside case.
3) Tighten bolt (5).
4) Fit O-ring, align lever (4) with spool, then install
case assembly (2).
63-20 WA350-1
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
MAIN
a
423 F459
WA350-1 63-21
0
DISASSEMBLY AND ASSEMBLY DUMP CYLINDER
REMOVAL OF DUMP CYLINDER

9! Loosen the oil filler cap slowly to release the

1 Bucket positioner
Disconnect connector (I 1.
2. Rod pin
Sling cylinder, remove lock bolt, then remove pin
(2).
* When raising the cylinder, sling at two places
and be careful to maintain the balance.
3. Hydraulic piping
I) Disconnect hose (3) at rod end from cylinder
63-22 WA350-1
0
2) Disconnect tube (4) and hose (5) at bottom

from connector.
4. Dump cylinder
1) Remove lock bolt, then remove pin (6) at
bottom end.
+ There are shims installed, so check the
2) Remove dump cylinder (7).

Dump cylinder: 185 kg
WA350-1 63-23
0
INSTALLATION OF DUMP CYLINDER

1. Dump cylinder
I) Raise dump cylinder (7) and set in mounting
position.
2) Align pin hole at bottom end, assemble shim so

that clearance a between cylindei and frame
on left and right is within specified range, then
install pin (6) and lock with bolt.
Clearance a: Max. 3 mm
423F461
3) Align pin hole at rod end, then install pin (2) and
lock with bolt.
a Use a bar to align the pin holes. Never use your

fingers.
2. Hydraulic piping
1) Connect tube (4) and hose (5) at bottom end.
2) Connect hose (3) at rod end.
* Fit the O-rings securely in the grooves.
+ Install the hose without twisting or
interference.
3. Bucket positioner
Connect connector (I ).
Sr For details of adjusting bucket positioner, see
62 TESTING AND ADJUSTING.
63-24 WA350-1
0
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
REMOVAL OF LIFT CYLINDER
a Stop
the safety
the machine
bar on the frame.
on level ground
Lower
and install
the bucket
+ Place a support under the lift arm.
1. Rod pin
I) Sling lift cylinder (I ), remove lock bolt, then
remove pin (2).
* If shims are inserted, check numbers of
shims.
2) Start engine, and operate control levers to re-
tract cylinder rod on side where pin has been
removed.
2. Hydraulic piping
1) Disconnect tube (3) and hose (4) at rod end
from connector.
2) Disconnect tube (5) and hose (6) at bottom end
from connector.
3. Lift cylinder
I) Remove lock bolt, then remove pin (7) at
bottom end.
2) Remove lift cylinder (I 1.
+ Be careful of the center of gravity, and
remove slowly.
Lift cylinder: 149 kg
WA350-1 63-25
@
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
INSTALLATION OF LIFT CYLINDER

1. Lift cylinder
1) Raise lift cylinder (1) and set in mounting
position.
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 (7) and lock with bolt.
A Use a bar to align the pin holes. Never use your
fingers.
Clearance a: Max. 3 mm
a a
423F461
2. Hydraulic piping
1) Connect tube (5) and hose (6) at bottom end.
2) Connect tube (3) and hose (4) at rod end.
t Fit the O-rings securely in the grooves.
* Install the hoses without twisting or
interference.
3. Rod pin
Start engine, operate control levers to extend rod,
align pin holes, insert shims so that clearances b
are even. Then install pin (2), lock with bolt.
* Remove the support. Clearance b must be
less than 2.0 mm
WA350-1
63-26
@I
HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
Special tool
Part number Part name wty

A 790-502-l 001 Cylinder repair stand 1
1. Set cylinder assembly (1) tool A.
2. Remove mounting bolts (2) of cylinder head.
3. Pull cylinder head and piston rod assembly (3)

about 900 mm out of cylinder (4) and lift off.
t Oil will come out when the piston rod assembly
is removed from the cylinder, SO place a
container in position to catch the oil.
4. Remove piston bolt (51, then remove spacer (6),

piston assembly (7) and cylinder head assembly
(8).
WA350-1
63-27
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
6. Disassemble piston assembly as follows.

Remove wear ring (12) and piston ring (13) from
piston (I 4).
7. Disassemble cylinder head assembly as follows.

1) Remove O-ring (I 5) and back-up ring (16).
2) Remove snap ring, then remove dust seal (I 7).
207P494A 207P495A
3) Remove rod packing (I 8)

4) Remove bushing (I 9).
207P496A I8 207P497A 79
WA350-1
63-28
0
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
Special tools
1 796-720-1690 1 Ring II
* 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
packing, dust seals or O-rings when installing.
1. Assemble cylinder head assembly as follows.

I) Using push tool 0, press fit bushing (19) on
cylinder head (20).
+ Be careful not to deform the bushing when
press fitting.
2) Assemble rod packing (I 8).
* Be careful to install the rod packing facing in
207P498A 207P497A 19
the right direction.
208F240A
3) install back-up ring (I 6) and O-ring (I 5).

* Do not try to force the back-up ring into
position. Warm it in warm water (50 to
60C) before fitting it.
4) Using push tool @, install dust seal (17) on

head, then secure with snap ring.
207P495A
WA350-1 63-29
0
2. Assemble piston assembly as follows.

1) Using tool B, expand piston ring (131.
* Set the piston ring on the tool C and turn the
handle 8 to 1 1 times to expand the ring.
2) Remove piston ring (13) from tool B and
assemble on piston (14).
3) Fit tool C on piston ring and compress piston
ring with clamp 0,
+ Parts No. of clamp 0,
07 28 1-O 19 19 (Lift cylinder)

07281-02169 (Bucket cylinder)
4) Assemble wear ring (12) on piston.
3. Assemble O-ring (IO) and back-up ring (I I) on

piston rod (9).
423F484
4. Assemble cylinder head assembly (8) and piston

assembly (7) on piston rod.
* Apply the grease to rod to prevent back-up ring
(I 1) from stick out.
5. Assemble spacer (6) then tighten piston bolt (5).

Zr Width across flats of socket: 19 mm
B Piston bolt: 10 - 12.5 kgm
63-30 WA350-1
0
6. Set cylinder (4) in tool A, then raise cylinder as-

sembly and piston assembly (3) and install in
cylinder.
7. Tighten mounting bolt (2) of cylinder head.
6. Remove cylinder assembly (I 1from tool A.
WA350- 1 63-31
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
RE MOVAL OF WORK EQUIPMENT
B Stop the machine on level ground and install

1. Bucket link
I) Remove mounting pin (I) of bucket link.
+ Tie the bucket link to the tilt lever with wire.
2) Remove left and right mounting pins (2) of

bucket hinge.
A Do not put your fingers in the pin hole.
3) Drive machine in reverse to disconnect bucket.
Bucket (with teeth): 1,900 kg
2. Dump cylinder pin

Sling dump cylinder (31, remove pin (41, then
disconnect cylinder rod and tilt lever.
+ Insert a block between the cylinder bottom and
frame.
Dump cylinder: 185 kg
3. Lift cylinder pin

Sling lift cylinder (51, remove pin (61, then remove
lift cylinder.
+ If shims are inserted, check numbers of shims.
t Place a support under the tip of the lift arm.
* Place a block on top of the axle, and lower the
cylinder onto it.
Lift cylinder: 149 kg
63-32 WA350-1
@
4. Lift arm, tilt lever, bucket link assembly

Sling lift arm, tilt lever and bucket link assembly
(71, remove mounting pin (8) of lift arm, then lift
off lift arm.
ks
C!Yl Lift arm, tilt lever, bucket link assembly:
1,290 kg
* If there are any shims, check the number and
thickness of the shims, and keep in a safe place.
5. Tilt lever, bucket link assembly

1) Remove pin (I 0) from tilt lever (I I) and bucket
link assembly (9). and disconnect tilt lever (I I)
and bucket link assembly (I 2).
2) Sling tilt lever (I I), remove mounting pin (131,

then lift off from lift arm (I 4).
&?Ikg
Tilt lever: 248 kg
Bucket link: 52 kg
6. Dust seal, bushing

1) Remove dust seal (I 5) and bushing (I 61 from
lift arm (I 4).
423F475
WA350-1 63-33
2) Remove dust seal (I 7) and bushing (18) from

tilt lever (1 1).
423F476
3) Remove dust seal (I 9) and bushing (20) from

bucket link (12).
423F477
63-34 WA350-1
0
INSTALLATION OF WORK EQUIPMENT
Q1 Use a bar to align the pin holes. Never use your

fingers.
1. Dust seal, bushing

Using a press, press fit bushing (16) in bucket link,
tilt lever, and lift arm, then assemble dust seal (I 5).
& Bushing: Grease (G2-LI)
423F478
2. Tilt lever, bucket link

I) Align holes of tilt lever (I I) and lift arm (141,
assemble shim so that clearance a on left
and right is equal, then install mounting pin (13)
and lock with bolt.
* Clearance a: Max. 1.5 mm
F42301009
2) Assemble cord ring on bucket link (121, align

holes of tilt lever (1 I), then install pin (I 0) and
lock with bolt.
t Tie the bucket link to the tilt lever with wire.
* Make sure that the cord ring is not caught.
WA350-1
3. Lift arm, tilt lever, bucket link assembly

1) Raise lift arm, tilt lever, and bucket link
assembly, and set in mounting position. Align
holes at mount of front frame and lift arm,
assemble shim so that clearance b on left
and right is equal, then install mounting pin and
lock with bolt.
+ When installing the lift arm, be careful not to
damage the boom kick-out switch, and set
in mounting position.
+ Clearance b: Max. 1.5 mm
* After installing the pin, set a support under
the tip of the boom.
b 423F479
4. Lift cylinder
Sling lift cylinder (5). start engine and align cylinder
rod with boom mounting hole. Then install shims
so that clearances e are even. Install pin (61,
then lock with bolt.
Before starting the engine, check that the gear

A
shift levers are locked.
5. Dump cylinder
Sling dump cylinder (3) and operate control lever
to align pin holes. Install pin (4), then lock with bolt.
* After installing the pin, remove the block.
WA350-1
63-36
&I
6. Bucket
1) Operate control lever to align hole of bucket
mounting pin (2). Assemble shim so that clear-
ance c on left and right is equal, then install
mounting pin (2) and lock with bolt.
+ Clearance c: Max. 1.5 mm
i:
423F480
2) Install cord ring (20).
7. Bucket link
1) Raise bucket link (I 21, align hole of mounting
pin (IO). Assemble shim so that clearance d
on left and right is equal, then install mounting
pin (IO). and lock with bolt.
Sr Clearance Id: Max. 1.5 mm
d
423F481
2) Install cord ring.
8. Greasing
Grease all pins.
WA350-1
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
a Stop the
the safety
and install
the bucket
1. Grille
Remove grille (I 1.
2. Counterweight
Sling counterweight (Z), remove mounting bolts,
then lift off counterweight.
+ Be careful to maintain the balance when remov-
ing the counterweight.
* Be careful not to damage the back-up lamp.
Counterweight: 785 kg
INSTALLATION OF COUN-
TERWEIGHT
1. Counterweight
Raise counterweight (2). set in mounting position,
* Be careful not to damage the back lamps.
w Mounting bolt: 94.5* 10.5 kgm
2. Grille
Install grille (1).
63-38 WA350-1
0
Main control valve (for 2-Spool) ............ 64- 2

Main control valve (for 3-Spool)lif equipped) 64- 3-l
Dumpcylinder ............................ 64- 4
Lift cylinder.............................. 64- 5
Bucket linkage ............................ 64- 6
Bucket positioner and boom kick-out ....... 64- 8
Bucket ................................... 64- 9
Hydraulic and steering pump ............... 64-l 0
WA350-1 64-l
@
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

For 2-Spool
6
16
1
11
10
18 17 3
Section A-A
423F229
64-2 WA350- 1
a
. Unit: mm
Standard size
Spool return spring

(for DUMP, LIFT)
Check valve spring
rque of plug at end of spool
g torque of adjustment lever
15 Tightening torque of plug 7.0* 1 .O kgm
16 Tightening torque of case mounting bolt 3.2kO.3 kgm
17 Tightening torque of plug 47.522.5 kgm
18 Tightening torque of plug 37 5* 2.5 kgm
WA350-1 64-3
MAIN CONTROL VALVE

For 3-Spool (If equipped)
F424CO126
64-3-l WA350-1
670
.. Unit: mm
Spool return spring Free installation installation Free Installation

1 length length load length load
(for DUMP, LIFT. ATTACHMENT)
76.3 49 9 kg - Replace
- possibly to
- - use again if
39.5 25 - - no damage or
2 Main valve spring of main relief valve 3 kg
deformation
32.6 24.5 4.5 kg - -

3 Check valve spring
4 Suction valve spring 27.9 18 0.7 kg - -

I
5 Poppet spring of relief valve 49.3 41.9 26.4 kg 47.8 21.2 kg Replace
Tightening torque of plug at end of spool 6.8 f 0.7 kgm

6
(DUMP, LIFT, ATTACHMENT)
7 Tightening torque of joint at end of spool 6.8 2 0.7 kgm

I I I
8 Tightening torque of adjustment lever 3.2 -C 0.3 kgm
lock bolt I
9 Tightening torque of cover mounting bolt 3.2 2 0.3 kgm
10 Tightening torque of main relief valve 15.5 ? 2.5 kgm
11
Tightening torque of adjustment screw
lock nut I
3.2 ? 0.3 kgm
1 Retighten
,2 Tightening torque of safety valve with suction 14.02 l.Okgm

valve
13 Tightening torque of suction valve 14.0 2 1.0 kgm
14 Tightening torque of plug 15.5 ? 2.5 kgm
15 Tightening torque of plug 7.0 ? 1 .O kgm
16 Tightening torque of case mounting bolt 3.2 2 0.3 kgm
17 Tightening torque of plug 47.5 t 2.5 kgm
18 Tightening torque of plug 37.5 f 2.5 kgm

I I
WA350-1 64-3-2
@
MAINTENANCE STANDARD DUMP CYLINDER
DUMP CYLINDER
@~
v~i ,,,
~
10 0
0
lo 0
r____~
4 0
L----J
c_________-____,
.tJ
,,,,,,, ys
,,
,,
423F230
Unit: mm
Clearance
limit
fi
1 Clearance between rod and bushing
0.777 Replace
bushing
Clearance between piston rod mounting pin
2 110
-0.036 +0.207 0.156 -
and bushing -0.090 +6.120 1 .o
0.297
Clearance between cylinder bottom mounting
3 110
-0.036 +0.207 0.156 -
pin and bushing -0.090 +0.120 1 .o
0.297
4 Cylinder bore 180 +0.4 - -

0 Replace
- I
Tightening torque of cylinder head
5 2002 50 kgm
mounting bolt
6 Tightening torque of piston mounting bolt 11.5fl.O kgm
64-4 WA350-1
MAINTENANCE STANDARD LIFT CYLINDER
LIFT CYLINDER
423F231
Unit: mm
1 Clearance between rod and bushing 1 1 ,
-
90 -0.120
-0.207
-10.270
+0.061
0.181
0.477
0.777
2 Clearance between piston rod mounting pin 95 -0.036 +0.35 0.156 - 1 .o Replace
and inside diameter of hole -0.090 +0.20 0.297
3 Clearance between cylinder bottom mounting 95 -0.036 +0.207 0.156 - 1 .o Replace

pin and bushing -0.090 +0.120 0.297 bushing
4 Cylinder bore 150 - +0.35 - - Replace

0
Tightening torque of cylinder head

5 12Oi30 kgm
mounting bolt
Retighten
6 Tightening torque of piston mounting bolt 11.5%1.0kgm
WA350-1 64-5
MAINTENANCE STANDARD BUCKET LINKAGE
BUCKET LINKAGE
J-l
Serial No. 11118 and up %&I i-i
U42301011
1, -SerialNo.
10001 - 11117
I \
a b
a b
Section A-A Section B-B Section C-C
5 4
a il a b a b
Section D-D Section E-E Section F-F
a b a b a b
Section G-G Section H-H Section J-J

423F233
64-6 WA350-1
0
MAINTENANCE STANDARD BUCKET LINKAGE
Unit: mm
No. Check Item Criteria Remedy
Clearance between pin and bushing at boss

ends of bucket link
9 Joint of bucket cylinder and frame
on both sides
11
12
12
14 Joint of tilt lever and bucket link 1 14i 1.2 116:; 0.6 - 4.2
-
15 Joint of tilt lever and lift arm 200 t 0.5 203 2 0.5 2-4 Replace
IE Joint of tilt lever and bucket cylinder 11o+o.*

0
113+; 2.2 - 4
li Joint of lift cylinder and lift arm 103 * 1.5 106 f 1.5 O-6
WA350-1 64-7
0
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
423F235
Section A-A
Unit: mm
1 Clearance of bucket positioner switch 3-6
Adjust
2 Clearance of boom kick-out switch 3-6
3 Tightening torque of mounting bolt for adjuster 9.0 ?z 3.5 kgm
Retighten
1.8 f 0.2 kgm
for switch
64-8 WA350-1
0
MAINTENANCE STANDARD BUCKET
BUCKET
Serial No. 10001 - 11117
Section B-B
Section A-A Section C-C
Serial No. 11118 and up 423F234
B 65 - 87 kgm
U42301007
Section K-K
Unit: mm
Remedy
No. Check item Criteria
I Standard size I Repair limit I

Replace
1 Wear of bucket tooth
50 18.5
2 Clearance of bucket tooth mounting

I
Less than 0.5
I Replace or
adjust
WA350-1 64-9
0
MAINTENANCE STANDARD HYDRAULIC AND STEERING PUMP
HYDRAULIC AND STEERING PUMP

SAR(S)-80 + 50
(SAR(3)-80 + 40)
i
2 5
423F228
Section A-A
I Hydraulic pump I Steering pump 1

I
SAR(3)-80 I SAR(3)-50
I
(SAR(3)-40)
k.
Unit: mm
No.
Clearance between gear case and side plate,

1
gear
3
-
4
-
Discharge
Oil: EO-CD
( 1: Serial No. 1 11 18 and up

64-10 WA350-1
0
ELECTRIC AND
ELECTRONIC SYSTEM
Electric and electronic system ........... 81- 2

Electrical wiring diagram ................ 81- 3
Electrical wiring diagram circuit. ......... 81- 5
Engine starting circuit 81- 6
Engine stop circuit ..................... 81- 7
Preheating circuit ...................... . 81- 8
l Preheating and after-heating
with heater switch .................. 81- 8
l Preheating with starting switch ....... 81- 9
l Automatic preheating 81-10
Combination switch .................... 81-11
Electrical transmission control ........... 81-12
l Electrical transmission control diagram . 81-13
l Transmission cut-off switch .......... . 81-14
l Transmission cut-off selector switch . . 81-15
l Neutralizer relay . 81-16
Electrical parking brake control .......... 81-17
Electronic vehicle monitoring system
(EVMS) .............................. 81-26
. Monitor panel ....................... 81-26
l Indication on monitor panel ........... . 81-28
l Controller .......................... . 81-30
l Sensor _.___.__________,___.____.___ 81-31
l Wiring harness 81-37
l Operation of proximity switch ........ 81-38
81-38
WA350-1 81-l
STRUCTURE AND FUNCTION ELECTRIC AND ELECTRONIC SYSTEM
ELECTRIC AND ELECTRONIC SYSTEM

Outline
The WA350-1 is equipped with electric and electron-
ic systems as shown in Fig. 423F167 and Fig.
423F168.
These systems can be broadly divided into the fol-
lowing two groups.
1. The Electric system which is found on most
vehicles.
2. The Electronic vehicle monitoring system,
which detects and shown any abnormalities in the
machine.
81-2 WA350-1
1. Air compressor relay
ELECTRICAL WIRING DIAGRAM 2. Radio
3. Rear wiper switch
I 4. Front wiper switch
5. Warning lamp
6. Transmission cut-off select switch
7. Parking brake switch
8. Working lamp switch
9. Glow switch
10. Starting switch
ll.Fusebox
12. Cigarette lighter
13. Caution buzzer
14. Controller
15. Work equipment solenoid valve
16. Head lamp
17. Front combination lamp
18. Front wiper
19. Front window washer
20. Brake oil level sensor
2 I. Rear window washer
22. Rear wiper
23. Torque converter oil temperature sensor
24. Main breaker
25. Engine oil level sensor
26. Battery relay
27. Alternator
28. Coolant level sensor
29. Coolant temperature sensor
30. Air compressor
View Z
31. Rear working lamp
32. Air governor
33. Battery
34. Engine oil pressure sensor
35. Fuel level sensor
36. Heater relay
37. Fuel cut solenoid valve
38. Air pressure sensor
39. Rotational speed sensor
40. Brake chamber stroke sensor
41. Brake chamber
42. Brake chamber stroke sensor
Serial No. 11118 and UD
423F167
lJ42401014
WA350- 1 81-3
0
81-4
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT

Operation
. When the starting switch is turned ON, electric When the starting switch is turned OFF, circuit (I)
current flows in following circuit. is shut off, but the engine is rotating, so there is
(I) Battery (+I + starting switch terminal B + still voltage at terminal R of the alternator. For this
starting switch terminal BR + fuel cut solenoid 4 reason, the following circuit is formed.
ground connection. (2) Alternator terminal R + battery relay terminal
When electric current flows to the fuel cut BR- ground connection.
solenoid, the fuel governor is put in the FREE posi- The battery relay is maintained, but because of
tion by the fuel control linkage. the diode inserted into the circuit, no electric cur-
Fuel flows to the fuel injection pump and the rent flows to the fuel cut solenoid, so the engine
engine starts. stops.
.
Fuel cut solenoid
Starting switch Alternator
Battery
42lFI IS
WA350- 1 81-7
6%)
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
PREHEATING CIRCUIT
PREHEATING WITH HEATER SWITCH
Operation
l When the startingswitch is at ON, and the preheat The starting switch is ON, and the battery relay is
switch is set to ON, the following circuit is formed. also closed, so electric current flows in the follow-
(1) Starting switch BR - heater switch - heater ing circuit.
relay signal terminal + heater relay coil - ground (2) Battery (+I - battery relay - heater relay -
connection. electrical air intake heater - ground connection,
The heater relay is closed. and the engine is preheated (or after-heated).
If the heater switch is released, it automatically re-
turns to AUTO.
Preheat swttch
AUTO
Electrical
air intake heater
Heater relay
Startq switch
To electronic vehicle
(for pilot display)
Battery
42lFl20
81-8 WA350- 1
&I
PREHEATING WITH STARTING SWITCH
Operation
. If the starting switch is turned one stage to the left (2) Starting switch terminal R, -t heater relay
from the OFF position to the HEAT position, the signal terminal - heater relay coil + ground
electric current from terminal B flows to terminals connection, and the heater relay is CLOSED.
BR and R,. The electric current from terminal BR Because of circuits (1) and (2). the electric current
flows in the following circuit. from battery flows through the following circuit.
(1) Starting switch terminal BR + battery relay (3) Battery (+) 4 battery relay -t heater relay -
terminal BR - battery relay coil -+ ground electrical air intake heater -t ground connection,
connection, and the battery relay is closed. and the engine is preheated.
The electric current from terminal R, flows in the
following circuit.
Preheat switch
423F186
Starting switch connection table
WA350-1 81-9
AUTOMATIC PREHEATING
. In cold areas, when the starting switch is turned to (4) Battery (+I 4 battery relay + heater relay 4
ON, the bimetal timer is at low temperature, so the electrical air intake heater + ground connection,
contacts are closed. and the engine is preheated.
As a result, electric current flows in the following When this happens, circuit (2) sends electric cur-
circuit. rent through the resistor inside the bimetal timer,
(1) Battery (+) -t starting switch terminal B -t so the resistor heats up and the bimetal between
starting switch terminal BR -t bimetal timer termi- bimetal timer terminal 2 and terminal 1 is
nal 2 - (2) and (3). heated.
(2) Bimetal timer terminal 3 - ground connec- As a result, after a time (the time depends on the
.
tion ambient temperature) the bimetal bends (opens)
(3) Bimetal timer terminal 1 + glow switch and circuit (3) is shut off.
terminal 3 + glow switch terminal 2 + The flow of electric current to the heater relay coil
heater relay signal terminal - heater relay coil + stops, so the heater relay is opened and preheating
ground connection. The electric current in circuit stops. Even after the preheating stops, electric
(3) closes the heater relay. As a result, electric cur- current continues to flow between terminals 2
rent flows in the following circuit. and 3 of the bimetal timer, so the bimetal is kept
heated. Therefore the bimetal does not become
straight until the starting switch is turned OFF, so
after the engine is started, there is no preheating.
While preheating Bimetal timer

Preheat switch
monitoring system
Bimetal timer
After preheating
Electrical air
intake heater
monitoring system
(for pilot display)
423F187
81-10 WA350-1
@
STRUCTURE AND FUNCTION COMBINATION SWITCH
COMBINATION SWITCH
423F188
Outline
. The FORWARD-REVERSE lever has three When the lever is moved to the desired position,
contacts; the speed control lever switch has four the switch, which is connected by a shaft, moves
contacts. The switch alone has no detent and electric current flows in only that circuit to
mechanism. The detent mechanism is in the com- move the machine.
bination switch itself. Each switch is held at two
palaces by pins. In addition, each switch is secured
to the base by three screws.
Function
1 FORWARD-REVERSE lever switch Selecting FORWARD, REVERSE or NEUTRAL
2 Speed control lever switch Selecting machine speed range
Prevents speed control lever from going into 3rd or 4th speed
3 Speed control lever stopper
during operations
4 Direction indicator lamp Indicates direction when turning left or right
Returns direction indicator lamp lever to neutral automatically

5 Self cancel
after turning left or right
6 Lamp switch Selects clearance lamps, headlamps, parking lamps
7 Dimmer switch Selects travel beam, low beam
8 Emergency flasher switch Makes left and right winkers flash at the same time
mergency flasher pilot lamp Flashes when emergency flasher lamp is ON
WA350-1 81-l 1
STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL
ELECTRICAL TRANSMISSION CONTROL
Transmission cut-off
selector switch
Combination switch
FOR \RD-REVERSE lever
Transmission hut-off switch

reaker
Tranimission wiring harness
Function
423F189
Selection of FORWARD, REVERSE FORWARD-REVERSE lever

and NEUTRAL
Selection of travel speed range Speed control lever
Transmission cut-off function Transmission returned to neutral when left brake pedal is
operated
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 function 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.
6 Neutral safetv 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 startig
suddenly. (For detalis, see STARTING CIRCUIT.)
Warning fuction 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 WA350-1
ELECTRICAL TRANSMISSION CONTROL DIAGRAM
Neutralizer relay Parking safety relay

Parking brake (installed (installed
switch (manual) Parking brake in operators in operators
relay _ comoartment) compartment)
ON -,, -OFF ---- 1
Alternator terminal R
Parking brake
valve
To machine monitor
Emergency brake switch
(installed to wet tank)
selector switch (manual)
Transmission cut-off switch
Starting motor (terminal E)
controt switch
Madhine monitor system

neutral terminal
Back-up lamp relay
U42401016
WA350-1 81-13
0
TRANSMISSION CUT-OFF SWITCH
l When the left pedal is operated, the switch

detects the air pressure in a brake circuit. It shuts
off the power supply of the solenoid valve circuit
for the FORWARD-REVERSE clutch, and returns
the transmission to neutral.
- From rear air tank
brake valve (right)
Two-way check valve
Stop-lamp switch
I c From rear brake tank
/ Two-way check MIYI

- To rear brake
- From front brake tank
w -c To front brake
- From front air tank
Diaphragm
To transmission
directional circuit
--T--l---- ON
IOFF
Restored Actuated
Low voltage c-t High voltage

421F123
81-14 WA350-1
Q
TRANSMISSION CUT-OFF SELECTOR SWITCH
Outline Operation
l The transmission cut-off selector switch is a 2- * If the transmission cut-off selector switch is put
circuit waterproof toggle switch. It is installed in to CLOSED, there is always the (+) 24V in the cir-
series with the transmission cut-off switch at the cuit of the FORWARD-REVERSE clutch solenoid
power supply side of the transmission FORWARD- valve passing through this switch. Therefore,
REVERSE circuit. when the left brake is operated and the transmis-
sion cut-off switch is moved to OPEN, no electric
will flow to the solenoid valve, and the transmis-
sion will be placed in neutral.
~-~.-~---c_-- Neutralizer relay 7 - Neutralizer relay

i: (battery power source) I (battery power source)
B L
$
Transmission Transmission
cut-off selector cut-off selector
switch (manual) switch (manual)
(actuated by air pressure)
Starting motor Starting motor

(terminal E) (terminal E)
To Buck-up Machine monitor To Buck-up Machine monitor

lamp relay system neutral lamp relay system neutral
terminal terminal
421 F124
WA350-1
NEUTRALIZER RELAY
l When the parking brake is being used, no electric For this reason, no electric current flows to the
current flows to the relay coil. The input terminal FORWARD-REVERSE circuit of the transmission
is connected to output terminal 6. which is connected to output terminal 5. When
the parking brake is being used, the transmission
is kept in neutral. Therefore, the machine does not
start.
Parking brake Parking brake Parking brake Neutralizer relay

switch (manual) relay safety relay
OFF
Battery relay
Starting switch
Parking
brake
valve
I ransmlsslon 3.IL,,ll
(with wet tank)
cut-off selector : :
switch (manual)
!z?
Transmission cut-off switch
OFFTN
(actuated by air pressure)
Starting motor
(terminal E)
Machine monitor system

natural terminal
power source
Back-up horn Back-up lamp
421F125
WA350-1
STRUCTURE AND FUNCTION ELECTRICAL PARKING BRAKE CONTROL
ELECTRICAL PARKING BRAKE CONTROL

Outline
l When electric current flows to the parking brake . When the electric current is stopped, the air pres-
valve (solenoid valve), air pressure from the air sure from the air tank is cut off. The air pressure
tank (wet tank) is applied to the spring cylinder inside the spring cylinder passes through the park-
and the parking brake is released. ing brake valve and is released. The parking brake
is then actuated by the force of the spring.
423F194
1. Parking brake switch 5. Parking brake valve

2. Parking safety relay 6. Air tank (wet)
3. Parking brake relay 7. Emergency brake switch
4. Neutralizer relay 8. Spring cylinder
WA350-1 81-17
0
Function
Actuation and release of parking brake Parking brake switch used
Automatic parking brake Parking brake is automatically applied when engine is stopped
(starting switch is turned to OFF). This prevents the machine
from running away when the operator leaves his seat.
Emergency brake The parkingbrake 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,
the parking brake acts as an emergency brake.
Parking brake safety After the automatic parking brake is actuated, it is dangerous if
the parking brake can be released simply by turning the starting
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.
Neutralizer 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 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 transmssion is not returned to
neutral when the emergency brake is applied.
Parking brake switch

Connection table
Large size multi-pin connector

(3 pole blue) with lock
Soft polyvinyl chloride
I OFF (released)
View 2 Water proof O-ring 423F195
for panel face
81-18 WA3W1
PARKING BRAKE VALVE
Port ho.3 P0rtNo.l

423F196
PARKING BRAKE RELAY

PARKING SAFETY RELAY
NEUTRALIZER RELAY
Relay connection chart
Terminal No.1
Terminal No.2 Port No. 5 Relay actuation table
mi
, 423F197
Black Terminal No. 6
EMERGENCY BRAKE SWITCH
Diaphragm Contact
\ \
423F198
WA350-1
81-19
0
1. STARTING SWITCH OFF

l When the starting switch is turned OFF, the bat-
tery relay is opened, so no electricity flows to
the parking brake circuit. For this reason, if the
starting switch is OFF, no electricity flows to
the parking brake valve regardless of whether
the parking brake switch is ON (actuated) or
OFF (released). As a result, the parking brake is
actuated. (Automatic parking brake)

-- ___- -__ -
1
OFF ON
Batten/ relay
Starting switch
To transmission Emergency brake

speed circuit switch
(with wet tank)
421 F126
81-20 WA350-1
0
2. STARTING SWITCH ON
2-l. When parking brake switch is turned ON The circuit of the parking safety relay re-
before starting switch is turned ON mains closed because of circuit 3 until the
l Electric current flows as follows. starting switch is turned OFF.
(1) Battery (+) + starting switch + battery l In this condition, no electric current flows to
relay coil + ground connection, so the bat- the parking brake valve, so the parking brake
tery relay is CLOSED. is actuated.
Electric current also flows as follows. l Also, in this condition, the circuit between
(2) Battery (+) -+ battery relay -+ parking terminal 3 and 5 of the neutralizer relay
brake switch terminal 3 + parking brake is open, so no electric current flows to the
switch terminal 2 -, parking safety relay FORWARD-REVERSE circuit of the trans-
terminal 1 - parking safety relay terminal mission, and the transmission is kept in
2 -+ ground connection. neutral.
When this happens, the parkig safety relay
is actuated and circuit is closed. Therefore,
the following circuit is formed.
(3) Battery (+) + battery relay + parking
safety relay terminal 3 + parking safety
relay terminal 5 - parking safety relay
terminal 1 + parkig safety relay terminal
2 + ground connection.

r
--
OFF ON I
Starting switch
t
f I I
To transmission
FORWARD-REVERSE
circuit
Parking
brake
valve
TO transmission Emergency brake
(with wet tank) ii
421F127
WA350- 1 81-21
0
2-2. Parking brake switch turned OFF (released) valve. Therefore, after the automatic park-
before starting switch is turned ON ing brake is actuated, even if the starting
l Electric current flows as follows. switch is turned to ON, the parking brake is
(1) Battery (+) + starting switch + battery not automatically released.
relay coil + ground connection, so the bat- l In addition, no electric current flows to the
tery relay is CLOSED. FORWARD-REVERSE circuit of the
However, in this case, the parking brake transmission, so the machine does not move.
switch is OFF (released), so the parking
safety relay is not actuated. For this reason,
no electricity flows to the parking brake
Parking brake Parking brake Parking brake

switch (manual) Neutralizer relay
relay safety relay
--
OFF ON r -6
Battery relay
Starting switch
To transmission
speed circuit
421F128
*l&22 WA350- 1
3.PARKlNG BRAKE SWITCH TURNED OFF

(released) AFTER STARTING SWITCH
IS TURNED ON
l If the parking brake switch is turned OFF (4) Battery (+I + battery relay - parking
(released), circuits 1 and 2 of the parking brake brake relay terminal 3 + parking brake relay
switch are connected. When this happens, terminal 5 + parking brake valve + ground
electric current flows as follows. connection.
(I) Battery (+) + battery relay -, parking The parking brake is released, and at the same
safety relay -L parking brake switch + (2) and the following circuit is formed.
(3). (5) Battery (+I + battery relay -. neutralizer
(2) Emergency brake switch 4 parking brake relay terminal 3 + neutralizer relay terminal 5
relay cdii + ground connection. + transmission FORWARD-REVERSE circuit.
(3) Neutralizer relay coil - ground connection. When the transmission switch is put to FOR-
The parking brake relay and neutralizer relay WARD or REVERSE, the machine will move.
are actuated, and the circuit between terminals
3 and 5 of each relay is closed. As a result, the
following circuit if formed.

r -_-
1 I---
Battery relay
Battery
---- -
Starting switch
I L n,rarnaror
t Lf BR
.A
terminal R
w1
To transmission
speed circuit
I-
I
To transmission
FORWARD-REVERSE
circuit
switch
-
Emergency brake
(with wet tank)
421F129
WA350- 1 81-23
0
4. PARKING BRAKE SWITCH ON

(operated)
After operating with the parking brake switch l At the same time, the neutralizer relay is also
at OFF (released), if the parking brake switch is restored, so the circuit between terminals 3
turned to ON (operated), the circuit becomes as and 5 is OPEN. No electric current flows to
shown below. the FORWARD-REVERSE circuit of the
No electric current flows to the parking brake transmission, so the transmission is placed in
valve, so the air pressure from the air tank neutral. In this way, when the parking brake is
acting on the spring cylinder is shut off. At the operated, the neutralizer relay shuts off the
same time, the air pressure inside the spring electric current to the transmission solenoid
cylinder passes through the parking brake valve valve and puts the transmission in neutral. As a
and is released, so the parking brake is actuated result, there will be no seizing of the parking
by the force of the spring. brake caused by the machine being driven with
the parking brake still applied.
Parking brake Parking brake Parking brake Neutralizer

switch (manual) relay safety relay relay
-- ---- ---1 --- -
OFF n ON I
Battery relay
Battery
.-_I ----
Starting switch

(with wet tank)
421 F130
81-24 WA350- 1
0
5. WHEN AIR PRESSURE DROPS

(Emergency brake actuated)
Operation
l If the air pressure drops, the emergency brake l For this reason, electric current flows to the
switch installed to the wet tank is opened. FORWARD-REVERSE circuit of the transmission,
For this reason, no electric current flows to the and it is possible to connect the transmission
coil of the parking brake relay. The parking brake clutch. Therefore, when the emergency brake is
relay is restored, and the circuit between terminals actuated, the engine also acts as a brake. This
3 and 5 becomes OPEN. No electric current makes the braking distance shorter, and at the
flows to the parking brake valve, so the air pres- same time, if the emergency brake is actuated,
sure inside- the spring cylinder is released and the and it is necessary to move the machine (for
parking brake is actuated. However, this case is example, if the emergency brake was actuated on
different from when the parking brake switch is a railroad crossing), the machine can be driven by
turned ON (operated). In this case, there is electric operating the transmission lever.
current flowing to the coil of the neutralizer relay.

-- ---1 --- 1
OFF ON
Battery
Starting switch
A !
To transmission Parking
FORWARD-REVERSE brake
circuit valve

(with wet tank)
421 F131
WA350-1
8:5
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)

MONITOR PANEL
Outline
The electronic vehicle monitoring system is a l The monitor consists of the following
system to inform the operator of the condition of components. CHECK module (11, CAUTION
the machine. It consists of sensors installed in module (21, CAUTION module (3). gauge module
various parts of the machine, which observe the (5). speedometer module (including service
condition of the machine and process the informa- meter), the case, and various other components.
tion speedily, and display the situation on the l Each module (excluding the service meter) has its
monitor panel. own microcomputer which processes the signals
The electronic vehicle monitoring system consists from the sensor and gives a display.
of the monitor panel, sensors, controller, warning The panel uses a liquid crystal display.
buzzer, warning lamp and power source. l CHECK (11, and CAUTION (2) and (3) modules all
The displays can be broadly divided into CHECK use common parts.
items (1) and CAUTION items (2) and (3). which The microcomputer judges which module it is
display warnings if any abnormality arises in the from the wiring harness to which it is connected.
machine; and gauges (51, speedometer (71, and
service meter (9). which always display the condi-
tion of the machine.
Warning lamp Warning buzzer
Controller Battery
Q
24V
.Qzq e.. + -
a
C /YYYzTI
Buzzer signal
-XL
421F116A
81-26 WA350-1
0
View 2
423F170
1. Check 3D. Air pressure 5. Gauge

1 A. Brake oil level 3E. Coolant temperature 5A. Air pressure
1 B. Engine oil level 3F. Torque converter oil 5B. Coolant temperature
1 C. Coolant level temperature 5C. Torque converter oil
2. Caution (Warning) 4. Pilot indicator temperature
2A. Battery charge 4A. Transmission cut-off 50. Fuel level
28. Fuel level 4B. Parking brake 6. Winkers pilot lamp
3. Caution (Emergency warning) 4C. Work lamp 7. Speedometer
3A. Brake line failure 4D. Preheat monitor 8. Head lamp pilot lamp (High beam)
3B. Engine oil pressure 9. Service meter
3C. Coolant level 10. Serivce meter indicator
WA350-1 81-27
0
INDICATION ON MONITOR PANEL
Cate-
Symbol Indication item Indication range Description
gory
Brake oil level Below low mark
Displayed when starting switch is turned

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

8
-+
u Battery charge When charging
is defective
Emergency
Displays
steering
when engine
actuated
is running
when operated
m
Fuel level Below low mark Display flashes when abnormal and
lamps flash at the same time
When stroke is
(3) I. Brake chamber stroke
over
Coolant level Below low mark

Displays when engine is running
Display flashes when abnormal;
Air pressure Below specified buzzer and lamp actuated
pressure
Coolant temperature Above 105C
Tornue converter oil

Above 105C
temperature
Parking brake When operated
Displays when starting switch is turned ON;

Lights up when operated
Work lamp When operated
Transmission cut-off When operated

select

PREHEAT When preheating
lights up during preheating
81-28 WA350-1
0
Gate,
Symbol indication item Indication range Description
gory
0 - lOOkm/h
Travel speed Digital display
O-l&MPH
--
--
- 0 High beam When operated
Lights up when operated
a-- D Winkers (right, left) When operated
CID Hazard When operated Lights up when operated
0 Service meter
0 - 99999/h
displayed
Actuated
Advances
when engine
1 for every
oil pressure
hour of operation
is normal
0 Service meter indicator Flashes when service meter is operating
Air pressure One lamp lights up to indicate level
Red
N
Red
$ Coolant temperature 3reen One lamp lights up to indicate level
White
Red
Torque converter oil

One lamp lights up to indicate level
temperature 9oc
Sreen
70C
5oc
C
FULL
keen
Fuel level All lamps light up below indicated level
Red
WA350-1 81-29
0
CONTROLLER
Function
l The auxiliary controller acts as the power source
box and provides electric power to the panel.
The power source (battery, alternator) for the ma-
chine has a large difference in voltage, so the aux-
iliary controller converts this to a stable voltage
and supplies it to the panel.
Even if excessive voltage is generated by failure in
the alternator or regulator, it is cut by the auxiliary
controller. _-
423F171
Controller
Lamp
Buzzer
Battery
Battery relay
terminal E
423F172
81-30 WA350-1
SENSORS
Function
. The signals from the sensors are directly input to
the monitor panel. With contact type sensors, one
side is always grounded to the chassis. When the
contacts are closed, the panel recognizes the
signal as a normal signal.
Sensor actuation table
Check item Sensor type When normal When abnormal
Brake oil level Contact ON OFF
Engine oil level Contact ON OFF

I I I
Coolant level Contact ON OFF
Fuel level Resistor
Engine oil pressure Contact ON OFF
Coolant temperature Resistor
Torque converter oil temperature Resistor
Travel speed Solenoid

I I I
WA350-1 81-31
0
BRAKE OIL LEVEL SENSOR
1. Connector
2. Wire
1 2 3 4 5 3. Plug
4. Float
5. Switch
0
0
0J@J-
e
ON - OFF
Function _- Circuit structure
(UP) (DOWN)
423F173
Function
l The brake oil level sensor is installed on top of the
brake oil tank. When the brake oil goes below the
specified level, the float goes down and the
switch is turned OFF. The machine monitor lamp
then lights up to indicate the abnormality.
ENGINE OIL LEVEL SENSOR
1. Connector
2. Wire
3. Plug
4. Float
5. Switch
ON - OFF
e
Circuit structure
UP) (DOWN)
423F174
Function
. The engine oil level sensor is installed on top of
the engine oil pan. When the engine oil goes
below the specified level, the float goes down and
the switch is turned OFF. The machine monitor
lamp then lights up to indicate the abnormality.
81-32 WA350-1
0
COOLANT LEVEL SENSOR
1. Connector
2. Wire
3. Plug
4. Float
5. Switch
0N -
(UP)
OFF
(DOWN)
e
Circuit StructUre
423F175
Function
. The coolant level sensor is installed on top of the
radiator. When the coolant level goes down, the
float goes down and the electric current is shut
off. The machine monitor lamp then lights up to
indicate the abnormality.
BRAKE CHAMBER STROKE SENSOR
1. Ball
2. Shaft
3. Switch
4. Harness
5. Connector
w Circuit structure
423F180
Function
l The brake chamber stroke sensor is installed to
the brake chamber. When the stroke of the air
piston in the brake chamber goes above the speci-
fied stroke (over-stroke), the rod installed to the
brake chamber pushes the ball and shuts off the
electric current. This turns the switch OFF and the
machine monitor lamp lights up to indicate the
abnormality.
WA350-1 81-33
0
COOLANT TEMPERATURE ,
TORQUE CONVERTER OIL TEMPERATURE
SENSOR 1. Connector
2. Wire
1 2 3 4 5 3. Tube
4. Plug
5. Thermistor (beat type)
* 2
Circuit structure
423F176
Function
l These sensors are installed on the engine cylinder
block and transmission case. They use a thermis-
tor to detect the temperature, and when the tem-
perature goes above the specified temperature,
the machine monitor lamp lights up to indicate the
abnormality.
ENGINE OIL PRESSURE, PARKING BRAKE SENSOR
1. Connector
2. Wire
3. Switch
4. Diaphragm
5. Plug
c:@z=B
Circuit structure
423Fl77
Function
. These are installed on the engine block and park-
ing brake solenoid valve. 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.
81-34 WA350-1
0
ROTATIONAL SPEED SENSOR
Function
. The rotational speed sensor is installed on the
transmission output gear. A pulse voltage is Section A-A
generated by the rotation of the gear teeth, a

signal is then sent to the machine monitor, and 1
this displays the travel speed.
I-. Connector
2. Magnet
3. Case
@a3
Circuit structure
423F178
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 a gear 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. Lever
4. Float
Circuit structure
423F179A
WA350-1 81-35
0
AIR PRESSURE SENSOR
1. Connector
2. Ventilation tube
3. Wire
4. Resistor
5. Resistor selector con-
tact
Function
. The air pressure sensor is installed to the wet air
tank. It converts the changes in the air pressure to
changes in resistance. 2
&x
It then sends a signal to the machine monitor to in-
Circuit structure
dicate the air pressure. If the air pressure goes 423F181
below the specified pressure, the module inside

the machine monitor generates a signal and the
warning lamp lights up.
81-36 WA350- 1
WIRING HARNESS
CNP8
(16P)
CNP9
(5P)
CNP2
(16P)
423F182
Operation of monitor panel

If the monitor panel is working normally, the lamps
on the monitor panel will work as follows. c) The CHECK item lamps will go out when the
1) When the starting switch is turned to ON. engine is started. (Judge whether the engine is
a)- All monitor lamps will light up for 3 seconds. running by the rise in the engine oil pressure, or
b) The warning buzzer will sound for 2 seconds. see if there is a voltage of over IOV from the
2) CHECK MONITOR GROUP alternator.)
a) All monitor lamps will light up for 3 seconds, 3) CAUTION MONITOR GROUPS
then if there is any abnormality in any check a) All monitors are working from the time the
item, that item will flash. (About 0.8 seconds engine starts to the time the engine stops and
ON, then 0.8 seconds OFF repeated.) the starting switch is turned to OFF.
b) If the outside air temperature is low (below If there is any abnormality in the machine, the
about - 1 OC), the flashing interval will change lamp for that item will start to flash (0.8
slightly, but this is not an abnormality. seconds ON, 0.8 seconds OFF).
WA350-1 81-37
0
OPERATION OF PROXIMITY SWITCH
Lift arm RAISE

l When the lift arm is lower than the set position for
the boom kick-out, the detection unit (steel plate) Proximityswitchfor
is on the sensing surface of the proximity switch. boom kick-out
Electricity flows through the proximity switch. .,-,_+- To battery relay
The relay switch is at OFF and the electric current

of the magnet switch coil is shut off.
Solenoid for
kick-out
Lift lever
Solenoid
II\
Proximity switch
Lift a
ain control valve
423F205A
l When the lift control lever is moved to the RAISE

position, the lever cam and the cam follower keep Proximity switch for
the lift spool in the RAISE position, so the lift arm boom kick-out
goes up. To battery relay
Lift lever
_/ / II Solenoid
ller
am
Detection unit.
423F206A
81-38 WA350-1
@
l When the lift arm goes up and reaches the set po-
sition for the kick-out (that is, the detection unit
(steel plate) is separated from the sensing surface
of the proximity switch), the proximity switch and
relay circuit act to send electric current to the
magnet coil. This actuates the magnet, the cam is
pulled out of the cam detent, and the lift spool is
returned to the neutral position by the return
spring.
Proximity switch for

boom kick-out
To battery relay
Kick-out relay
Solenoid for
Lift lever
Solenoid
Lift arm -
Proximity switch
423 F207A
Movement of proximity switch
Sensing surface of magnet switch Sensing surface of proximity switch

Position
is in contact with detection unit is separated from detection unit
Proximity switch display ON OFF
Proximity switch load circuit

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

Current flows Current shuts off
(solenoid circuit)
WA350-1 81-39
@I
Bucket TILT
l When the bucket is lower than the set position for
the bucket positioner, the detection unit (steel Proximity switch for
plate) is on the sensing surface of the proximity bucket positioner
switch. No electricity flows through the proximity To battery relay

switch. The relay switch is at ON and the electric
current from the battery flows through the
magnet switch coil.
Solenoid for
bucket positioner
Dump lever
Solenoid
-
ain control valve
Detection unit Proximity switch

423 F208
. When Proximity switch for

the bucket control lever is moved to the
bucket positioner
TILT position, the lever cam and the cam follower ,,,
To battery relay
keep the dump spool in the TILT position, so the ~$1
bucket tilts.
Solenoid for Positioner relay
Dump lever
Solenoid
Roller
Cam
423 F209
81-40 WA350-1
a
l When the bucket tilts and reaches the set position

for the bucket positioner (that is, the detection
unit (steel plate) is separated from the sensing sur-
face of the proximity switch), the proximity switch
and relay circuit act to send electric current to the
magnet coil. This actuates the magnet, the cam is
pulled out of the cam detent, and the dump spool
is returned to the neutral position by the return
spring.
Proximity switch for

bucket positioner
_- To battery relay
Solenoid for
bucket positioner
Dump lever
Solenoid

423F210
Movement of proximity switch
Sensing surface of magnet switch Sensing surface of proximity switch

Position
is in contact with detection unit is separated from detection unit
Proximity switch display ON OFF

I
Proximity switch load circuit

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

Current shut off Current flows
(solenoid circuit)
WA350-1 81-41
0
ELECTRIC AND
ELECTRONIC SYSTEM
Adjusting speedometer module

in the vehicle monitor . . 82-2
Troubleshooting . . . . . 82-5
t The following precautions are necessary when using the Standard Value Tables to make judgements during
WA350-1 82-1
0
ADJUSTING SPEEDOMETER
TESTING AND ADJUSTING MODULE IN THE VEHICLE MONITOR
ADJUSTING SPEEDOMETER MODULE IN

THE VEHICLE MONITOR
The speedometer of the vehicle monitor is the same
in all models. However, the input signals for vehicle
speed differs on each model. In addition, the vehicle
speeds will differ according to the diameter and tire
types, so the speedometer must be adjusted for each
model.
It is not necessary to adjust the speedometer of
new machine, because it has been completed by
Komatsu.
When replacing the speedometer module in
speedometer, or replacing the tires, adjust the
speedometer.
Speedometer which supplied as parts supply
route, is setted the position of switch as follows:
Switch position II: 5
Switch position Ill: D
Switch I has no relation to the speedometer

adjustment.
Do not touch this switch. The normal position of
this switch is F.
HOW TO ADJUST THE SPEEDOMETER

Remove the vehicle monitor from the vehicle and Driver (-1 I 423F336A
Parts No. here
make the adjustment on the back of the speed-
ometer.
Adjustment
I) Remove rubber caps II and Ill on the rear side of
the speedometer module.
Rotary
2) When the rubber cap is removed, a rotary switch I Switch
can be seen inside. Then, make the adjustment by
turning this switch with a screwdriver as shown
below.
PER KILOMETER
Switch position
Tire size 423F337
I II
20.5-25 STD B 8 (B)
23.5-25 OP B C
PER MILE Reference: Correction factor (o/o)of switch Ill
Switch position Switch

Speedometer position 0 1 2 3 4 5 6 7
Tire size
Module Parts No. II Ill Correction -12 -10 -8 -6 -4 -2 0
factor (%) -14
Switch
8 9 A B C D E F
position , I I I I 1 I I
Correction o
+2 +4 +6 +8 +lO +I2 +14
factor (%)
3) After completing the adjustment, restore the

rubber cap to its original position and install the
vehicle monitor.
WA350-1
82-2
0
TROUBLESHOOTING
Before troubleshooting .. . . . 82- 6

Method of using YES-NO Troubleshooting
flow chart . . . .. . 82- 8
Connector terminal numbers . 82-l 0
Precautions when handling connector.. . 82-l 5
Electrical wiring diagram . . .. . 82-l 7
Electrical circuit system . . . 82-l 8
Troubleshooting chart for electric system
(E-l to E-l 5) . . . . 82-23
Electronic vehicle monitoring system . 82-56
Troubleshooting table
(Electronic vehicle monitoring system) . 82-57
Troubleshooting chart for electronic vehicle
monitoring system (M-l to M-33) 82-59
RENCE OF TROUBLE page 22-l 6.
WA350- 1 82-5
0
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
item Standard value Remedy
1. Check fuel level - Add fuel

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

10. Check for loose or corroded alternator terminals - Tighten or replace
1 I-. Check for loose or corroded starting motor - Tighten or replace
terminals
12. Check for abnormal noise or smell - Repair

13. Check for oil leakage - Repair
14. Bleed air from system - Bleed air
15. Check battery voltage (engine stopped) 20 - 3ov Replace

16. Check level of battery electrolyte - Add or replace
17. Check for discolored, burnt, or bare wiring - Replace
18. Check for missing wiring clamps, hanging wires - Repair
19. Checks for water leaking onto wiring (check care- - Xsconnect connector
fully water leakage at connectors and terminals) and dry connection
20. Check for broken or corroded fuses - Replace
2 1. Check alternator voltage 27.5 - 29.5 V Replace
(engine running at over half throttle)
22. Noise when battery relay is operated - Replace
(switch starting switch from on to off)
82-6 WA350-1
a
METHOD OF USING YES-NO TROUBLESHOOTING
TROUBLESHOOTING FLOW CHART

FLOW CHART
The electric system can be broadly divided into the following two parts.
1. Starting system, transmission electrical control system, brake system.

2. ELECTRONIC VEHICLE MONITORING SYSTEM.
The charts for these systems ars marked as E-xx, and M-xx respectively.
Troubleshooting
Item
chart No.
E-xx Troubleshooting of starting system, transmission electrical control system, brake system.
M-xx 1 Troubleshooting of electronic vehicle monitoring system
1. Method for troubleshooting YES

--
Check or measure the items inside the rectangle 1 H I.
NO
According to the result, follow the YES arrow or the NO arrow and proceed to the next rectangle. (Note:
The number given at the top right of the rectangle is a reference number. It does not indicate the order for
troubleshooting.)
If the result of the check or measurement leads directly to the CAUSE column, note the cause and take the
action given in the REMEDY column.
The value for the check and the measurement method is given inside the rectangle. If the value is correct, or
the answer is yes, follow the YES arrow; if the value is not correct, or the answer is no, follow the NO arrow.
Below the rectangle, there is a list giving preparatory work, methods of operating and handling, and judge-
ment values needed for checking and measuring. If the preparatory work is ignored, or the wrong method of
operating or handling is used, or the judgement is wrong, this could result in damage to the equipment.
Therefore, always read the procedure carefully before starting the check or measurement, and carry out the
operations in the order given.
2. Precautions when carrying out troubleshooting
The precautions to be followed when carrying out troubleshooting for each failure is marked t under the de-
scription of the failure. Always follow these precautions when making measurements.
3. Tools needed for troubleshooting
The tools needed for troubleshooting for each problem are listed as follows.
1
ITroubleshooting
tools I
Prepare these tools before starting troubleshooting
Place to install connectors, connector pin numbers

When troubleshooting some problems, measurements have to be made of continuity, voltage and resistance at
each step during the troubleshooting procedure. The location for measurement at each step (location of
connector, connector pin number) is shown in a photograph or diagram. For this reason, use these photographs
together with the YES- NO type troubleshooting flow charts to carry out troubleshooting quickly and
accurately.
82- 8 WA350-1
0
TROUBLESHOOTING FLOW CHART
Example
* When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when
disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ()I
Sr When disconnecting connectors or connecting T-adapters, return them to the original condition immediately
after checking, then go to the next check.
Cause Remedy
a) q IighKup.
Defective transmlsslon cut-off
eplace
swtch
IES Defective CHECKS BEFORE :eplace

*
STARTING module
Is there continuity
q
YES between CNP4
goout
I
Does fiij (fernale) and
chaws ground?
Disconnection I wiring ifter inspectlon,
NO harness, or defective contact epair (clean) or
1) Short-circuit CN18 .
between CN18 (female)(3) ano eplace
(femaleI(3) and (4).
2) Connect T-adapter to CNP4 (fernale)
2) Turn starting switch
ON. CNP4 (female).
3) Turn starttrrg swtch
OFF
Is there contuwity
betwew CN18
Imale) and chassis
Dlsconnectlon I wiring 4fter inspection,

NO harness. ordefectlve contact repair (clean) or
Turr startng switch c betwew CN18 (female) (4) ant replace
OFF
chass6 ground
Tester
Troubleshooting _
tools T-adapter or socket adapter
T-adapter (for DLI) (for Frono+,=nll
CN18
WA350-1 82-9
0
TROUBLESHOOTING CONNECTOR TERMINAL NUMBERS
CONNECTOR TERMINAL NUMBERS
Connector
-r Female terminal (Socket)
ECONOSEAL CONNECTOR
Male terminal (Pin)
CN21 ,CN35
CN47,CN83
CN84.CN86
CN87.CN88
CN92.CN93
CN96,CNlOl
CN105.CN107
CN163
142F401A 142F400A
2 3
CN41 1
CN42 I
J""]
1
142F403A 142F402A
CN14
CN43
142F405A 142 F404A
5 2 '1
142F407A
B

142F406A
CN15
CN16
CN60
CN61
3 142F408A
82-10 WA350-1
@
Connector
r DLI CONNECTOR (For monitor panel)
Female terminal (Socket) Male terminal (Pin)
5 6 1 4
CNPI -- 1 4 5 6
CNP3
CNP5
CNP7
142F418 142F419
CNP2
142F420 142F421
CNP4
CNP6
CNP8
CNPI 0
142F422 142F423
WA350-1 82-11
@
Connector
T N-SLC CONNECTOR
PEI
CN12
CN17
CN25
1
423F349 423F350
1
CNI 1
CN13
CN48
CN102
CNI 04
423F351 3 2
CN18
423F353 423F354
CN40
423F355 4 6 4 423F356
5
423F357 423F358
82-12 WA350-1
@
MIC CONNECTOR
Connector
1
3 1
CNP9 4
5 4
142F410
I3 142F411
142F412 J 142F413
142F414 I 142F415
142F416
i 423F417
WA350-1 82-13
0
BENDIX CONNECTOR
connector
CN85
E MF G
423F346 423F347
Connector RELAY CONNECTOR
CN51
CN52
5
CN53
CN54
3
423F348
82-14 WA350-1
@
TROUBLESHOOTING PRECAUTION WHEN HANDLING CONNECTOR
PRECAUTION WHEN HANDLING CONNECTOR

I. 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 When removing, press When connecting, align
cover tightly. this part in and pull the guide inside the
n the connector out.
emoving. press In
on both sides a%d pull
the connector out. F 142AO93
F 142A092
2. Never pull the cord to disconnect the connector.
F142A094 F 142A095
3. If the connector is difficult to disconnect, 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.
\
F 142A096
WA350-1 82-15
0
TROUBLESHOOTING PRECAUTION WHEN HANDLING CONNECTOR
4. After pulling out the connector, cover with a vinyl

bag to protect the contacts from dirt or oil.
5. When cleaning the connector, never use cleaning F 142A097
agents such as trichloroethane or

trich-loroethylene. If the connector is very dirty,
use a neutral-cleaning agent. After cleaning wash
well and dry completely immediately. (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

correctly. F 142A098
(For connectors with locks, it should be possible

to hear the locks click as they fit completely into
position.)
F142AlOO
F 142A099
l Correct any protrusion of the boots.
82-16 WA350-1
a
ELECTRICAL WIRING DIAGRAM
/
\ CNIOI
View 2
(CN80),
CNP\8
,,,,ac163cN75
CNP6 CNPIO CyP2 CplP4
, , , ,,., .. i ,,.\
/ I \ \ \
LI\Jb
CNP ChiP5 CtiP9 CrjPl CNP3
\ _
View Y
( ) : Connector number of diode
423F345A
WA350- 1 82-17
0
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM
ELECTRICAL CIRCUIT SYSTEM

1. ENGINE STARTING CIRCUIT SYSTEM
Startino switch
Transmission
control swtch III To meter panel
w
control solenoid 12140mlx2
Main breaker
Alternator
otor
2. ENGINE STOP CIRCUIT SYSTEM

423F338A
Startmg switch
CWS
Ill
Fuel cut solenofd
Alternator
423F339
82-18 WA350-1
0
3. TRANSMISSION CONTROL, TRANSMISSION CUT-OFF CIRCUIT SYSTEM
Neutralizer relay
To parking brake switch -
J
I
I
Transmission
Main breaker
cut-off switch
Cllll
To battery relay
Transmission control
Reverse
Forward
4th
3rd
:ns:
selector switch
Monitor
panel
423F34OC
WA350-1 82-19
8
4. PARKING BRAKE CIRCUIT SYSTEM
Parking brake switch
OFF
(Parking)
ON
Parking brake safety relay To main breaker

II
Monltor
panel
Park11g brake
valve
Parking brake
indicator switch
423F341 B
5. PREHEATING CIRCUIT SYSTEM
Relay breaker
Glow switch
Auto-preheating timer cm*
AUTO
OFF
ON
2OA
relay
CNFa ml64 0497

-
- U 1 I , Electrical air
intake heater
Monitoring panel
423 F342A
82-20 WA350-1
8
6. ELECTRICAL CIRCUIT SYSTEM

Serial
423F344A
WA350-1 82-21
0

/G-l rx
423 F3448
82-22 WA350-1
0
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM
(E-l. to E-15.)
.
E- 1. Engine does not start. . . . . . . . . . ............... 82-24
E- 2. ...............................................
Engine does not stop. ............... 82-27
E- 3. Engine stops when traveling. ......................................... . ............... 82-27
E- 4. Parking brake does not work. ........................................ . ............... 82-28
E- 5. Parking-brake is applied when traveling. ............................... ............... 82-32
E- 6. Parking brake is released when starting switch is turned to ON. .......... ............... 82-36
E- 7. Transmission is not returned to Neutral when parking brake is applied. ... . . ............... 82-36
E- 8. Machine does not travel Forward. .................................... ............... 82-38
E- 9. Machine does not travel Reverse. ..................................... ............... 82-42
E- 10. Transmission does not shift gear (F-R switch normal). .................. ............... 82-46
E-l 1. Machine does not travel when transmission cut-off switch is ON. .... ............... 82-48
E-l 2. Transmission cannot .......................................
be cut-off ............... 82-48
E-l 3. Transmission does not return to Neutral. .............................. . ............... 82-50
E-l 4. Preheating display does not go out. ................................... . ............... 82-54
E-l 5. Preheating does not work. ........................................... . . ............... 82-54
WA350-1 82-23
0
TROUBLESHOOTING E-l
E-l. ENGINE DOES NOT START
* When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when discon-
necting the connector for checking, turn the starting switch OFF to prevent accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1)
* When disconnecting connectors or connecting T-adapters, return
them to the original condition immediately after checking, then go to Cause Remedy
the next check.
(a) Checking star_ting circuit YES

) Defective starttng motor ieplace
I assembly
Defective contact, or 4fter

disconnection I wiring harnez :hecklng,
between CN102 (3) (female) .epair or
CN97 (7) - CN64 (9) - CNl replace
(9) (female).
Defective F-R switch, or lfter

defective contact or :hecklng,
IS voltage
between
dtsconnection in wiring .epair or
CN102 (female1 (11 1) Connect T-adapter
harness between F-R x?Place
and chassis ground (or socket adapter) to
switch and chaws ground.
20 - 3OV? I CN16.
2) Place F-R lever at N.
1 I Disconnect 31 Turn starting switch
CN102 (safety OFF.
relay inlet). Defective contact or lfter
YES disconnection in wiring harnes
2) Measure with :hecking,
between CN14 between CN102 (1) (female) .epair or
starting swtch at
(3) (female) and F3y!37 (4) - CN63 (5) - CNl eplace
START.
1) Disconnect CN14
) Defective starting switch +eplace
2) Measure with 0
starting switch at
START.
(b) Checking battery - battery relay - starting switch

Defective contact or
2 YES disconnection in wiring harnes
w 4fter
IS voltage between between battery relay and :hecking,
YES both ,hlCk term,r,a,s starting mortar assembly. .epair or
Of battery relay and - eolace
ChaSSlSground 20
- 3OV? If NO for both terminals
* Defective contact or 4fter
1) Turn starting NO :hecking,
disconnection in wiring harnes
switch ON. .epair or
between battery and battery
21 Measure voltage
relay. elIlaCe
between two
Is there sound of If NO for one terminal
terminals
battery relay Defective battery relay
connected by
working? iep1ace
thick insulated
cable Defective contact or
1) Turn starttng switc h disconnection between
ON - OFF. YES CN104(3) - battery relay -
chassis ground, or defective ReplaCe
battery relay.
YE!
a Defective contact or After
3 YES 5 disconnection in wiring harnes checking,
Is voltage between CN104 (3) ifemalel repair or
between CN104 Is voltage between CN95 (1) - (diode) - CN95 reDlace
! (3) (female) and - NO CN14 (2) (female) (2) - CN63 (2) - CN14 (2)
NO 4- and chassis ground
chassis ground
20 - 3ow F 20 -3OV?
_ Is voltage between
1) Disconnect CN104. - CN14 (1) hx+d _ 1) Connect T-adapter
Replace
2) Turn starting switch yodch;;&;ground (Or socket adapter) tO$
ON. CNld(female).
- 2) Turn starting switch
1) Connect T-adapter ON.
D Defective contact or After
(Or socket adapter) to ,,,(,
disconnection in wiring hame> checking
CN14ifemale).
between batterv r&v - repair or
CN104 (2) - 6~63 17) - WPlFG?
CN58 (1) - fuse - CN58 (21
- CN14 (1)
T-adapter or socket adapter
Tester
TroubleshootIng (for Econoseali
tools
82-24 WA350-1
8
TROUBLESHOOTING E-l
BATTERY RELAY
CN14
CN16
CN102
B
WA350-1 82-25
0
TROUBLESHOOTING E-l
CN104
1 1
B EiD
82-26 WA350-1
0
TROUBLESHOOTING E-2, E-3
E-2. ENGINE DOES NOT STOP
* When disconnecting or connecting the T-adapter (or socket adapter)

or short socket adapter, or when disconnecting the connector for
checking, turn the starting switch OFF to prevent accidents.
* When connecting the T-adapter (or socket adapter), connect to the
connector specified. (CNxx (1)
Sr When disconnecting connectors or connecting T-adapters, return
the next check.
efective adjustment of linkage

YES
m etween fuel-cut solenoid vaIv( idiust
nd fuel injection pump
1
3 YES
L lefective fuel solenoid tep1ace
Is fuel-cut solenoid
valve spool operating - YES Is voltage between
normaly? _ - both terminals of fuel -
cut-off solenoid OV? bbnormal contact, or mistaken
(iring between +24V termina
1) Visual check when 2 _ _m after inspection.
nd wiring harness of CN 14 (2
epair or replace
starting switch ON *
Is voltage between 1) ~u~;n
starting switch NO $e) - CN63 (2) - CN97
OFF
starting switch BR
and chassis ground
No OV?

OFF.
m lefective starting switch. leplace
NO
E-3. ENGINE STOPS WHEN TRAVELING
defective adjustment of linkage

etween fuel-cut solenoid valve idjust
nd fuel injection pump
)isconnection in wiring
harness or defective contact
n?tween starting switch After inspection.
erminal BR - CN 14 (2) - ep1ace
:N63 (2) - CN97 (11). orfue
ut solenoid - CN97 (12) -
hassis ground
Is fuel-cut solenoid
valve spool operating
I) Visual check when Is voltage between

starting switch ON - YE fuel cut-off solenoid.
terminal BR and 2) Turn starting switch defective fuel cut solenoid iep1ace
OFF
OFF. NC1

ON.
lefective starting switch ?eplace
chassis ground 20 -
1I Turn starting switch lisconnection in wiring hames

OFF. ,r defective contact between Sfter inspection.
tarting switch terminal Band .eplace
,attery relay
Tester
Troubleshooting I
tools
WA350-1 82-27
8
TROUBLESHOOTING E-4
E-4. PARKING BRAKE DOES NOT WORK.

(Even when air pressure drops, parking brake does not work)
When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when discon-
When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( 1)
When disconnecting connectors or connecting T-adapters, return them to the original condition immediatelv
Parking brake does not work when parking brake switch is ON.
Cause Remedy
Defective parking brake

solenoid
Defective perking brake relay
c 1
1) Connect T-adaDter
(Orsocket ada&) t( NO 2
CN35.
2) Turn parking brake
switch ON (Parkmg) Is problem removed
31 Start engine (Air YES
charge). Abnormal contact or mistaken ifter inspection,
wiring between CNl 1 (male)(l epair or replace
- CN93(li, (2) - CN6316) -
1) Replace CN54
CN51 (2)
(back-up lamp YE between CNl 1
relayiand CN51
(male) (1) and (21 as
(parking brake relay)
shown in table?
2) Turn parklng brake
switch ON (parking). NO 1
3) Start engine (Au Defective parklng brake swltct FlepL3X
pressure gauge).
Is problem removed
when disconnect
1) Disconnect CN5 1.
2) Start engine (Air
pressure gaugel.
Abnormal contact or mistaken After inspection,

winng between CN51 (5)(mal< repair or replace
- CN39 (11) - CN35 11)
b) Parking brake does not work when air pressure drops.

(Does not work as emergency brake.)
YES
c Defective emergency brake Reolace
1 switch
Doesparking brake
work when CN93 is -
disconnected?
1) Starting switch ON c Defective parking brake Repair

2) Parking brake switch NO
OFF

Short socket adapter
TroubleshootIng (for Econoseall
tools
Tester
82-28 WA350-1
8
TROUBLESHOOTING E-4
CNll
2
Eia
CN35
CN51
6 3
CN93
WA350-1 82-29
8
TROUBLESHOOTING E-5
E-5. PARKING BRAKE IS APPLIED WHEN TRAVELING
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ())
* When disconnecting connectors or connecting T-adapters, return them to the original condition immediately
1 YES
H
Is there continuity
YE: between CN35
(2)(male) and chassis
gyound,
NO
1) Connect T-adapter
(or socket adapter) to
CN35.
21 Turn starting switch
1 OFF.
Is voltage between
CN35 (1 )(male) and
chassis ground 20 -
I I
1 I Connect T-adapter YES
CN35.
2) Start engine (Air NO 3
pressure charge).
switch ON + OFF. Is problem removed
when relays are
I) Interchange CN54 2) Start engine (Air

(back-up lamp relay pressure charge). Is problem removed
and CN5 1 (parking 3) Turn parking brake
when short socket
brake relay). switch ON - OFF. adapter IS connected? un
2) Start engine (Air 7
pressure charge).
NO d
switch ON - OFF.
Ifemalel.
Is voltage between 2) Start engine (Air _._ =._
~~51 (3)(male) and oressur&charael. I .-. I
chassis ground 20 - 3) iurn parking b;ake -
switch ON - OFF 11 Interchange CN54
3OV?
(back-up lamp relay)
and CN52 (oarkina
II Disconnect CN51.
brake relay): -
!I Turn starting switcl
21 Start engine (Air
ON.
pressure charge).
switch ON - OFF.

Troubleshooting (for Econoseal)
tools
82-32 WA350-1
8
TROUBLESHOOTING E-5
Cause Remedy
w Defective parking brake ReplaCe

solenoid valve
a Disconnection in wiring After inspection.

harness, or defective contact replace
between CN35 I2)(male) and
chassis ground
v Defective parklng brake relay ReplaG?
. DisconnectIon in winng After uxpection.

harness. or defective contact replace
between CN51 (5)(malel -
CN39 (11) - CN35 (1)
14 tl;:l,c,tve emergency brake Replace
YES
- Defective parkmg safety relay Replace
NO 8 YES
_ Defective parking brake switch Replace
Is there continuity
- between CNl 1
(male)(l) and (2).
CNl 1 (male)l2) and NO After ispeCti0.
. Disconnection in wiring
(3). as shown in harness, or defective contact replace
Table 1 ? between CNl
1 (female) (1) -
CN93 11J.12) - CN63 16) -
1) Disconnect CNl 1. CN51 (2),orCN51 (3) -
2) Turn starting switch CN52 (51,(2) - CNl 1 (2)
OFF.
Table 1
Terminal No.
Operation
(l)-(2) 1 (21-(3)
ON (Park) NO continuity Continuity
OFF (Travel) Continuity No continuiW
WA350-1 82-33
8
TROUBLESHOOTING E-5
CNll
% I
2
IriB
2
CN35
CN51
CN52
CN54
82-3 4 iVA350-1
@
TROUBLESHOOTING E-5
*
CN93
1 1
WA350-1 82-35
0
E-6. PARKING BRAKE IS RELEASED WHEN STARTING

SWITCH IS TURNED TO ON
When disconnecting or connecting the T-adapter (or socket adapter)

When connecting the T-adapter (or socket adapter), connect to the
When disconnecting connectors or connecting T-adapters, return Cause Remedy
them to the original condition immediately after checking, then go to
the next check.
YES
* )efecttve parkIng brake safety Replace
&V
YES
Defective parklng brake relay ReplZG?
Isproblem removed
NO 2
I
1) Interchange parkIng
brake safety relay )efectwe parking brake swtct
lCN52) and back-up
lamp relay (CN54).
21 Start engnne and
charge au pressure.
31 Turn startnng switch
ON.
1) Disconnect CNl 1.
charge arpressure. 2 Start engine and
c :ontact between +24V Grins Sfter Inspection,
3) Turn startlng swatch NO iane~s between CN35 (1) - WlaCe
charge air pressure.
ON. 31 TUT starzg switch :N39Il l)- CN51 (51,orCNl
1) - CN51 (2),or
&taken wiring.
E-7. TRANSMISSION IS NOT RETURNED TO NEUTRAL

WHEN PARKING BRAKE IS APPLIED.
,i_ :ontact between +24V wiring \fter inspection,
1 harness between CN53 (5) - eDlace
:N21 (1). (21 - CN85 (A),or
Is problem removed nistaken wiring.
when relay is
replaced?
-
1) Interchange NO
neutralizer relay ) Iefective neutralizer relay
KN53) and back-up
lamp relay (CN54).
21 Start engnne and
charge ar pressure.
31 Turn starting swtch
ON.
82-36 WA350-1
8
CNII
B 2 3 3
FB
2
CN51
CN52
CN54
WA35071 82-37
0
TROUBLESHOOTING E-8
E-8. MACHINE DOES NOT TRAVEL FORWARD
YES Is there continuity

3 - betweenCN16 -
(male) (1) and l2)?
Is there contiruty
between CN16 1) Place F-R lever I NO
(female) (8) and - FORWARD.
chaws ground? 2) Turn startlrrg swtch
ON.
) Connect T-adapter
CN16 (female).
) Turn starting switch
OFF. NO
YE between CN85 0)
(female) and chassis
1) Place F-R lever tn

FORWARD.
2) Turn startlng swtch
OFF.
YES
Is problem removed
I) Disconnect CN85. when relay 1s
Turn starting switch Ir -NO 6 YES
2) replaced?
ON.(Do not start
engine). - Is problem removed
1) Interchange - when relay IS
7
neutralizer relay replaced? NO YES
switch ON - OFF.
(CN53) and back-up
- Is problem removed
lamp relay (CN54).
1) Interchange parking when short socket
2) Start engine.
brake safety relay L adapter is
lCN52) and back-up connected7
switch ON - OFF.
lamp relay iCN54).
2) Start engine. YES
1I Connect short socket
3) Turn parking brake adapter to CN2 1 3
switch ON - OFF. (female).
2) Start engine. YES Is problem removed
3) Turn parking brake when CNl 1 (female) _
switch ON - OFF. 8 - (1) and (3) are
shortclrculted?
Is problem removed .
_ when CN53 (female) _ 1) Disconnect CNl 1. _
NO (3) and 15) are 2) Start engine NO
shortcircuited?
1) Disconnect CN53.
2) Start enghne.

tools
82-38 WA350-1
8
TROUBLESHOOTING E-8
- Disconnection in wiring After inspecton,

harness. or defective contact repair or replace
between CN16 (2) (female) -
. CN75 (51 - CN85 (D) -
CN85 (A) (female)
F Defective F-R switch Replace
t Disconnection in wiring After inspection,

harness. or defective contact repair or replace
between CN16 (1) hale)
and
chassis ground
w Defective Forward solenoid RepliKe
=c Defective neutralizer relay ReplaCe
t Defectwe parking brake safety Replace

relay
c Defectwe transnxss~on cut-off Replace

swtch
- Defective parklng brake swtch Replace
WA350-1 82-39
8
TROUBLESHOOTING E-8
CNII
CN16
CN21
2 1
CN52
CN53
CN54
82-40 WA350-1
@
E-8
TROUBLESHOOTING
CN85
..
82-4 1
WA350-1
@I
TROUBLESHOOTING E-9
E-9. MACHINE DOES NOT TRAVEL IN REVERSE
YES Is there continuity

- betweenCN16 -
3 (male1 (1) and l3)?
IS there cont,u,ty
1 betweenCN16 (11 1) Place F-R lever I NO
Ifemale) and chaws REVERSE.
ground 2) Turn starting switch
OFF.
(or socket adapter)
to CN16 (female).
OFF. NO
2
CN85 (A) Ifemale)

and chassis ground
Y ES
1) Disconnect CN85.
ON. (Do not start
enginei
switch ON - OFF. YES
I Id
I Is problem removed
1) interchange YES
neutralizer relay h
(CN53) and back-up
t i
_, lamp relay (CN54). Is problem removed
ZJ startengnne. 1) Interchange parking when short socket
3) Turn parking brake brake safety relay
switch ON - OFF (CN52) and back-up
lamp relay (CN54).
2) Start engine.
switch ON - OFF
adapter CN21 9
(female).
2) Start engine. Is problem removed
3) Turn parking brake YE$_ when CN53 (female)
switch ON - OFF 8 (3) and 151 are
shortcircuited?
Is problem removed _ NO
_ when CN53 (femalei _ 1)
Disconnect CNl1.
NO (3) and (5) are 2) start eng,ne.
shortcircuited?
1) Disconnect CN53.
2) Start engine.

Tester
tools NO
82-42 WA350-1
8
TROUBLESHOOTING E-9
Cause Remedy
Iisconnectlon In winng
harness. or defective contact
4fter inspection,
xtween CN16 (female) (31 -
.epair or replace
1N75 16) - CN85 (0 -
CN85 iA) (male1
Defective F-R switch Replace
harness, or defective c&tact After inspection,

between CN16 (male) (1) and epair or replace
chassis ground
>efectwe Reverse solenoid ReplaCe
Defective neutralizer relay Replace
Iefectwe parking brake safety Replace

?lay
Iefective transmission cut-off

Replace
witch
Defectwe parking brake switc
Disconnection in wr!ng
harness, or defective contact After Inspecton.
between main breaker - CN6 repair or replace
(3) - fuse - CN60 14) CN52
- CNll - CN52
Disconnection in wiring
harness, or defective contact After inspection,
between main breaker - CN5 repair or replace
- CN21 (11, (2) - CN85 (A)
(female)
WA350-1 82-43
CD
TROUBLESHOOTING E-Q
CNll
1 1
b?I EB
3 3
CN16
CN21
CN52
CN53
CN54
? /
82-44 WA350-1
@
TROUBLESHOOTING E-9
CN85
WA350-1 82-45
@
TROUBLESHOOTING E-10
E-IO. TRANSMISSION DOES NOT SHIFT GEAR (F-R

SWITCH NORMAL)

checking, turn the starting switch OFF to prevent accidents. Cause Remedy
When disconnecting connectors or connecting T-adapters, return
the next check
Defective 1 st solenoid
Disconnection in wring
harness, or defective contact
between CN85 (H) (female) an
OFF. CN16 (4). or defective speed
switch
3) Palace speed lever in
1 St.
YES
Defective 2nd solenoid
)
Disconnection in wiring
between CN16 (8) harness, or defective contact
Ifemale) and chassis between CNB5 (G) (female)
OFF. :;11~;;16 (5). or d-d speed
3) i%l!,ce speed lever in
) Connect T-adapter
lor socket adapter) t(
CN16 lfemalel
) Turn starting switch
OFF. YES
Defective 3rd solenoid
H
Is there continuity
CN85 (B) (female)
between CN85 (F)
and chassis ground
and chassis ground?
Disconnection in wirtng
I) Disconnect CN85. harness, or defectw contact
1) Disconnect CN85.
2) Turn starting switch INO Detween CNB5 (F) (female) ant
OFF. ZN16 16). or defective speed
ON.
3) ;;l$ce speed lever in switch
switch ON-OFF.
YES
Defective 4th solenobd
2 >isconnection in wnng
lames% or defective contact
xtween CN85 (E) (female) ant
1) Disconnect CN85. XNl6 (7). ordefect~ve soeed
2) Turn starting switch witch
_.
nFF
3) Palace speed lever in
Iisconnection in wiring
4th
larness, or defective contact
xtween CN16 (8) (female) an,
:hassis ground
Dlsconnect!on in winng
harness, ordefect~ve contact
between man breaker - CN7!
(1) - CNB5 (B) (female)
Troubleshooting
WA350-1
CN16
CN85
WA350-1 82-47
@
TROUBLESHOOTING E-l 1, E-l 2
E-II. MACHINE DOES NOT TRAVEL WHEN TRANSMISSION CUT-OFF SWITCH IS ON

(MACHINE TRAVELS WHEN TRANSMISSION CUT-OFF SWITCH IS OFF)

connector specified. (CNxx ()I
Cause Remedy
the next check.
Iwxnnection in wiring
YES wrness, or defective contact 4fter inspectlon,
I
xtweenCN21 (1) - CN53 .epLxe
:5). or CN21 (2) - CN75 (8)
Is therecontinuty
between CN21
(female) (1) and (21?
CN21 (female). Iefective transmlsslon cut-off
2) Turn starting switch I leplace
;wltch
ON. NO
* Do not press the left
brake pedal.
E-12. TRANSMISSION CANNOT BE CUT-OFF.
Iefectwe transmission cut-off Gplace

witch
ES Iefective transmission cut-off

L ?eplace
ielector switch
4bnormal contact, or mistaken

YES Ninng between +24V termina
e snd wiring harness of main ifter Inspection.
1) Disconnect CN18 sreaker - CN53 (3). 15) - epalr or replace
2) Start engine 3 ZN21 (11, (2) - CN85 (A)
Table Iscontinuity between

CN76 (male1 (1) and -
(2) as shown in table,
1) Disconnect CN76.
OFF. I 1efectlve diode (CN76)
NO

Troubleshootmg (for Econoseal)
tools
82-48 WA350-1
8
CN21
CN18
1 1
f!tFI
4 4
WA350-1 82-49
0
E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL
When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when
When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1)
When disconnecting connectors or connecting T-adapters, return them to the original condition immediately
If the head lamps and other electrical parts are working normally, check battery - battery relay - starting
switch first.
YE
OFF. 1) Disconnect CN85.

2) Turn starting switct
OFF.
NO 5
Iscontinuitybetween
CN76 (male) (1) and
(2) as shown in table?
r-l
L-t
Is transmission
Y ; returned to NEUTRAL II Connect T-adapter
when parking brake (or socket adapter) tc
is applied? CN76 (male).
Turn startlna swtch OFF.
1)
ON. -
2) Turn transmission
cut-off selector
switch ON.
1
returned to NEUTRAL
when left brake is
I J
1) Turn starting switch 0
ON.
2) Turn transmission
cut-off Selector
switch OFF.
switch ON - OFF.

toots
82-50 WA350-1
0
Cause Remedy
-
Defectwe F-R switch Replace
After inspection.
repair or replace
After inspection.
repair or replace
See E-7 Transmission is not

returned to NEUTRAL when
parking brake is applied.
See E-l 2 Transmission

cannot be cut off.
WA350-1 82-51
a
CN16
3 3
CN85
82-52 WA350-1
@
E-14. PREHEATING DISPLAY DOES NOT GO OUT

Cause Remedy
the next check.
Iefectlve glow switch IeplXe
II
Is there contlnulty
between CN13 -
(male) (1) and 121? -
1) Turn glow switch , Iefectlve heater relay leplace

OFF IAUTO).
2) pisc;ryct CN13
m
E-15. PREHEATING DOES NOT WORK
S
m Defective glow switch %?pb2
ES
Is there continuity Defective automatic xep1ace
between CNI 3 preheating timer
(male) (I) and (2)
1) Turn glow switch 4 YES

OFF (AUTO). Defective heater relay bSpk%
2) ~;isc~;nect CN13 Is voltage between
r CN48 (I 1 and (3) 20 YES jjjjzJ( Contact between wiring

- 3OV? harness of f24V terminal and
o&put terminal? 1 heater relay output terminal -
r L
1I Turn glow switch L nput terminal of electrical air 7epair or replace
_, OFF (AUTO). 1) Turn starting switch NC intake heater, or CN13 (2) -
2) Measure voltage OFF. heater relay - automatic
after 2 minutes Is there continuitV preheating timer
when starting between CN48 (3)
switch is ON.
Iefectiue contact or
disconnection in wiring harries!
?epair or replace
xtween CN48 (3) and chassis
ground
Tester
Troubleshooting ,
tools
82-54 WA350-1
8
E-14, E-15
TROUBLESHOOTING
CN13
CN48
fz3 3 3
WA350-1
TROUBLESHOOTING ELECTRONIC VEHICLE MONITORING SYSTEM
ELECTRONIC VEHICLE MONITORING SYSTEM __,_
Air pressure
-
--
-
--
--
Jain switch
-
? Fuel level sensor
Brake stroke
CNBS sensor
-_
2I
11 -0>
T_
Brake stroke
CN8 sensor
__
/ Transmission cut-off 1
Brake oil
capacity sensor
relay Engine oil

Speedometer sensor
I Engine oil
CN,63
pressure sensor
Parking brake temperature sensor

indicator switch
Monitor panel
82-56 WA350-1
0
TRouBLEsHOOTlNG TABLE (ELECTRONIC VEHICLE MONITORING SYSTEM)
Module group Electrical parts group Sensor group
HX- Engine ira%lX

Service Speed0 Alterna- y$:g bbn,? ~f~$~~~ D. d Lamp ~~~~~~~~~Engine Brake Coolant.$glne Parkmg Ezn?i water A1r Brake
nes5 Checks Caution Caution
No. Trouble phenomenia Gauge meter meter tar off SWliChheater lo e buzzer Controer 011level oil level level pressure brake &erlng H,;rnw- Pressure line :,v,, Speed Tg$.
1 2 switch failure f"W
1
Even
when engine is stopped,
level) flashes.
and there is no abnormality in machine,
q co, (Brake 011
00 0
Even when engme is stopped, and there is no abnormahty IR machine. (Engine 011
2
level) flashes. rg 00 0
Even when engine IS stopped, and there IS no ablormallty III machme, (coolant
3 level) flashes. I 00 0 0
4 q (Battery charge) flashes.
0 0
1 5 1 q (Fuel level) flashes

loI loI IOI --I/
Even when engine is stopped, and there IS no abnormality in machine (Fallwe in
6 brake Ilne) flashes. 0 0 -
Even when engine is stopped, and there is no abnormality in machlne (Engine 011
7
pressure) flashes. ,a 0 0 0
8 Even when engine
level) flashes.
is stopped, and there is no abnormality in machIne
,I
(coolant
00 0
Even when engme is stopped, and there is no abnormality in machine (Drop in
9 air pressure) flashes. +zj 0 00 -
Even when engine is stopped, and there IS no abnormality in machine (Coolant
10
temperature) flashes. ,x!I 0 00
11
Even when engine IS stopped, and there IS no abnormality
converter 011temperature) flashes.
in machine ,[e (Torque 0
00
-
12 b( (Park1 ng brake) lights up abnormally, or does not light up. 0 0 0
13 m (Working lamp) lights up abnormally, or does not light up 0 n 0
.I4 i73F1 (Preheat) hghts up abnormally.
0 0
I5 IZT (Fatlure in main steering 1lights up abnormally, or does not light up (If equIppedI 0
0 0
.r II (Emerqencv steerinq normal) liqhts LID abnormallv. or does not liaht UD. (If n n n
17 M (T ransmmission cut-off) lights up abnormally, or does not light up. IOlOj 101
18 Turn slgnal lamps, high beam light up abnormally, or do not light up.
0 0
19 Speedometer display does not work normally.
0 0 0
20 Servicemeter does no? work normally
0 0 0
All or part of monitor panel does not work normally.
21
If any fuse is broken, replace after checking. 00000 0
22 E;;;g;;;,sy:;ne 1s stopped. q (Engine oil pressure) flashes, or
!ol
(Battery
00000 0 0
23
No IamPS On monitor
engrne stopped)
light up (Immediately after turning starting switch to ON,
00000 0
24 Central warning lamp does not go out.
0 00 00
I
25
I
Central warning buzzer does not stop.
.0 00 ,o,o; ; ; ; / : : I : : / )
26 None of panel lamps on monitor light up.
0 0 00
27 Some of panel lamps on monitor do not hght up.
000000 0
28 Emergency Item is flashing, but alarm buzzer does not sound.
00000 On,
29 Emergency item or non-emergency Item is flashing, but warning lamp does not flash.
00000
30 Abnormality in x (Fuel gauge)

0 0 0
31 Abnormality in a (Air pressure gauge)
0 0 0
*
32 Abnormality in &, (Coolant temperature gauge)
0 0 0
1 33 1Abnormality in F1
,&
(Torqu e converter oil temperature gauge)
IOI I I lOI I I I 1 I I 1 I I I I I I I I I I I I IO
WA350-1 82-57
0
82-58
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE
MONITORING SYSTEM
(M-l. to M-33.)
M- 1. Even when engine is stopped, and there is no abnormality in machine,

brake oil level display flashes. ................................... . . . 82- 60
engine oil level display flashes. .................................. .. . .. 82- 60
coolant level display flashes. .................................... . . 82- 62
M- 4. Battery charge display flashes. ................................... . . 82- 62
M- 5. Fuel le.vel display flashes. ........................................ 82- 64
failure in brake line display flashes. .............................. 82- 64
engine oil pressure display flashes. .............................. 82- 66
coolant level display flashes. .................................... . 82- 66
drop in air pressure display flashes. .............................. . 82- 68
M-l 0. Even when engine is stopped, and there is no abnormality in machine,
coolant temperature display flashes .............................. . . 82- 68
M-l 1. Even when engine is stopped, and there is no abnormality in machine,
torque converter oil temperature display flashes ................... . 82- 69
M-l 2. Parking brake display lights up abnormally, ....... or does not light up 82- 70
M-l 3. Working lamp display lights up abnormally, or does not light up. ..... . . 82- 72
M-l 4. Preheat display lights up abnormally. ............................. 82- 74
M-l 5. Failure in main steering display lights up abnormally,
or does not light up (if equipped). ................................ 82- 76
M-l 6. Emergency steering normal display lights up abnormally,
or does not light up (if equipped). ................................ . 82- 78
M-l 7. Transmission cut-off display lights up abnormally,
or does not light up. ........................................... 82- 80
M-l 8. Turn signal lamps, high beam light up abnormally,
ordonotlightup ............................................... 82- 82
M-l 9. Speedometer display does not work normally. ..................... 82- 86
M-20. Servicemeter does not work normally. ............................ . 82- 88
M-21. All or part of monitor panel does not work normally.
If any fuse is broken, replace after checking ....................... 82- 90
M-22. Even when engine stopped, engine oil pressure display flashes,
or battery charge display flashes. ............................... 82- 92
M-23. No lamps on monitor light up (Immediately after
turning starting switch to ON, engine ...................
stopped). 82- 93
M-24. Central warning ............................
lamp does not go out. 82- 94
M-25. Central warning buzzer does not stop. ............................ 82- 96
M-26. None of panel lamps on monitor light up. .......................... . 82- 98
M-27. Some of panel lamps on monitor do not light up. ................... . . 82-l 02
M-28. Emergency item is flashing, but alarm buzzer does not sound. ....... 82-l 04
M-29. Emergency item or non-emergency item is flashing,
but warning lamp does not flash. ................................ 82-l 06
M-30. Abnormality in fuel gauge. ....................................... 82-l 08
M-30-1. Abnormality in fuel gauge sensor. 82-l 09
M-3 1. Abnormality in air pressure gauge. ............................... 82-l IO
M-32. Abnormality in coolant temperature gauge. ....................... . . 82-l 12
M-33. Abnormality in torque converter oil temperature gauge. ............ 82-l 14
WA350-1 82-59
0
TROUBLESHOOTING M-l ,M-2
M-l. EVEN WHEN ENGINE IS STOPPED, AND THERE IS NO ABNORMALITY IN

MACHINE, (0, (BRAKE OIL LEVEL) FLASHES.
I_
t When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when
Cause Remedy
Defective brake oil level sense Replace
YES
Defective CHECKS BEFORE Replace
STARTING module
1) Connect short socket

adapter to CN86 Disconnection in wiring After inspection,
(femak?)(brake oil harness, or defective contact repair (clean) or
2 (female).
between CN86 (female)(l) -
level sensor). 2) Connect T-adapter replace
2) Turn starting switch CN64 (1 1) - CNP4 (female)C
ISthere continuitv (or socket adapted to
ON. between CN86 CNP4 (female).
N (female)(2) and c 3) Turn starting switch
1 chassisground? 1 OFF.
I I
1I Connect T-adapter
(or socket adapter) tc
CN86 (female).
OFF. Disconnection in wiring harnes After inspection.
between CN86 (femaleI(2) - repair (clean1 or
CN163 (2) - fuel cut solenoid replace
M-2. EVEN WHEN ENGINE IS STOPPED, AND THERE - CN97 (12) - chassis grow
IS NO ABNORMALITY IN MACHINE,
(ENGINE OIL LEVEL) FLASHES. q$)
Defective engine oil level sew, Replace
q
STARTING module
IDoes goout?t
1, Connect short sockel

adaDter to CN96 Disconnection in wiring After inspection,
(female)kangine oil (female). harness, or defective &tact repair (clean) or
level sensorl. to between CN96 (female)(l) - replace
Connect T-adapter
2) Turn starting switch CNP3 (female). CN97 (5) - CN62 (1) - CNP.
ON. Turn starting switch (female)(3)
2 3)
OFF.
Is there continuity
between CN96
NE (famale)(2) and -
chassis ground?
2) ?~r?l,t!~~~$&h &NO
c 3isconnection in wiring After inspection,
OFF
,arness, or defective contact repair (clean) or
x?tween CN96 (female)(2) - replace
3N163 (femaleI(2) - fuel cut
solenoid - CN97 (12) -
:hassis ground
Tester Short socket adapter
Troubleshooting
T-adapter (for DLI)
(for Econoseal)
82-60 WA350-1
0
TROUBLESHOOTING M-l ,M-2
CN86
CN96
2 1
CNP3
CNP4
4 8
4 8
WA350-1 82-61
0
TROUBLESHOOTING M-3,M-4
M-3. EVEN WHEN ENGINE IS STOPPED, AND THERE IS NO ABNORMALITY IN

MACHINE, 0 (COOLANT LEVEL) FLASHES.
/_
Cause Remedy
Defective radntor water level

ieneor
YES
jTARTlNG module
VI
~~7
adapter to CN107 Iisconnectlon In wiring After inspection.

Ifemalel~Radiator (female). urness. or defective contact repar (clean1 or
water level sensor). 2) Connect T-adapter to ,etween CN107 (female)(l) - WPlXX
21 Turn starting swtch CNP3 (female). 3N106 (1) - CN62 (21 -
ON. 3) Turn starting switch 3NP3 (femalel(5)
OFF.
Is there continuity
between CN 107
chassis ground,
Ior socket adapter1 tc
CN107 (femaleI,
21 Turn starting watch
OFF.
Xsconnection in wiring After inspection,
nmess. or defective contact repair (clean) or
,etween CN107 (female) (21 - replace
- ZN106 (21 - chassis ground
M-4. w (BATTERY CHARGE) FLASHES.
YES
* defective CAUTION module 1 Replace
2
ISvoltage between
YES CNP5 (female) and
1 chassis ground 20 -
3OV?
Is voltage et
alternator termlIla R _ 1 i Disconnect
20 - 3ov7 connector CNP5. NO
2) Connect
T-adapter
to c IIsconnection in wiring After Inspect,on,
CNP5 (female). larness, or defective contact repar (clean1 or
1) Turn start,ng ewltch 3) To?; starting swtch Ietween alternator terminal R replace
ON. CN97 (Ii - CN64 11) -
Start engine. :NP5 (1)
2) Measure voltaoe
between alter&tor
termne R and
chassis ground.
c Iefectwe alternatol
NO

Troubleshooting
T-adapter (for DLI)
(for Econosealj
82-62 WA350-1
CN107
\
2 1 1 2
CNP3
CNP5
WA350-1 82-63
0
M-5. m
I_
(FUEL LEVEL) FLASHES.
sr When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( ))
Cause Remedy
jee M-30 Abnormality in fuel

<ES -
gauge.
Does fuel gauge

YES
display show Defective CAUTION module 1 &place
EMPTY?
1) Turn starting switch Defective gauge module Gaplace

Does 101 goout? 1
ON. I
I
Interchange
CAUTION modules ,
1 and 2. ~~.
Turn starting switch
ON.
Iisconnection in wiring lfter inspection,
lames% or defective contact xpalr (clean) or
CNP5 (female).
xtween CNP2 (femalej(3) and eplace
:NP5 (female)(6)
OFF.
M-6. EV EN WHEN ENGINE IS STOPPED, AND THERE

IS NO ABNORMALITY IN MACHINE, (a) (FAILUREYE:
1 Defective CAUTION module 1 ?eplace
IN BRAKE LINE) FLASHES.
r
4
Is there continuity
YES between CNP8
3- (femalel(1 1) and
p chassis ground?
Is there continuity 1
YES between CN87 1) Connect T-adapter to
2 - (female)(2) and - CNP8 (female).
chaws ground? 2) Turn starting switch
OFF. c )isconnection in wiring
Is there
continuity After inspection,
between CN87
11 Connect short socket N( Iarness, or defective contact repair (clean) or
hale)(l) and (2)7
adapter to CN88 letween CN87 (female)(l) - replace
(female). :N64 (12) - CNP8
II Connect T-adapter female)il 1)
Is there continuity
1 Connect T-adapter (or socket adapter) to
between CN88
(or socket adapter) tc CN87 (female).
(male)ll) and l2)?
CN87 (male). 3) Turn starting switch
!I Turn starting switch OFF.
OFF.
(or socket adapter) tl
CN88 (malel.
OFF.
. Disconnection in wiring After inspection,

NO
harness, or defective contact repair l&an1 or
between CN87 (female) 121 - replace
CN88 (female)(l), or CN88
(female)(21 - chassis graounc
c Defective brake line failure 1 Replace

3 %?SW
Defective brake I~ne failure 2

SeSOr

Troubleshooting
T-adapter (for DLI) (for Econoseal)
82-64 WA350-1
0
CN87
CN88
1 1
CNP5
CNP8
11
\
WA350-1 82-65

MACHINE, + (ENGINE OIL PRESSURE) FLASHES.
I
the next check.
_ I3efective engine oil pressure
sensor
YES
IDefective CAUTION module 2
31
I3isconnection I wring
I?arness, or defective contact After inspection,
I) Connect short socket I~etweenCN163 (femaleI - repair (clean1 or
adapter to CN163 ! ,SN97 (81 - CN64 (6) - CNP7 replace
lfeniale)(engine oil (engine oil preessure ,Ifemale) (2)
pressure sensor). sensor).
21 Turn starting switch _ !I Connect T-adapter to
ON. 2 CNP7 (female).
31 Start engine. 3) Turn starting switch
Is there continuity OFF.
between CN163
(femalel(2) and
NO
chassis ground?
---I
(or socket adapter) tc
CN163 (female).
OFF. C)isconnection in vwring
(Engine stopped) lames% or defective contact After inspection,
letween CN163 (female1121 - repair (clean) or
0 f uel cut solenoid - CN97 I1 2) replace
- chassis ground
Note: If flashes : see M-22 Even when engine

After inspection,
when the engine _ i,s stopped, engine oil pressure
q
repair (clean) or
is stopped, amp or battery charge lamp
replace
is defective. (;lashes.
M-8. EVEN WHEN ENGINE IS STOPPED, AND THERE

IS NO ABNORMALITY IN MACHINE, 0
sl
(COOLANT LEVEL) FLASHES.
3efective coolant level sensor Replace
Does
Defective CAUTION 2 module Replace
I I
1) Connect short sockel
adapter to radiator
water level sensor
CN107 (female). Is there continuity
2) Turn starting switch YES between CNP7
ON. - (femaMl2) and -
NO 2 chassis ground?
31 Start engine.
Defective contact, or
Is there contwity
After inspection,
between CN107 11 Connect short socket disconnection in wiring harness
- (femalej(2) and - adapter to ~107 i
c between CN107 (female)(l) - repair (clean) or
chassis ground? (female).
IO CN106 (1) -
CN62 (2) - replace
2) Connect T-adapter to CNP7 (female)(6)
1) Disconnect short CNP7 (female).
socket adapter to 31 Turn starting switch
OFF. Defective contact, or
CN107.
disconnection in wiring harness After inspection,
2) Connect T-adapter 1 * between CN107 (femalel(2) - repair (clean) or
(or socket adapter) to NO
CN106 (2) - chassis ground replace
CN107 (female).
OFF.

Troubleshooting
T-adapter (for DLII
(for Econoseal)
82-66 WA350-1
0
CNI 07
CN163
i 1 1 2
CNP7
WA350- 1 82-67
0
TROUBLESHOOTING M-9,M-lO,M-11

MACHINE, @+ (DROP IN AIR PRESSURE) FLASHES.
n
Cause Remedy
ke M-31 Abnormality in air ?eDlace

Iressure.
Does air pressure

gauge move to red efective CAUTION module 2 k?place
II
level?
t
11 Turn
I~~~
starting switch
efective gauge module kzplace
ON. N
~lsconnection in wiring
NO arness, or defectwe contact \fter inspection,
1) Connect T-adaoter to
*
CNPZ (female)and etween CNP2 (fern&)(71 and .epair (clean) or
CNP7 (female). :NP7 (female)(3) splace
2) Turn starting Switch
OFF.
M-10. EVEN WHEN ENGINE IS STOPPED, AND THERE

IS NO ABNORMALITY IN MACHINE,
m
(COOLANT TEMPERATURE) FLASHES.
;ee M-32 Abnormality in

Replace
&ant temoerature.
lefective CAUTION module 2 qeplace
kfective gauge module Redace

1) Interchange
CAUTION modules 1
and 2.
2) Turn starting watch Iisconnectwn in wiring
ON. After inspection,
Iarness, or defective contact
repar Wan) or
1) Connect T-adapter to
etween CNP2 lfemale)(2) ant
replace
:NP7 ifemale)(7)
CNP2 (female) and
CNP7 (female).
OFF.
Tester
Troubleshooting
tools
T-adapter (for Xl)
826% WA350-1
0
TROUBLESHOOTING M-9,M-lO,M-11

MACHINE, , (TORQUE CONVERTER OIL TEMPERATURE) FLASHES.
i%fJ
+ When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1)
the next check.
See M-33 Abnormality in

torque converter oil Replace
temperature gauge.
..
/ES
b Defective CAUTION module 2 Replace
converter 011
temperature gauge
move to red level?
1) Turn starting swtch NO Does q go out?
4 Defective gauge module

1) Interchange
CAUTION modules 1
Dlsconnectlon in wiring
After Inspection.
harness. or defective COntaCt
repair (clean) or
between CNPP (femal418) ant
11 Connect T-adapter replace
CNP7 ifemaleI(5)
CNP2 (female) and
CNP7 (female).
21 0;~ starting swtch
CNP2
CNP7
5 7
WA350-1 82-6 9
TROUBLESHOOTING M-12
M-12. w (PARKING BRAKE) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.
When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx 0)
Cause Remedy
M does not go out.

Defective parklng brake sensor Replace
I I
) Connect short sockei YES
adapter to CN36 4, Defective CAUTION module 2 Replace
(female)(parkig
brake sensor). Is there contlnulty
.) Turn starting switch YES between CNPB
ON. 3 - lfemale)(Zl and -
chaws ground? Disconnection in wiring
Is there continuity harness. or defective contact After inspection,
1) Connect short *
when parkIng brake between CN36 between CN36 (female)(l I- .epair (clean) or
switch is turned to r i (femalel(2) and - connectorto CN36 No CN38 (4) - CNP8 lfemale112) .eplace
chassis ground? lfemalellparklng
I brake sensor).
1) Turn starting switch 2) Connect T-adapter to
ON. CNP8 (female).
CN36 (female)
(parking brake
sensor).
OFF.
Disconnection I wring
NO harness, or defective contact After inspection,
* between CN36 (female)W and repair (clean) or
chassis ground replace
See troubleshooting for After inspection.
q does
machine. repair (clean) or
replace
b) not light up.
Defective parking brake sensor
;z Does q light up) _

3-
YES
Short circuit between chassis
ground and wiring harness
between CN36 (female)(l) -
After inspection,
repair (clean) or
CN38 (4) - CNPB (femalel(2) replace
Is there continuity
DoA%oot _ 1) c between CNP8
when parklng brake (femalel(2) and -
connectorCN36. NO
switch IS turned to chassis ground?
ON?
ON.
) PI, starting switch 1) Connect T-adapter to
Defective CAUTION module Replace
CNP8 (female). +
NO
21 Disconnect CN36.
OFF.
See troubleshooting for

Replace
machine

Troubleshooting
to015 T-adapter or socket adapter
T-adapter (for DLI)
(for Econoseall
82-70 NA350-1
a
CN36
CNP8
2
\
WA350-1 82-71
a
M-13. 1,,Q 1 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.
t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ()I
Note: Is all working lamp bulbs are broken, or there is defective

contact or a disconnection in the wiring harness of the
working lamp, q (working lamp) will stay on. Cause Remedy
a) q does not go out. YES

c Contact between +24V
terminal and working lamp
After fnspectlon.
repair (clean) or
switch assembly lCNl2 (2)) - E&Ce
CN40 (female)(l I
IScontinuity between
CN12 (male)lll and
(2) as shown in table?
NO
2) Turn starting switch c Defective working lamp swtch Replace
OFF.
1) Disconnect CN40. 3) Operate working
2) Turn starting switch lamp switch.
ON.
YES
3 * Defective CAUTION module 2 ReplaCe
h
Is there continuity
between CNP8
r (female) I1 0) and
CN40 (female)15)?
1) Connect T-adapter to NO
CNP8 (female). c Disconnection in wiring After inspection.
2) Turn startina switch harness, or defective contact repair (clean) or
OFF. - between CNP8 ifemale) replace
and CN40 (female)(5)
b) q d oes not light up.

4 YE
Defective CAUTION module 2
Y Disconnection in wiring After inspection,

CN40 (male)(l) and harness, or defective contact repair (clean) or
chassis ground 20 -
2) Turn starting swatch
between CN40 imale) I1 1- replaCe
CN40 (5) - CNP (81
ON.
YES Is continuity between Ifemale)
1I Disconnect CN40 3) Turn working lamp
, - CN12 (male)(l) and . (female). switch ON.
(2) as shown I table?
Is voltage between ON.
CN60 (male)(l) and _ 11 ~isc~ynectCN12 3) Turn working lamp
chassis ground 20 - switch ON.
3OV? 2) T:rn starting switch
OFF.
1) Connect T-adapter 3) Turn working lamp
Ior socket adapter) to switch OFF - ON. Iisconnection in winng After inspection.
CN60 (male). ?arness, or defective contact repair (clean) or
Turn startina switch ,etween CN60 (female)(l) - replace
ON. - fuse - CN60 (2) - CN12 -
:N40 (female)(l)
IL
I
NO
Iefectlve
Xxonnection
working
in wlnng
lamp switch Qpkace
After Inspection.
,amess. or defective contact repair (clean) or
Table 3etween main breaker and replace
3N60 imale)
Working lamp switch
Tester
CN12 connector Troubleshooting
Continuity No cont,nuty
(1) - (2) tools T-adapter or socket adapter
T-adapter (for DLII
(for Econoseall
82-72 WA350-1
0
CN12
2
\
CN40
CN60
CNP8
WA350-1 82-73
0
~-14. 153-v/ (PREHEAT) LIGHTS up ABNORMALLY.
a) q lights up. Cause Remedy
YES
* Iefectwe CAUTION module 2 7eplace
1 I
electrical intake air
1) Connect T-adapter t,
CNP8 (female).
chassis ground less
2) Turn starting switch c Diconnectlo I wiring harness ifter Inspection.
OFF. JO DTdefectwe contact between epar (clean) or
1) Turn starting switch electrical Intake a~ heater - ep1ace
ON. heater relay terrmnal - CN97
(9) - CN64 (7) - CNP8
lfemale)(3)
2efectwe electrical Wake air 7erhce

heater
b) @does not light up.
Note: If the engine oil pressure and battery charge are abnormal, the
preheating will not work.
Contact between +24V 4fter inspection,

terminal and electrical Intake a~ repair (clean) or
heater (+I - CN97 (9) - reLIace.
CN64 17) - CN98 lfemale)(3)
1
ISthere continuity
between CNP8 _
(femalej(3) and
chassis ground?
1) Disconnect electcal
intakeair heater (+)
terminal.
2) Connect T-adapter to NO
Defective CAUTION module 2 Replace
CNP8 (female).
Troubleshooting Tester
T-adapter (for DLli
(for Econoseali
82-74 WA350-1
0
ELECTRICAL AIR INTAKE HEATER
HEATER RELAY
CNP8
WA350-1 82-75
0
M-15. iU- (FAILURE IN MAIN STEERING) LIGHTS UP ABNORMALLY, OR DOES NOT

LIGHT UP&F EQUIPPED)
Cause Remedy
a) w (failure in main steering) lights up.
Defective main steering failure teplace

YES sensor
Defective CAUTION module 1
1) Connect short sockei

adapter to CN200 Iisconnection in wiring ifter Inspection,
(femalel(main wness. or defective contact epair or replace
steering sensor). xtween CN200 (femalell2i -
adapter to CN200
2) Turn starting switch ZN150 (connector) - CN45
(female).
ON. 3) Turn starting switch
female)(l) - CN45
femalej(2) - CNP6
OFF.
female)(2), or defective diode
Is there continuity
ZN45 (male)
between CN200
(or socket adapted t(
CN200 (female).
2) Turn starting swtch
OFF.
NO
c Iisconnection in vwng rfter Inspection,
wness. or defective contact epair (clean) or
>etween CN200 (female)121 eplace
gnd chassis ground
b) w (failure in main steering) does not light up.
YES
Defective ma, steering failure ?eplace
I-
sensor
YES
Does ZT
I
light up? - D Short circuit between chassis After inspection,
2 ground and CN200 (female)(l repair (clean) or
- CN150 (connector) - replace
Isthere continuity CN45 (1). (2) - CNP6
1) Disconnect CN200 between CNP6 (fern&)(21
(female)(main NE (femaleI(2) and -
steering sensor). chassis ground?
ON. I) Connect T-adapter to NO
Defective CAUTION module 1 Replace
CNP6 (female).
2) Turn start!g switch
OFF.

TroubleshootIng _
T-adapter (for DLli (for Econoseal)
82-76 WA350-1
a
CNP6
WA350-1 82-77
0
M-16. -LJ- (EMERGENCY

cl STEERING NORMAL) LIGHTS UP ABNORMALLY, OR DOES
NOT LIGHT UP. (IF EQUIPPED)
a) q (emergency steering normal) lights up.

Cause Remedy
imergency steering NORMAL

;ensordefective
YES
Iefectlve CAUTION module 1
1) Disconnect CN201
and CN202.
YF
1 Disconnection in wiring
harness, or defective contact
4fter inspection.
-epair (clean) or
2) Connect CN201 2) Connec?CNPOl
between chassis ground - ~~Pl~C~
(female) and CN202 ~rn$ly, and CN202
CN202 (male) - CN201
lmalel.
(female) - CN149 connector
3) Turn starting switch 31 T?n starting switch
- CNP6 lfemalel(3)
ON. OFF.
Is there continuity
i between CN202
) (male connector) and
chassis ground?
t-
Disconnection in wnng 4fter inspection,
OFF.
harness, or defective contact ,epair (clean) or
between CN202 (male) .eolace
connector and chassis ground
b) w (emergency steering normal) does not light up.
YES
Emergency steering NORMAL After inspection.
sensordefectlve repair (clean) or
reDlace
I - II YES
0 c Contact between chassis
ground and CN201 (female1 -
After inspection.
repair (clean1 or
CN149 (connector) - CNP6 replace
(female1 (3)
I I
1I Connect T-adapter to
CNP6 (female). NO
2) Disconnect sensor c Defective CAUTION module 1 Replace
connector CN20 1.
3) Tun starting switch
OFF.
Tester
Troubleshooting
82-78 WA350-1
0
CNP6
WA350-1
82-79
a
M-17. 18 (TRANSMISSION CUT-OFF) LIGHTS UP ABNORMALLY, OR DOES NOT

LIGHT UP.
sr When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ())
Cause Remedy
a) 181 lights up.
fective transmission cut-off

ritch
IES !fective CHECKS BEFORE

*
-ARTING module
Is there continuity
between CNP4
(femaleIll 01 and
1 chassisground?
sconnection in wiring ter inspection,
NO ~mess, or defective contact xair (clean1 or
1I Short-circuit CN18 1) Transmission cut-off c
switch ON. tween CN18 lfemalel(3) and )lace
(female)(3) and (41.
21 Connect T-adapter to 1P4 (fernale)
ON. CNP4 (female).
OFF.
--1
Is there continuity
between CN18
NO
(m&)(4) and chassis
1 ground?
sconnection in wiring fter inspection.
wness, or defective contact pair (clean) or
?tween CN18 (femaleI(4) and place
OFF.
lassis ground
b) m does not light up.
efectwe transmission cut-off

eplace
YES Nitch
1
:ontact between chassis Prfter inspection,
YES round and CNlB (female)(3) napair (clean) or
4
- CNP4 (femaleI naplace
Is there contwity
1) Disconnect CN18. between CNP4
2) Turn starting switch . (fernale) and -
ON. chassis ground?
1) Connect T-adapter to NO )efectwe CHECKS BEFORE FIeplace

.
CNP4 (female). ;TARTING module
21 Turn starting swtch
ON.
Tester
Troubleshooting
82-80 WA350- 1
0
CN18
fzI
4 4
CNP8
10
WA350-1 82-8 1
0
M-18. TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY, OR DO NOT

LIGHT UP.
Cause Remedy
a) Pilot display of turn signal lamp (right) lights up.
ontact between +24V line
?d wiring harness between After inspection,
NPlO (femaleI(3) and CN15 repair (clean) or
nale) (3) replace
efective speedometer module Replace
3) Turn turn signal

switch OFF.
b) Pilot display of turn signal lamp (left) lights up.

ontact between +24V line fter inspection,
YES ?d wiring harness between
* ipair (clean) or
I NPlO (female111 1) and CN15
!place
nale)(6)
2) Turn starting switch efective speedometer module eplace

ON. NO
3) Turn turn slgnal
switch OFF.
C) Pilot display of turn signal lamp {right) does not light up.
efectlve speedometer module
CNPlO Ifemale) (3)

and chassis ground
Dofront and rear turn :onnect T-adapter to efective contact, or

slgnal lamps work cfter inspection,
:NPlO (female). isconnection in wiring harness
* ?pair (clean) or
NO etween CNPlO (female)(3) splace
I I nd CN15 (male)(3)
Operate right turn
signal lamp.
Iefective turn slgnal Replace

NO
Tester
Troubleshooting
T-adapter (for DLI)
(for Econoseal)
82-82 WA350-1
0
d) Pilot display of turn signal lamp (left) does not light up.
Cause Remedy
YES
C Defective speedometer module Replace
2
Isresistance between
YES CNPlO (female)(3)
1- and chassis ground
- less than 5I1.
Do front and rear turn I) Connect T-adapter to Defective contact. or

signal lamps work _- - CNP~O (female). After inspection,
disconnection in wiring harness
normally? - repair (clean) or
NO between CNPlO (female)(l 1) reolace
and CN15 (malel(6)
I Operate left turn
signal lamp.
Defective turn signal Replace
Tester
Troubleshooting
T-adapter (for DLI)
(for Econoseall
CN15
CNPlO
WA350-1 82-83
0
e) HIGH BEAM pilot lamp does not light up.

Cause Remedy
ISvoltage between
YES CNPlO (female)(4)
1- and chassisground -
20 - 3OV?
Do both left and right 11 Connect T-adapter to

head lamps light up7 - CNPlO (female) NO
21 Turn starting switch c Defective contact. or r\fter inspection,
disconnectw I wiring harries: epalr (clean) or
1) 2h.nmrmg sW,tch 3) % comblnatio between CNPl 0 (female)(4) TPkKX
switch to head lamp and CN39 (female) (1)
2) iurn combination position
switch to head lamp 41 Turn dimmer switch
posltlon. to HIGH BEAM
3) Turn dimmer switch
to LOW BEAM. -
Bulbs broken I both head 4fter inspection,

lamps (low beam lamps) .epair (clean) or
(If the low beam bulb 1s broken, WlCaCe
the pilot lamp wll not light up
eve If the switch IS turned to
HIGH BEAM.)
f) HIGH BEAM pilot lamp does not go out.
Defectwe speedometer module
DO both left and right YES

head lamps light up? * Iefect1ve contact. or Sfter inspection.
%sconection in wiring harness ,epair (clean) or
xtwee CN15 (fern&)(91 and zplcace
dimmer switch
2) Turn combination
switch to head lamp
positlon.
3) Turn dimmer switch
to LOW BEAM.
2
YES
Defective contact. or After Inspection,
Does head lamp light disconnection in wiring harries! repair (clean) or
NC patHIGHBEAM? - between CN15 (fern&)(1 2) WplC.%X
and dimmer switch
Is there cont,u,ty
1) Turn starting switch _ between CN15
ON. NO (m&)(1 2) and
2) Turn comblnatlon chaws ground?
sbwtcn to Ilea3 lamp
posltio. 1) Connect T-adapter
3) Turn drnmer swtch
to HIGH BEAM Defectwe contact, or After inspection.
disconnection in wring harries! repair (clean) or
between CN15 (m&)(1 2) and replcace
chassis ground
Tester
Troubleshooting
T-adapter (for DLI)
(for Econoseai)
82-84 WA350-1
0
DIMMER SWITCH
COMBINATION SWITCH
CNPlO
WA350-1 82-85
0
M-19. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.
t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately
Cause Remedy
lefective speedometer module FIeplace
YI
lefectwe speed sensor mount Frdjust
of the speed sensor,

and turn the sensor
Is resistance between clockwise. If it
h
YES CNPIO (fernale) contacts the gear
- y;di; 3OOQ - within one turn, the
gap is within 1.5 mm.
1) Connect T-adapter tc
CNPlO (female).
OFF.
i lisconnection in wring L\fter inspection,

N lamess. or defective contact r epair (clean) or
Is resistancebetween letween CNPlO r eplace
CN83 (male)(l) and female)~10l,~21 - CN22
(2) 3OOa - 1 kfl? 3).(4) - CN83 (female)(ll,(2)
lefective speed sensor
Tester
Troubleshooting
T-adapter (for DLI)
(for Econoseal)
82-86 WA350-1
0
CN83
2 11 2
CNPIO
WA350-1 82-87
0
M-20. SERVICEMETER DOES NOT WORK NORMALLY.
+ When disconnecting connectors or connecting T-adapters, return them to the original condition immediately
Cause Remedy
Iefective engna oil pressure 3eplace

jensor
YES
1 ToA
Does servicemeter
move, or display -
lamp flash?
1) Connect
short socket between CN163
adapter to CN 163 YES 3
(female)lengine oil chassis ground?
pressure sensed.
2) Turn starting switch ISvoltage between
ON. CNP9 (female)(l)
NO 2 and (3120 - 3Ov?
CN163 (female).
Isvoltage between
1) Connect CNP9
2) Turn startrng switch
- CN43 (female)(l I - (female).
.o B
and (4) 20 - 3OV?
ON.
CN43 (female).
NO
2) Turn starting swtch + )wonnection ,n wlnng 4fter inspection,
ON.
~arnass. or defective contact .epair l&an1 or
Wvveen CN43 (male)(l) and eplace
:NP9 (female)(l), 13)
r
ice M-21 All or part of
nonltor panel does not work
iormally.
3efectlve service meter module
between CNP9
A--c (femaleI(4) and
chassis ground?
Disconnection in wiring After inspection,

adapter to CN163 harness, or defective contact repair (clean) or
(female). between CN163 (femaleill 1- replace
2) Connect T-adapter to ZN97 18) - CN64 (6) - CNPS
CNP9 (female). [female)(d)
OFF.
B- N )Isconnection m vmng After inspection,

?amass, or defective contact repair (clean) or
)etween CN163 (female)121 - replace
3N97 (male)(l2) - chassis
around

Troubleshooting
T-adapter (for DLI)
(for Econoseall
82-88 WA350-1
CN43
4 4
1 I
CNI 63
CNP9
WA350-1 82-89
0
M-21. ALL OR PART OF MONITOR PANEL DOES NOT WORK NORMALLY.

IF ANY FUSE IS BROKEN, REPLACE AFTER CHECKING.
Cause Remedy
the next check.
Defective contact or After inspection,

a) None of monitor panel works. disconnection in wiring harness repair (clean) or
between CN43 Imale) - all
modules (+24). and CN43
(male)/4) - all modules
(ground connection)
ES 3
; Is voltage between
_ YES CN43 (1) and 14) 20
- 3OV?
- One of modules defective. After Inspection,
Is voltage between is voltage between (Contact connectors in turn. If repair (clean) or
1 CN43 (female)(l) 11 Er4rgctT-adapter t
CN43 (1) and (4) 20 there is no voltage for any replace
and (4) 20 - 3OV? module, check it.)
ti 2 1 Turn starting switch
1 I ON.
Is voltage between 11) Connect T-adapter I
CN41 lfemale)ll)
(or socket adapter) t( > connectors ICNPl,
and (2) 20 - 3OV? CN43 (female). P4, P6. P8. P9 and
I I !I Turn starting swtch Short circuit between CN43 After inspection,
1) Connect T-adapter ON. 2) Turn starting switch NC connector (1) and (4) repair (clean) or
replace
(or socket adapter) tg ON. I (Power shut off to orotect
CN41 (female).
2) Turn startbng switch
ON.
i -_ _I
N
; 1 Awllaw controller defective Reolace
DIsconnection in wlrlng After inspection.

YES harness. or defective contact repair (clean) or
between CN41 - (female)(l) replace
- CN60 (6) - fuse - C~60
(5) - fuse - main breaker,
~~~.:
Disconnection in wiring After inspection,
harness, or defective contact repair (clean) or
-_
between CN41 (femaleI(21 -
CN41 (female). CN64 (5) - chassis ground
r
OFF.
Socket adapter c Dlsconnectlon I wiring harness Replace
YES between CN43 (female)il andi
(4)
YES t
One of modules defective After inspection.
3 (connect connectors one at a repair (clean) or
time to check) reolace
Is there contlnu,ty
between CN43 1
(male)(l) and l4)?
El
1) Disconnect between CN43
connectors (CNPl, connector (4) and (1)
P4, P6. P8, P9 and and all connectors r
Defective contact or After inspection,
, PlO). disconnection in wiring harness repaIr (clean) or
2) Connect socket to 1) Connect to CN43 I between CN43 (male)(l i-all replace
CN43 (male). connector. modules (+ 24). and CN43
3) Turn starting switch Connect sockets to (male)(B) - all modules
OFF. CNP connectors. (ground connection)
I
Table 1 I- _-_A 1
CNPl CNP4 CNP6 CNP8 CNP9 CNPlO
CN43 connector -(8) --13) -116)

- (8) - (8) - (8)
(male) (4)
CN43 connector
(female)(l)
- 14) -116) -116) -116) --il) - (8)
82-90 WA350-1
0
b) Part of monitor panel does not work. Cause Remedy
Defective module
Isvoltage at power
source pin of module -
20 - 3OV?
connector of module
;vich does not light ND
p Disconnection in wiring After inspection.
KNP connector) harness, or defective contact al repair (clean) or
2) Turn starting switch power source pin WpliXe
ON.
Table 2
CNPl CNP4 CNP6 CNP8 CNP9 CNPlO
Power source pin if) (4) (I 6) (16) (16) (I) (8)
Power ~ourc.5 pin (-) (8) (8) (8) (8) (3) (16)
I
Tester
Troubleshooting
tools T-adapter (for DLII
(for Econoseal)
CN41
CN43
WA350-1 82-91
M-22. EVEN WHEN ENGINE IS STOPPED, )a/ (ENGINE OIL PRESSURE) FLASHES, OR
I0 (BATTERY CHARGE) FLASHES. -
& (Engine oil pressure) flashes, caution buzzer sounds and

/
warning lamp also lights up. Cause Remedy
Defective alternator eplace
Defective module
I 1 Is problem removed
1I Remove wring
when modules are
harness of alternatol
Interchanged?
terminal R.
21 Turn starting switch 1
tl
1
ON. (Do not start I J Turn starting switch NO

c Contact between + 24V fter inspection,
engine.) OFF.
ermlnal and alternator terminal qair (clean) or
1) CHECKS, CAUTION
1 and CAUTION 2 1 - CN97 (1) - CN64 (1) - !place
modules are :NP3. P5, P7 (1)
interchangeable, so
interchange them.
ON.
(Leave terminal R
disconnected)
b) q (Battery charge) flashes and warning lamp lights up.
)efective engine oil pressure leplace

sensor
Defective module Replace
11 Disconnect CN163
(engine oil pressure
SellsOr).
2) Turn startmg switch
ON.
Contact between chaws After inspection,

ground and CN163 (femalelI1 I repair (clean) or
modules are - CN97 (81 - CN64 (6) - replace
interchangeable, so CNP3 (21, CNP5 (2). CNP7 (21
interchange them.
ON.
82-92 NA350- 1
a
MODULE 1, MODULE 2
CN163
M-23. NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING

SWITCH TO ON, ENGINE STOPPED)
* When disconnecting or connecting the (T-adapter or socket adapter) or short connector, or when
Cause Remedy
a) No lamps on any module light up when starting switch is turned ON.

All lamps go out when engine is started.
c See M-21 and M-22
b) Lamps on some modules do not light up.
Defective module
WA350-1 82-93
0
M-24. CENTRAL WARNING LAMP DOES NOT GO OUT.
Monitor displays no abnormality, but central warning lamp lights

Cause Remedy
up intermittently.
Defective CAUTION 2 module eplace
. 2
Does central warrung
I) Stop engine.
2) Connect CN43.
4) Turn starting witch Defective CAUTION 1 module

ON.
21 Turn starting swtch 5) Start engine.
ON.
31 Start engine.
NO
Defective Auxiliary controller leplace
b) Central warning lamp lights up continuously.
YES
- Defective CAUTION 2 module replace
Y Does central warning
1) Stop engine.
Defective CAUTION 1 module leplace
2) Connect CN43.

1 ON.
5) Start engine.
YES
* :ontact between chassis \fter inspection,
Does central warning I ground and wiring harness epair (clean) or
lamp go out? )etwee CN42 (male)131 and eolace
:N17 (female)(2)
is there continuity
t ;;is3ryection in between CN42
(m&e)(3) and chassis
ON.
3) Start engine. 1) Stop engine.
(or socket adapter) t( Iefective auxiliary controller ?eplace
CN42 (male).
Tester
Troubleshooting
tools
T-adapter (for Econoseal)
82-94 NA350-1
0
CN17
CN42
CN43
CNP7
/* 1
1
'8
WA350-1 82-95
M-25. CENTRAL WARNING BUZZER DOES NOT STOP.
When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx 0)
Monitor displays no abnormality, but central warning buzzer

Cause Remedy
sounds intermittently.
m efective CAUTION module 2 leplace

YES
Does central warning
1) DIsconnection in
CN43. NO
2) Turn starting switch ) Nefectlve auxiliary controller
ON.
3) Start engnne.
b) Central warning buzzer sounds continuously.
YES
I . lefectwe CAUTION module 2 leolace
- :ontact between chassis rfter inspection,

NO 2 round and wring harness epalr (clean) or
I etween CN42 lmalej(3) and epiace
N131 (male)
1) Dwonnection in
CN43.
ON.
3) Start engine.
(or socket adapted to
CN42 (male).
NO
. lefectwe auxlllary controller
Tester
Troubleshooting
(for Econoseall
82-96 WA350-1
0
MODULE 1, MODULE 2
CN42
3 3
D c?
ad @hiI +[
CN43
WA350-1 82-97
0
M-26. NONE OF PANEL LAMPS ON MONITOR LIGHT UP.
t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1)
Remedy
a) No panel lamps light up even when only small lamp in
combination lamp is used.
Defective contact or .fter inspection,
disconnection in wiring harness ?pair (clean) or
between CN26 (female)(l) - 3place
CNPl (femalel(3). CNP4
(female)(l5). CNP6
(femaleIll 51. CNPE
(female)(l5); CNPG
YES (female)(2). CNPlO
H (fern&)(1 5)
(in a rare case, all panel lamps
may be broken)
1) Turn combination
lamp switch to side
IhlPS.
IO
2) Check voltage w Disconnection I wiring
T-adapter Gfter inspection,
between CN26 harness, or defective contact spa? (clean1 or
(female) wiring between CN15 (maleI(8) - splace
harness end (1) and CN58 (1 1). (12) - CN26
chassis ground with (felale)(2), or defective diode
Is voltage between
diode assembly still assembly
connected.
1) Connect T-adapter tc
YES
2) Turn starting switch _ Disconnection in wiring ,fter inspection,
harness. or defective contact spair (clean) or
between CN15 (female)(4) - ,place
front lamp and parking lamp
NO 4 switch - CN15 (femalel(8). or
defective switch
Is voltage between Is there continuity
CN15 (male)(2) and between T-adapter
chassis ground 20 - . CN15 (femaM(4) -
and (8)?
-
1) Disconnect CN15 NO
(orsocket adapter) to I (female). - Defective contact of front lamp 4fter inspection,
J
CNI 5 (male). 2) Turn starting switch and parking lamp switch .epair (clean) or
IL_-__
2) $II starting switch OFF. .eplace
Combination lamp
NO switch Continuity
t Disconnection in wiring r\fter inspection,
harness, or defective contact .epair (clean1 or
between battery relay output - vplace
CN59 (1). (21 - CN15
(male)(4)
1 Sidelamps 1 YES 1
NO OFF
Table 1
YES
Socket adapter t To step 3
Defective front lamp and

parking lamp switch
2) Operatewmbinationl
i lampswtch. )
Tester
Troubleshooting
T-adapter or socket adapter (for DLI) (for Econoseall
82-98 JVA350-1
0
b) No panel lamps light up even working lamp is switched on.
Remedy
. cbefective contact or .fter inspection.

clisconnection in wiring harness spair Mean) or
jetween CN25 (female)(l) - 3place
: :NPl (female)(3). CNP4
(female)11 51 CNP6
fern&)(1 5). CNP8
Ifemale)(l51, CNP9
YES (female)(2), CNPlO
female)(l5)
(in a rare case, all panel lamps
rnay be broken)
YES
pijjijg\
M
I I
Is voltage between
CN12 (2) and chassis
1) Turn working lamp
ground 20 - 3OV? switch ON.
2) Check voltage
t
between CN25 . I:)Isconnection in wiring ifter inspectlon.
I) Connect T-adapter (female) winng
tjarness, or defectwe contact epair (clean) or
(or socket adapter) t( harness end (1) and
petween CN 12 Ifemale) (2) - eolace
CNI 2 (female)(2). chassis ground with
: :N40 (1) - CN40 15) - CNZE
!) Turn starting swtch diode assembly still
ON.
(femaleI(2). or defective diode
1) Connect T-adapter connected.
!I Turn working lamp
alssemblv
(Or socket adapter) t
CN12 (female)(l). switch ON.
ON.
UO
-[ IIsconnectlon in wiring \fter inspection,
t larness, or defective contact epair (clean) or
tletween CN12 Imale) - eplace
vorking lamp switch - CN12
; m&l(2). or defective working
Iamp switch
uo
- [)Isconnection in wiring rfter inspection,
larness. or defective contact spair (clean) or
tMween battery relay output - eplace
(:N60 (1). (2) - CN12
(female) (I 1
Side lamps YES
OFF NO
Table 2
WA350-1 82-99
a
CN12
B 1
CN15
CN25
82-100 WA350-1
0
M-27. SOME OF PANEL LAMPS ON MONITOR DO NOT LIGHT UP.
* When connecting the T-adapter (or socket adapter). connect to the connector specified. (CNxx ()I
+ When disconnecting connectors or connecting T-adapters, return them to the original condition immediately
Cause Remedy
a) Panel lamps of gauge module do not light up.
* Defective lamp leDlaCe
Defective gauge module 3eplXe
oleconnectlon I wmng harness, or 4fter inspection,

defective contact between CN26 ,epair (clean) or
Ifemalel(li - 0425 (female)(l) -
,eplGXe
CNPl ifemale)Oi - CNP4
(femaiel(l5) - CNP6 (female)<1 5)
3) Turn light switch ON. - CNP lfemale)ll51 - CNP9
lfemaieiill - CNPlO lfemale)(l51
b) Panel lamps of CHECKS, CAUTION 1 and 2, speedometer module
) Defectwe lamp %?pl?lCe
do not light up. 2 YES
YES
, - Islamp bulb broke? -
Is voltage between
chassis ground and
cOnnector pf module - 1) Remove lamp socket ,NO, Defectwe module %SpkG3
which does not light of module and check
up 20 - 3OV? resistance of small
bulb. I wmng harness, \fter inspection,
Dlsconnectlo or
If it is over 1 OOn. defecwe contact between CN26
connector of module epair (clean) or
bulb if broken. ifemalelll) - CN25 (female)il) -
w$ch does not light I NO eDlace
w CNPl (femaI413) - CNP4
(temalel~l5l - CNP6 (femaleill 5)
2) Turn starting switch - CNP ifemalei~l5l - CNP9
ON. lfemaleli2) - CNPlO (femaleill 51
3) Turn light switch ON. Module Coector
I CHECKS 1 CNP4(15) 1
I CAUTION 1 1 CNP6 (15) I
CAUTION 2 CNP8 I1 5)
Speedometer CNPlO(15)
c) Panel lamps of service meter do not light up.

Defectwe lamp ?eplXe
Is lamp bulb broken?
INO
Is voltage between
CNP9 (femaleI(2)
and chassis ground
20 - 3ow
+ggijgi _
Defective service meter modult ReplXe
1) Connect T-adapter tc IfitisoverlOO~,
CNP (female. bulb is broken.
ON. oisconnectlon I wlrlng harness. or After inspection.
31 Turn light swtch ON. defectwe contact between 0426 repair Iclean) Or
ifemalel(ll - CN25 (female)(l I- replaCe
CNPl Ifemale - CNPL
lfemale)il51 - CNP6 (fern&)(1 51
- CNP lfemal4~15~ - CNPS
ifemale)lZl - CNPlO lfemaIe)(l5)
Tester
Troubleshooting
to015 T-adapter or socket adapter
T-adapter lfor DLI)
(for Econoseal)
82-102 WA350-1
0
MONITOR PANEL LAMP
CNPI
CNP9
WA350-1 82- 103

0
M-28. EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND.
$r When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ())
Cause Remedy
Xefective buzzer f3eplace
Does voltage between
!
CNl30 Ifemale and
CN131 (female) change
between ov and 20 -
I
I) Disconnect CN130,
13 1 (buzzer I
connector).
2) Disconnect CN107 No
Iisconnection in wiring I tfter inspection,
(coolant levell.
wness, or defective contact I epair (clean) or
_.
ON
retwee CN42 (male1 (1) - I eplace
IN1 30 (female), or CN42
(Start engine.)
between CN42 male)(Z) - CN131 (male)
(female) (1) and (2)
change between OV
Ior socket adapted I
CN42 (female).
2) Disconnect CN107
(coolant levell.
ON.
4) Start engine.
ES
YES I Defective module Replace
I-----+
Is problem removed
when modules are
NO 3 i replaced?
sound when CN43

(female) (1) and (2) emergency display Disconnection in wiring After inspection,
are shortcircuited? item CAUTION harness, or defective contact repair (clean) or
module and CHECK between CNP7 (femalel(8) ant i /replace
) Stop engine. module. CN43 (male)(Z)
) Connect T-adapter 21 Turn starting switch
(or socket adapted to ON.
CN43 (female).
3) Short circuit when
CN 43 (female)(l)
and (2).
ON. NO
Defective auxiliary controller . I+eplace
01
contact between CN42
(female)(l) and (2)
(CN42 (female) (1) and (2) (repaIr or replace)
are in contact, so protection
device in auxiliary controller
is actuated)
* The voltage, can be checked in parking, FORWARD and REVERSE

positions, and when the power is ON (starting switch at ON).

Troubleshooting
T-adapter (for DLI)
(for Econoseal)
82-104 1WA350-1
0
CN42
CN43
WA350-1 82-105
0
M-29. EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING

LAMP DOES NOT FLASH.
Cause Remedy
Iefectw lamp
Juno lisconnection in wiring

harness, or defective contact after inspection.
etween CN42 (m&)(1 I - apaw (clean1 or
koolant level) :N17 (female)(l). or CN43 &3X
3) Start engine. m&)(3) - CN17 (female)(2)
Does voltage
between CN42
(fern&l(l) and (31
change between OV
and 20 - 3OV? YES
defective module 7eplace
)
1 Connect T-adapter
(or socket ada&) tc
CN42 Ifemale).
2) Disconnect CN107
(coolant level).
:ontact with chassis ground, c
ON.
4) Start engme. NO 3 lisconnection in wiring harnas: ifter inspection,
letween CNP7 (femaleI(4) - epair (clean) or
r-l
:NP5 (female)(4) - CNPJ eplace
up with other module.
Does warning lamp m&)(3)
light up? ON.
Stop engine.
:, Connect T-adapter
ruxiliary controller defective 01 3eplace
ontact between CN42
CN43 (female)
female)(l) and (3)
3) Short circuit CN43
(CN42 (female)(l) and (3) .epair or replace)
(female)(l) and (3).
are in contact, so protection
device in auxiliary controller
is actuated)
* The voltage can be checked when the power is ON (starting switch at

ON).
Tester
Troubleshooting
(for Econoseal)
82-106 WA350-1
0
TROUBLESHOOTING
M-29
CN17
CN42
CN43
a
1
CN107
WA350-1 82.107
co
M-30. ABNORMALITY IN m
- (FUEL GAUGE)
Cause Remedy
a) Nothing shown in display area
Defective fuel level sensor Ieplace
YES
L Defective gauge module Ieplace
I 1
h
Is there continuity
1) Connect
short
adaptertoCN105
(female)(fuel
sensor),
sccket
level I between CNP2

(female)(6) and (12)?

ON. IOr Socket adapterJ to
CNP2 Ifemale).
2) Connect short NO
> Iisconnection in wiring Jfter inspection,
connector to CN105
namess, or defective contact epair (clean) or
Ifemale).
between CN105 (female)(2) - eDlace
CN64(4) - CNP2 (femalell61.
OFF.
or CN105 Ifemale) -
CN64(3) - CNP2 (female) I1 2)
b) Stays at FULL and does not move.
Defective fuel level sensor 3epkCe
1 YES
c Contact between chassis 4fter inspection,
ground and wiring harness Ppair (clean) or
Doesallof display I between CNP2 (femalel(6) - .eplace
area for fuel gauge CN64 (4) - CN105
NO 2 Ifemale)l2), CNP2 Ifemale)(l21
CN64 131 - CN105
Is there continuity (female)(l)
1) Disconnect CN105
- between CNP2
(fuel level sensor).
(femalel(6) and (12)?
ON.
CNP2 (female).
2) Disconnect CN105. NO
3) Turn starting switch * Defective gauge module
OFF.
I
Troubleshooting
tools
T-adapter (for DLI)
I I I I
82-108 WA350-1
CN105
CNP2
M-30-1. ABNORMALITY IN FUEL LEVEL SENSOR
l If there is a big difference between the fuel level

shown on the monitor display and the amount of
fuel actually remaining in the fuel tank (for
example, the tank is full but the monitor display
lamps are all out), remove the sensor and measure
the resistances at the following three points to
check if they are the standard value.
* The standard values are given as only a guideline.
FULL (top) l/2 (horizontal) EMPTY (bottom)
10?2R 36250 95k 1oa
Put on probe in contact with Econoseal terminal
EMPTY
nal 0, and measure the resistance. (bottom)
423F179A
WA350-1 82-109
0
M-31. ABNORMALITY IN m (AIR PRESSURE GAUGE)
Cause Remedy
al Nothing shown in display area
Xfective air pressure sensor 7eplaCe
YES
defective gauge module Replace
NO 2
Is there continuity
1) Connect short - between CNP2
connector to CN92 Ifemalej(4) and W7
(air pressyre senior) , ,
2) Turn startmg swtch
ON. 1) Connect T-adapter to NO
Iisconnection in wiring 4fter inspection,
CNP2 (female).
wrness, or defective contact vzpair (clean) or
adapter to CN92 between CN92 (female)(l) - Wpl.Xe
CN63 (1) - CNP2 (femalel(9).
(female).
3) Turn starting switch w CN92 (female)(2) - CN62
(101 - CNP2 (female)(4)
OFF.
b) Stays at top level and does not move.
(ES
- Iefective air pressure sensor
YES
w :ontact between chassis After inspection,
ground and wiring harness repair Mean) or
xtween CNPP (fern&l@) - replaCe
Does all of display :N63 (11 - CN92 (female)(l).
area for air pressure x contact between chassis
NO 2 yound and wiring harness
x!tween CNP2 (femalel(4) -
Is there continuity EN62 (I 0) - CNg2 (fern&)(2 I
1) Disconnect CN92 lair
. between CNP2
pressure sensor).
(female1 (41 and M?
ON.
CNP2 (femaleI.
2) Disconnection CN92.
OFF. NO
;r Iefectlve gauge module ReDlace

Troubleshooting
tools
T-adapter (for DLI)
82-110 WA350-I
0
CN92
CNPP
9,
WA3504
82-i

M-32. ABNORMALITY IN w (COOLANT TEMPERATURE GAUGE)
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ()j
Cause Remedy
a) Nothing shown in display area
YES Iefective coolant temperature

* ?eplace
iaSClr
1 :ontact with wiring harness

,etween CNl 01 (female)il) -
After inspection.
DoesCoolant c :N97 (3) - CN62 (9) - CNP:
epair (clean) or
temperature
gauge_ femaleI and CNlOl
eplace
display bottom 2 femalel(2) - CN97 (2) -
position? :N62 (10) - CNP2 (female)V
- Is there continuity
1) DisconnectCNlOl _
between CNPZ
(coolant
fiD (female)(d) and IlO)?
temperature).
ON. 11 Connect T-adapter to
CNP2 (female).
21 Disconnect CNl 01.
OFF. NO
c Iefective gauge module qeolace
b) Stays at bottom position and does not move.
YES
I- lefective coolant temperature
ZSW
Does all of display
area for coolant _ YES
* Xfective gauge module
temperature gauge 2
go out?
1) Connect short socket Is there continuity

adaptertoCNlO1 - between CNP2
(female). NO (femaM(4) and (lo)! Xsconnection in wiring
2) Turn starting switch larness. or defective contact
ON. Ktween CNPP (femalel(lO1 - After inspection,
1) Connect T-adapt&& ND
:N62 (9) - CN97 (3) - xpair (clean) or
CNP2 (female)
:NlOl (femalel(l).orCN92 eplace
2) Connect short
fern&)(41 - CN62 (10) -
connector to CNlO 1
ZN97 (2) - CNlO (femalej(2)
(female).
OFF.
Tester Short connector

Troubleshooting
tools
T-adapter (for DLI) lfnr Frnnn+wll
82-112 WA350- 1
a
CNlOl
CNP2
- 10 4
WA350-1 82-113
0
M-33. ABNORMALITY IN q (TORQUE CONVERTER OIL TEMPERATURE GAUGE)
Cause Remedy
Nothing shown in display area
YES Defective torque converter oil

L Replace
temperature sensor
1 Contact wtth wiring harness

Does torque _
between CN84 (female)(l I-
YES CN22 (1) - CNP2 After inspection,
converter oil ) repair (clean) or
(female)(l 1). orCN84
temperature gauge - replaca
display bottom 2 (femaleIl2) - CN22 (2) -
CNP2 (fern&)(51
position?
- Is there continuity
1) Disconnect CN84
(torque converter oil NC ~et~~,elee;,$Na~~ (, , )? -
temperature).
ON. 11 Connect T-adapter to
CNP2 (female).
2) Disconnection CN84.
OFF. NO
w 3efective gauge module Replace
b) Stays at bottom position and does not move.
Iefective torque converter oil Replace

:emperature sensor
Defective gauge module
1s
2) Turn starting
ON.
switch I I Iisconnection in wiring
1) Connect T-adapter to Tarness, or defective contact
CNP2 (female). NO 9etween CNP2 (female)(l 1) - After inspection.
2) Connect short socket ) repair (clean) or
:N22 (1) - CN84 (female)(l),
adapter to CN84 xCNP2 (female)(5) - CN22 replace
(female). 21 - CN84 (female)(2)
3) Turn startlog switch
OFF.

Troubleshooting
tools
T-adapter (for DLI)
82-114 WA350-1
0
TROUBLESHOOTING
M-33
CN84
_/
1 1
CNP2
WA350-1
82-115
0
ELECTRIC AND
ELECTRONIC SYSTEM
MACHINE MONITOR
Removal . . . . . .._......_................ 83-2
Installation . . . . . 83-2
WA350-1 83-l
0
DISASSEMBLY AND ASSEMBLY MACHINE MONITOR
REMOVAL OF MACHINE MONITOR
A Stop the machine

the safety
on level ground
and install
the bucket
A Disconnect
terminal
the
of the battery.
cable from the negative (-1
1. Covers
Remove covers (I) and (2) of machine monitor.
2. Electric wiring --
Disconnect the wiring from the following
connectors.
Connectors (3) and (4) of CAUTION 2 module.
Connector (7) of speedometer module.
Connector (8) of service meter.
Connectors (9) and (I 0) of gauge module.
Connectors (I I) and (I 2) of CHECK module.
After removing the connectors, mark with a tag
to distinguish when installing.
3. Machine monitor
Remove mounting bolts, then remove machine
monitor (I 3).
* When removing the machine monitor, be care-
ful to protect it from any shock.
INSTALLATION OF
MACHINE MONITOR
1. Machine monitor
Set machine monitor (I 3) in mounting position
and install.
* Do not tighten the screws too tight.
2. Electric wiring
Connect the wiring to the following connectors.
Connectors (I I) and (I 2) of CHECK module.
Connectors (9) and (I 0) of gauge module.
Connector (8) of service meter.
Connector (7) of speedometer module.
After inserting the connectors, apply the
connector locks securely. Install the wiring so
that there is no strain on the wires.
3. Cover
Install covers (I ) and (2) of machine monitor.
83-2 WA350-1
0
91 OTHERS
Cab ..,,_.._.._............... 91-2

Air conditioner (if equipped) . 91-3
. Piping . 91-3
. Air conditioner wiring diagram . 91-4
. Air conditioner electric circuit . 91-4
l Air conditioner unit 91-5
WA350- 1 91-1
@
STRUCTURE AND FUNCTION CAB
CAB
~_I--______~
---------7,
; : I
~I /I
:. <_>
/ /j
/ 1
1 / II
II
, L__~~___--j---A,
I :-----_______,
I I /j
I
~ II
423F159
1. Front glass
2. Front wiper
3. Rear wiper
4. Door
View 2
91-2 WA350-1
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER (if equipped)
Model: DAIKIN CO. LTD..
PIPING
423F160A
1. Compressor
2. Hot water outlet port
3. Hot water inlet port
4. Dry reservoir
5. Air vent
6. Condenser
7. Air conditioner unit
WA350-1 91-3
0
AIR CONDITIONER WIRING DIAGRAM
Screw 3/4-l 6UNF

Cabin unit
nl Side condenser unit

Screw 7/8-l 4UNF
Screw I
518-l 8UNF
f
q
I
--
423F165
Screw 7/8-14UNF
AIR CONDITIONER ELECTRIC CIRCUIT
n Blower box
m -- ___
Cab unit
-..-
Therm0 protector i__ CL Condensor fan motor
L:_h
Compressor 423Fl66A
91-4 WA350- 1
@
AIR CONDITIONER UNIT
Function Cooling
l The air conditioner acts to reduce operator fatigue . The refrigerant gas is compressed and pressurized
by providing the operator with a comfortable in air conditioner compressor. It then enters the
operating environment. air conditioner condenser where it is cooled, and
goes to air conditioner unit.
Heating The fan blows out cold air, the temperature of the
. The heating system uses the engine cooling water. refrigerant gas rises and it returns to the
Hot water enters the air conditioner unit from hot compressor.
water outlet port (2). A fan blows hot air out. The
temperature of the cooling water goes down, it re-
turns to inlet port (I) and then flows back to the
engine cooling circuit.
/xl
423F161
5 6 7
1. Hot water inlet port 5. Refrigerant gas inlet port

2. Hot water outlet port 6. Refrigerant gas outlet port
3. Electrical wiring 7. Condensation drain port
4. Outside air intake filter
WA350-1 91-5
COMPESSOR
1. Charge valve
2. Clutch
A 3. Front head
1 4. Case
A. Air outlet port
B. Air inlet port
423F163
CONDENSOR
Condenser motor
3
I 2
/
1. Electrical wiring
2. Fan
3. Refrigerant gas inlet port
4. Refrigerant gas outlet port
423F162
91-6 WA350-1
AIR CONDITIONER
DRY RESERVOIR
View Z
423F164
1. Body
2. Side glass
3. Drier
4. Filter
WA350-1
91-7
OTHERS
CAB
Removal . . . . 93- 2
Installation . . .. .. 93- 3
AIR CONDITIONER UNIT

Removal . . . . . . . . . 93- 4
Installation . . . . . . . . 93- 6
CONDENSER FOR AIR CONDITIONER

Removal . ... . .. .. .. . 93- 8
Installation .. .. . . 93- 8
DRY RECEIVER
Removal . . .. .. . .. 93- 9
Installation .. . .. .. .. . . . 93- 9
COMPRESSOR FOR AIR CONDITIONER

Removal . . . . . . . . . . ....... 93-10
Installation . . . .. ... ... 93-l 0
WA350-1 93-1
0
DISASSEMBLY AND ASSEMBLY CAB
REMOVAL OF CAB
1. Electric wiring
1) Disconnect cab wiring (1) from connector (2) at
rear left of seat.
t Remove the-cap for the mounting bolt.
2. Cab
I) Disconnect vinyl tube (3) for window washer.
2) Remove cap at rear of seat, then remove
mounting bolts (4) and (5).
3) Remove mounting bolts (6) and (7) under cab
(6) on left and right.
4) Sling cab (6). remove mounting bolts (8) and
(91, then lift off cab.
* When lifting off the cab, be careful not to hit
the window on the front frame.
Cab: 305 kg
93-2 WA350- 1
0
DISASSEMBLY AND ASSEMBLY CAB
INSTALLATION OF CAB
1. Cab
1) Raise cab (6), set in mounting position, then
tighten mounting bolts (8) and (9).
* Be careful not to hit the window with the
front frame when installing.
Zr Coat all the seals evenly with gasket sealant.
6 Gasket sealant
2) Install mounting bolts (6) and (7) under cab (61

on left and right.
3) Install mounting bolts (4) and (5) at rear of seat.
4) Connect vinyl tube (3) for window washer
2. Electric wiring
Connect cab wiring (I) to connector (2) at rear left
of seat.
* Install the cap for the mounting bolt.
WA350-1
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR CONDITIONER UNIT

m Stop the machine on level ground and install
Disconnect the cable from the negative (-) termi-
nal of the battery.
Loosen air conditioner hoses (I 1 and (2). and drain
the gas from the air conditioner.
* When draining the gas, do not completely dis-
connect the hoses. Loosen them slightly.
Air conditioner, heater hoses

1) Disconnect air conditioner hoses (I) and (2)
from bottom of air conditioner unit.
* After disconnecting the air conditioner
hoses, cover the openings to prevent dirt
and water from entering.
2) Loosen clamps of heater hoses (31 and (41,
then disconnect hoses.
Operators seat
Remove operators seat (5).
& kg Operators seat: 40 kg
Arm rest, covers

Remove arm rest (61, then remove covers (7) and
(8).
4. Electric wiring
Disconnect the following wiring from the
connectors.
l Wiper wiring (9) and (I 0).
l Air conditioner relay wiring (I I).
* After disconnecting the connectors, discon-
nect the clamps.
l Radio wiring (I 21, (I 3) and (I 4).
l Air conditioner unit wiring (I 5).
l Radio antenna wiring (I 6).
l Air blower wiring (17).
5. Air duct
Disconnect clamp (18) of cable, and connector
(19) of blower wiring, then remove air duct (20).
93-4
0
6. Air blower
Remove mounting bolts, then remove air blower
(21).
* Be careful not to damage the seal at the contact
face between the air blower and the air condi-
tioner unit.

Remove mounting bolts (221, (23) and (24), then
remove air conditioner unit (25).
* Move the air conditioner unti outside the cab,
then lift off.
* Be careful not to damage the connectors of the
air conditioner hoses.
& kg Air conditioner unit: 80 kg
423 F482
t When repairing the inside of the air conditioner
unit, follow Steps 1 - 4, then remove cover (26).
l When removing the cover, disconnect the
connectors of the air conditioner wiring and the
temperature regulator cable, then remove the
cover.
WA350-1
INSTALLATION OF AIR CONDITIONER UNIT

Set air conditioner unit (25) in mounting position,
then tighten mounting bolts (221, (23) and (241.
23
22
423 F482
2. Air blower
Set air blower (21) in mounting position, then
Sr Be careful not to damage the seal at the contact
face between the air blower and the air condi-
tioner unit.
3. Air duct
Set air duct (20) in mounting position, then con-
nect clamp (18) of cable, and connector (19) of
blower wiring.
4. Electric wiring
Connect the following wiring to the connectors.
l Air blower wiring (I 7).
l Radio antenna wiring (I 6).
l Radio wiring (121, (I 3) and (14).
l Air conditioner unit wiring (15).
l Air conditioner relay wiring (1 1).
Sr After connecting the connectors, install the
clamps.
9 Wiper wiring (9) and (10).
93-6 WA350-1
0
5. Arm rest, covers

Install covers (7) and (81, then install arm rest (61
6. Operators seat
Install operators seat (5).
7. Air conditioner, heater hoses

I) Connect heater hoses (3) and (4), then tighten
clamps.
2) Connect air conditioner hoses (I) and (2) to
bottom of air conditioner unit.
t To prevent dirt and water from entering the
hoses, do not remove the covers until just
before installing.
Sr To prevent the hoses from twisting, hold
them securely with a wrench tightening.
&IL Hose connector, flare: Compressor oil
m Hose nut (I): 7.Okl.O kgm
w Hose nut (2): 3.720.4 kgm
8. Refilling with gas

Fill air conditioner with gas.
l Connect cable to negative (-) terminal of
battery.
WA350-1 93-7
0
DISASSEMBLY AND ASSEMBLY CONDENSER FOR AIR CONDITIONER
REMOVAL OF CONDENSER FOR AIR CONDITIONER
A Stop
the safety
and install
the bucket
1. Cover
Remove mounting bolts, then remove cover (1)
under cab.
2. Condenser for air conditioner
I) Remove mounting bolts, then remove cover (2).
* Loosen air conditioner hoses (3) and (41, and
drain the gas from the air conditioner.
* When draining the gas, do not completely
disconnect the hoses. Loosen them slightly.
2) Disconnect electric wiring from connector (5).
3) Disconnect-hoses (3) and (4).
* After disconnecting the hoses, cover the
openings to prevent dirt and water from
entering.
4) Remove mounting bolts, then remove conden-
ser (7) for air conditioner from bracket (6).
INSTALLATION OF CONDEN-
SER FOR AIR CONDITIONER
1. Air condenser
I) Set condenser (7) of air conditioner in mounting
2) Connect hoses (3) and (4).
* To prevent dirt and water from entering the
before installing.
* To prevent the hoses from twisting, hold
them securely with a wrench when
tightening.
a Hose connector, flare: Compressor oil
B Hose nut (3): 5.620.6 kgm
m Hose nut (4): 3.7f0.4 kgm
3) Connect electric wiring at connector (5).

4) Set cover (2) in mounting position, then tighten
mounting bolts.
2. Cover
Set cover (I) in mounting position, then tighten
mounting bolts.
3. Refilling with gas
Fill air conditioner with gas.
93-8 WA350-1
0
DISASSEMBLY AND ASSEMBLY DRY RECEIVER
REMOVAL OF DRY RECEIVER
A Stop the
the safety
and install
the bucket
A Open the hood, then fit the lock.
l Loosen air conditioner hoses (I ) and (2). and drain

the gas from the air conditioner.
t When draining the gas, do not completely dis-
connect-the hoses. Loosen them slightly.
INSTALLATION OF
DRY RECEIVER
1. Install dry receiver (4) on plate with clamp, set in
2. Connect hoses (I) and (2).

t To prevent dirt and water from entering the
before installing.
* To prevent the hoses from twisting, hold them
securely with a wrench when tightening.
a Hose connector, flare: Compressor oil
w Hose connector nut: 3.7 -t 0.4 kgm
3. Connect electric wiring at connector (3).
WA350-1 93-9
0
DISASSEMBLY AND ASSEMBLY COMPRESSOR FOR AIR CONDITIONER
REMOVAL OF COMPRESSOR FOR AIR CONDITIONER
Qt Open the hood, then fit the lock.
l Disconnect the cable from the negative (-1 termi-

nal of the battery.
1. Remove bolt (1) and V-belt, then remove alterna-
tor (2).
t To remove the alternator without removing the
wiring, locate the clamps SO that there is no
strain on the wiring.
2. Remove bracket (3) of alternator.
3. Disconnect electric wiring from connector (4).
4. Loosen hoses (5).and (61, and drain gas from air
conditioner.
t When draining the gas, do not completely dis-
connect the hoses. Loosen them slightly.
* After draining the gas, disconnect hoses (5)
and (6).
* After disconnecting the hoses, cover the open-
ings to prevent dirt and water from entering.
5. Remove bolts (7) and (81, remove V-belt, then
remove compressor (9) of air conditioner.
Sr There is little space, so be careful when
working.
INSTALLATION OF
COMPRESSOR FOR AIR
CONDITIONER
1. Set compressor (9) of air conditioner in mounting
position, fit V-belt, then secure with bolts (7) and
(8).
* Clearance a between bracket and compressor
for air conditioner: a = Within 0.6 mm
B Mounting bolt of bracket:

5.5kO.5 kgm
2. Connect hoses (5) and (6).

k To prevent dirt and water from entering the
before installing.
* To prevent the hoses from twisting, hold them
securely with a wrench when tightening.
x2, Hose connector thread, flare:

Compressor oil
m Hose nut (5): 7.020.7 kgm
w Hose nut (6): 5.6kO.6 kgm
3. Connect electric wiring at connector (4).
4 r-j-
4. Set alternator (2) in mounting position, fit V-belt,
then tighten bolt.
* For details of adjusting V-belt, see 12 TEST-
kl 423F483
ING AND ADJUSTING.
5. Fill air conditioner with gas.
93-10 WA350- 1
@
OTHERS
97 GEAR PUMP
GENERAL
General ................................ 97-002
Principle of operation ................... 97-003
Pressure loaded type gear pump. ......... 97-006
Fixed side plate type gear pump .......... 97-008
SA SERIES
Structure .............................. 97-102
Testing and adjusting ................... 97-105
Disassembly ........................... 97-l 08
Assembly .............................. 97-112
Maintenance standard ................... 97-l 17
WA350-1 97-l
0
GEAR PUMP
97 GENERAL
General .......................... 97-002

Principle of operation ................. 97-003
Pressure loaded type gear pump .......... 97-006
Fixed side plate type gear pump .......... 97-008
WA350-1 97-00 1
0
GEAR PUMP GENERAL
GENERAL
The hydraulic pump is a device which receives mechani- Gear pumps installed on KOMATSU machines are called
cal energy from a prime mover such as an engine, converts KOMATSU standard pumps. They are designated as
the energy into fluid energy, and functions as the source follows.
of energy in a hydraulic system.
The fluid energy can be divided into the energy of
velocity, pressure, and potential. Almost all of the fluid
energy used for hydraulic pressure is pressure energy.
The hydraulic pump receives and transmits the energy S: For high pressure: 210 kg/cm,
through the static pressure of a fluid, and easily produces pressure loaded type
a high pressure since its delivery is determined by the K: For high pressure: 175 kg/cm2,
transfer of volumetric displacement enclosed by the (210 kg/cm2 for some pumps)
fixed wails. Therefore, the pump delivery is not changed pressure loaded type
significantly with variations in the load. P: For medium pressure: 140 kg/cm2
It follows that the pump itself is a device whicti makes (155 kg/cm2 for some pumps)
the oil flow, ratherthan a device to produce pressure. pressure loaded type
The pump pressure is generated by the resistance (the G: For medium pressure: 125 kg/cm2,
load) against the oil flow. Therefore, when there is no fixed side plate type
resistance, no pressure is produced. F: For low pressure: 30 kg/cm2,
Structurally, hydraulic pumps can be broadly classified fixed side plate type
into rotary pumpsand reciprocating pumps. Functionally,
they can be classified into fixed displacement pumps c- A: Flange type mount section
and variable displacement pumps. B: Foot type mount section

The hydraulic pumps used in construction machinery
are external gear pumps and are classified as fixed
displacement rotary pumps.
External gear pumps employ involute spur gears, and
can be structurally classified into the following types. E- L: Counter-clockwise rotation
0 Type of side plate adjustment R: Clockwise rotation

Fixed side plate type (FAL, FAR)
(GAL, GAR)
Pressure loaded type (PAL, PAR)
(KAL, KAR) Theoretical pump delivery at
(SAL, SAR) 1,000 rpm (liters/min)
Pressure plate type
l Type of bearing
Ball or roller bearing type
t Plain bearing type
97-002 WA350-1
0
GEAR PUMP PRINCIPLE OF OPERATION
PRINCIPLE OF OPERATION
a MECHANISM FOR DELIVERING OIL

The drawing at right shows the operational principle
of an external gear pump in which two gears are
rotating in mesh.
The oil entering through the suction port is trapped
Suction Discharge
in the space between two gear teeth, and is delivered
to the discharge port as the gear rotates.
Except for the oil at the bottom of the gear teeth,
the oil trapped between the gear teeth is prevented
from returning to the suction side with the gears 230F 137
in mesh.
Since the gears are constantly delivering oil, the oil
delivered to the discharge port is forced out of
the port.
The-amount of discharge increases with the speed
of rotation of the gear.
If there is no resistance in the oil passage into which
the discharged oil flows, the oil merely flows
through the passage, producing no increase in
pressure.
If, however, the oil passage is blocked with some- 23OF138
thing like a hydraulic cylinder, there will be no
other place for the oil to flow, so the oil pressure
will rise. But the pressure which rises in this way
will never go higher, once the hydraulic cylinder
piston starts moving because of the oil pressure.
As described earlier, the pump produces the oil
flow, but not the oil pressure. We can therefore
conclude that pressure is a consequence of load.
In other words, the pressure depends on a counter-
part.
23OF139
23OF140
WA350-1 97-003
0
l INTERNAL 01 L LEAKAGE
Oil leaks from a place under higher pressure to a
place under lower pressure, provided that a gap or
a clearance exists in between.
In the gear pump, small clearances are provided
between the gear and the case and between the gear
and the side plate to allow the oil to leak out and
to serve as a lubricant so that the pump will be
protected from seizure and binding.
The drawing at right shows how the leaked oil
flows in the pump. As such, there is always oil
leakage in the pump from the discharge side (under
higher pressure)-to the suction side. The delivery
of the pump is reduced by an amount equal to the
pump discharge.
In addition, the delivery of the pump will also
decrease as _the amount of oil leakage increases
because of expanded radial clearance resulting from
the wear of pump parts, the lower oil viscosity
resulting from increases in the oil temperature, and
230F 141
the initial use of low viscosity oil.
0 FORCES ACTING ON THE GEAR

The gear, whose outer surface is subjected to oil
pressure, receives forces poining towards its center.
Due to the action of the delivery pressure, the oil
pressure is higher on the delivery side of the pump,
and, due to suction pressure, is lower on the suction
side. In the intermediate section, the pressure will
gradually lower as the position moves from the
delivery side to the suction side. This phenomenon
is shown in the drawing at right.
In addition, the gears in mesh will receive interact-
ing forces.
These forces pushing the gears toward the suction
side are received by the bearings. Since the gears are sc harge side
pressed toward the suction side by these forces, the
radial clearance becomes smaller on the suction side
in the case. In some pumps (PAL, PAR, KAL, KAR),
the clearance may become zero, thus allowing the
gear teeth and the case to come into light contact.
For this reason, an excessive increase in the delivery
pressure must be avoided, since it will produce a
large force which will act on the gears, placing an
overload on the bearings, and resulting in a shortened Pressure distribution
service life of the bearing or interference of the gear
with the case.
23OF142
97-004 WA350-1
a
0 TRAPPING PHENOMENON OF THE OIL

When a gear pump is rotating with the gears in mesh
as shown in the drawing at right, in some instances
two sets of gear teeth are in mesh while in other
instances only one set of the gear teeth is in mesh.
Suction side
When two sets of the teeth are in mesh simultaneous-
ly, the oil in the space between the meshed gear
teeth will be trapped inside - the front and rear
exits will be completely shut.
This is called the trapping phenomenon of oil.
The space in which the oil is trapped moves from Trapping starts
the suction side to the delivery side as the gears
rotate. The volume of the space gradually decreases
from the start of trapping until the space reaches the
center section, and then gradually increases after
leaving the center section until the end of trapping. The space reaches
the minimum
Since-the oil itself is non-shrinkable, a reduction of
the volume of space will greatly increase the oil
pressure, unless some prosion is made to relieve oil Trapping ends
pressure. The high pressure oil will cause the pump
to make noise and vibrate.
To prevent this, relief notches are provided on the
side plates to release the oil to the delivery side.
As shown in the drawing below, the relief notches
are provided in such a way that the oil can be
relieved from the trapping space to the delivery side
when the volume of the space is reduced.
Relief notches are also provided on the suction side 23OF143
to prevent the formation of a vaccum in the space
by allowing the oil to enter the space from the
suction side when the space is expanded.
Fixed side plate type Pressure loaded type
Side plate
Bushing
230F144 23OF145
WA350-1 97-005
0
GEAR PUMP PRESSURE LOADED TYPE GEAR PUMP
PRESSURE LOADED TYPE GEAR PUMP
9
23OF146
GENERAL DESCRIPTION
Hydraulic pumps used for the work equipment 1. Drive gear
hydraulic units on construction machinery are 2. Bracket
pressure loaded type gear pumps. Some gear pumps 3. Bushing
of this type have a maximum delivery pressure of 4. Gear case
210 kg/cm* or higher. 5. Cover
The pressure loaded type gear pump is designed so 6. Seal plate
that the clearance between the gear and the side 7. Collar
plate can be automatically adjusted according to 8. Back-up ring
the delivery pressure. Therefore, the oil leakage 9. Driven gear
from the side plate is less than that in the case of
the fixed side plate type under a high discharge
pressure. Consequently, no significant reduction of
the pump delivery occurs, even when the pump is
operated under high pressure.
97-006 WA350-1
0
GEAR PUMP PRESSURE LOADED TYPE GEAR PUMP
STRUCTURE AND OPERATION

In a pressure loaded type pump, two bushings acting
as side plates are inserted into the pump case, and
are pressed toward the sides of the gears. The oil
leakage from the gear sides is thus minimized.
Since the bushings are constantly pressed toward
the gears by the oil pressure, there is no fear of an
increase in oil leakage, even when the bushings
are worn out and the clearances are expanded many
hours of operation.
The bushings are pushed towards the gears from the
cover side by the oil pressure, and they are pushed
from the gear side by the pressure of oil trapped
between the gear teeth and that which has leaked
out from the clearance between the gear and the
bushing.
Since the oil pressure in the gears is higher on the
pump delivery side and is lower on the suction side,
provisions are made so that the pressing force acting
on the bushings from the cover side is regulated
in such a way that the delivery side is pressed harder
and the suction side weaker to match the counter
pressure.
More specifically, the area of the bushing on the
discharge side is made larger than that on the
suction side by partitioning the area of the bushing
subjected to pressure on the cover side, with a back-
up ring installed to the seal plate as shown in
the drawing at right.
When the pump is operated at high speed, the
pressure on the suction side is lowered and the distri-
bution of pressure around the periphery of the
gear will change into the state shown in the drawing
at right below.
Pressure balance grooves are therefore provided on
(low speed)
the bushings to keep the balance of the force on Suction >
wthout balance groove
the cover side against the pressure acting on the \ (high speed)
bushing from the gear side that varies with the
pump rotation and the pressure distribution. Thus
the delivery pressure is led as shown in the drawing 05F I40
and the pressure distribution is stabilized at any

rotational speed.
WA350-1 97-007
0
GEAR PUMP FIXED SIDE PLATE TYPE GEAR PUMP
FIXED SIDE PLATE TYPE GEAR PUMP
GENERAL DESCRIPTION
Hydraulic pumps used for the main clutch, trans- 1. Drive gear
mission, and steering system on bulldozers are 2. Bracket
fixed side plate type gear pumps which can be 3. Gear case
classified as follows: pumps generally called FAL or 4. Cover
FAR pumps having a maximum delivery pressure of 5. Driven gear
30 kg/cm2 and pumps generally called GAL or GAR
pumps having a maximum delivery pressure of
125 kg/cm2.
Since the bracket and the case cover serve as the side
plates and the gear teeth bottom land is closer to
the outer race of the bearing in the case of the
fixed side plate type gear pump, oil leakage is liable
to occur at the clearance between the gear and the
side plate. However, this is only a small problem,
as the pump is used for steering control which is
operated at a low service pressure.
97-008 WA350-1
0
GEAR PUMP
97 SA SERIES
Structure ......................... 97-102

Testing and adjusting ................. 97-105
Disassembly ....................... 97-108
Assembly ......................... 97-112
Maintenance standard ................. 97-117
WA350-1 97-101
0
SASERIES STRUCTURE
STRUCTURE
Side plate
FEATURES
The gear pump is a high quality, reliable product that is

specially designed for use in construction equipment
which works under severe conditions.
0 The side plate, given surface treatment to improve
its matching characteristics with the special copper
alloy, ensures minimum torque loss and excellent
wear resistance.
0 With the improved hydraulic balance mechanism,
the pump offers stable performance and high
durability.
2OOF132
STRUCTURE
5 1. Drive gear
\ g,\l Y
2. Driven gear
3. Snap ring
4. Oil seal
5. Plate
6. Bracket
7. O-ring
8. Side plate
9. Back-up ring
10. Seal ring
11. Gear case
12. Side plate
\ 13. Back-up ring
18
14. Seal ring
i
15 15. Cover
16. O-ring
\
11 17. Bolt
18. Dowel pin
21 F023
97-102 WA350-1
0
SA SERIES STRUCTURE
SA-1 Series single pump
rF;;::4--, -,
q$ipth: H
Del ivery port
(The drawing above shows a pump of the counterclockwise rotation type. In a clockwise
rotation pump, the positions of the suction and delivery ports are reversed.)
SA-2 series single pump
l Side port type
%eepth: H
Delivery port
(The drawing above shows a pump of the counter-clockwise rotation type. In a clockwise
l Rear port type
2-14,
1-m 65-l--65--l
WA350-1 97-103
0
SA SERIES STRUCTURE
SA-3 series single PUIIIP
l Side port type
Delivery port
--75---85-
0 Rear port type
f::
l-75-1--88-/
(The drawing above shows a pump of the counterclockwise rotation type. In a clockwise
SA-4 series single pump
-l81-
-I l4.5-
35.8
+L-J2
(Note) Dimensions A through H in the drawings vary with the pump capacity.
97-104 WA350-1
0
SA SERIES TESTING AND ADJUSTING

Measure the pump delivery with a test bench or flow meter kit (790-303-1001).
% See Note on page 97-107. The capacity codes marked * are for triple pumps.
Series apacity
Delivery
Standard l- Reoair limit
No. Check item pressure

Rotation Delivery Rotation Delivery
No. code
(kg/cm*) (liters/min) (liters/min)
(rpm) (rpm)
erformance 008 25 23
Hydraulic oil: 010 32 29
EOlO-CD 012 38 34
Oil temperature: 1 014 210 47 43
50C 016 52 48
020 66 61
025 83 76
*016 44 40
l 020 55 50
l 025 67 62
028 77 71
2 032 210 88 3000 82
036 100 92
040 111 103
045 121 111
050 138 128
l 020 45 42
1 l 025 55 51
* 040 90 82
l050 112 102
056 210 129 2500 119
3 063 145 134
071 158 146
080 184 170
100 231 214
112 212 192

140 2000 2000
125 236 213
112 233 215
125 253 234

2200 2200
140 287 266
160 328 303

4 210
180 336 310
200 373 345
224 411 385
250 460 425
For SA pumps operating at a service pressure of 50 kg/cm2 or less, see the standard and the repair limit in Table,
No. 2. (Examples: Pumps for power traines and servo-hydraulic pumps for excavators)
WA350-1 97-105
0
Series Zapacity
Delivery T Standard
T Repair limit
NO. Check item pressure

No. code Rotation Delivery Rotation _ Delivery
(kg/cm* 1 (liters/min) (liters/min)
(rpm) (rpm)
Performance 008 27 25
Hydraulic oil: 010 33 30
EOIO-CD 012 40 37
Oil temperature: 014 30 3500 48 44
5oc 016 54 50
020 68 63
025 86 79
l 008 23 21
l 016 47 43
l 020 59 53
* 025 72 66
028 80 74
30 3000 3000
032 92 84
036 104 95
040 115 106
045 126 115
050 144 132
* 020 49 44
* 025 60 55
l 040 96 88
* 050 119 109
056 30 2500 134 2500 123
063 151 138
071 164 150
080 192 176
100 241 221
112 217 198

30 2000 2000
125 240 220
112 242 222
125 264 242
140 300 275
160 342 314

4 30
180 350 321
200 389 357
224 434 398
250 480 440
97-106 WA350-1
0
Note 1,) If it is impossible to raise the pump speed to

the value shown in the table because of limita-
tions of the test bench, calculate the allowance
for the delivery from the following formula:
Q = Q. _ (No - N) Qth
1000
however, N => 1000 rpm

where, N: RPM of test bench
Q: Repair limit for delivery at N rpm
(liters/min)
No: RPM in the table
Qo: Repair limit for delivery in the table
(liters/min)
Qth: Capacity code
Note 2.) If the test bench allows the pump to raise its
delivery pressure above 140 kg/cm2 but not
above 210 kg/cm2, use the repair limit for
delivery given in Table, No. 1.
Note 3.) For pumps whose service pressure exceeds

50 kg/cm2 in operation, use Table, No. 1.
(Do not use Table, No. 2)
Note 4). The volumetric efficiency of a pump decreases

after the pump is reassembled. After reassembly,
therefore, perform the following tests with a
test bench or flow-meter kit (790-303-1001).
(1) Shock test

20 times
252 kg/cm max.

t
Time
Performance test (measure the delivery)
WA350-1 97- 107

0
SA SERIES DISASSEMBLY
DISASSEMBLY
c Match mark
(1) Single pump
* Cautions before disassembly
To avoid confusion in the reassembly, stamp
match marks on connecting sections of bracket
(6) to gear case (11) and gear case (11) to cover
(15).
I OOPO50
1) Put the pump assembly on a work bench with

the bracket side facing down, and loosen
mounting bolts (17) for cover (15).
* Use the bracket mounting bolt holes to secure

the pump assembly.
j I OOPO5 I
2) Remove cover assembly (15).

* Place the internal parts in line in the order of
removal, taking care not to damage the contact-
ing surfaces or sliding surfaces of the parts.
* Pull out cover assembly (15). taking care not
to damage the hole for the dowel pin. Do not
pry the cover.
IOOP052
3) Remove O-ring (16) from the cover.
I OOPO53
97-108 WA350-1
0
4) Pull out side plate (12) on the cover side.

/
I OOPO54
5) Remove backup ring (13) and seal ring (14).
23OF221
6) Remove drive gear (1) and driven gear (2).

* Pull out the gears by hand. Do not use a
hammer.
* If the oil seal is not replaced, tape the drive gear
1
and the spline section to protect the oil seal
from damage.
I OOPO55
7) Remove bracket (6) from gear case (II).

* When removing bracket (6) from gear case (111,
take care not to let side plate (8) on the bracket
side fall down and leave the side plate-installed
as is to the gear case.
* Do not hit the side plate surface.
j6
_,
IOOP056
WA350-1 97- 109

0
8) Pull out side plate (8) from gear case (1 I).
9) Remove-backup ring (13) and seal ring (14).
IOOP058
IO) Remove O-ring (7) from the bracket.
I OOPO59
97-110 WA350-1
0
(2) Tandem pump
1) Stamp match marks.
2) Put the pump on a work bench with the front

pump bracket surface facing down, and remove
the four bolts that connect the front pump to
the rear pump. ,,
Match n&k
3) Disconnect the front pump from the rear pump.
4) For the disassembly of single pumps, see the

section on single pumps.
P7050 I003
(3) Triple pump

Follow the same procedure for tandem pumps.
WA35071 97-111
0
ASSEMBLY
(1) Single pump
* When a used gear case is assembled, remove the
burrs from the case and make sure that the side
plate can be slided smoothly.
* Make sure that the dowel pin on the case
has specified length (II).
c R = Length of dowel pin

2 3
.. ,:::I OOPO60
1) Put cover (15) on a work bench.
:,IOOP06 I
2) Install side plate (12) into gear case (II) with

the seal groove facing outside.
* Do not install the backup ring and the seal to
side plate (12) at this stage.
* Do not confuse the suction side of the side
plate with the delivery side.
* Do not damage the periphery of the side plate,
especially around the seal section.
Measurement of side clearance

Temporarily assemble bracket (6) and gear case (II)
as shown in the drawing at right. Place the assembly on
a work bench and measure the difference between the
stack height including drive gear (I ), side plates (8)
and (12) and the height of gear case (I I).
Measure with a depth dial gauge or depth micrometer.
Judgement criteria
Confirm that the measurements conform to the standard
clearance given in the Maintenance Standard Table.
97-112 WA350-1
0
SA SERIES ASSEMBLY
3) Install gear case (11) to cover (15) with the

match marks aligned.
4) Install drive gear (1) and driven gear (2).
5) Install side plate (8) with the backup and seal

ring grooves facing upward.
IOOP065
l\
6) Install backup ring (9) and seal ring (10).
* Install them with care to prevent gaps between
the ring and the gear case as shown in Fig. P.
* If it is impossible to eliminate the gap, replace
the seal ring and the backup ring.
Gap
23OF223
WA350-1 97-113
0
SA SERIES ASSEMBLY
7) Apply some hydraulic oil to the shafts of gears

(I) and (2) and also to the sliding section of
the side plate.
* Take care to keep the gear case free from oil.
8) Install O-ring (7) to bracket (6).
9) Install bracket (6).

* Align the match marks when installing the
bracket.
* Before installing the bracket, make sure that
the seal and backup rings are properly installed
according to the precautions in item 6.
* Make sure O-ring (7) is fit properly.
* Confirm that the contact surface is free from
dirt and dust.
10) Carefully turn the gear pump assembly upside

down so that the bracket side will face down-
ward, and put the gear pump assembly on a
work bench.
* When turning the pump upside down, take care
not to let the contact surfaces open out and not
to let the O-ring and seal come off.
97-114 WA350-1
0
SASERIES ASSEMBLY
II ) Remove the cover (I 5) and install O-ring (16).

12) Install backup ring and seal ring to side plate
(I 2) in the manner described in item 6). i15
13) Install cover (15).

* Align the match marks when installing the cover. :16 12
* Before installing the cover, make sure backup
ring and seal ring are properly installed accord-
ing to the precautions given in item 6).
* Make sure O-ring (I 6) is fit properly.
:lOOP053A
14) Tighten mounting bolts (I 7).

* Use a torque wrench and tighten the bolts
to the specified torque in the order shown in
the drawing.
For the tightening torque, see the Maintenance
Standard Table on page 97-l 17.
Tightening order
15) After assembly,check the rotational torque of

the pump shaft to see if it conforms to the Series Rotational torque
value given in the table. 1 0.2 - 0.5 kgm
* After the pump is assembled, carry out the 2 0.3 - 0.7 kam
performance test (measure the pump delivery) 3 I 0.7 - 1.2 kam
with a test bench or flow meter kit (790- 4 I l.O- 1.5 kgm
303-1001). Confirm that the performance is
with the repair limits.
(2) Tandem pump

1) For the assembly of individual units of the
front and rear pump, follow the same assembly
procedure as for the single pump.
2) Put the front pump on a work bench.
WA350-1 97-115
0
SA SERIES ASSEMBLY
,\,,,,,
3) Install the coupling to the front pump. Coupling
..
4) Fit the O-ring to the rear pump bracket.

5) Put the rear pump on top of the front pump. O-ring
* Take care-not to let the O-ring come off.
* Align the match marks.
~7050 IO06
6) Tighten four mounting bolts.
* Tighten the bolts with a torque wrench to
the specified torque in the order shown in the
drawing below.
I,:: [R]
Tightening order
* After the pump is assembled, carry out the

performance test (measure the pump delivery)
with a test bench or flow-meter kit (790-
303-1001). Confirm that the performance
is within the repair limits.
3) Triple pump
Follow the same assembly procedure as for the
tandem pump.
97-116 WA350-1
0
SA SERIES MAINTENANCE STANDARD
MAINTENANCE STANDARD
Unit: mm
-
NC Remedy
\
Clearance between the SA;020-080 0.10 - 0.15 0.19

gear case and the gear Replace the side plate
3
or the pump assembly
plus the side plate SAk 100 - 125 0.13 - 0.18 0.22
SA; 112 - 180 0.11 - 0.16 0.19

4
SA:, 200 - 250 0.14- 0.19 0.22
2 Replace
I 4
I 0.06 - 0.140
I
I 1 I 10 - 12.5 kgm I
Tightening torque for 2 10 - 12.5 kgm
the case mounting
3olts. 3 23.5 - 27 kgm
I 4 I 15 - 18 kgm I
WA350-1 97-117
0
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

Wa350 1

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Wa350 1

Hochgeladen von

Copyright:

Verfügbare Formate

SEBM04230107

WA350- 1 10001 and up

l WA350-1 mount the S6Dll O-l engine.

50 BRAKE AND AIR SYSTEM

60 WORK EQUIPMENT SYSTEM

80 ELECTRIC AND ELECTRONIC SYSTEM

0 Page to be newly added Add

0 Page to be replaced Replace

( 1 Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

oo- 1 @ l3- 6 @ 13-47 21-40 @ 23- 8 @

oo- 2 0 13-8 @ 21- 1 21-41 @ 23- 9 @

00- 2-l @ 13-g @ 21- 2 21-42 @ 23-10 @

oo- 2-2 @ 13-10 @ 2l- 3 21-43 @ 23-11 @

00- 2-3 @ 13-11 @ 21- 4 21-44 23-12 @

00- 2-4 @ 13-12 @ 21- 5 21-45 @ 23-13 @

oo- 3 13-13 @ 21- 6 21-46 @ 23-14 @

oo- 4 13-14 @ 21- 7 21-47 @ 23-15 @

23- 49 @ 23-105 @ 41-21 44- 2 52-20

54- 7 @ 63- 5 81-10 82-27 82- 86 @

2.When carrying out any operation, always PREPARATIONS FOR WORK

work. 9. When disassembling or assembling, sup-

16. When removing components, be careful not

17. When removing piping, stop the fuel or oil

18.As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

So that the shop manual can be of ample

page. File the pages in correct order. Safety

Slinging near the edge of the hook may

1. If a part cannot be smoothly removed from

4) Do not sling a heavy load with ropes

The allowable load value is estimated to

2) Sling wire ropes from the middle portion

m STANDARD TIGHTENING TORQUE

Thread diameter Width

.. 10 1.35kO.15 13.2* 1.4

27 41 135+15 1320+ 140

Sr Nm (newton meter): 1 Nm + 0.1 kgm

2.TlGHTENlNG TORQUE OF SPLIT FLANGE BOLTS

Thread: gtl,eter Width Tightening torque

10 14 6.7kO.7 65.7 k6.8

3.TlGHTENlNG TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

14 19 2.5kO.5 24.5 k4.9

18. 24 522 49* 19.6

22 27 822 78.5 f 19.6

33 41 20*5 196.1 &49

Nomenclature Komatsu code Applications

Used to apply resin, rubber, metallic and

Provides an airtight, electrically insulating seal.

LG-1 Used with gaskets and packings to increase sealing effect.

Heat-resistant gasket for precombustion chambers

Vaseline - Used for protecting battery electrode terminals from corrosion.

lLT-2 is also called LOCTITE in the shop manuals.

ELECTRIC WIRE CODE

0.85 1 11 1 0.32 1 0.88 1 2.4 1 12 1 Starting, lighting, signal etc.

2 1 26 1 0.32 / 2.09 I 3.1 I 20 1 Lighting, signal etc.

15 84 0.45 13.36 7.0 59 Starting (Glow plug)