Manual Servicio GD825A-2

SEBM002309
HD785-7
SJA01316-02
GD825A- 2
MACHINE MODEL SERIAL No.
GD825A-2 11001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• GD825A-2 mount the S6D140-1 and S6D140E-2 engine.

For details of the engine, see the 6D140-1 and 6D140-2 Series Engine Shop Manual.
2011 1
© 2016
All Rights Reserved 00-1
00-1
Printed
Printed ininJapan
Japan10-16
02-11(01)
(01) (9) (8)
CONTENTS
No. of page
01 GENERAL ........................................................................ 01-1
10 STRUCTURE AND FUNCTION ...................................... 10-1
20 TESTING AND ADJUSTING .......................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ................................. 30-1
40 MAINTENANCE STANDARD ......................................... 40-1
023502
00-2
2
LIST OF REVISED PAGES
Notice of revision
9th revision 2016/10
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the Q Page to be newly added Add
list below.
q Page to be replaced Replace
() Page to be deleted Discard
List of revised pages

Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page
number number number number
q 00-1 (9) 00-37 (7) 10-22 10-44 (2)
00-2 00-38 (7) 10-23 10-45 (2)
q 00-2-1 (9) 00-39 (7) 10-24 10-46 (2)
q 00-2-2 (9) 00-40 (7) 10-25 10-47 (2)
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q 00-2-5 (9) 01-1 (2) 10-28 10-50
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10-80 (2) 10-113-2 (2) 10-152 (2) 20-20
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10-80-6 (2) 10-115 (2) 10-155-1 (4) 20-23-1 (5)
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10-80-8 (2) 10-117 (2) 10-155-3 (4) 20-25
10-80-10 (2) 10-118 (2) 10-156 (6) 20-26
10-80-11 (2) 10-119 (2) 10-156-1 (6) 20-27 (6)
10-80-12 (2) 10-120 (6) 10-157 (2) 20-28 (6)
10-81-1 (1) 10-120-1 (6) 10-158 (2) 20-29
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10-82 (2) 10-120-4 (6) 10-161 (2) 20-32
10-83 10-121 (6) 10-162 (2) 20-33
10-84 10-122 (6) 10-163 (2) 20-34 (2)
10-85 10-123 (6) 10-164 (2) 20-35
10-86 10-123-1 (6) 10-165 (2) 20-36 (2)
10-87 10-124 (2) 10-166 (4) 20-37 (2)
10-88 10-125 (2) 10-166-1 (6) 20-38 (2)
10-89 (2) 10-126 (2) 10-166-2 (6) 20-39 (2)
10-90 10-127 (2) 10-167 (2) 20-40 (2)
10-91 10-128 (2) 10-168 (2) 20-41 (6)
10-92 10-129 (2) 10-169 (2) 20-42 (2)
10-93 10-130 (2) 10-170 (4) 20-43 (2)
10-94 10-131 (2) 10-171 (6) 20-45 (5)
10-95 10-132 (2) 10-172 (6) 20-46 (2)
10-96 (2) 10-134 (4) 10-173 (6) 20-47 (2)
10-97 (2) 10-135 (4) 20-48 (5)
10-97-1 (2) 10-136 (6) 20-1 20-49 (5)
10-97-2 (2) 10-136-1 (6) 20-2 20-50 (5)
10-98 (2) 10-137 (2) 20-3 (2) 20-51 (5)
10-99 10-138 (2) q 20-3-1 (9) 20-52 (5)
10-100 10-140 (4) 20-4 (3) 20-53 (5)
10-100-1 (2) 10-141 (2) 20-5 (3) 20-54 (5)
10-100-2 (2) 10-141-2 (6) 20-6 (3) 20-55 (5)
10-100-3 (2) 10-142 (4) 20-7 (3) 20-55-1 (5)
10-100-4 (2) 10-142-1 (6) 20-7-1 (3) 20-56 (2)
10-101 (2) 10-143 (6) 20-8 (5) 20-57 (2)
10-102 10-144 (6) 20-9 (5) 20-58 (4)
10-103 10-145 (2) 20-10 (2) 20-59 (2)
10-104 10-146-1 (6) 20-11 (2) 20-59-1 (4)
10-105 (2) 10-146-3 (6) 20-12 (2) 20-59-2 (4)
10-106 (2) 10-146-5 (6) 20-13 (2) 20-60 (2)
10-107 10-146-7 (6) 20-13-1 (2) 20-60-1 (2)
10-108 (2) 10-146-9 (6) 20-14 20-60-2 (2)
10-109 (2) 10-146-11 (6) 20-15 (5) 20-60-3 (2)
10-110 (2) 10-147 (2) 20-16 20-60-4 (4)
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20-60-51 (4) 20-60-104 (5) 20-107 (4) 20-188 (4)
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20-60-60 (6) 20-65 20-113 (2) 20-196 (8)
20-60-61 (6) 20-66 20-114 (2) 20-197 (8)
20-60-62 (6) 20-67 20-115 (2) 20-198 (8)
20-60-63 (7) 20-68 20-116 (2) 20-201 (2)
20-60-64 (7) 20-69 20-151 (8) 20-202 (2)
20-60-65 (7) 20-70 20-152 (8) 20-204 (2)
20-60-66 (7) 20-71 20-153 (2) 20-205 (2)
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20-60-68 (7) 20-73 20-153-2 (8) 20-207 (2)
20-60-69 (7) 20-74 20-154 (2) 20-208 (2)
20-60-70 (7) 20-75 20-155 (8) 20-209 (2)
20-60-71 (7) 20-76 20-156 (2) 20-210 (2)
20-60-72 (7) 20-77 20-157 (2) 20-211 (2)
20-60-73 (7) 20-78 20-158 (2) 20-212 (2)
20-60-74 (7) 20-79 20-159 (2)
20-60-75 (7) 20-81 (2) 20-160 (2) q 30-1 (9)
20-60-76 (7) 20-82 20-161 (2) 30-1-1 (6)
20-60-77 (7) 20-83 20-162 (2) 30-1-2 (7)
20-60-78 (7) 20-84 20-163 (2) 30-1-3 (7)
20-60-79 (7) 20-85 (4) 20-164 (2) 30-1-4 (6)
20-60-80 (7) 20-85-1 (4) 20-165 (2) 30-1-5 (6)
20-60-81 (7) 20-86 20-166 (2) 30-1-6 (6)
20-60-82 (7) 20-87 (4) 20-167 (2) 30-2 (6)
20-60-83 (7) 20-88 20-168 (2) 30-3 (6)
20-60-84 (7) 20-89 (4) 20-169 (2) 30-4 (2)
20-60-85 (7) 20-90 (4) 20-170 (2) 30-4-1 (2)
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20-60-87 (7) 20-91 20-172 (2) 30-5 (2)
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20-60-89 (7) 20-92-1 (4) 20-174 (4) 30-7 (2)
20-60-90 (7) 20-93 20-175 (4) 30-8 (1)
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30-19 (1) 30-62 (1) 30-114 (1) 30-161 (1)
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30-21 (1) 30-64 (1) 30-116 (1) 30-163 (1)
30-22 (1) 30-65 (1) 30-117 (1) 30-164 (1)
30-23 (1) 30-66 (1) 30-118 (1) 30-165 (1)
30-24 (1) 30-67 (1) 30-119 (1) 30-166 (1)
30-25 (1) 30-68 (1) 30-120 (1) 30-167 (1)
30-26 (1) 30-69 (1) q 30-121 (9) 30-168 (1)
30-27 (1) 30-70 (1) 30-122 (6) 30-169 (1)
30-28 (2) 30-71 (1) 30-123 (6) 30-170 (1)
30-28-1 (2) 30-72 (4) 30-124 (6) 30-171 (1)
30-29 (1) 30-73 (4) 30-124-1 (6) 30-172 (1)
30-30 (1) 30-74 (4) 30-125 (1) 30-173 (1)
30-31 (1) 30-75 (4) 30-126 (1) 30-174 (1)
30-32 (1) 30-76 (1) 30-127 (1) 30-175 (1)
30-33 (1) 30-77 (1) 30-128 (1) 30-176 (1)
30-34 (1) 30-78 (1) 30-129 (1) 30-177 (1)
30-35 (2) 30-79 (4) 30-130 (1) 30-178 (1)
30-36 (1) 30-80 (1) 30-131 (1) 30-179 (2)
30-37 (1) 30-81 (1) Q 30-131-1 (9) 30-180 (1)
30-38 (1) 30-82 (1) Q 30-131-2 (9) 30-181 (1)
30-39 (1) 30-83 (1) Q 30-131-3 (9) 30-182 (1)
30-40 (1) 30-84 (1) Q 30-131-4 (9) 30-183 (1)
30-41 (1) 30-85 (1) 30-132 (1) 30-184 (1)
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30-45-1 (2) 30-90 (1) 30-137 (2) 30-189 (2)
30-45-2 (2) 30-91 (1) 30-138 (1) 30-190 (1)
30-45-3 (2) 30-92 (1) 30-139 (1) 30-191 (1)
30-45-4 (2) 30-93 (1) 30-140 (2) 30-192 (1)
30-45-5 (2) 30-94 (1) 30-141 (1) 30-193 (1)
30-45-6 (2) 30-95 (1) 30-142 (1) 30-194 (1)
30-45-7 (2) 30-96 (1) 30-143 (1) 30-194-1 (2)
30-45-8 (2) 30-97 (1) 30-144 (1) 30-194-2 (2)
30-46 (1) 30-98 (1) 30-145 (1) 30-194-3 (2)
30-47 (1) 30-99 (1) 30-146 (1) 30-194-4 (2)
30-48 (1) 30-100 (1) 30-147 (1) 30-194-5 (2)
30-49 (1) 30-101 (1) 30-148 (1) 30-194-6 (2)
30-50 (1) 30-102 (1) 30-149 (1) 30-194-7 (2)
30-51 (1) 30-103 (1) 30-150 (1) 30-194-8 (2)
30-52 (1) 30-104 (1) 30-151 (1) 30-194-9 (2)
30-53 (1) 30-105 (1) 30-152 (1) 30-194-10 (2)
30-54 (1) 30-106 (1) 30-153 (1) 30-195 (1)
30-55 (1) 30-107 (1) 30-154 (1) 30-196 (1)
30-56 (1) 30-108 (1) 30-155 (1) 30-197 (1)
30-57 (1) 30-109 (1) 30-156 (1) 30-198 (1)
30-58 (1) 30-110 (1) 30-157 (1) 30-199 (1)
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Revision Revision Revision

Mark Page Mark Page Mark Page
number number number
30-200 (1) 30-228 (1) 40-21-2 (2)
30-201 (6) 30-229 (2) 40-22 (2)
30-202 (6) 30-230 (2) 40-23 (2)
30-203 (6) 30-231 (2) 40-23-1 (2)
30-204 (6) 30-232 (2) 40-23-2 (2)
30-205 (6) 30-233 (2) 40-24 (2)
30-205-1 (6) 30-234 (2) 40-26 (2)
30-205-2 (6) 30-235 (2) 40-27 (2)
30-205-3 (6) 30-236 (2) 40-27-1 (2)
30-205-4 (6) 30-237 (2) 40-27-2 (2)
30-205-5 (6) 30-238 (6) 40-28 (2)
30-205-6 (6) 30-239 (5) 40-29 (2)
30-205-7 (6) 30-240 (5) 40-29-1 (2)
30-205-8 (6) 30-241 (6) 40-29-2 (2)
30-206 (2) 30-242 (6) 40-30 (2)
30-207 (2) 30-243 (6) 40-31 (6)
30-207-1 (2) 30-244 (6)
30-207-2 (2) 30-245 (6)
30-208 (2) 30-246 (6)
30-209 (1) 30-247 (6)
30-210 (1)
30-211 (2) 40-1 (2)
30-212 (2) 40-2 (4)
30-213 (2) 40-3
30-214 (2) q 40-3-1 (9)
30-214-1 (6) 40-3-2 (6)
30-214-2 (2) Q 40-3-3 (9)
30-214-3 (2) Q 40-3-4 (9)
30-214-4 (2) 40-4 (4)
30-214-5 (2) 40-5 (6)
30-214-6 (2) 40-6
30-214-7 (2) 40-7 (4)
30-214-8 (2) 40-8 (2)
30-215 (2) 40-9
30-215-1 (2) 40-9-1 (2)
30-216 (2) 40-9-2 (2)
30-217 (2) 40-10 (2)
30-218 (1) 40-10-1 (2)
30-219 (2) 40-11
30-220 (1) 40-12 (2)
30-221 (2) 40-13 (6)
30-222 (2) 40-14 (4)
30-223 (2) 40-15
30-223-1 (2) 40-15-1 (6)
30-223-2 (2) 40-15-2 (6)
30-223-3 (2) 40-16
30-223-4 (6) 40-17
30-223-5 (2) 40-18
30-224 (2) 40-19 (2)
30-225 (1) 40-20 (2)
30-226 (1) 40-21 (2)
30-227 (1) 40-21-1 (2)
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Safety notice (Rev. 2008/08)1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

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

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

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

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

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

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

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

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

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

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

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

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

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

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

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

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

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

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
00- 13
(7)
3. Removing, installing, and drying connec-
tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

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

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

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

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
00- 18
(7)
Points to remember when handling hydraulic equipment
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
00- 19
(7)
5. Change hydraulic oil when the temperature
is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
00- 20
(7)
Handling of connectors newly used for engines 1
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
00- 36
(7)
Conversion table 1
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

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

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

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

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00- 41
(7)
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION AND TRANSFER
Structure
*1. Serial No.: 12099 - 12116, R clutch disc: 4 pieces
10-11-1
(9)
HYDROSHIFT TRANSMISSION AND TRANSFER STRUCTURE AND FUNCTION
Structure
*1. Serial No.: 12117 and up: R clutch disc: 5 pieces
10-11-1-1
(9)
023502
10-12
(6)
023502
10-14
(6)
Serial No.: 11001 – 12021
023502
1. Chain 8. Gear (105 teeth)

2. Breather 9. Plate (138 teeth)
3. Shaft 10. Disc
4. Sprocket 11. Tandem case
5. Cage 12. Sprocket
6. Piston 13. Oil level gauge
7. Spring 14. Drain plug
10-39
(6)
Serial No.: 12022 and up
023502
1. Chain 8. Gear (105 teeth)

2. Breather 9. Plate (138 teeth)
3. Shaft 10. Disc
4. Sprocket 11. Tandem case
5. Cage 12. Sprocket
6. Piston 13. Oil level gauge
7. Spring 14. Drain plug
10-40
(6)
STRUCTURE AND FUNCTION FRONT AXLE
Serial No.: 12099 – 12502

023502
10-51-2
(6)
STRUCTURE AND FUNCTION FRONT AXLE
023502
10-51-3
(6)
Serial No.: 11001 – 12502
023502
10-120
(6)
023502
1. Main frame
2. Articulate cylinder
3. Center pin
4. Pin
5. Grease fitting
10-120-1
(6)
STRUCTURE AND FUNCTION AIR CONDITIONER
Serial No.: 11001 – 11013
023502
10-120-2
(6)

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

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

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

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

2. Turn signal lamp switch 10. Emergency steering relay
3. Monitor panel 11. Engine stop motor relay
4. Fuse box 1 12. Emergency steering controller
5. Fuse box 2 13. Warning buzzer (for emergency steering)
6. Stop lamp switch 14. Engine oil pressure relay
7. Hazard relay 15. Warning buzzer
8. Flasher relay
10-123-1
(6)
(1/2)
Serial No.: 12099 – 12502
023502
10-136
(6)
(2/2)
Serial No.: 12099 – 12502
023502
10-136-1
(6)
Serial No.: 12099 – 12502
023502
10-141-2
(6)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
Serial No.: 12001 – 12502

023502
10-142-1
(6)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
EELCTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER

(Refrigerant for R-12)
Serial No.: 11001 – 11013
023502
10-143
(6)
(Refrigerant for R134a)
Serial No.: 11014 – 12502
023502
10-144
(6)
ELECTRICAL CIRCUIT DIAGRAM (1/6)
023502
10-146-1
(6)
023502
10-146-3
(6)
023502
10-146-5
(6)
(Transmission)
023502
10-146-7
(6)
(Steel cab)
023502
10-146-9
(6)
(Air conditioner)
023502
10-146-11
(6)
STRUCTURE AND FUNCTION SENSORS
SENSORS
Display (use) category
Machine monitor Transmission controller
Check before starting
Type of sensor Sensor method When normal When abnormal

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

Q Q Coolant level (Radiator upper tank) (if equipped) Contact OFF (OPEN) ON (Close)
Q Engine oil pressure Contact OFF (OPEN) ON (Close)
Q Q Engine water temperature Resistance — —
Q Hydraulic oil temperature Resistance — —
Q Final drive oil temperature Resistance — —
Q Transmission oil temperature Resistance — —
Q Q Speedometer Pulse — —
Q Engine speed Pulse — —
Q Air pressure (for air pressure gauge) Resistance — —
Q Air pressure Contact ON (Close) OFF (OPEN)
023502
Q Engine oil level Contact ON (Close) OFF (OPEN)
Q Q Hydraulic oil level Contact ON (Close) OFF (OPEN)
Q Fuel level Resistance — —
Q Shift potentiometer Resistance — —
Q Inching potentiometer Resistance — —
10-156
(6)
STRUCTURE AND FUNCTION SENSORS
COOLANT LEVEL SENSOR
1. Sub-tank
2. Float
3. Sensor
4. Connector
Function
• The coolant level sensor is
installed to the radiator
sub-tank. If the coolant
goes below the specified
level, the float goes down
and the switch is turned
OFF. The warning lamp
then flashes.
023502
COOLANT LEVEL SENSOR (IF EQUIPPED)
1. Float Function
2. Sensor • The coolant level sensor is installed to the radia-
3. Tube tor upper-tank. If the coolant goes below the
4. Wire specified level, the float goes down and the
5. Connector switch is turned OFF. The warning lamp then
flashes.
10-156-1
(6)
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
Serial No.: 12099 – 12502

023502
10-166-1
(6)
023502
10-166-2
(6)
STRUCTURE AND FUNCTION ENGINE STOPPING CIRCUIT
Serial No.: 12099 – 12502

023502
10-171
(6)
023502
10-172
(6)
023502
10-173
(6)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

Engine S6D140E-2
Classi-
Item Condition Unit Standard value Permissible value
fication
Performance
High idling speed rpm 2,350 ± 50 2,350 ± 50

Engine
+50
Low idling speed rpm 650 0 -
Quick acceleration Bosch

Max. 4.0 6.0
(Low idling → High idling) scale
Exhaust gas color
Bosch
At high idling Max. 1.0 2.0
Intake and exhaust system
scale
See "Measuring intake air
Min. 78.7 {590} 66.7 {500}
Intake pressure pressure (boost pressure)" kPa
(Boost pressure) High idling and work equipment {mmHg} Min. 32.7 {245} Min. 26.7 {200}
relief (Reference value) (Reference value)
See "Measuring exhaust gas
Exhaust temperature °C Max. 700 700
temperature"
Valve clearance Intake valve mm 0.43 -
(When engine is hot
or cold) Exhaust valve mm 0.8 -
Oil temperature: 40 - 60 °C MPa Max. 3.8 (39) 2.7 {27}

Compression
{kg/cm2}
Engine body
pressure (SAE30 oil) (Engine speed) (160 - 200) (160 - 200)

(rpm)
(Water temperature inside
Blow-by pressure kPa
operating range) Max. 0.98 {100} 1.96 {200}
(SAE30 oil) {mmH20}
At rated output
(Water temperature inside
operating range)
(Oil temperature: 80 °C above)
MPa
At high idling (SAE 30) 0.3 - 0.5 {3.0 - 5.0} 0.2 {2.0}
Lubrication system
{kg/cm2}
Oil pressure
MPa
(SAE30 oil) At high idling (SAE 10W) 0.25 - 0.44 {2.5 - 4.5} 0.18 {1.8}
{kgcm2}
MPa
At low idling (SAE 30) 0.12 {1.2} 0.07 {0.7}
{kg/cm2}
MPa
At low idling (SAE 10W) 0.10 {1.0} 0.07 {0.7}
{kg/cm2}
Oil temperature All speed (Oil in oil pan) °C 80 - 110 120
system
Before top dead center

Fuel
Fuel injection timing degree 16 ± 0.5 16 ± 0.5

(B. T. D. C.)
Cooling system
Alternator belt
13 - 16 -
tension
Deflects when pushed with a
mm
force of 58.8 N {6 kg}
Fan belt tension 17 - 19 -
a The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel infection pump.
20-3-1
(9)
6 – 99999.9 rpm
799-205-1100 Tachometer kit
2.5, 6, 40, 60 MPa

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

{ }
79A-264-0021 0 – 294 Nm {0 – 30 kg}
0 – 1 MPa {0 – 10 kg/cm2}
0 – 1,080 Nm {0 – 110 kg}
(5)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 1
k When removing or installing measuring

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

(1).
k When taking measurements, be careful not to touch
any hot parts or rotating parts.
Note:
Run the engine at a mid-range speed or above, then
use the self-seal portion of the gauge to remove oil
from inside the hose.
q Insert the gauge about half-way and repeat the
movement to open the self-seal and remove the
oil.
a If there is any oil inside the hose, the gauge will
not move, so always be sure to remove the oil.
2. Run the engine at high idle and measure the boost pres-
sure as follows.
1) Before starting measurements, set the work equip-
ment to the following posture.
A: k When setting the work equipment in position,
be careful not to let the blade hit the tire.
B: For the drawbar shift, take the center position as
the standard position.
C: Shift the blade fully to the right.
D: Rotate the circle to give a propulsion angle of
50°.
E: Raise the blade fully on both the left and right
sides.
2) Pull right blade lift lever (1) back, and hold it at the
end of its stroke.
a Raise the right end of the blade, and relieve the
circuit.
3) In the condition in Step 2), operate blade left shift
lever (2) and circle left rotation lever (3) at the same
time to the front to move the work equipment.
a Use the blade left shift lever and the circle left
rotation lever to set the oil discharge amount to
the maximum.
20-18
(9)
4) In the condition in Step 3), measure the boost pres-
sure.
k The blade moves during the measurement, so be
careful to avoid the contact shown in the dia-
gram, and stop operation of the lever before
there is any contact.
A: kBe careful not to let the work equipment
hit the main frame.
B: kBe careful not to let the blade hit the tire.
a Standard intake air pressure (reference):
Min 26.7 kPa {Min. 200 mmHg}
TESTING AND ADJUSTING BELT TENTION 1
Serial.: 11001 - 12000
1. Fan belt
1) Testing
Check that the deflection of the belt is within the stan-
dard range when central portion "a" between fan
pulley (2) and belt tension adjustment pulley (1) is
pressed with a force of approx. 58.8 N {6 kg}. If it is
not within the standard value, adjust the belt tension.
a Standard belt tension: 5 - 9 mm
2) Adjusting
Use adjustment bolt (3) to adjust the belt tension as
follows.
If deflection is too LARGE, TIGHTEN bolt.
If deflection is too SMALL, LOOSEN bolt.
2. Alternator belt
1) Testing
Check that the deflection of the belt is within the stan-
dard range when central portion "b" between alter-
nator (4) and accessory pulley (5) is pressed with a
force of approx. 58.8 N {6 kg}. If it is not within the
standard value, adjust the belt tension.
a Standard belt tension: 8 - 12 mm
2) Adjusting
i] Loosen belt tension adjustment bolt (6) and
mount bolt (7) of alternator (4).
ii] Using bar, pull alternator (4) up to adjust the belt
tension, then tighten adjustment bolt (6) and
mount bolt (7).
20-19
(9)
023502
20-27
(6)
INSTALLATION OF ARTICULATE CENTER PINS
1. Insert the front frame in the rear frame. Serial No.: 11001 – 12502
2. Insert center pins (1) and (2), adjust with bottom

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

to center pins (1) and (2).
3. Tighten top nut (3).
3 Nut (3)
(1st pass): 255 ± 9.8 Nm {26 ± 1 kgm}
(2nd pass): Loosen temporarily and then
tighten to
215 ± 9.8 Nm {22 ± 1 kgm}.
4. Set lock plates (5) to nuts (3) and (4) and secure
them with the bolts.
a For serial No. 12503 and after, install washer
(6) between lock plate (5) and frame.
023502
20-28
(6)
TESTING AND ADJUSTING ADJUSTING SHIFT POTENTIOMETER
ADJUSTING SHIFT
POTENTIOMETER
Serial No.: 12013 – 12015, 12019 – 12098
023502
20-41
(6)
TROUBLESHOOTING
Points to remember when troubleshooting ....................................................................................... 20- 46

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

Troubleshooting chart for transmission controller (ET mode) ......................................................... 20-151
Troubleshooting chart for hydraulic system (H mode) ..................................................................... 20-201
20-45
(5)
2
POINTS TO REMEMBER WHEN TROUBLESHOOTING
¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
023502
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- • Confirm the extent of the failure yourself,
sembled. and judge whether to handle it as a real fail-
• It will become impossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or fl When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in • Use the results of the investigation and in-
accordance with the fixed procedure. spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Was there anything strange about the ma- fl The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? • Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred be- will occur again.
fore? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-46
2
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the
failure
• Operating environment
• Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
023502
Step 3
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
Step 6
Re-enacting failure
• Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
• Was there anything strange about the ma-

chine before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
failure?
20-47
2
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness
023502
1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

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

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

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
20-49
(5)
3. Removing, installing, and drying connec-
tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

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

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
20-50
(5)
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
023502
per clicks into position.

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

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

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
023502
openings should be sealed with caps, tapes, or

vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-55
(5)
5. Change hydraulic oil when the temperature
is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
023502
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
20-55-1
(5)
TESTING AND ADJUSTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Serial No.: 12019 – 12502
023502
20-60-52
(6)

Connector No. Connector type No. of pins Mounting location Address
CN1 DT-T 8 Intermediate connector (articulate section) F9, A4
CN2 DT-T 8 Intermediate connector (articulate section) F7, A3
CN3 DT-T 12 Intermediate connector (below left side of floor frame) H1
CN6 KES2 8 Intermediate connector (inside of R.H. console box) G3, J3
CN7 DT-T 12 Intermediate connector (left side of radiator) E2, J7
CN8 SWP 16 Intermediate connector (inside of R.H. console box) G2
CN9 SWP 12 Intermediate connector (inside of R.H. console box) G2
CN10 Relay 5 Engine oil pressure relay H4
CN11 — 1 Buzzer (inside of R.H. console box) —
CN12 — — Intermediate connector —
CN13 DT-T 8 Intermediate connector (below left side of floor frame) G2
CN14 DT-T 8 Intermediate connector (inside of R.H. console box) A4, G9, I4, M5
CN15 SWP 12 Intermediate connector (next to L.H. battery) D2
CN16 KES1 2 Monitor module —
CN17 DLI 8 Monitor module —
023502
CN18 DLI 12 Monitor module —

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

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

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

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

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

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

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
20-60 - 100
(7)
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
20-60 - 101
(7)
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(ET MODE)
LED display for transmission controller .............................................................................................. 20-152

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

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

Serial No. 12013 – 12015, 12019 – 12098
1) Self-diagnostic display
The error code is displayed by LEDs using a 2-digit code. If an abnormality is detected, the warning
lamp and alarm buzzer are actuated.
2) Method of displaying error codes and abnormal operation codes again
Turn the starting switch OFF Æ ON and the error code and abnormal operation code will be
displayed in the following order:
[CHECK.SUM] Æ [Past failures] Æ [Existing failures] Æ [Abnormal operation]
When the [Abnormal operation] display finishes, the [Existing failure] display is repeated.
Trouble-
Error Warning Alarm shooting
Abnormal system and content of abnormality lamp buzzer
code code
A1 Short circuit in 1st clutch solenoid output system fi fi ET-1
A2 Short circuit in 2nd clutch solenoid output system fi fi ET-2
A3 Short circuit in 3rd clutch solenoid output system fi fi ET-3
A4 Short circuit in 4th clutch solenoid output system fi fi ET-4
A5 Short circuit in High/Low clutch solenoid output system fi fi ET-5
A7 Short circuit in FORWARD/REVERSE clutch solenoid output system fi fi ET-6
b1 Disconnection in 1st clutch solenoid output system fi fi ET-7
023502
b2 Disconnection in 2nd clutch solenoid output system fi fi ET-8
b3 Disconnection in 3rd clutch solenoid output system fi fi ET-9
b4 Disconnection in 4th clutch solenoid output system fi fi ET-10
b5 Disconnection in Low clutch solenoid output system fi fi ET-11
b6 Disconnection in High clutch solenoid output system fi fi ET-12
b7 Disconnection in FORWARD clutch solenoid output system fi fi ET-13
b8 Disconnection in REVERSE clutch solenoid output system fi fi ET-14
c1 Disconnection in inching potentiometer system fi — ET-15
c2 Abnormality in voltage of shift potentiometer (1) signal fi — ET-16
c3 Abnormality in voltage of shift potentiometer (2) signal fi — ET-17
c4 Discrepancy in shift potentiometers (1), (2) signals fi — (ET-16·17)
c5 Abnormality in both shift potentiometer signal systems fi fi (ET-16·17)
d1 Both F and R switches are ON fi fi ET-18
d4 Disconnection in engine speed sensor system fi — ET-19
d5 Disconnection in speed sensor system fi — ET-20
d6 Failure in transmission oil temperature sensor — — ET-21
d7 Shift lever is not at P position when starting switch is ON fi fi —
20-152
(8)
Trouble-
Error Warning Alarm shooting
Abnormal system and content of abnormality lamp buzzer
code code
E0 Power source voltage below 18 V fi — ET-22
E1 Short circuit in parking brake solenoid system fi fi ET-23
E2 Short circuit in parking lamp system — — ET-24
E3 Short circuit in differential lock solenoid system fi fi ET-25
E4 Short circuit in backup buzzer system fi — ET-26
E5 Short circuit in caution lamp system — fi ET-27
E6 Short circuit in alarm buzzer system fi — ET-28
E7 Short circuit in starting motor relay system fi — ET-29
F1 Disconnection in parking brake solenoid system, short circuit fi — ET-30
F2 Disconnection in parking lamp system, short circuit fi — ET-24
F3 Disconnection in differential lock relay system, short circuit fi fi ET-25
F4 Disconnection in backup buzzer system, short circuit fi — ET-26
F5 Disconnection in caution lamp system, short circuit — fi ET-27
F6 Disconnection in alarm buzzer system, short circuit fi — ET-28
F7 Disconnection in starting motor relay system, short circuit fi — ET-29
10 Detection of overrun by deceleration fi fi —
Operation to switch between FORWARD and REVERSE
11
at above 9 km/h fi — —
12 Operation to shift to 4th or above at below 2 km/h fi fi —
13 Clutch plate temperature above 200°C — — —
fi
023502
14 Inching used continuously for more than 10 seconds — —

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

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

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

After carrying out troubleshooting and completing repairs of the failure, the self-diagnostic display
returns to the normal display. Always do as follows to delete the transmission controller error
codes from memory.
fl The abnormal operation items are deleted from memory at the same time.
(1) Turn the starting switch to the ON position, and after completing the display for all the past
failures in memory, check that the display returns to .
(2) Take the connector (color of wiring harness: green) connected to connector number [FR] inside the
right console box, and ground it to the chassis. (When doing this, make sure that the starting
switch is at the ON position.)
• After grounding the connector, install the blind connector to the FR connector in the original
way.
(3) Turn the starting switch OFF, then turn it ON again and check that the past error codes have been
deleted from memory.
• If the past error codes have been deleted from memory, CHECK.SUM is displayed, then
is displayed immediately.
023502
20-155
(8)
TROUBLESHOOTING ET-31
ET-31 [C4] (Disconnection in totary switch photo-interrupter) is displayed

(Serial No.: 12099 and up)
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
display, the problem has been removed.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 YES Defective rotary switch

(Abnormality in photo- Replace
interrupter)
YES Is voltage between
T01 (female) (11)
2 and (12) normal?
When T01 (female) Defective transmission Repair or
(11) is grounded to controller replace
YES chassis, is resist- • 24V NO
ance between E1 • Connect T-adapter to
1 (female) (12) and T01. Defective contact or
When T01 (female) chassis normal? • Shift lever (P). disconnection in wiring
(12) is grounded to • Max. 1 Ω • Turn starting switch ON. harness between T01 Repair or
chassis, is resist- • Turn starting (female) (11) and E1 replace
ance between E1 switch OFF. NO
(female) (13) and (female) (12)
• Disconnect T01, E1.
chassis normal?
• T01 (female) (11) is Defective contact or
• Max. 1 Ω chassis ground. disconnection in wiring Repair or
• Turn starting harness between T01
023502
switch OFF. NO replace
(female) (12) and E1
• Disconnect T01, E1. (female) (13)
• T01 (female) (12) is
chassis ground.
ET-31 Related electrical circuit diagram

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

fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
display, the problem has been removed.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 YES to A
Is resistance
YES between T01
(female) (5), E3
2 (female) (26) and Short circuit with ground
Is resistance chassis normal? in wiring harness between Repair or
YES between T01 • Min. 1 MΩ NO T01 (female) (5) and E3 replace
(female) (4), E3 • Turn starting (female) (26)
1 (female) (33) and switch OFF.
chassis normal? • Disconnect T01, E3. Short circuit with ground
Is resistance
between T01 • Min. 1 MΩ in wiring harness between Repair or
(female) (3), E3 • Turn starting NO T01 (female) (4) and E3 replace
(female) (25) and switch OFF. (female) (33)
chassis normal? • Disconnect T01, E3.
• Min. 1 MΩ Short circuit with ground
• Turn starting in wiring harness between Repair or
023502
switch OFF. NO T01 (female) (3) and E3 replace

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

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

(Abnormality Replace
When E3 is in photo-interrupter)
resistance between
35 T01 (female) (9) and harness between T01
When E3 is (10) normal? (female) (9) and E3 (female) Repair or
(28) and wiring harness
YES disconnected, is • Min. 1 MΩ NO between T01 (female) (10) replace
resistance between • Turn starting and E3 (female) (36)
(10) normal? • Disconnect T01, E3. Defective contact in wiring
When E3 is harness between T01
from K resistance between • Turn starting NO (35) and wiring harness replace
• Turn starting Repair or
harness between T01
023502
ET-32 Related electrical circuit diagram
20-198
(8)
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL. . . . . . . . . . . . . . . . 30-1-2 BEVEL PINION
COATING MATERIAL LIST . . . . . . . . . . . . . . . . . . . 30-1-4 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
SPECIAL TOOL LIST. . . . . . . . . . . . . . . . . . . . . . . . . 30- 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
STARTING MOTOR FRONT AXLE
Removal and Installation . . . . . . . . . . . . . . . . . . . . 30- 4 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
ALTERNATOR Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
Removal and Installation . . . . . . . . . . . . . . . . . . . 30- 4 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
NOZZLE HOLDER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121
Removal and Installation . . . . . . . . . . . . . . . . . . . 30- 5 STEERING VALVE
FUEL INJECTION PUMP Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
Removal and Installation . . . . . . . . . . . . . . . . . . . . 30- 6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
WATER PUMP WHEEL BRAKE
Removal and Installation . . . . . . . . . . . . . . . . . . . 30- 7 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-131-1
ENGINE OIL COOLER CORE Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-131-3
Removal and Installation . . . . . . . . . . . . . . . . . . . . 30- 8 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
TURBOCHARGER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134
Removal and Installation . . . . . . . . . . . . . . . . . . . . 30- 9 AIR TANK
AIR COMPRESSOR Removal and Installation . . . . . . . . . . . . . . . . . . 30-137
Removal and Installation . . . . . . . . . . . . . . . . . . . 30- 10 HYDRAULIC TANK
CYLINDER HEAD Removal and Installation . . . . . . . . . . . . . . . . . . 30-138
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 11 HYDRAULIC PUMP
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 15 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139
ENGINE (INCL. TRANSMISSION) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 18 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156
RADIATOR HYDRAULIC CONTROL VALVE
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 29 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
FUEL TANK MAIN CONTROL VALVE
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 33 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 34 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
PTO CIRCLE ROTATION MOTOR
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 36 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-168
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 41 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189
TRANSMISSION DRAWBAR SHIFT CYLINDER, BLADE
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45-1 LIFT CYLINDER, LIFTER GUIDE
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45-5 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 54 ARTICULATE CYLINDER
TRANSFER Removal and Installation . . . . . . . . . . . . . . . . . . 30-199
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 69 REAR MOUNT RIPPER CYLINDER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 72 Removal and Installation . . . . . . . . . . . . . . . . . . 30-200
TRANSMISSION CONTROL VALVE HYDRAULIC CYLINDER
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 76 Serial No. 11001 – 12502
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 78 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201
HYDROSHIFT TRANSMISSION PUMP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
Removal and Installation . . . . . . . . . . . . . . . . . . . 30- 80 Serial No. 12503 and up
TANDEM AND FINAL DRIVE Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .30-205-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 81 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-205-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 83 CIRCLE ROTATION GEAR AND
FINAL DRIVE HYDRAULIC OIL MOTOR
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 85 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 94 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207
BEVEL GEAR Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
30-1
(9)
BLADE
Removal and Installation . . . . . . . . . . . . . . . . . . 30-215
CIRCLE AND DRAWBAR
Removal and Installation . . . . . . . . . . . . . . . . . . 30-216
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
REAR MOUNT RIPPER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
METHOD FOR LIFTING UP ROPS CAB . . . . . . . . 30-226
INSTALLATION OF ROPS . . . . . . . . . . . . . . . . . . . 30-228
ROPS cab
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223
DISCONNECTION AND CONNECTION
OF ARTICULATE SECTION
Serial No. 11001 – 12502
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
Serial No. 12503 and up
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 30-243
023502
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246
30-1-1
(6)
How to read this manual (Rev. 2009.01)1
1. Removal and installation of assemblies
Special tools Removal

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

30-3
(6)
ASSEMBLY OF FRONT AXLE ASSEMBLY 1
1. Hub shaft assembly

1) Install housing (27) to hub shaft (28).
2) Adjust rotating torque

q Reduce shims (30) and tighten bolts (25) with
washers (26) so that it starts to rotate at 294 to
343 N {30 to 35 kg}, as measured by a spring bal-
ance [1] hooked to hub bolt (29).
Turn the shaft at least 3 times left and right.
a Adjust the preload after the bearing temperature
becomes normal.
q Loosen bolt (25) and insert shims (30) so that it
can start to rotate at 147 to 196 N {15 to 20 kg}.
a Shim (30): Thickness of 0.1 or 0.2 mm
q Measure the rotating force again after rotating
housing (27) 3 times and after the bearing roller
fits well. Confirm that the starting torque becomes
147 to 196 N {15 to 20 kg}.
q Then bend lock washer (31) securely.
3) Install cover (24) with bolts (23).
30-121
(9)
2. Bracket
Serial No.: 11001 – 12502

1) Assemble bracket (22) to front axle (4), and
insert shaft (21).
2 Shaft and shaft insertion portion:
Grease (G2-LI)
2) Insert lock (21A) into groove [A] of shaft
(21), then assemble collar, bolt, and nut
(21B), (21C), (21D), (21E), and (21F) tem-
porarily. (Do not assemble shim (21G).)
3) Measure clearance [B].
Standard clearance: 1.5 mm
4) Insert shim of thickness [B] + 0.2 mm, then
assemble.
3 Bolt (21D):
343 – 427 Nm {35 – 43.5 kgm} Serial No.: 11001 –
a Standard shim thickness: 1.7 mm
a Types of shims:
t = 0.1 mm, t = 0.5 mm, t = 1.0 mm
5) Insert nut (20) to shaft (21).
3 Nut: 490 – 608 Nm {50 – 62 kgm}
023502
1) Assemble bracket (22) to front axle (4), and
insert shaft (21).
2 Shaft and shaft insertion portion:
Grease (G2-LI)
2) Install nut (20) to shaft (21).
3 Nut: 490 – 608 Nm {50 – 62 kgm}
30-122
(6)
3. King pin
1) Assemble hub shaft assembly (6) and bear-
ing (33) to bracket (22), then insert king pin
(19).
2) Measure clearance (C).
a Standard clearance: 6 mm
3) Select one thrust washer of a thickness
closest to (C) – 0.2 mm.
a Types of thrust washer:
t = 4.5 mm, t = 5.5 mm, t = 6.5 mm
4) Pull out king pin (19), and assemble
selected thrust washer (32) to bracket (22).
5) Insert king pin into hub shaft assembly and
bracket, insert bolt into hole [1] and secure.
3 Stopper bolt:
59 – 74 Nm {6.0 – 7.5 kgm} Serial No.: 11001 – 12502
023502
30-123
(6)
023502
30-124
(6)
023502
30-124-1
(6)
REMOVAL OF WHEEL BRAKE ASSEMBLY 1
1. Remove tandem case assembly. For details, see steps

1. to 4. of "Disassembly of final drive assembly".
2. Remove bolt (1), and remove cover (2).
3. Fix shaft (3) and cage (4) with guide bolts [1] (10 mm ×
1.5 mm - 95 mm) (2 pieces).
4. Remove bolt (5), and remove cover (6).
5. Set lock washer (7) up, remove bolt (8), and remove
holder (9) and shim (10).
6. Tighten forcing screw (20 mm x 2.5 mm) into cage (11),

and remove it together with bearing (12).
7. Remove shim (13).
30-131-1
(9)
8. Set collar [2] (φ 95), tighten holder (9) lightly with bolt
(8).
9. Remove bolt (14), and remove wheel brake assembly.
30-131-2
(9)
INSTALLATION OF WHEEL BRAKE ASSEMBLY 1
a See, "Removal of wheel brake assembly" for guide bolts

[1] and collar [2].
1. Install O-ring (16) to support (15).

2 O-ring: Grease (G2-LI)
2. Install wheel brake assembly to tandem case with bolt

(14).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt: 490 to 608 Nm {50 to 62 kgm}
3. Remove bolt (8), and remove holder (9) and collar [2] (φ
95).
4. Install O-ring (17) to cage (11).

2 O-ring: Grease (G2-LI)
5. Install cage (11) loosely with bolt (5).
6. Press fit bearing (12).
7. After tightening holder (9) with bolt (8), remove it once.
8. Measure clearance (A), and insert shim (10) of clear-

ance (A) - 0.2 mm.
9. Install holder (9) and lock washer (7) with bolt (8).
3 Mounting bolt: 245 to 309 Nm {25 to 31.5
kgm}
10. Remove guide bolt [1] (10 mm × 1.5 mm - 95 mm).
11. Measure the starting torque of shaft (3).
12. Loosen bolt (5), and install shim (13).
13. Measure the starting torque again.
14. Adjust thickness of shim (13) so that starting torque

becomes the value measured at step 11. + 19.6 to 24.5
Nm {2.0 to 2.5 kgm}.
15. Remove bolt (5) once, and install cover (6).

2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt: 490 to 608 Nm {50 to 62 kgm}
30-131-3
(9)
16. Install cover (2) with bolt (1).
3 Mounting bolt: 44.1 to 53.9 Nm {4.5 to 5.5 kgm}
17. Install tandem case assembly. For details, see steps 24

to 27. of "Assembly of final drive assembly".
30-131-4
(9)
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
Serial No.: 11001 – 12502
023502
30-201
(6)
3. Piston and head assembly
1) Set piston rod assembly (6) to tool A1.
2) Using tool A3, remove nut (7).
Cylinder Width across flats

of nut
Steering 46 mm
50 mm (*1)
Leaning
60 mm (*2)
Blade shift 70 mm
Blade lift 70 mm
Drawbar shift 70 mm
Articulate 75 mm
Power tilt 75 mm
Ripper 80 mm
(*1) Serial No.: 11001 – 12050
3) Remove piston (8) and slider (9).

a Slider (9) is installed to the steering cyl-
inder only.
4) Remove cylinder head assembly (10).
4. Disassembly of piston assembly
023502
Remove piston ring (11) and water ring (12)
from piston (8).
5. Disassembly of head assembly

1) Remove O-ring and backup ring (13).
2) Remove snap ring (14), then remove dust
seal (15).
3) Remove rod packing (16).
4) Remove bushing (17).
30-202
(6)
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
Serial No.: 11001 – 12502
023502
30-203
(6)
023502
3. Piston, head assembly
1) Set piston rod to tool A1.
2) Assemble cylinder head (10) to piston rod.
3) Fit slider (9) and install piston assembly (8),
then using tool A3, tighten nut (7).
inder only.
a Wash and remove all grease and oil
from the thread of the piston rod where
the nylon nut is fitted.
2 Rod thread:
Thread tightener (Loctite #262)
3 Piston nut
Width across Nm
Cylinder flats of nut {kgm}
785 ± 78.5
Steering 46 mm {80 ± 8}
50 mm (*1) 1,080 ± 110
{110 ± 11}
Leaning
1,770 ± 177
60 mm (*2)
{180 ± 18}
Blade shift 2,600 ± 260
{265 ± 26.5}
Blade lift 3,330 ± 333
70 mm {340 ± 34}
Drawbar shift 2,600 ± 260
{265 ± 26.5}
Articulate 3,140 ± 314
{320 ± 32}
75 mm
2,840 ± 284
Power tilt
{290 ± 29}
Ripper 80 mm 3970 ± 397
{405 ± 40.5}
(*1) Serial No.: 11001 – 12050
30-204
(6)
023502
30-205
(6)
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
a The symbols used in the special tools and illus- 1. Set cylinder assemble (1) to tool A1.
trations indicate the following cylinders.
Cylinder Cylinder symbol
Steering ST
Leaning LE
Blade shift BS
Blade lift BL
Drawbar shift DS
Articulate AR
Power tilt PT
Ripper RP
Special tools
Sym-
Parts No. Part Name Q’ty Remarks
bol
790-502-1003 Repair stand 1
1 790-502-2000 Repair stand 1
790-101-1102 Pump 1
2 790-330-1100 Wrench 1
790-302-1290 Socket (60 mm) 1 LE
790-102-1320 Socket (70 mm) 1 BL, BS, DS
3
790-102-1330 Socket (75 mm) 1 PT, AR
790-302-1340 Socket (80 mm) 1 RP
023502
790-201-1702 Push tool KIT 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1741 • Push tool 1 ST
4
790-201-1761 • Push tool 1 LE
790-201-1781 • Push tool 1 DS
790-201-1791 • Push tool 1 BL, BS, PT, AR
790-201-1811 • Push tool 1 RP
790-201-1500 Push tool KIT 1
A 790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1550 • Plate 1 ST
5
790-201-1570 • Plate 1 LE
790-201-1590 • Plate 1 DS
790-201-1610 • Plate 1 BL, BS, PT, AR
790-201-1620 • Plate 1 RP
6 790-702-1000 Expander 1
796-720-1630 Ring 1
ST
07281-00709 Clamp 1
796-720-1650 Ring 1
LE
07281-01019 Clamp 1
796-720-1650 Ring 1
7 BL, BS, DS
07281-01159 Clamp 1
796-720-1670 Ring 1
PT, AR
07281-01279 Clamp 1
796-720-1680 Ring 1
RP
07281-01589 Clamp 1
30-205-1
(6)
2. Cylinder head assembly • Blade shift cylinder
• Power tilt, Blade lift, Drawbar shift, Articulate, Using tool A2, loosen cylinder head assembly
Ripper cylinder (4) and disconnect from the cylinder.
1) Remove cylinder head bolt. a Do not loosen bolt (18) but disconnect plate
2) Disconnect cylinder head assembly (2) from (19), collar (20) and cylinder head (4) as an
the cylinder. assembly.
Width across flats of
Cylinder
mounting bolt
Blade lift, Drawbar shift 22 mm
Power tilt, Articulate 24 mm
Ripper 27 mm
023502
• Steering, leaning cylinder

1) Raise rotation stopper.
2) Using tool A2, disconnect cylinder head
assembly (4) from the cylinder.
30-205-2
(6)
3. Piston rod assembly 4. Piston and head assembly
Pull out piston rod assembly (5). 1) Set piston rod assembly (5) to tool A1.
a Put a container under the cylinder to catch 2) Using tool A3, remove nut (7).
the oil.
Width across flats of
Cylinder
mounting bolt
Steering 46 mm
Leaning 60 mm
Blade shift 70 mm
Blade lift 70 mm
Drawbar shift 70 mm
Articulate 75 mm
Power tilt 75 mm
Ripper 80 mm
3) Remove piston (8) and slider (9).

023502
inder only.
4) Remove cylinder head assembly (10).
30-205-3
(6)
5. Disassembly of piston assembly • Blade shift cylinder
Remove piston ring (11) and wear ring (12) from 1) Remove bolts (18) (width across flats: 13
piston (8). mm) to remove plate (19) and collar (20).
2) Remove ring (21) and dust seal (22) from
collar (20).
3) Remove O-ring, backup ring (13) and O-ring
(23).
4) Remove dust seal (15) and rod packing
(16).
6. Disassembly of head assembly

• Steering, Leaning, Blade lift, Drawbar shift,
Articulate, Power tilt, Ripper cylinder
1) Remove O-ring and backup ring (13).
2) Remove snap ring (14), then remove dust
seat (15).
3) Remove rod packing (16).
023502
30-205-4
(6)
ASSEMBLY OF HYDRAULIC 2) Using tool A5, assemble dust seal (15).
CYLINDER ASSEMBLY
a The symbols used in the illustrations indicate
the following cylinders.
Cylinder Cylinder symbol
Steering ST
Leaning LE
Blade shift BS
Blade lift BL
Drawbar shift DS
Articulate AR
Power tilt PT
Ripper RP
a Be careful not to damage the packings, dust

seals, and O-rings when assembling.
1. Assembly of head assembly

• Cylinders other than blade shift cylinder
1) Using tool A4, press fit bushing (17) to head
(10).
3) Install snap ring (14) to dust seal (15).
023502
4) Install rod packing (16), then install O-ring
and backup ring (13).
a Do not try to force the backup ring into
position. Warm it in warm water (50 –
60°C) before fitting it.
30-205-5
(6)
• Blade shift cylinder 2. Assembly of piston assembly
1) Using tool A4, press fit bushing (17) to head 1) Using tool A6, expand piston ring (11).
(10). a Set the piston ring on the expander and
2) Using tool A5, assemble dust seal (15). turn the handle 8 – 10 times to expand
a Take care of the installed direction of the the ring.
dust seal. 2) Remove piston ring (11) from tool A6, and
install to piston (8).
3) Using tool A7, retract piston ring (11).
3) Install rod packing (16), O-ring (23), O-ring

and backup ring (13).
a Take care of the installed direction of the 4) Install wear ring (12).
rod packing.
a Do not try to force the backup ring into
position. Warm it in warm water (50 –
60°C) before fitting it.
023502
4) Set dust seal (22) and ring (21) to collar (20)

and install them to head (10).
a Take care of the installed direction of the
dust seal.
5) Install plate (19) and tighten bolts (18).
30-205-6
(6)
3. Piston, head assembly
1) Set piston rod (5) to tool A1.
2) Assemble cylinder head (10) to piston rod.
3) Fit slider (9) and install piston assembly (8),
then using tool A3, tighten nut (7).
inder only.
a Wash and remove all grease and oil
from the thread of the piston rod where
the nylon nut is fitted.
2 Rod thread:
Thread tightener (Loctite #262)
3 Piston nut
Width across Nm
Cylinder 4. Piston rod assembly
flats of nut {kgm)
Steering 46 mm
785 ± 78.5 • Steering, blade shift, leaning cylinder.
{80 ± 8} 1) Set cylinder to tool A1.
1,770 ± 177 2) Assemble piston rod assembly (5) to cylin-
Leaning 60 mm
{180 ± 18}
2,600 ± 260 der.
Blade shift
{265 ± 26.5}
3,330 ± 333
Blade lift 70 mm
{340 ± 34}
2,600 ± 260
Drawbar shift {265 ± 26.5}
3,140 ± 314
Articulate
{320 ± 32}
75 mm
2,840 ± 284
Power tilt
{290 ± 29}
3,970 ± 397
Ripper 80 mm {405 ± 40.5}
023502
3) Using tool A2, install cylinder head (4).
3 Cylinder head
Cylinder Nm {kgm}
Steering 441 ± 44.1 {45 ± 4.5}
Blade shift 785 ± 78.5 {80 ± 8}
Leaning 677 ± 67.6 {69 ± 6.9}
4) Caulk rotation stopper to cylinder.

a Steering and leaning cylinder only.
30-205-7
(6)
• Power tilt, ripper, blade lift, drawbar shift, ar-
ticulate cylinder.
1) Set cylinder to tool A1.
2) Assemble piston rod assembly (5) to cylin-
der.
5. Remove cylinder assembly (1) from tool A.

023502
3) Assemble cylinder head (2) to cylinder, then

tighten with a torque wrench.
3 Cylinder head mounting bolt
Width across Nm
Cylinder flats {kgm}
Blade lift
177 ± 19.6
22 mm
{18 ± 2}
Drawbar shift
Power tilt
278 ± 32.3
24 mm {28.3 ± 3.3}
Articulate
385 ± 42.1
Ripper 27 mm {39.3 ± 4.3}
30-205-8
(6)
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
8. Circle rotation gear, hydraulic oil motor assem-

bly
Align circle rotation gear assembly (4) and hy-
draulic oil motor assembly, then tighten with
bolts (3).
9. Refilling with oil

1) Tighten drain plug (1), then add gear oil to
the specified level.
5 Circle rotation gear case:

Approx. 16 ¬ (GO90)
2) Tighten drain plug (2), then add engine oil

to the specified level.
5 Clutch: Approx. 180 m¬ (EO30)

023502
30-214-1
(6)
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
DISASSEMBLY OF CIRCLE
ROTATION GEAR, HYDRAULIC
MOTOR ASSEMBLY
1. Draining oil
1) Remove drain plug (1) and drain oil.
6 Upper case: Approx. 9.8 ¬
2) Remove drain plug (2) and drain oil.
6 Lower case: Approx. 0.2 ¬
2. Hydraulic motor assembly

Remove 4 bolts (3), then remove motor (4).
fl Be careful not to drop key (41) fitted to the
shaft of the motor.
023502
3. Clutch
1) Remove 8 bolts (6), then remove cover (7).
2) Remove 3 bolts (8), then remove holder (9)
and shims (10).
fl Check the number and thickness of the
shims, and keep in a safe place.
3) Remove collar (11), spring (12), and plate
(13).
4) Remove clutch discs (14) and plates (15) in
order, then remove washer (16).
Clutch disc (14) : 11
Clutch plate (15) : 10
30-214-2
2
DISASSEMBLY AND ASSEMBLY CIRCLE, DRAWBAR
5. Circle guide
1) Set wear plate (28), put circle assembly on
drawbar, lay out shims (29), then temporar-
ily tighten guides (5), (6), (7) and (7A) with
bolts.
fl Lay out 2 wear plates (28) each.
fl Install wear plate (27) to each circle
guide.
• Standard shim thickness : 5.5 mm
• Bolt length
• (8) : 175 mm (16 bolts)
• (8A) for circle guide (7A): 155 mm (2
bolts)
6. Adjusting clearance of circle guide

1) Adjusting top and bottom clearances be-
tween circle and wear plate
i) Loosen all mounting bolts, expand each
023502
circle guide towards outside, then make

sideways clearance between wear plate
and circle 0 mm.
ii) Adjust thickness of shims (29) to adjust
clearance P in vertical direction of wear
plate (27) and circle.
fl Adjust for all circle guides.
fl Measure the clearance with the wear
plate pushed tightly against the cir-
cle guide.
• Clearance P: 1.5 ± 0.5 mm
2) Adjusting clearance from circle rotation gear
case
i) Loosen locknut (30) and pull in pushing
bolt (31). (For front, center, and rear cir-
cle guides)
ii) Loosen all mounting bolts, and move cir-
cle towards rear.
iii) Push front circle guide (5) to front with
pushing bolt (31) so that clearance H be-
tween circle (33) and circle rotation gear
case (32) is specified value.
• Clearance H: 20 – 21 mm
iv) Tighten bolt to hold front circle guide (5)
in position.
• Clearance F: 0 mm
30-223-4
(6)
DISASSEMBLY AND ASSEMBLY CIRCLE, DRAWBAR
3) Adjust clearance between circle and circle

guide (center, rear)
i) Set clearance F to 0 mm, then adjust
clearance C between circle and center
circle guide (6), and tighten bolt (8) to
hold in position.
Clearance C: 0.7 mm
ii) Set clearance F to 0 mm, then adjust

clearance R between circle and rear cir-
cle guides (7) and (7A), and tighten bolts
(8) and (8A) to hold in position.
Clearance R: 1.5 mm
023502
7. Ball joint
Install ball joint (2) and cover (3) to drawbar,
and tighten bolt (1).
3 Bolt : 534.5 ± 73.5 Nm {54.50 ± 7.50 kgm}
30-223-5
2
Serial No.: 11001 – 12502
k Lower the work equipment to the ground. 4. Remove right and left articulate cylinder assem-
k Stop the engine and move the each work blies (4). For details, see “Removal and installa-
equipment control lever to release the resid- tion of articulate cylinder assembly”.
ual pressure in the piping.
k Disconnect the cable from the negative (–)
terminal of the battery.
Disconnection
1. Remove the ROPS cab. For details, see “Re-
moval and installation of ROPS cab”.
2. Lift off floor assembly (1).
5. Disconnect 9 left-hand hoses (5).
023502
3. Remove engine mount brackets (2) and (3).
6. Disconnect grease hose (7) from lower center

pin (6).
30-238
(6)
7. Disconnect grease hose (9) from upper center
pin (8).
11. Remove bolts (14) and remove lock washers

(15) from the upper and lower center pin
nuts.
8. Disconnect 9 right-hand hoses (10). fl Secure plates (16) with bolts (14) tempo-
9. Disconnect wiring harness (11). rarily.
(Serial No. 12051 and up)
023502
10. Remove O-rings (12) and (13) from the upper

and lower center pins. 12. Remove upper center pin nut (17). 1
30-239
(5)
13. Remove upper center pin (8). 2 16. Remove upper and lower plates (16) from
fl Loosen the lower center pin nut. the rear frame.
fl Serial No. 12051 and up
14. Remove nut (18) of lower center pin (6) and

remove lower center pin (6). 3 17. When replacing bushings (21) and (22)
 When removing the nut, take care that the fitted to the rear frame, cut them with
center pin will not fall. gas. 4
023502
15. Sling front frame (19) and slowly pull out and 18. When replacing bushing (23) fitted to the
disconnect it from rear frame (20). front frame, cut it with gas. 5
fl Check that all the connections are discon-
nected.
 When disconnecting, take care of the bal-
ance of the front frame.
30-240
(5)
Connection 3. Install lock washers (15) to the upper and lower
• Carry out connection in the reverse order to dis- center pins and tighten the nuts.
connection. a Install plates (16) before tightening the nuts.
(Serial No. 12051 and up)
• Install the upper and lower center pins according
to the following procedure.
1. Insert upper and lower center pins (8) and (6) in
front frame (19) and rear frame (20) and then
tighten lower center pin nut (18) so that upper
and lower clearances "A" will be even.
2. After adjusting the clearance, tighten nut (17) of
upper center pin (8) to torque of 255 ± 9.8 Nm
{26 ± 1 kgm} and then loosen it and tighten
again to torque of 215 ± 9.8 Nm {22 ± 1 kgm}.
• Install bushings (21) and (22) by expansion fit.

023502
• Install bushing (23) by expansion fit.
30-241
(6)
• Bleeding air
Bleed air from the hydraulic cylinders. For
details, see “Precautions when carrying out
operation, 2. Precautions when carrying out
installation work”.
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
023502
30-242
(6)
k Lower the work equipment to the ground. 5. Disconnect left-hand hoses (5).
k Stop the engine and move the each work
equipment control lever to release the resid-
ual pressure in the piping.
k Disconnect the cable from the negative (–)
terminal of the battery.
Disconnection
1. Remove the ROPS cab. For details, see
“Removal and installation of ROPS cab”.
2. Lift off floor assembly (1).
6. Disconnect grease hose (7) from lower center

pin (6).
023502
3. Remove engine mount brackets (2) and (3).
7. Disconnect grease hose (9) from upper center

pin (8).
4. Remove right and left articulate cylinder assem-

blies (4). For details, see “Removal and installa-
tion of articulate cylinder assembly”.
30-243
(6)
8. Disconnect right-hand hoses (10).
11. Remove bolts and washer (14) and remove lock

9. Disconnect wiring harness (11). washers (15) from the upper and lower center
pin nuts.
a When removing, take care not to lose wash-
ers (16) between lock washers (15) and
frame.
023502
10. Remove O-rings (12) and (13) from the upper
and lower center pins.
30-244
(6)
12. Remove upper center pin nut (17). 15. Sling front frame (19) and slowly pull out and
disconnect it from rear frame (20).
a Check that all the connections are discon-
nected.
k When disconnecting, take care of the bal-
ance of the front frame.
13. Remove upper center pin (8).

a Loosen the lower center pin nut.
16. When replacing bushings (21) fitted to the rear

frame, cut them with gas.
023502
14. Remove nut (18) of lower center pin (6) and

remove lower center pin (6).
k When removing the nut, take care that the
center pin will not fall.
17. When replacing bushing (22) fitted to the front

frame, cut it with gas.
30-245
(6)
Connection 3. Install lock washers (15) to the nuts of the upper
• Carry out connection in the reverse order to dis- and lower center pins and tighten bolts and
connection. washers (14).
a Be sure to install washers (16) between lock
washers (15) and frame.
• Install the upper and lower center pins ac-
cording to the following procedure.
1. Insert upper and lower center pins (8) and (6) in
front frame (19) and rear frame (20) and then
tighten lower center pin nut (18) so that upper
and lower clearances "A" will be even.
a Install O-rings (23) to upper and lower center
pins (8) and (6).
2. After adjusting the clearance, tighten nut (17) of
upper center pin (8) to torque of 255 ± 9.8 Nm
{26 ± 1 kgm} and then loosen it and tighten
again to torque of 215 ± 9.8 Nm {22 ± 1 kgm}.
023502
• Install bushings (21) by expansion fit.
30-246
(6)
• Install bushing (22) by expansion fit.
• Bleeding air
Bleed air from the hydraulic cylinders. For
details, see “Precautions when carrying out
operation, 2. Precautions when carrying out
installation work”.
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
023502
system. Then, check the oil level again.
30-247
(6)
1
Serial No. 12099 - 12116
40-3-1
(9)
023502
40-3-2
(6)
1
40-3-3
(9)
37.8 35.1
40-3-4
(9)
MAINTENANCE STANDARD TRANSMISSION PUMP

SAR (3)-080
023502
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

Clearance between gear
1 case and side plate gear 0.10 – 0.15 0.19
Clearance between plain Replace

2 bearing I.D. and gear shaft O.D. 0.06 – 0.149 0.20
0
3 Pin insertion depth 14 –0.5
Spline shaft rotating 6.9 – 11.8 Nm (0.7 – 1.2 kgm)
4 torque
Pump Delivery Standard Repair limit
Deliver speed pressure delivery of delivery
— Engine oil CLASS-CD (rpm) (MPa {kg/cm2}) (¬/min) (¬/min) —
45 – 55°C 20.6
2,500 {210} 184 169
40-5
2
(6)
TANDEM DRIVE
023502
40-13
(6)
023502
40-15-1
(6)
023502
40-15-2
(6)
FRAME
023502
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit

1 Outside diameter of center pin Replace
–0.036
118 –0.090 116.910
1. Adjust nut at bottom pin end when tightening so that clearance A

and B are uniform.
2 Tightening torque of nut
2. After tightening nut at top pin end to 255 ± 10 Nm {26 ± 1 kgm},
Tighten
loosen once, then tighten again to 235 ± 30 Nm {22 ± 1 kgm}.
40-31
(6)

Manual Servicio GD825A-2

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SEBM002309

GD825A-2 11001 and up

• GD825A-2 mount the S6D140-1 and S6D140E-2 engine.

01 GENERAL ........................................................................ 01-1

10 STRUCTURE AND FUNCTION ...................................... 10-1

20 TESTING AND ADJUSTING .......................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................. 30-1

40 MAINTENANCE STANDARD ......................................... 40-1

() Page to be deleted Discard

List of revised pages

Revision Revision Revision Revision

Revision Revision Revision Revision

Revision Revision Revision Revision

Revision Revision Revision

1. General precautions 7) If welding repairs are needed, always

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

4. Repair limit and allowable value or allow-

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

5. Points to remember when troubleshooting

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the

4. Do not let any dirt or dust get in during

Disconnect connector (1) according to the fol-

Disconnect connector (3) according to the fol-

q 107, 114 engines

3) While pressing lock (D), pull out connector

a If the lock is on the underside, use

2) Connect the connector according to the

Indicates size of wire by nominal No.

Indicates type of wire by symbol.

1. Type, symbol, and material

Nominal No. 8 15 20 30 40 50 60 85 100

“f” of nominal No. denotes flexible”.

4. Types of circuits and color codes

1. Precautions when carrying out removal work

2) Split flange type hoses and tubes

3. Precautions when completing the operation

1. Table of tightening torques for bolts and nuts

a The following table applies to the bolts in Fig. A.

Thread diameter of bolt Width across flats Tightening torque

a The following table applies to the bolts in Fig. B.

Thread diameter of bolt Width across flats Tightening torque

Thread diameter of bolt Width across flats Tightening torque