Beruflich Dokumente
Kultur Dokumente
Shop
Manual
SK1026-5N
SKID STEER LOADER
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to continuous programs of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
00-21 SK1026-5N
FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
00-2-2 1 SK1026-5N
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
SK1026-5N 00-2-3 1
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
❍ 50-42 1 ❍ 50-75 1
❍ 50-43 1 ❍ 50-76 1
❍ 50-44 1 ❍ 50-77 1
❍ 50-45 1 ❍ 50-78 1
❍ 50-46 1 ❍ 50-79 1
❍ 50-47 1 ❍ 50-80 1
❍ 50-48 1 ❍ 50-81 1
❍ 50-49 1 ❍ 50-82 1
❍ 50-50 1 ❍ 50-83 1
❍ 50-51 1 ❍ 50-84 1
❍ 50-52 1
❍ 50-53 1 ❍ 90-1 1
❍ 50-54 1 ❍ 90-2 1
❍ 50-55 1 ❍ 90-3 1
❍ 50-56 1 ❍ 90-4 1
❍ 50-57 1 ❍ 90-5 1
❍ 50-58 1 ❍ 90-6 1
❍ 50-59 1 ❍ 90-7 1
❍ 50-60 1 ❍ 90-8 1
❍ 50-61 1 ❍ 90-9 1
❍ 50-62 1 ❍ 90-10 1
❍ 50-63 1 ❍ 90-11 1
❍ 50-64 1 ❍ 90-12 1
❍ 50-65 1 ❍ 90-13 1
❍ 50-66 1 ❍ 90-14 1
❍ 50-67 1 ❍ 90-15 1
❍ 50-68 1 ❍ 90-16 1
❍ 50-69 1 ❍ 90-17 1
00-2-4 1 SK1026-5N
FOREWORD SAFETY
12
SAFETY 00
Safety Notice 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
General Precautions 00
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
Mistakes in operation are extremely dangerous. Read the only in the areas provided for smoking. Never smoke
OPERATION & MAINTENANCE MANUAL carefully while working.
BEFORE operating the machine.
Preparations for Work 00
SK1026-5N 00-31
FOREWORD SAFETY
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical
generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the
machine.
00-41 SK1026-5N
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your Komatsu distributor for the latest information.
SK1026-5N 00-51
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
Volumes 00 Revisions 00
Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows: between the title page and SAFETY page.
Weight
Caution necessary when selecting
hoisting wire or when working
1. See the page number on the bottom of the page. File the posture is important, etc.
pages in correct order. Places that require special
2. Following examples show how to read the page number: Tightening
attention for tightening torque
Example: torque
during assembly.
10-5
00-61 SK1026-5N
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
Hoisting 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the sym-
bol.
SK1026-5N 00-71
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00
Type 1 00
Disconnection 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure from
hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold
the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
Connection 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.
00-81 SK1026-5N
FOREWORD PUSH PULL COUPLER
Type 2 00
Disconnection 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the right -
clockwise.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
Connection 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
SK1026-5N 00-91
FOREWORD PUSH PULL COUPLER
12
Type 3 00
Disconnection 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3) contacts
surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
Connection 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
00-101 SK1026-5N
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and
non-metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three
Polyethylene ● Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container ● Used mainly for adhesion of metals,
1735
rubbers, plastics and woods.
● Quick hardening type adhesive.
Aron- ● Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 ● Used mainly for adhesion of rubbers,
plastics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tem-
648-50 container
perature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
● Used as sealant for flange surfaces and
Gasket bolts at high temperature locations; used to
sealant prevent seizure.
LG-3 790-129-9070 1 kg Can
● Used as sealant for heat resistant gasket for
at high temperature locations such as
engine pre-combustion chamber, exhaust
pipe.
SK1026-5N 00-111
FOREWORD COATING MATERIALS
prevent squeaking).
disulphide
lubricant
00-121 SK1026-5N
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
mm mm Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
mm mm Nm lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
SK1026-5N 00-131
FOREWORD STANDARD TIGHTENING TORQUE
12
Tightening Torque of Hose Nuts 00
00-141 SK1026-5N
FOREWORD STANDARD TIGHTENING TORQUE
12
Tightening Torques Table for O-Ring Boss Piping Joints 00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf ft})
Norminal No.
mm mm Range Target
02 14 35 - 63 {25.81 - 46.46} 44 {32.45}
03, 04 20 84 - 132 {61.95 - 97.35} 103 {75.96}
Varies depending on
05, 06 24 128 - 186 {94.40 - 137.18} 157 {115.79}
type of connector.
10, 12 33 363 - 480 {267.73 - 354.02} 422 {311.25}
14 42 746 - 1010 {550.22 - 744.93} 883 {651.26}
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf lb})
Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42}
10 10 17 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31}
12 12 19 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01}
14 14 22 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62}
16 16 24 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68}
18 18 27 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91}
20 20 30 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14}
24 24 32 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59}
30 30 32 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50}
33 33 _ 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75}
36 36 36 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03}
42 42 _ 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40}
52 52 _ 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
Tightening Torque Table for Hoses (Taper Seal Type and Face Seal Type) 00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {lbf ft}) Face seal type
type
Nominal Width
Nominal thread
size of hose across flats Thread size Root diameter (mm)
Range Target size - Threads per
(mm) (Reference)
inch, Thread series
34 - 54 {25.0 - 39.8} 44 {32.4} - 9/16 - 18UN 14.3
02 19
34 - 63 {25.0 - 46.4} 44 {32.4} 14 - -
22 54 - 93 {39.8 - 68.5} 74 {54.5} - 11/16 -16UN 17.5
03
24 59 - 98 {43.5 - 72.2} 78 57.5} 18 - -
04 27 84 - 132 {61.9 - 97.3} 103 {75.9} 22 13/16 - 16UN 20.6
05 32 128 - 186 {94.4 - 137.1} 157 {115.7} 24 1 - 14UNS 25.4
06 36 177 - 245 {130.5 - 180.7} 216 {159.3} 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 {130.5 - 180.7} 216 {159.3} 33 - -
(12) 46 197 - 294 {145.3 - 216.8} 245 {180.7} 36 - -
(14) 55 246 - 343 {181.4 - 252.9} 294 {216.8} 42 - -
SK1026-5N 00-151
FOREWORD ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
Classification by Thickness 00
Copper wire
Nominal Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
number (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yellow & Green &
Color — Red & Black Blue & Red
Black Yellow Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yellow & Green & Blue &
Color — Black & Red
Blue Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-161 SK1026-5N
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
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.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
c
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
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
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
SK1026-5N 00-171
FOREWORD CONVERSION TABLES
12
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
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-181 SK1026-5N
FOREWORD CONVERSION TABLES
12
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
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
SK1026-5N 00-191
FOREWORD CONVERSION TABLES
12
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 1352.63 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
00-201 SK1026-5N
FOREWORD CONVERSION TABLES
12
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
SK1026-5N 00-211
FOREWORD CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 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
00-221 SK1026-5N
01 GENERAL
SK1026-5N 01-11
GENERAL TECHNICAL DATA
TECHNICAL DATA
• The weight of the machine increases by 200 kg (441 lb.) when this is equipped with solid tires and by 120 kg (264 lb.)
when it is equipped with additional rear counterweights.
• If the bucket is provided with teeth, the machine length increases by 100 mm (3.9 in).
Overall Dimensions with Standard Bucket L 1880 mm (6’ 2”) and Tires (12 x 16.5)
01-21 SK1026-5N
GENERAL TECHNICAL DATA
Overall Dimensions with Bucket L 1730 mm (5’ 8’) and Tires (12 x 16.5)
Overall Dimensions With Bucket L 2030 mm (6’ 8”) and Tires (33 x 15.5 - 16.5)
SK1026-5N 01-3 b
GENERAL TECHNICAL DATA
01-41 SK1026-5N
GENERAL TECHNICAL DATA
SK1026-5N 01-51
GENERAL TECHNICAL DATA
01-61 SK1026-5N
GENERAL TECHNICAL DATA
Technical Characteristics
Total Mass
Standard machine max. total mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3690 kg (8,135 lb)
Max. total mass with bucket L 1730 (5ft.8in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3670 kg (8,091 lb)
Max. total mass with bucket L 2030 (6ft 8in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3710 kg (8,179 lb)
Max. total mass with backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4620 kg (10,185 lb)
Max. total mass with cold planer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4550 kg (10,031 lb)
Bucket Capacity
Standard bucket L 1880 (6ft 2in) capacity (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.415 m³ (0.54 yd.³)
Narrow bucket L 1730 (5ft 8in) capacity (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.380 m³(0.49 yd.³)
Wide bucket L 2030 (6ft 8in) capacity (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.448 m³ (0.58 yd.³)
Engine
Komatsu diesel engine model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S4D98E-2NFE
Rated power (2500 rpm EEC 80/1269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 kW (85.8 HP)
Maximum torque (1600 rpm EEC 80/1269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 N•m (211 lbf ft)
Electrical System
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Electrical output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 A
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . negative
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ah-12 V
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 kW (4.02 HP)
SK1026-5N 01-71
GENERAL WEIGHT TABLE
Speed
Forward Reverse
Gears 1 2 1 2
Tires
SIZE MAKE INFLATION PRESSURE
WEIGHT TABLE
WARNING! This weight table is a guide for use when transporting or handling equipment components
Seat
• Standard 10 kg (22 lbs)
• With adjustable suspension 16 kg (35 lbs)
Piston pump
• Standard 91 kg (201 lbs)
• High-flow 98 kg (216 lbs)
Control valve
• 3-spool (Standard) 21 kg (46 lbs)
• 4-spool (High-flow) 24 kg (53 lbs)
Work equipment
• Arm 480 kg (1,058 lbs)
• Lift lever 24 kg (53 lbs)
• Fulcrum lever 15 kg (33 lbs)
• Work equipment support 80 kg (176 lbs)
• Bucket 205 kg (452 lbs)
• Tilt cylinder 27 kg (60 lbs)
• Dump cylinder 16 kg (35 lbs)
01-81 SK1026-5N
GENERAL FUEL, COOLANT AND LUBRICANTS
SAE 10W
SAE30
Oil 10 liters 10 liters
Engine oil pan SAE40
API CD 2.64 gal 2.64 gal
SAE 10W-30
SAE 5W-30
Final
transmission case SAE 10W-30 13.5 liters 13.5 liters
(each) 3.5 gal 3.5 gal
SK1026-5N 01-91
GENERAL FUEL, COOLANT AND LUBRICANTS
NOTE (1)
The recommended lubricating grease is No. 2 multipurpose lithium grease with 3% molybdenum disulfide
(Lithio EP + Mo S2).
IMPORTANT
• When the diesel oil sulphur content is less than 0.5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual. If the diesel oil sulphur content exceeds 0.5%,
change the engine oil according to the following table:
Fuel sulphur content Change interval of oil in engine oil pan
• When starting the engine at temperatures below 0°C (32°F), use engine oil SAE 10W, 10W-30, 5W-30, even if during the
day the temperature increases by 10°C (18°F).
• Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a half.
• Use Komatsu genuine products whose characteristics have been specifically formulated and approved for use in the
engine, in the equipment hydraulic circuit, in the reduction gears and in the transmission.
First filling quantity: Total quantity of oil, including the oil for the components and pipes.
Oil change quantity: Quantity of oil necessary to fill the system or unit during the normal inspection and maintenance
operations.
Transmission Oil GM
Engine Oil Grease LI, EP, Anti-freeze Coolant
No. Supplier Dexron II C4 Allison
API CD, CE, or CF-4 MoS2 (Permanent type)
C4
01-101 SK1026-5N
GENERAL FUEL, COOLANT AND LUBRICANTS
• Others.
Measurements are made of items such as the ratio of water in the
oil, density of the antifreeze coolant, ratio of fuel in the oil, and
dynamic viscosity, enabling a highly precise diagnosis of the
machine's health.
Oil Sampling
• Sampling interval.
• 250 hours: Engine.
• 500 hours: Other components.
• Precautions when sampling.
• Make sure that the oil is well mixed before sampling.
• Perform sampling regularly at fixed intervals.
• Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, contact your Komatsu distributor.
SK1026-5N 01-111
GENERAL HOMOLOGATED (HEES) SYNTHETIC BIODEGRADABLE LUBRICANTS
• It Is not possible to mix synthetic biodegradable ooluble compounds are generated, which are deposited on the fil-
ters and clog them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil).
• The synthetic biodegradable oil can be used only in the hydraulic system; it cannot be used for the endothermic
engine, the transmissions, the braking system, etc.
• Before introducing synthetic biodegradable oil into the hydraulic system, completely empty the system,
disconnecting the cylinders and all the parts that may contain ordinary oil, and replace the drain filter with a new
one. Start the engine and let it idle without using the work equipment, wait until the oil reaches a temperature of at
least 40°C (104°F), then start moving the equipment, so that all the parts of the system are filled with oil. Stop the
engine and check the oil level.
01-121 SK1026-5N
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Flushing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Reduction Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
HST Pump LPV45 + 45 (Standard Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
HST Pump LPV45 + 45 (High Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Pump Internal View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Suction Safety Valve Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Charge Safety Valve Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
ANTI ENGINE-STALL VALVE (AS VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Standard 3-Spool Valve Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Valve Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Super High-Flow 4-Spool Valve Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Valve Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Standard 3-spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Super High Flow 4-Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
CLOSED CENTER LOAD SENSING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Pressure Compensation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Hydraulic Circuit Diagram and Names of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
System Series Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
Self Leveling Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
System In Series-Parallel Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
Pressure Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
Dividing Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
Valve Group ST1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
SK1026-5N 10-11
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
10-21 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12
MEMORANDUM
SK1026-5N 10-31
STRUCTURE, FUNCTION AND
PTO MAINTENANCE STANDARD
PTO
1. Disc 4. Joint
2. Flywheel 5. Pump
10-41 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PTO
Maintenance Standards
Torque Values
SK1026-5N 10-51
STRUCTURE, FUNCTION AND
POWER TRAIN MAINTENANCE STANDARD
POWER TRAIN
10-61 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
Maintenance Standards
Torque Values
a. 98 N•m (72 lbf ft) with Loctite 270 d. 200 N•m (148 lbf ft)
SK1026-5N 10-71
STRUCTURE, FUNCTION AND
TRANSMISSION MAINTENANCE STANDARD
TRANSMISSION
10-81 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRANSMISSION
4. Shaft
SK1026-5N 10-91
STRUCTURE, FUNCTION AND
TRANSMISSION MAINTENANCE STANDARD
Maintenance Standards
Torque Values
a. 98 N•m (72 lbf ft) with Loctite 270 d. 200 N•m (148 lbf ft)
10-101 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
a. A Port - To hydraulic pump (PA2 port) a. A Port - To hydraulic pump (PB1 port)
b. B Port - To hydraulic pump (PB2 port) b. B Port - To hydraulic pump (PA1 port)
c. PP1 Port - From solenoid valve group ST1(A Port) (2nd c. PP1 Port - From solenoid valve group ST1(A Port) (2nd
speed) speed)
d. PP2 Port - From solenoid valve group ST1 (C Port) d. PP2 Port - From solenoid valve group ST1 (C Port)
(parking brake) (parking brake)
SK1026-5N 10-111
STRUCTURE, FUNCTION AND
FINAL DRIVE MAINTENANCE STANDARD
10-121 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD FINAL DRIVE
Description
The final drive motor consists of:
1. 2-speed hydraulic motor
2. Selector valve
3. Reduction gearing
Hydraulic Motor
Function
The hydraulic motor is of the axial piston type, and converts hydraulic energy supplied by the pump into rotary motion.
Operation
• The hydraulic oil arriving from the selector valve is sent on to the
valve plate (1). When the oil is sent to port “A” of the valve, it
flows into the corresponding port on the cylinder block (2) and
presses against the pistons (3).
• This pressure is converted into rotary motion by a swash plate (4)
and transmitted to shaft (5). The shaft and cylinder block have been
integrated into one piece by means of splined teeth.
• The return oil is sent to the pump through port “B”.
• Rotation in the opposite direction is achieved by sending the oil to
port “B” instead of to port “A”.
SK1026-5N 10-131
STRUCTURE, FUNCTION AND
FINAL DRIVE MAINTENANCE STANDARD
• Swash plate (4), which has two surfaces "A" and "B" on side opposite the sliding side for shoes (6), is supported by two
bearings (7) attached to the body of motor (8).
• Position of the bearings is eccentric with respect to axis of the shaft and when running at low speed, surface "A" remains
in contact with the body of the motor through pressure exerted by pistons (3) and by the force of a spring (9) mounted in
cylinder block (2).
• Angle of the swash plate is α.
• When an increase in speed is demanded, oil is sent under pressure to command piston (10). Command piston (10) moves
to the left (←) until surface "B" makes contact with the housing and the angle of the swash plate becomes β.
Displacement of the motor is reduced.
Brake
10-141 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD FINAL DRIVE
When oil is sent under pressure to port “A”, the oil that activated the motor returns to the pump through port “B”.
• Pressurized oil sent to port “A” is also introduced into chamber “C”. It now pushes selector valve (1) to the right (→).
This opens communication between port “B” and oil gallery “D”, which is connected to the overpressure limitation valve
(2).
• If the pressure present at port “B” exceeds the calibration value of the overpressure limitation valve (2), this valve will
open and discharge excess oil into the reduction gears.
• The valve also functions in the same way when pressurized oil is sent to port “B”. The only difference is that the selector
valve moves to the left (←), and oil gallery “D” communicates with port “A”.
SK1026-5N 10-151
STRUCTURE, FUNCTION AND
FINAL DRIVE MAINTENANCE STANDARD
Reduction Gearing
Function
This final drive motor is equipped with a one-stage epicyclic reduction gear that converts the high rotation speed and low
torque of the hydraulic motor into low speed and high torque at the swing pinion.
Operating Principle
Rotary movement of the output shaft of the motor is transmitted to gear (s1) and then to bevel gears (b1) which are integrated
with planetary gear (1). Since gear (a1) is fixed with respect to the output shaft of the hydraulic motor, the planetary gear is
obliged to turn, moving with it output shaft (2) of the reduction gearing (connected to the planetary gear by means of grooved
teething).
★ Reduction ratio of the rotation speed is described by the formula:
R= Zs1/(Zs1+Za1)
Zs1= number of sun gear teeth
Za1= number of ring gear teeth
10-161 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD FINAL DRIVE
Maintenance Standards
Torque Values
a. 61.8 - 75.5 N•m (46 - 56 lbf ft) d. 167 - 196 N•m (123 - 145 lbf ft)
b. 28.4 - 31.4 N•m (21 - 23 lbf ft) e. 51.0 - 64.7 N•m (38 - 48 lbf ft)
SK1026-5N 10-171
STRUCTURE, FUNCTION AND
HYDRAULIC PUMP MAINTENANCE STANDARD
12
HYDRAULIC PUMP
10-181 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
Structure
This pump is comprised of a variable swash plate type tandem piston pumps (1), control pistons (2), suction safety valves (3),
charge safety valve (4), charge pump (5), work equipment gear pump (6), adjustment screws (7), (8), (9), AS valve (10), and
shuttle valves (11).
SK1026-5N 10-191
STRUCTURE, FUNCTION AND
HYDRAULIC PUMP MAINTENANCE STANDARD
10-201 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
Structure
This pump is comprised of a variable swash plate type tandem piston pumps (1), control pistons (2), suction safety valves (3),
charge safety valve (4), charge pump (5), work equipment gear pump (6), adjustment screws (7), (8), (9), AS valve (10), and
shuttle valves (11).
• The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged
according to the load.
• It is possible to change the discharge amount by changing the swash plate angle (plus, zero and minus)
SK1026-5N 10-211
STRUCTURE, FUNCTION AND
HYDRAULIC PUMP MAINTENANCE STANDARD
Structure
• Cylinder block (9) is supported to shaft (1), by spline (12), and shaft (1) is supported by the front and rear bearings (11)
and (13). The tip of piston (8) is a concave ball, and shoe (7) is caulked to it to form one complete unit. Piston (8) and shoe
(7) form a spherical bearing.
• Rocker cam (4) has flat surface “A”, and shoe (7) is always pressing against this surface while sliding in a circular
motion. There is a cradle bearing (3) between cradle and rocker cam (4) which is secured to the case. Rocker cam (4)
sways on the cradle bearing.
• Piston (8) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (9).
• The cylinder block seals the pressurized oil to valve plate (10) and carries out the relative rotation. This surface is
designed so the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder
block (9) is drawn in and discharged through valve plate (10).
Operation
1. Operation of Pump
● Cylinder block (9) rotates together with shaft (1), and shoe (7) slides on surface A. When this happens, rocker cam (4)
moves along cylindrical surface B, so angle α between center line X of rocker cam (4) and the axial direction of
cylinder block (9) changes. (Angle α is called the swash plate angle).
ii. If center line X of rocker cam (4) is in line with the axial
direction of cylinder block (9) (swash plate angle = 0), the
difference between volumes E and F inside cylinder block
(9) becomes 0, so the pump does not carry out any suction
or discharge of oil (Fig. 2).
10-221 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
SK1026-5N 10-231
STRUCTURE, FUNCTION AND
HYDRAULIC PUMP MAINTENANCE STANDARD
• If there is no pressure, control piston (5) does not move and main
pump is to a neutral condition.
• When pressurized oil which has the pressure PPA, PPB (PPA>PPB)
is led from pilot line (PPC or AS valve), control piston (5) moves
the (→) direction. Control piston (5) moves the balanced position
by spring force and pressure PPA, PPB.
Shuttle Valve
1. Valve
2. Plug
3. Cover
Function
The shuttle valves are installed in the covers of the pump and are part of
the swash plate control pistons. They select the lower pressure either
travel PPC pressure or AS valve pressure, and supply the pump swash
plate with control pressure.
10-241 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
Maintenance Standards
Torque Values
a. 147 - 186.2 N•m (108 - 137 lbf ft) c. 58.8 - 73.5 N•m (43 - 54 lbf ft)
b. 19.6 - 27.4 N•m (15 - 20 lbf ft) d. 49 - 58.8 N•m (36 - 43 lbf ft)
SK1026-5N 10-251
STRUCTURE, FUNCTION AND
SAFETY VALVES MAINTENANCE STANDARD
SAFETY VALVES
1. Charge pump
2. Charge safety valve
3. Suction safety valve
3A: Valve
3B: Rod
3C: Sleeve
3D: Spring
3E: Spring
3F: Plug
4. Piston pump
5. Travel motor
Functions
There are two suction safety valves installed to each HST pump, and
they have the following functions:
★ High pressure safety valve
The valve restricts maximum pressure inside the HST circuit in
order to protect the HST circuit.
★ Suction safety valve
The valve ensures the flow of charge oil to the closed HST circuit
and prevents charge oil from flowing into the pump high pressure
side (delivery side).
10-261 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SAFETY VALVES
SK1026-5N 10-271
STRUCTURE, FUNCTION AND
SAFETY VALVES MAINTENANCE STANDARD
10-281 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SAFETY VALVES
1. Charge pump
2. Charge safety valve
2A: Valve
2B: Spring
2C: Valve seat
2D: Poppet
2E: Spring
2F: Adjustment screw
3. Piston pump
Function
There is the charge safety valve installed to the HST pump. The charge
safety valve restricts maximum pressure inside the charge circuit in
order to protect the charge circuit.
SK1026-5N 10-291
STRUCTURE, FUNCTION AND
SAFETY VALVES MAINTENANCE STANDARD
When the pressure of the oil at port C goes down, a differential pressure
is occurred between ports A and C because of orifice a in valve (2A).
Valve (2A) is pushed to (→) direction by oil pressure at port A, and oil
at port A is relieved to port B. In this way, pressure in the charge circuit
is prevented from going any higher.
10-301 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SAFETY VALVES
Charge Pump
1 Slide plate
2 Coupling
3 Shaft
4 Outer ring
5 Case
6 Inner rotor
7 Outer rotor
Function
• HST charge pump is built-in the HST pump
and driven with HST pump at the same time.
• Discharged oil is delivered to AS valve and
charge safety valve.
• Charge pump sucks oil from hydraulic tank.
Specifications
• Type: trochoid pump
• Theological delivery: 25 cm³/rev
Function
• Charge pump is connected to HST pump shaft by coupling (2), so inner rotor (6) and outer rotor (7) rotate.
• When inner rotor (6) and outer rotor (7) rotate, capacity of A increase and oil is sucked, and capacity of B decrease and oil
discharge.
SK1026-5N 10-311
STRUCTURE, FUNCTION AND
ANTI ENGINE-STALL VALVE (AS VALVE) MAINTENANCE STANDARD
Function
• The AS valve is attached on the main piston pump. It reduces pressure for pump swash plate control from charge circuit.
• The AS valve outputs pressure correspond with engine revolutions.
10-321 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ANTI ENGINE-STALL VALVE (AS VALVE)
Operation
• The oil from the charge pump (2) flows through a orifice (3) installed in the main piston pump. Oil always flows to pump
charge circuit.
• Charge pump (2) is a fixed capacity pump, so that discharge flow is proportionate to engine speed. When oil from the
charge pump (2) passes through the orifice, differential pressure is generated at port A and port B. This differential
pressure actuates the differential pressure sensing valve (1G) and produces hydraulic force F.
• Because of the hydraulic force F, the differential pressure sensing valve (1G) is moved > direction. That causes a change
in spring (1D) load. In port C, the AS valve output pressure that is balanced with spring (1C) and (1D) load is generated
by reducing charge pressure from port G. So the AS valve output pressure corresponds with charge flow that changes with
engine (5) revolution.
SK1026-5N 10-331
STRUCTURE, FUNCTION AND
ANTI ENGINE-STALL VALVE (AS VALVE) MAINTENANCE STANDARD
Maintenance Standards
Criteria
38.1 mm 30 mm 52 N 41.1 N
1. Spring -
(1.50 in) (1.18 in) (11.7 lbf) (9.2 lbf)
Torque Values
10-341 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
CONTROL VALVES
Standard 3-Spool Valve Port Location
SK1026-5N 10-351
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
10-361 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
SK1026-5N 10-371
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
10-381 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
SK1026-5N 10-391
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
10-401 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
1. Pressure compensation valve F (lift arm) 12. Pressure compensation valve R (bucket)
2. Spool (lift arm) 13. Shuttle valve
3. Stop plug 14. Pressure compensation valve F (attachment)
4. Float valve 15. Spool (attachment)
5. On-Off solenoid 16. Stop plug for individual relief valve
6. Spool (float) 17. Pressure compensation valve R (attachment)
7. Pressure compensation valve F (lift arm) 18. Pressure compensation valve F (High-Flow)
8. Shuttle valve 19. Spool (High-Flow)
9. Pressure compensation valve R (bucket) 20. Pressure compensation valve R (High-Flow)
10. Spool (bucket) 21. Check valve (High-Flow joining circuit)
11. Suction valve 22. Spool (High-Flow joining)
SK1026-5N 10-411
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
Maintenance Standards
Standard 3-spool
10-421 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
Torque Values
SK1026-5N 10-431
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
10-441 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
Criteria
Torque Value
SK1026-5N 10-451
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
10-461 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
Criteria
Torque Value
SK1026-5N 10-471
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
10-481 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
Torque Values
SK1026-5N 10-491
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
10-501 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
Criteria
Torque Value
SK1026-5N 10-511
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
10-521 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVES
Criteria
Torque Value
SK1026-5N 10-531
STRUCTURE, FUNCTION AND
CONTROL VALVES MAINTENANCE STANDARD
Criteria
Torque Values
10-541 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLOSED CENTER LOAD SENSING SYSTEM
• CLSS stands for Closed center Load Sensing System, and has the followings characteristics.
A. Control ability, not influenced by load.
SK1026-5N 10-551
STRUCTURE, FUNCTION AND
CLOSED CENTER LOAD SENSING SYSTEM MAINTENANCE STANDARD
Features
• The small capacity gear pump provides high flow movement because lift arm and the bucket circuit are connected in a
series circuit.
• The control valve has built in self leveling function.
• If loading pressure on the bucket goes beyond a certain value, the lift arm and the bucket circuits automatically change to
a parallel circuit to provide a strong digging force.
• The lift arm, attachment and High-flow section are connected in a parallel circuit and are provided with a pressure
compensational function in each section.
• During individual operations, attachment High-flow keeps individual demand flow rate normal. However during
compound operations, they are divided in a proportion of 1 to 9 flow rate.
10-561 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLOSED CENTER LOAD SENSING SYSTEM
Function
• Return flow rate from the lift arm is recirculated to the bucket.
Operation
When (lift arm raise) and (bucket dump) are operated at the same time.
• The lift arm spool (1) is at full stroke and bucket spool (2) is at half stroke.
• When this happens, notch (a) does not open, so all flow from pump supplies to the lift arm raise.
• The lift arm and bucket PPC pressure are sent through passages E and F. Then the leveling circulating valve (3) and the
combination circulating valve (4) are at full stroke.
• Return flow rate from the lift arm cylinder passes through passage A. Then it is divided and sent to passage B and C, by
the leveling circulating valve (4) and combination circulating valve (3).
• When this happens, flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passages B and C in
proportion to the area of opening of notch (b) and (c) as expressed below.
★ Q1:Q2= (notch (b) + notch (d)): notch (C)
★ Q1= flow rate flows to B, Q2= flow rate flows to C
• Q1 passes through check valve (6) and then supplies the bucket cylinder.
SK1026-5N 10-571
STRUCTURE, FUNCTION AND
CLOSED CENTER LOAD SENSING SYSTEM MAINTENANCE STANDARD
Function
When the only lever of the lift arm raise is operated, the lift arm raise and the bucket dump are worked. When this happens, the
work equipment can raise with constant bucket bottom angle. (Only the lift arm raise.)
Operation
10-581 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLOSED CENTER LOAD SENSING SYSTEM
Function
SK1026-5N 10-591
STRUCTURE, FUNCTION AND
CLOSED CENTER LOAD SENSING SYSTEM MAINTENANCE STANDARD
Operation
When the (lift arm raise) and (bucket digging) are operated at the same time.
• Lift arm spool (1) and bucket spool (2) are at full stroke.
• When this happens, the bucket digging PPC pressure is sent through passage H. Then the combination circulating valve
(3) fully strokes to the right and the lift arm raise PPC pressure is sent through passage E. Then the leveling circulating
valve (4) is at full stroke to the left.
• Return flow rate from the lift arm cylinder passes through passage A. Then it is divided and sent to passage B and C, by
the leveling circulating valve (4) and the combination circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passages B and C in
proportion to the area of opening as below expression.
★ Q1:Q2= (notch (b) + notch (d)): notch (C)
★ Q1= flow rate flows to B Q2=flow rate flows to C
• If the bucket load goes beyond a certain load, the series-parallel switching valve (7) strokes to the right. Then it passes
thorough passage G by opening notch (e). And then the spring chamber of flow divider (5) is connected to tank.
• As a result, flow divider strokes fully to the right, and P2=T Return flow rate from the lift arm is connected with tank
totally, and Q1=0L/min.
• When this happens, notch (f) of the lift arm spool and notch (a) of the bucket spool open, so the lift arm and the bucket
become parallel circuit (CLSS). And flow rate of the lift arm raise (Q3) and then bucket digging flow rate are divided as
below expression. Q3:Q4= notch (f): notch (a)
10-601 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLOSED CENTER LOAD SENSING SYSTEM
Function
During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to increase,
compensation is received. (When this happens, the other actuator being used for compound operation (right side) is at a higher
load than the actuator on this side (left side).
Operation
• If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in actuator
circuit A on this side (left side) tries to increase.
• If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, and reducing valve (1) and flow
control valve (2) are pushed to the left in the direction of the arrow ➮.
• Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA, and pressure loss
is generated between PP and PPA.
• Flow control valve (2) and reducing valve (1) are balanced in position where the difference in pressure between PLS and
PA acting on both ends of reducing valve (2) and the pressure loss between PP and PPA on both sides of flow control
valve (2) are the same.
• In this way, the pressure difference between upstream pressure PPA and down stream pressure PA of both spools used
during compound operations is the same, so the pump flow is divided in proportion to the area of opening of notch (a) of
each spool.
SK1026-5N 10-611
STRUCTURE, FUNCTION AND
CLOSED CENTER LOAD SENSING SYSTEM MAINTENANCE STANDARD
Dividing Function
Operation
10-621 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
12
SOLENOID VALVE
Function
SK1026-5N 10-631
STRUCTURE, FUNCTION AND
SOLENOID VALVE MAINTENANCE STANDARD
10-641 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
Technical Data
Servo control
• Nominal volume: 0.35 liters (21.4 in3)
• Pre-loading: 8.2 kg/cm2 (116 psi)
• Working pressure: 25.5 - 27.5 kg/cm2 (363 - 391 psi)
Function
An elastic rubber bag (1) containing nitrogen is fitted inside the accumulator to maintain oil pressure in the circuit to which the
accumulator is connected.
Operation
• When the engine is running chamber A bag (1) (containing nitrogen) is compressed by oil under pressure coming from
line B.
• If the oil under line B falls below the maximum calibration pressure (even after intensive use), the rubber bag (1) will
expand due to pressure from the nitrogen.
SK1026-5N 10-651
STRUCTURE, FUNCTION AND
ACCUMULATOR MAINTENANCE STANDARD
MEMORANDUM
10-661 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PARTERN CHANGE VALVE
P in 1. - From L.H. PPC valve (P4 port) P out 1. - To hydraulic pump (DA1 port)
P in 2. - From L.H. PPC valve (P1 port) P out 2. - To hydraulic pump (DA2 port)
P in 3. - From L.H. PPC valve (P3 port) P out 3. - To hydraulic pump (DB1 port)
P in 4. - From L.H. PPC valve (P2 port) P out 4. - To hydraulic pump (DB2 port)
P in 5. - From R.H. PPC valve (P1 port) P out 5. - To control valve (PA1 port)
P in 6. - From R.H. PPC valve (P2 port) P out 6. - To control valve (PB1 port)
SK1026-5N 10-671
STRUCTURE, FUNCTION AND
PARTERN CHANGE VALVE MAINTENANCE STANDARD
10-681 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PARTERN CHANGE VALVE
1. Lever
2. Rotor
3. Valve seat
4. Ball
5. Upper cover
6. Lower cover
7. Pin lock
SK1026-5N 10-691
STRUCTURE, FUNCTION AND
PARTERN CHANGE VALVE MAINTENANCE STANDARD
Pattern Optional
10-701 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PARTERN CHANGE VALVE
Maintenance Standards
Torque Values
SK1026-5N 10-711
STRUCTURE, FUNCTION AND
R.H. PPC VALVE (STANDARD) MAINTENANCE STANDARD
10-721 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD R.H. PPC VALVE (STANDARD)
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body
SK1026-5N 10-731
STRUCTURE, FUNCTION AND
R.H. PPC VALVE (STANDARD) MAINTENANCE STANDARD
Function
1. Neutral
Ports P1 and P2 of the PPC valve are connected to drain chamber D
through fine control hole f in spool (Fig. 1)
10-741 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD R.H. PPC VALVE (STANDARD)
MEMORANDUM
SK1026-5N 10-751
STRUCTURE, FUNCTION AND
R.H. PPC VALVE (STANDARD) MAINTENANCE STANDARD
Maintenance Standards
10-761 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD R.H. PPC VALVE (STANDARD)
Criteria
Torque Values
SK1026-5N 10-771
STRUCTURE, FUNCTION AND
R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL) MAINTENANCE STANDARD
10-781 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body
SK1026-5N 10-791
STRUCTURE, FUNCTION AND
R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL) MAINTENANCE STANDARD
Function
1. Neutral
Ports P1 and P2 of the PPC valve are connected to drain chamber D
through fine control hole f in spool (Fig. 1).
10-801 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD L.H. PPC VALVE (STANDARD)
SK1026-5N 10-811
STRUCTURE, FUNCTION AND
L.H. PPC VALVE (STANDARD) MAINTENANCE STANDARD
1. Spool 8. Cover
2. Metering spring 9. Stopper
3. Centering spring 10. Body
4. Piston 11. Plug
5. Disc 12. Ball
6. Nut 13. Seat
7. Joint 14. Body (for shuttle valve)
10-821 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD L.H. PPC VALVE (STANDARD)
Function
1. Neutral
Ports P1 and P2 of the PPC valve are connected to drain chamber D
through fine control hole f in spool (Fig. 1).
SK1026-5N 10-831
STRUCTURE, FUNCTION AND
L.H. PPC VALVE (STANDARD) MAINTENANCE STANDARD
Maintenance Standards
10-841 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD L.H. PPC VALVE (STANDARD)
Criteria
Torque Values
SK1026-5N 10-851
STRUCTURE, FUNCTION AND
L.H. PPC VALVE (PATTERN CHANGE) MAINTENANCE STANDARD
10-861 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD L.H. PPC VALVE (PATTERN CHANGE)
Pattern Change
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body
SK1026-5N 10-871
STRUCTURE, FUNCTION AND
L.H. PPC VALVE (PATTERN CHANGE) MAINTENANCE STANDARD
Function
1. Neutral
Ports P1 and P2 of the PPC valve are connected to drain chamber D
through fine control hole f in spool (Fig. 1).
10-881 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD L.H. PPC VALVE (PATTERN CHANGE)
MEMORANDUM
SK1026-5N 10-891
STRUCTURE, FUNCTION AND
L.H. PPC VALVE (PATTERN CHANGE) MAINTENANCE STANDARD
Maintenance Standards
10-901 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD L.H. PPC VALVE (PATTERN CHANGE)
Criteria
Torque Values
SK1026-5N 10-911
STRUCTURE, FUNCTION AND
CYLINDERS MAINTENANCE STANDARD
CYLINDERS
Boom
Bucket
Unit: mm (in)
Cylinder Rod Piston Stroke Cylinder length Max. Cylinder length Min. Key size
Boom 40 (1.6) 65 (2.5) 690 (27.2) 1634 (64.3) 944 (37.2) 41 (1.6)
Bucket 35 (1.4) 65 (2.5) 423 (16.6) 1110 (43.7) 687 (27.0) 41 (1.6)
10-921 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CYLINDERS
MEMORANDUM
SK1026-5N 10-931
STRUCTURE, FUNCTION AND
CYLINDERS MAINTENANCE STANDARD
Maintenance Standards
Criteria
-0.025 mm +0.105 mm
Lifting 40 mm -0.064 mm +0.135 mm 0.130 - 0.199 mm 1.0 mm
Tolerance bucket (1.58 in) (-0.001 in) (+0.004 in) (0.005 - 0.008 in) (0.039 in)
between (-0.003 in) (+0.005 in)
1. bushing and
piston rod -0.01 mm +0.072 mm
mounting pin Tilting 35 mm -0.05 mm +0.134 mm 0.082 - 0.184 mm 1.0 mm
bucket (1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
(-0.0020 in) (+0.005 in) Replace
-0.025 mm +0.105 mm bushing
Lifting 40 mm -0.064 mm +0.135 mm 0.130 - 0.199 mm 1.0 mm
Tolerance bucket (1.58 in) (-0.001 in) (+0.004 in) (0.005 - 0.008 in) (0.039 in)
between (-0.003 in) (+0.005 in)
2. bushing and
cylinder -0.01 mm +0.072 mm
mounting pin Tilting 35 mm -0.05 mm +0.134 mm 0.082 - 0.184 mm 1.0 mm
bucket (1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
(-0.0020 in) (+0.005 in)
-0.025 mm +0 mm
Lifting 40 mm -0.087 mm +0.039 mm 0.025 - 0.126 mm 0.426 mm
bucket (1.58 in) (-0.001 in) (+0 in) (0.001 - 0.005 in) (0.017 in)
Tolerance (-0.003 in) (+0.002 in)
between piston Replace
3.
rod and head
cylinder head -0.025 mm +0 mm
Tilting 35 mm -0.087 mm +0.039 mm 0.025 - 0.126 mm 0.426 mm
bucket (1.38 in) (-0.001 in) (+0 in) (0.001 - 0.005 in) (0.017 in)
(-0.003 in) (+0.002 in)
10-941 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CYLINDERS
Torque Values
SK1026-5N 10-951
STRUCTURE, FUNCTION AND
WORKING EQUIPMENT MAINTENANCE STANDARD
WORKING EQUIPMENT
Maintenance Standards
10-961 SK1026-5N
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORKING EQUIPMENT
Criteria
-0.012 mm +0.012 mm
Clearance between bushing 45 mm -0.065 mm +0.056 mm 0.024 - 0.121 mm 1.0 mm
1.
and mounting pin of lift lever (1.77 in) (-0.0005 in) (+0.0005 in) (0.001 - 0.005 in) (0.039 in)
(-0.0030 in) (+0.0022 in)
-0.01 mm +0.072 mm
Clearance between bushing 35 mm -0.05 mm +0.134 mm 0.082 - 0.184 mm 1.0 mm
2. and mounting pin of work
equipment support frame (1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
(-0.0020 in) (+0.005 in)
-0.012 mm +0.012 mm
Clearance between bushing 45 mm -0.065 mm +0.056 mm 0.024 - 0.121 mm 1.0 mm
3. and mounting pin of fulcrum
lever (1.77 in) (-0.0005 in) (+0.0005 in) (0.001 - 0.005 in) (0.039 in)
(-0.0030 in) (+0.0022 in)
-0.012 mm +0.012 mm
Clearance between bushing 45 mm -0.065 mm +0.056 mm 0.024 - 0.121 mm 1.0 mm
4. and mounting pin of lift lever (1.77 in) (-0.0005 in) (+0.0005 in) (0.001 - 0.005 in) (0.039 in)
(-0.0030 in) (+0.0022 in)
-0.012 mm +0.012 mm
Clearance between bushing 45 mm -0.065 mm +0.056 mm 0.024 - 0.121 mm 1.0 mm Replace
5. and mounting pin of fulcrum
lever (1.77 in) (-0.0005 in) (+0.0005 in) (0.001 - 0.005 in) (0.039 in) bushing
(-0.0030 in) (+0.0022 in)
-0.01 mm +0.072 mm
Clearance between bushing
35 mm -0.05 mm +0.134 mm 0.082 - 0.184 mm 1.0 mm
6. and mounting pin bucket cyl-
(1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
inder (bottom side)
(-0.0020 in) (+0.005 in)
-0.01 mm +0.072 mm
Clearance between bushing 35 mm -0.05 mm +0.134 mm 0.082 - 0.184 mm 1.0 mm
7. and mounting pin bucket
cylinder (head side) (1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
(-0.0020 in) (+0.005 in)
-0.025 mm +0.105 mm
Clearance between bushing 40 mm -0.064 mm +0.135 mm 0.130 - 0.199 mm 1.0 mm
8. and mounting pin lift cylinder
(head side) (1.58 in) (-0.001 in) (+0.004 in) (0.005 - 0.008 in) (0.039 in)
(-0.003 in) (+0.005 in)
-0.025 mm +0.105 mm
Clearance between bushing 40 mm -0.064 mm +0.135 mm 0.130 - 0.199 mm 1.0 mm
9. and mounting pin lift cylinder
(bottom side) (1.58 in) (-0.001 in) (+0.004 in) (0.005 - 0.008 in) (0.039 in)
(-0.003 in) (+0.005 in)
SK1026-5N 10-971
STRUCTURE, FUNCTION AND
WORKING EQUIPMENT MAINTENANCE STANDARD
MEMORANDUM
10-981 SK1026-5N
20 STANDARD VALUE TABLES
SK1026-5N 20-1
STANDARD VALUE TABLES STANDARD SERVICE VALUE TABLE
1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and
is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as
a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various
tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level
ground, insert the safety pins, and use blocks to prevent the machine from moving.
WARNING! When carrying out work together with other workers, always use signals and do not let
unauthorized people near the machine.
WARNING! When checking the coolant level, always wait for the coolant to cool down. If the radiator
cap is removed when the coolant is still hot, the coolant will spurt out and cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
WARNING! Be careful the hydraulic tank on this machine is pressurized, always relieve tank
pressure before removing any hydraulic components.
20-2 SK1026-5N
STANDARD VALUE TABLES STANDARD SERVICE VALUE TABLE
SK1026-5N 20-3
STANDARD VALUE TABLES STANDARD SERVICE VALUE TABLE
Chassis
Machine model SK1020-5N and SK1020-5NA
L.H. travel • Instrument coupling at center of control lever 2.0 (70.5) 1.8-2.2 (63-78)
knob
Raise arm • Instrument coupling on outside edge (for control 1.8 (63) 1.5-2.1 (53-74)
Lower arm pedal) 1.8 (63) 1.5-2.1 (53-74)
Dump bucket 1.8 (63) 1.5-2.1 (53-74)
Curl bucket back 1.8 (63) 1.5-2.1 (53-74)
Attachment pedal Right 5.0 (176) 4.0-6.0 (141-212)
20-4 SK1026-5N
STANDARD VALUE TABLES STANDARD SERVICE VALUE TABLE
Rasing
cylinder
(Retraction) Max 15 Max. 25
Front bucket
(0.59) (0.98)
mm
(in)
SK1026-5N 20-5
STANDARD VALUE TABLES STANDARD SERVICE VALUE TABLE
★ Arm
Raise Raise
Lower Lower
Cylinder fully • Engine speed: Maximum
extended 3.8 3.42 - 4.18
• Oil temperature: 45-55°C (113-131°F)
Standard
retracted
• Engine speed: Maximum 2.2 1.98 - 2.42
• Oil temperature: 45-55°C (113-131°F)
★ Arm
Raise Raise
Lower Lower
Pattern change version
Cylinder fully
extended 3.3 2.97 - 3.63
• Engine speed: Maximum
• Oil temperature: 45-55°C (113-131°F)
sec.
• Average Value in 3 tests
20-6 SK1026-5N
STANDARD VALUE TABLES STANDARD SERVICE VALUE TABLE
72 68 - 76
Wheel rotation
(without load) rpm With With increment
increment
Normal Normal
increment
Max. 250
Max. 250
(Max. 9.8) (Max. 9.8)
Travel deviation mm
(in)
Value with speed
Value with
increment
★ This surface must be firn and horizontal speed
• Engine speed: Maximum increment
• Oil temperature: 45-55°C (113-131°F) Max.250 Max.250
(Max. 9.8)
• Wheel pressure: Min 2.8 bar (41 psi) (Max. 9.8)
• Travel 20 meters (21 yards) on flat ground and
then check the deviation
• Check all direction
SK1026-5N 20-7
STANDARD VALUE TABLES STANDARD SERVICE VALUE TABLE
MEMORANDUM
20-8 SK1026-5N
30 TESTING AND ADJUSTING
SK1026-5N 30-1
TESTING AND ADJUSTING SPECIAL TOOLS
SPECIAL TOOLS
Check or
Symbol Part number Part Name Qty Remarks
measurement item
Commercially
1 Multi-scale tachometer 1 20 to 4000 rpm
available
Engine speed A
Commercially
2 Stroboscope tachometer 1 6 to 30000 rpm
available
Commercially
Valve clearance B 1 Feeler gauge 1
available
Commercially
1 Pressure adapter 1 Thread 1/8 in.
available
Engine oil pressure D
Commercially Scale 10.2 KG/CM2
2 Pressure gauge 1
available (145 psi)
Commercially
5 Pressure adapter 1 Thread M10
available
30-2 SK1026-5N
TESTING AND ADJUSTING T-ADAPTER PROCEDURES AND KITS
12
T-ADAPTER PROCEDURES AND KITS
★ For machines equipped with the weather sealing connectors these procedures must be followed in order to prevent
damage to the connector then testing a circuit for an open or a short.
★ The following KOMATSU Harness Checker Kits are available
1. For testing circuits the T-adapters listed for the circuit should be
used.
Remark
For testing the RC connectors, a Bosch Rexroth MA-RC1-1/10
must be used.
SK1026-5N 30-3
TESTING AND ADJUSTING ENGINE COMPONENTS
ENGINE COMPONENTS
Remark
To tune, test and troubleshoot the following procedures you must refer to ENGINE SHOP MANUAL for tools and
proper procedures.
30-4 SK1026-5N
TESTING AND ADJUSTING ENGINE COMPONENTS
★ Check the engine speed after the following conditions have been
reached:
• Temperature of engine cooling water: 68 - 80°C (154 - 176°F).
• Oil temperature: 45 - 55°C (113 - 131°F).
1. Mount and connect the tachometer A1.
★ If the stroboscopic tachometer A2 is used, remove plug (1).
SK1026-5N 30-5
TESTING AND ADJUSTING ENGINE COMPONENTS
E. Operate on rocker (5) adjustment screw (4) for seat the block
on inner valve.
★ Check that the valve cap is lying flat on the valve stem and
that there is no lop-sided wear.
2. Adjustment
A. Turn the drive shaft in the normal direction of rotation until the
line (1) marked as no. 1 on the flywheel is in alignment with
the reference notch (2) on the flywheel housing.
★ If the cylinder is in a compression stroke, the valves do not
move when the drive shaft is rotated slightly. If the valves
do move, rotate the drive shaft by one turn and realign the
reference marks (1) and (2).
30-6 SK1026-5N
TESTING AND ADJUSTING ENGINE COMPONENTS
B. Loosen the lock nut (3) and unscrew the adjustment screw (4)
by approximately 1 turn.
C. Insert feeler gauge B1 between rocker (6) and valve cap (5).
Rotate adjusting screw (4) until it rubs against feeler gauge B1.
Secure this position with nut (3).
★ After locking nut (3), check the valve clearance again.
D. Adjust clearance between valve and rockers to the following
values:
E. After adjusting the No. 1 cylinder, rotate drive shaft 180° each
time and adjust the valve clearance of the other cylinders
according to the ignition sequence.
★ Ignition sequence: 1 - 3 - 4 - 2.
SK1026-5N 30-7
TESTING AND ADJUSTING ENGINE COMPONENTS
★ Test conditions:
• Engine: at working temperature.
• Oil temperature: 45 - 55°C (113 - 131°F).
• Battery: fully charged.
• Valve clearance: adjusted (see “Adjustment of Valve Clearance” on page 30-6).
1. Remove the air intake filter.
2. Remove the valve cover.
3. Disconnect the connector (1) of the engine-stopping solenoid and
close the fuel cock (2).
4. Turn the engine over a few times, using the starting motor.
5. Mount the adapter C2 and connect the test pressure gauge C1.
★ Check that the seal is mounted in the adapter, and that it is
undamaged.
6. Turn the engine using the starting motor and read the compression
value.
★ Read the compression value when the pressure gauge has
stabilised.
★ While reading the compression, also check the engine rpm
using tachometer A1 or A2. If the speed does not correspond
with the control value, check it against the diagram.
7. After the reading, re-assemble valve cover, the air intake pipe and
the connector (1).
Nut that secures the nozzle: 7.84 ±0.98 N•m (69 ±9 lbf in)
30-8 SK1026-5N
TESTING AND ADJUSTING ENGINE COMPONENTS
SK1026-5N 30-9
TESTING AND ADJUSTING ENGINE COMPONENTS
3. Take off clamp (3) and disconnect all fuel delivery pipes (4) from
the injection pump.
4. Rotate the flywheel slowly in a counter-clockwise direction (seen
from the flywheel side), carefully checking the level of fuel in the
No. 1 union of the injection pump. Stop the rotation when the fuel
level starts to rise.
5. Check the position of the notches at 15° and 10° that appear in the
hole in the casing and, in function of the position, establish the true
fuel injection timing.
★ In order to determine the degrees of intermediate fuel injection
timing, sub-divide the space between 10° and 15°.
30-10 SK1026-5N
TESTING AND ADJUSTING ENGINE COMPONENTS
6. Rotate injection pump (5) towards the outside or towards the motor,
after having loosened pump (6) retaining nuts and screw (7).
• To BRING FORWARD the injection, rotate pump (4) towards
the outside.
• To DELAY the injection rotate pump (4) towards the cylinder
block.
★ Check the extent of movement on scale (8).
7. Lock the nuts (6) that fasten the pump to its block.
★ After adjustment of the fuel injection timing.
8. Connect fuel delivery pipes (5) to the pump and replace clamp (3).
9. Bleed any air from the fuel circuit.
SK1026-5N 30-11
TESTING AND ADJUSTING ENGINE COMPONENTS
30-12 SK1026-5N
TESTING AND ADJUSTING ENGINE COMPONENTS
4. Use nuts (7) and (8) to reset the position of injection pump lever (5)
to approx. 0.5 mm (0.020 in.) from high idle adjustment screw (6).
5. Bring the accelerator command lever back to the low idle position
and check that retainer (3) has sufficient clearance.
6. Repeat this same procedure for the accelerator pedal cable.
SK1026-5N 30-13
TESTING AND ADJUSTING ADJUSTING PPC VALVE PRESSURES
3. Loosen screw (4), remove washer (5) and pull out the complete handle
(6).
6. Loosen 4 retaining screws (11) from plate (12) and remove the plate.
30-14 SK1026-5N
TESTING AND ADJUSTING ADJUSTING PPC VALVE PRESSURES
7. Remove stopper (13) and the seals.
★ Use a soft tool to remove.
8. Remove the complete spool (14).
9. Remove retainer (15), spring (16) and shims (17) from the spool (14).
Assembly
★ Add shims until you reach calibration value; bear in mind that 0.3 mm
(0.012 in.) thickness corresponds to a variation in pressure of about
0.6 bar (9 psi).
★ To assemble, perform the disassembly procedure in the reverse order.
★ Thoroughly clean all parts.
★ Press down on stoppers (13) to ease setting into place; tighten retainer plate (8) until it is properly seated and adjust the
clearance. (For details, see “Adjusting PPC Valve” on page 30-16).
SK1026-5N 30-15
TESTING AND ADJUSTING ADJUSTING PPC VALVE PRESSURES
★ The clearance on the PPC valve (hand and foot) levers are adjusted as follows:
1. Slowly loosen the oil-tank cap to eliminate any residual pressure.
2. Remove cap (1).
3. Loosen nut (2) that retains disc (3).
4. Tighten disc (3) until it makes light contact with four push-rods (4).
★ During this adjustment, take care not to activate any of the
push-rods (4) individually.
5. Secure this position by tightening retaining nut (2) to the specific
torque.
30-16 SK1026-5N
TESTING AND ADJUSTING ADJUSTING SERVO-CONTROL SAFETY
1. Lower the LH safety bar (1) and adjust the position of sensor (2) by
loosening then tightening adjustment nuts (3).
SK1026-5N 30-17
TESTING AND ADJUSTING CHAIN TENSION
CHAIN TENSION
Test
★ Test conditions:
• Machine: Raised from the ground and level
• Work equipment: In road-driving position
★ Check all the wheels.
1. Position an appropriate indicator and check the wheel rotation
diameter at 600 mm (23.62 in). Make a notch “A” close to the
indicator.
2. Rotate the tire by hand in both directions and check the total
displacement of the notch. See if it remains within the permissible
limits.
★ Standard displacement: 4 mm (0.16 in)
★ Permissible displacement: 2-6 mm (0.08 - 0.24 in)
Adjustment
★ For greater clarity, the illustration shows the adjustment operations
with the tires removed. It is not necessary to remove the tires for
this adjustment.
1. Adjust screw “A” (M10 x 50, fully threaded) in until it makes
contact with the wheel hub.
2. Loosen retaining screws (1) on the wheel hub until it can move.
3. Gradually tighten screw “A” until correct tension has been restored
to the chain.
4. Tighten nuts (1).
30-18 SK1026-5N
TESTING AND ADJUSTING HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
WARNING! Before removing the plugs, release residual pressures in the circuits (for details see
“RELEAVING HYDRAULIC PRESSURE” on page 30-30) and place safety engagement
levers into their locked positions.
After having connected the pressure gauges, pressurize the tank.
★ Test conditions
• Engine: At working temperature.
• MIN and MAX. engine speeds: Within permissible limits.
• Oil temperature: 45°C - 55°C (113°F - 131°F)
Command Ports
Arm (Lower - Raise) A1 - B1
Bucket (Dump - Curled) A2 - B2
Equipment (R.H. - L.H.) A3 - B3
SK1026-5N 30-19
TESTING AND ADJUSTING HYDRAULIC PUMP
HYDRAULIC PUMP
Checking Working Pressure of Travel HST Charge Valve
★ Test conditions:
• Engine: High idle
• Hydraulic Oil temperature: 45-55°C (113-131°F)
• Safety bar: Raised
1. Remove plugs (1) and (2) and install the two pressure adapters E5.
2. Connect pressure gauges E1 61.2 kg/cm2 (870 psi), start the engine
and accelerate to high idle.
3. Check to see if the pressure is within permissible limits.
• Use the lower of the two pressure values taken.
• Normal pressure: 25.5 - 29.6 kg/cm2 (363-421 psi)
4. Remove the pressure adapters and install the plugs (1) and (2).
30-20 SK1026-5N
TESTING AND ADJUSTING HYDRAULIC PUMP
12
MEMORANDUM
SK1026-5N 30-21
TESTING AND ADJUSTING CALIBRATING VALVE
12
CALIBRATING VALVE
HST Valve Calibration
1. Loosen nut (1), be careful not to move adjustment screw (2).
2. Adjust the working pressure of the HST valve as follows:
• To INCREASE pressure, turn screw (2) in a
CLOCKWISE direction.
• To REDUCE pressure, turn screw (2) in a
COUNTER-CLOCKWISE direction.
AS Valve Calibration
Pressure Adjustment Made at Low Idle
1. Loosen nut (1), and adjust the working pressure of the AS valve
(with the engine at low idle), proceed as follows:
• To INCREASE pressure, turn screw (2) in a
CLOCKWISE direction.
• To REDUCE pressure, turn screw (2) in a
COUNTER-CLOCKWISE direction.
★ One complete turn of screw (2) varies the pressure by
3.44 kg/cm2 (49 psi)
2. Tighten nut (1) and check to be sure the working pressure remains
within permissible limits.
30-22 SK1026-5N
TESTING AND ADJUSTING CALIBRATING VALVE
Pressure Adjustment At Working Pressure
1. Loosen nut (3),. and adjust the working pressure of the AS valve
(with the engine at working pressure), proceeding as follows:
• To INCREASE pressure, turn screw (4) in a
CLOCKWISE direction.
• To REDUCE pressure, turn screw (4) in a
COUNTER-CLOCKWISE direction.
★ One complete turn of screw (4) varies the pressure by
2.0 kg/cm2 (28.4 psi).
2. Tighten nut (3) and check to see if the working pressure remains
within permissible limits.
SK1026-5N 30-23
TESTING AND ADJUSTING CALIBRATING VALVE
30-24 SK1026-5N
TESTING AND ADJUSTING CALIBRATING VALVE
Adjusting the Deviation
1. Select the adjustment screw to be re-set:
SK1026-5N 30-25
TESTING AND ADJUSTING CONTROL VALVE
CONTROL VALVE
Special Tools
Commercially
1 Pressure gauge 2 Scale 61.2 kg/cm2 (870 psi)
available
Commercially
5 Pressure adapter 1 Thread M10
available
1. Operating Pressure (Unloading Valve)
A. Remove plug (1) and install a pressure adapter.
B. Connect pressure gauge E3, 10.2 kg/cm2 (145 psi).
C. Start the engine and bring it up to a high idle with all levers in
neutral position.
D. Check the pressure.
★ Normal pressure: 4.9 kg/cm2 (70 psi)
★ Take care do not operate the equipment levers.
★ The unloading valve cannot be re-adjusted. If the pressure
differs from the normal value, the valve must be replaced.
30-26 SK1026-5N
TESTING AND ADJUSTING CONTROL VALVE
Valve Adjustment
★ The unloading valve cannot be re-adjusted, only replaced.
Adjustment Of Main Relief Valve
1. If the pressures measured for the working equipment and machine
travel do not fall within normal values, adjust the main relief valve
(1) as follows:
★ Loosen lock nut (2) and rotate the adjusting screw (3).
• To INCREASE pressure, turn in a CLOCKWISE
direction.
• To DECREASE pressure, turn in a
COUNTERCLOCKWISE direction.
★ Each turn of the adjusting screw (3) varies the pressure by
about 56.1 kg/cm2 (798 psi).
2. Lock the nut (2).
SK1026-5N 30-27
TESTING AND ADJUSTING SERVO-CONTROL POWER SUPPLY
★ Test conditions:
• Engine: At working temperature.
• Oil temperature: 45-55°C (113-131°F)
Action involved
Action
A1 A2 B1 B2
FORWARD ❍ ❍
REVERSE ❍ ❍
RIGHT ❍ ❍
LEFT ❍ ❍
30-28 SK1026-5N
TESTING AND ADJUSTING SERVO-CONTROL POWER SUPPLY
Parking Brake System Pressure Check
1. Disconnect the brake control hose (1); connect a “T” fitting and a
pressure tap and reconnect the hose.
2. Connect pressure gauge E1, 61.2 kg/cm2 (870 psi).
3. Lower the cab and sit down in the drivers seat.
4. Start the engine and bring it up to operating speed (2500 rpm) with
all the levers in neutral position.
5. Lower the safety bars; operate the parking brake control and check
the pressure.
★ Parking brake pressure:
• Normal: Minimum 25.5 kg/cm2 (363 psi)
• Minimum: 25.5 kg/cm2 (363 psi)
SK1026-5N 30-29
TESTING AND ADJUSTING RELEAVING HYDRAULIC PRESSURE
Elimination of Pressure
1. This operation should be performed every time the hydraulic tank
cap is removed for installation of equipment or hydraulic lines are
removed.
2. Start the engine and position the machine as in the figure.
3. Stop the engine, loosen the tank cap (1) and then close it again.
★ This operation lets air into the tank when the level of the
remaining oil is at minimum.
4. Start the engine and lower the working equipment to the ground.
30-30 SK1026-5N
TESTING AND ADJUSTING BLEEDING HYDRAULIC CIRCUITS
SK1026-5N 30-31
TESTING AND ADJUSTING BLEEDING HYDRAULIC CIRCUITS
MEMORANDUM
30-32 SK1026-5N
40 TROUBLESHOOTING
SK1026-5N 40-1
TROUBLESHOOTING
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60
Installing Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61
Purging Air from Service Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-62
Adding Refrigerant to the System (Without a Charging Station) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-63
Stabilizing the AC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-63
Adding Refrigerant and Stabilizing the System (With a Recovery/Recycling Station) . . . . . . . . . . . . . . . . . 40-64
Recovering and Recycling the Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
Performing the Recovery Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
Performing the Recycling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-65
Evacuating and Charging the AC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-65
System Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66
System Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
Electronic Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
Tracer Dyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
Soap and Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Hoses and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-69
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-69
Checking Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-69
Evacuating The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70
Troubleshooting - Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
Pre-Diagnosis Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
Preparing for Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
System Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
Diagnosis of Gauge Readings and System Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-73
Troubleshooting by Manifold Gauge Set Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-74
Preventive Maintenance Schedule for A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80
40-2 SK1026-5N
TROUBLESHOOTING
MEMORANDUM
SK1026-5N 40-3
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.
WARNING! When performing the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
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 perform repairs swiftly, and to prevent reoccurrence
of the failure.
When performing troubleshooting, an important point is to understand the structure and function of the machine. 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 performing troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
• It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when performing troubleshooting, it is necessary to perform thorough prior
investigation and to perform troubleshooting in accordance with the fixed procedure.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
40-4 SK1026-5N
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
3. Check before troubleshooting.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not perform any investigation or
measurement that may make the problem worse.
5. Troubleshooting.
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
SK1026-5N 40-5
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLE-
40-6 SK1026-5N
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
SK1026-5N 40-7
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
C. Disconnections in wiring.
If the wiring is held and tugged 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
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.
40-8 SK1026-5N
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
D. High pressure water entering a connector.
The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter the connector
depending on the direction of the water jet.
The connector is designed to prevent water from entering, but
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.
SK1026-5N 40-9
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
3. Removing, installing, and drying connectors and wiring harnesses.
A. Disconnecting connectors.
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up
and down, the housing may break.
40-10 SK1026-5N
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
B. Connecting connectors.
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.
SK1026-5N 40-11
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
D. Drying wiring harness.
If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:
40-12 SK1026-5N
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
6. Do not place the control box on oil, water, or soil, or in any hot
place, even for a short time.
★ Place it on a suitable dry stand.
SK1026-5N 40-13
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
2. Before performing troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3. Always connect any disconnected connectors before going on to the next step.
★ If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When performing troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.
40-14 SK1026-5N
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
SK1026-5N 40-15
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but 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 equipment, 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, perform oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3µ) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.
40-16 SK1026-5N
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
Air charge or
11. Check tire inflation pressure and damage -
replace
Before Starting Checking Item
Tightening torque
12. Check loosening of hub nut (See DISASSENBLY AND Tighten
ASSEMBLY)
13. Check effect of foot brake - Adjust
14. Check effect of parking brake - Adjust or repair
15. Check effect of emergency brake - Adjust or repair
16. Check operation of steering - Adjust or repair
17. Check direction of rear view mirror and under mirror - Adjust
18. Check effect of exhaust gas color and sound - Adjust or repair
19. Check effect retarder brake - Adjust or repair
20. Check effect body mounting rubber - Replace
21. Check sound of horn - Repair
22. Check flashing of lamps - Repair or replace
Electrical equipment
SK1026-5N 40-17
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
B. If no failure code is displayed on the machine monitor but the failure is recorded in memory.
If it is impossible to check the failure code display on the machine monitor when a problem occurs, use the
troubleshooting history display function in the service mode of the machine monitor to check if there is a failure code.
If a failure code is recorded, it is probable that it is the cause, so go to the applicable troubleshooting for the failure
code.
40-18 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
SK1026-5N 40-19
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
40-20 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
16 799-601-7320
SK1026-5N 40-21
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
M Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
40-22 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
8 799-601-7340
SK1026-5N 40-23
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
8 799-601-7140
10 (white) 799-601-7150
12 (white) 799-601-7350
16 (white) 799-601-7330
40-24 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
10 (blue) —
— —
12 (blue) 799-601-7160
16 (blue) 799-601-7170
SK1026-5N 40-25
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
5 799-601-2710
9 799-601-2950
13 799-601-2720
40-26 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
17 799-601-2730
21 799-601-2740
SK1026-5N 40-27
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
40-28 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
SK1026-5N 40-29
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
20 799-601-7550
L Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
2 —
— —
PA Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
9 —
— —
40-30 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
10 799-601-3460
— —
SK1026-5N 40-31
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
40-32 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
8 —
Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
SK1026-5N 40-33
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
5 799-601-7360
— —
6 799-601-7370
— —
4 —
— —
40-34 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9210
799-601-9210
799-601-9220
799-601-9220
SK1026-5N 40-35
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9230
799-601-9230
799-601-9240
799-601-9240
40-36 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9250
799-601-9250
799-601-9260
799-601-9260
SK1026-5N 40-37
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9270
799-601-9270
799-601-9280
799-601-9280
40-38 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9290
799-601-9290
SK1026-5N 40-39
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
40-40 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
SK1026-5N 40-41
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
DTM Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9010
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
40-42 SK1026-5N
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
★ The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker
assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Port No. Connector type Pin No.
—
799-601-2600 For measuring box Econo-21P O O O O O O
799-601-3100 For measuring box MS-37P O
799-601-3200 For measuring box MS-37P O
799-601-3300 For measuring box Econo-24P O
799-601-3360 Plate For MS box
799-601-3370 Plate For MS box
799-601-3380 Plate For MS box
799-601-3410 BENDIX(MS) 24P O O
799-601-3420 BENDIX(MS) 24P O O
799-601-3430 BENDIX(MS) 17P O O
799-601-3440 BENDIX(MS) 17P O O
799-601-3450 BENDIX(MS) 5P O O
799-601-3460 BENDIX(MS) 10P O O
799-601-3510 BENDIX(MS) 5P O O
799-601-3520 BENDIX(MS) 14P O O
799-601-3530 BENDIX(MS) 19P O O
799-601-2910 BENDIX(MS) 14P O O
799-601-3470 CASE O
799-601-2710 MIC 5P O O O O
799-601-2720 MIC 13P O O O O
799-601-2730 MIC 17P O O O O O O O
799-601-2740 MIC 21P O O O O O O O
799-601-2950 MIC 9P O O O O
799-601-2750 ECONO 2P O O
799-601-2760 ECONO 3P O O
799-601-2770 ECONO 4P O O
799-601-2780 ECONO 8P O O
799-601-2790 ECONO 12P O O
799-601-2810 DLI 8P O O
799-601-2820 DLI 12P O O
799-601-2830 DLI 16P O O
799-601-2840 Extension cable O O O
799-601-2850 CASE O
799-601-7010 X 1P O O
799-601-7020 X 2P O O O O
799-601-7030 X 3P O O O O
799-601-7040 X 4P O O O O
799-601-7050 SWP 6P O O O
799-601-7060 SWP 8P O O O
799-601-7310 SWP 12P O
SK1026-5N 40-43
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Port No. Connector type Pin No.
—
799-601-7070 SWP 14P O O
799-601-7320 SWP 16P O
799-601-7080 M 1P O O
799-601-7090 M 2P O O O O
799-601-7110 M 3P O O O O
799-601-7120 M 4P O O O O
799-601-7130 M 6P O O O O
799-601-7340 M 8P O
799-601-7140 S 8P O O O O
799-601-7150 S 10P-White O O O O
799-601-7160 S 12P-Blue O O O
799-601-7170 S 16P-Blue O O O O
799-601-7330 S 16P-White O
799-601-7350 S 12P-White O
799-601-7180 AMP040 8P O
799-601-7190 AMP040 12P O O
799-601-7210 AMP040 16P O O O O
799-601-7220 AMP040 20P O O O O
799-601-7230 Short connector X-2 O O O O
799-601-7240 Case O O
799-601-7270 Case O
799-601-7510 070 10P O
799-601-7520 070 12P O
799-601-7530 070 14P O
799-601-7540 070 18P O
799-601-7550 070 20P O
799-601-7360 Relay connector 5P O
799-601-7370 Relay connector 6P O
799-601-7380 JFC connector 2P O
799-601-9010 DTM 2P O O
799-601-9020 DT 2P O O
799-601-9030 DT 3P O O
799-601-9040 DT 4P O O
799-601-9050 DT 6P O O
799-601-9060 DT 8P-Gray O O
799-601-9070 DT 8P-Black O O
799-601-9080 DT 8P-Green O O
799-601-9090 DT 8P-Blown O O
799-601-9110 DT 12P-Gray O O
799-601-9120 DT 12P-Black O O
799-601-9130 DT 12P-Green O O
799-601-9140 DT 12P-Blown O O
799-601-9210 HD30 18-8 O O
799-601-9220 HD30 18-14 O O
40-44 SK1026-5N
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Port No. Connector type Pin No.
—
799-601-9230 HD30 18-20 O O
799-601-9240 HD30 18-21 O O
799-601-9250 HD24 24-9 O O
799-601-9260 HD30 2-16 O O
799-601-9270 HD30 24-21 O O
799-601-9280 HD30 24-23 O O
799-601-9290 HD30 24-31 O O
799-601-9310 Plate For HD30 O O O
799-601-9320 For measuring box For DT, HD O O O
799-601-9330 Case O
799-601-9340 Case O
799-601-9350 DEUTSCH 40P O
799-601-9360 DEUTSCH 24P O
799-601-9410 For NE, G sensor 2P O
SK1026-5N 40-45
TROUBLESHOOTING TRAVEL MOTOR
TRAVEL MOTOR
Reduction gear Damage to the gears Replace the body kit, carrier 1 kit, shaft kit
Abnormal Noise
Possible Reasons Countermeasures
Hydraulic motor Damage to sliding parts Replace the hydraulic motor assembly
Output shaft Damage to the gears surface Replace the body kit
Oil Leakage
Possible Reasons Countermeasures
Hydraulic motor Burned or damaged sliding parts Replace the hydraulic motor assembly
40-46 SK1026-5N
TROUBLESHOOTING TRAVEL MOTOR
Faulty operation of the hydraulic equipment except the hydraulic motor Inspect the hydraulic equipment
Faulty operation of the hydraulic equipment except the hydraulic motor Inspect the hydraulic equipment
Other
Damage, excessive rust Replace each part
(screw, etc.)
SK1026-5N 40-47
TROUBLESHOOTING TRAVEL MOTOR
Replace carrier 1
Carrier 1 Damage to spline section By visual
kit
Replace carrier 1
Excessive wear of the surface
kit and shaft kit
b1 Gear Shaft
By visual pitching, flaking
Replace carrier 1
Excessive wear of the bearing surface
kit
Replace carrier 1
Ring Excessive wear of the bearing surface
kit
Replace carrier 1
Roller Excessive wear of the bearing surface
kit
40-48 SK1026-5N
TROUBLESHOOTING TRAVEL MOTOR
MEMORANDUM
SK1026-5N 40-49
TROUBLESHOOTING AIR CONDITIONING SYSTEM
40-50 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
1. Blower Switch 7. Evaporator 13. Magnetic Clutch
2. Thermostatic Switch 8. Expansion Valve 14. Compressor Drive Pulley
3. Battery Supply 9. Suction Line 15. Receiver/Dryer
4. Circuit breaker 10. Test gauges & Manifold 16. Discharge Line
5. Blower 11. Compressor 17. Condenser
6. Temperature Sensor 12. Refrigerant Container
The cab tightness, insulation, and isolation from heat sources is very important to the efficiency of the system. It is advisable to
close all vents, even the intakes of pressurization systems, when there are high humidity conditions.
The general cleanliness of the system and components is important. Dust or dirt collected in the condenser, evaporator, or air
filters decreases the system’s cooling capacity.
The compressor, condenser, evaporator units, hoses and fittings must be installed clean, tight, and be capable of withstanding
the strain and abuse they are subjected to on off-highway vehicles.
Equipment downtime costs are high enough to encourage service areas to perform preventative maintenance at regular
intervals on vehicle air conditioning systems. (Cleaning, checking belt tightness, and operation of electrical components).
Principles of Refrigeration
A brief review of the principles of air conditioning is necessary to relate the function of components and technique of
troubleshooting and the corrective action necessary to put the A/C unit into top operating efficiency.
Too frequently, the operator and serviceman over-look the primary fact that no A/C system will function properly unless it is
operated within a completely controlled cab environment. The circulation of air must be a directed flow. The cab must be
sealed against seepage of ambient air. The cab interior must be maintained for cleanliness, dust, and dirt which if picked up in
the air system, will clog the intake side of the evaporator coil.
Air Conditioning
Air conditioning is a form of environmental control. As applied to the cab, it refers to the control of temperature, humidity,
cleanliness, and circulation of air. In the broad sense, a heating unit is as much an air conditioner as is a cooling unit. The term
“Air Conditioner” is commonly used to identify an air cooling unit. To be consistent with common usage, the term “Air
Conditioner” will refer to the cooling unit utilizing the principles of refrigeration; sometimes referred to as the evaporator unit.
SK1026-5N 40-51
TROUBLESHOOTING AIR CONDITIONING SYSTEM
The compressor (refrigerant pump) takes in low pressure heat laden refrigerant gas through the suction valve (low side), and as
its name indicates, pressurizes the heat laden refrigerant and forces it through the discharge valve (high side) on to the
condenser.
Ambient air, passing through the condenser removes the heat from the circulating refrigerant resulting in the conversion of the
refrigerant from gas to liquid.
The liquid refrigerant moves on to the filter-receiver drier where impurities are filtered out, and moisture removed. This
component also serves as the temporary storage unit for the liquid refrigerant.
The liquid refrigerant, still under high pressure, then flows to the expansion valve. This valve meters the amount of refrigerant
entering the evaporator. As the refrigerant passes through the valve, it becomes a low temperature, low pressure liquid and
saturated vapor.
The remaining low pressure liquid immediately starts to boil and vaporize as it approaches the evaporator. This causes the
refrigerant to become cold. The hot, humid air of the cab is pulled through the evaporator by the evaporator blower. Since the
refrigerant is colder than the air, it absorbs the heat from the air producing cool air which is pushed back into the cab. The
moisture in the air condenses upon movement into the evaporator and drops into the drain pan from which it drains out of the
cab.
The cycle is completed when the heated low pressure gas is again drawn into the compressor through the suction side.
This simplified explanation of the principles of refrigeration does not call attention to the fine points of refrigeration
technology. Some of these will be covered in the following discussions of the components, controls, and techniques involved
in preparing the unit for efficient operation.
40-52 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
To create high pressure concentration, the compressor draws in refrigerant from the evaporator through the suction valve and
during compression strokes, forces it out through the discharge valve to the condenser. The pressure from the compressor
action moves the refrigerant through the condenser, receiver-drier and connecting hoses to the expansion valve.
The compressor is driven by the engine through a v-belt driving an electrically operated clutch mounted on the compressor
drive shaft.
Service Valves
Quick-connect hose end fittings with integral service valves attach to system service ports for servicing the unit. A manifold
gauge set is connected into the system at the service valve ports and all procedures, such as discharging, evacuating and
charging the system, are performed through the service valves.
Condenser
The condenser receives the high pressure, high temperature refrigerant vapor from the compressor and condenses it to high
pressure, hot liquid.
It is designed to allow heat movement from the hot refrigerant vapor to the cooler outside air. Cooling of refrigerant changes
the vapor to liquid. Heat exchange is accomplished using cooler air flowing through the condenser. Condenser cooling can be
with ram air provided by vehicle movement and sometimes aided by electric or hydraulic fans or by using the air movement
provided by the radiator fan.
Ram air condensers depend upon the vehicle movement to force a large volume of air past the fins and tubes of the condenser.
The condenser is usually located in front of the radiator or on the roof of the vehicle.
Condensing of refrigerant is the change of state of refrigerant from a vapor to a liquid. The action is affected by the pressure of
refrigerant in the coil and air flow through the condenser. Condensing pressure in an A/C system is the controlled pressure of
the refrigerant which affects the temperature at which it condenses to liquid, giving off large quantities of heat in the process.
The condensing point is sufficiently high to create a wide temperature differential between the hot refrigerant vapor and the air
passing over the condenser fins and tubes. This difference permits rapid heat transfer from the refrigerant to ambient air.
Receiver-Drier
The receiver-drier is an important part of the air conditioning system. The drier receives liquid refrigerant from the condenser
and removes any moisture and foreign matter present which may have entered the system. The receiver section of the tank is
designed to store extra refrigerant until it is needed by the evaporator. Storage of this refrigerant is temporary and is dependent
on the demand of the expansion valve.
A desiccant is a solid substance capable of removing moisture from gas, liquid or solid. It is held in place within the receiver
between two screens, which also act as strainers. Sometimes it is simply placed in a metal mesh or wool felt bag. Filtering is
accomplished by a separate strainer screen on the pickup tube.
SK1026-5N 40-53
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Some systems may utilize an accumulator instead of a receiver-drier. If an accumulator is used, an expansion (fixed-orifice)
tube is used instead of the thermostatic expansion valve described below. When used, the expansion tube is located inside the
inlet tube of the evaporator and is used to restrict, but still allow a continuous flow of refrigerant to the evaporator coil.
The expansion valve is located near the inlet of the evaporator and provides the functions of throttling, modulating, and
controlling the liquid refrigerant to the evaporator coil.
The refrigerant flows through a restriction creating a pressure drop across the valve. Since the expansion valve also separates
the high side of the system from the low side, the state of the refrigerant entering the valve is warm to hot high pressure liquid;
exiting it is low pressure liquid and gas. The change to low pressure allows the flowing refrigerant to immediately begin
changing to gas as it moves toward the evaporator.
The amount of refrigerant metered into the evaporator varies with different heat loads. The valve modulates from wide open to
the nearly closed position, seeking a point between for proper metering of the refrigerant.
As the load increases, the valve responds by opening wider to allow more refrigerant to pass into the evaporator. As the load
decreases, the valve reacts and allows less refrigerant into the evaporator. It is this controlling action that provides the proper
pressure and temperature control in the evaporator.
The externally equalized expansion valve is controlled by both the temperature of the power element bulb and the pressure of
the liquid in the evaporator.
Some systems may use an internally equalized, block type expansion valve. With this type valve, the refrigerant leaving the
evaporator coil is also directed back through the valve so the temperature of the refrigerant is monitored internally rather than
by a remote sensing bulb.
Remark
It is important that the sensing bulb, if present, is tight against the output line and protected from ambient
temperatures with insulation tape.
Evaporator
The evaporator cools and dehumidifies the air before it enters the cab. Cooling a large area requires that large volumes of air
be passed through the evaporator coil for heat exchange. Therefore, a blower becomes a vital part of the evaporator assembly.
It not only draws heat laden air into the evaporator, but also forces this air over the evaporator fins and coils where the heat is
surrendered to the refrigerant. The blower forces the cooled air out of the evaporator into the cab.
Heat exchange, as explained under condenser operation, depends upon a temperature differential of the air and the refrigerant.
The greater the temperature differential, the greater will be the amount of heat exchanged between the air and the refrigerant.
A high heat load condition, as is generally encountered when the air conditioning system is turned on, will allow rapid heat
transfer between the air and the cooler refrigerant.
The change of state of the refrigerant in and going through the evaporator coil is as important as that of the air flow over the
coil.
All or most of the liquid that did not change to vapor in the expansion valve or connecting tubes boils (expands) and vaporizes
immediately in the evaporator, becoming very cold. As the process of heat loss from the air to the evaporator coil surface is
taking place, any moisture (humidity) in the air condenses on the cool outside surface of the evaporator coil and is drained off
as water.
At atmospheric pressure, refrigerant boils at a point lower than water freezes. Therefore, the temperature in the evaporator
must be controlled so that the water collecting on the coil surface does not freeze on and between the fins and restrict air flow.
40-54 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
The evaporator temperature is controlled through pressure inside the evaporator, and temperature and pressure at the outlet of
the evaporator.
Electrical Circuit
The air conditioner’s electrical circuit is fed from an accessory circuit and is fused with a 30-ampere fuse or circuit breaker.
The blower control is a switch which provides a range of blower speeds from fast to slow. When the blower switch is turned
on, current is fed to the thermostat. Once the blower is turned on, fan speeds may be changed without affecting the thermostat
sensing level.
The thermostat reacts to changing temperatures which cause electrical contacts to open and close. The thermostat has a
capillary tube extended into the evaporator coil to sense temperature.
When the contacts are closed, current flows to the clutch field and energizes the clutch, causing the crankshaft to turn which
starts the refrigeration cycle. When the temperature of the evaporator coil drops to a predetermined point, the contacts open
and the clutch disengages.
When the clutch is disengaged, the blower remains at the set speed. After the evaporator temperature rises about twelve
degrees above the cutout point, the contacts in the thermostat close and the refrigeration cycle resumes.
Thermostat
An electromagnetic clutch is used on the compressor to provide a means of constant temperature control of the cab. The clutch
is controlled by a thermostat in the evaporator which is set initially by the driver to a predetermined point. Coil temperature is
then maintained by the cycling action of the clutch.
The thermostat is simply a thermal device which controls an electrical switch. When warm, the switch is closed; when cold, it
is open. Most thermostats have a positive OFF position as a means to turn the clutch OFF regardless of temperature.
The bellows type thermostat has a capillary tube connected to it which is filled with refrigerant. The capillary tube is attached
to the bellows inside of the thermostat. Expansion of the gases inside the capillary tube exerts pressure on the bellows, which
in turn closes the contacts at a predetermined temperature.
Compressor Clutch
An electromagnetic clutch is used in conjunction with the thermostat to disengage the compressor when it is not needed, such
as when a defrost cycle is indicated in the evaporator, or when the system is turned off.
The stationary field clutch is the most desirable type since it has fewer parts to wear out. The field is mounted to the
compressor by mechanical means depending on the type field and compressor. The rotor is held on the armature by a bearing
and snap rings. The armature is mounted on the compressor crankshaft.
When no current is fed to the field, there is no magnetic force applied to the clutch and the rotor is free to rotate on the
armature, which remains stationary on the crankshaft.
When the thermostat or switch is closed, current is fed to the field. This sets up a magnetic force between the field and
armature, pulling it into the rotor. When the armature becomes engaged with the rotor, the complete unit rotates while the field
remains stationary. This causes the compressor crankshaft to turn, starting the refrigeration cycle.
When the switch or thermostat is opened, current is cut off. The armature snaps back out and stops while the rotor continues to
turn. Pumping action of the compressor is stopped until current is again applied to the field. In addition, safety switches in the
compressor clutch electrical circuit control clutch operation, disengaging the clutch if system pressures are abnormal.
SK1026-5N 40-55
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Safety Switches
TrinaryTM Switch
The TrinaryTM switch performs three distinct functions to monitor and control refrigerant pressure in the system. This switch is
installed between the condenser and expansion valve, usually on the receiver-drier. The switch functions are:
• The low-pressure switch prevents compressor operation if the refrigerant has been lost or the ambient temperature is too
low. Low ambient temperature results in very low system pressure.
• The mid-range function actuates the engine fan clutch if installed.
• The high-range pressure function disengages the compressor clutch if system pressure is too high.
The switch functions will automatically reset when the system pressure returns to normal.
40-56 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
System Servicing
Servicing an air conditioning system really means closely monitoring refrigerant flow. For this reason, the following
procedures deal extensively with the proper use, handling, care and safety factors involved in the R-134a refrigerant quality
and quantity in an air conditioning system.
Because the refrigerant in an air conditioning system must remain pressurized and sealed within the unit to function properly,
safety is a major consideration when anything causes this pressurized, sealed condition to change. The following warnings are
provided here to alert service personnel to their importance BEFORE learning the correct procedures. Read, remember, and
observe each warning before beginning actual system servicing.
Remark
If the owner operates a fleet with some vehicles using R-12 and others using R-134a refrigerant, it is
essential that servicing tools that come into contact with the refrigerant (gauge sets, charging equipment,
recycle/recovery equipment etc.) be dedicated to one type refrigerant only, to prevent cross contamination.
WARNING! Federal regulations prohibit venting R-12 and R134a refrigerant into the atmosphere. An SAE and UL
approved recovery/recycle station must be used to remove refrigerant from the AC system.
Refrigerant is stored in a container on the unit for recycling, reclaiming, or transporting. In addition,
technicians servicing AC systems must be certified, they have been properly trained to service the
system.
WARNING! Although accidental release of refrigerant is a remote possibility when proper procedures are followed,
the following warnings must be observed when servicing AC systems:
• Provide appropriate protection for your eyes (goggles or face shield) when working around
refrigerant.
• A drop of the liquid refrigerant on your skin will produce frostbite. Wear gloves and exercise
extreme care when handling refrigerant.
• If even the slightest trace of refrigerant enters in your eye, flood the eye immediately with cool
water and seek medical attention as soon as possible.
• Ensure sufficient ventilation whenever refrigerant is being discharged from a system, keeping in
mind refrigerant is heavier than air and will seek low areas of the shop.
• When exposed to flames or sparks, the components of refrigerant change and become deadly
phosgene gas. This poison gas will damage the respiratory system if inhaled. NEVER smoke in
area where refrigerant is used or stored.
• Never direct steam cleaning hose or torch in direct contact with components in the air conditioning
system. Localized heat can raise the pressure to a dangerous level.
• Do not heat or store refrigerant containers above 120° F (49° C).
• Do not flush or pressure test the system using shop air or another compressed air source. Certain
mixtures of air and R-134a refrigerant are combustible when slightly pressurized. Shop air supplies
also contain moisture and other contaminants that could damage system components.
Always read the container label to verify the contents are correct for the
system being serviced. Note the containers for R-134a are painted light
blue.
SK1026-5N 40-57
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Remark
Test equipment is available to confirm refrigerant in the system is actually the type intended for the system
and has not been contaminated by a mixture of refrigerant types.
Remark
Recycled equipment must meet certain standards as published by the Society of Automotive Engineers
and carry a UL approved label. Basic principals of operation remain the same for all machines, even if
details of operation differ somewhat.
40-58 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Leak Detector
The electronic detector is very accurate and safe. It is a small
hand-held device with a flexible probe used to seek refrigerant
leaks. A buzzer, alarm or light will announce the presence of
even the smallest leak.
Remark
Electronic leak detectors are available for use
only with R-12 or only with R-134a.
Service Valves
Because an air conditioning system is a sealed system, two service
valves are provided on the compressor to enable diagnostic tests, system
charging or evacuation. Connecting applicable hoses from the manifold
gauge set to the compressor service valves enables each of these to be
readily performed. New and unique service hose fittings have been
specified for R-134a systems. Their purpose is to avoid accidental
cross-mixing of refrigerants and lubricants with R-12 based systems.
Service ports on the system are quick disconnect type with no external
threads. They do contain a Schrader type valve. The low side fitting has
a smaller diameter than the high side attachment.
Vacuum Pump
The vacuum pump is used to completely evacuate all of the refrigerant,
air, and moisture from the system by deliberately lowering the pressure
within the system to the point where water turns to a vapor (boils) and
together with all air and refrigerant is with-drawn (pumped) from the
system. Normally the vacuum pump is only used when a system has
completely lost its refrigerant charge.
SK1026-5N 40-59
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Remark
When hose replacement becomes necessary, the new hoses must be marked “SAE J2916 R-134a”.
Functions of the manifold gauge set are included in many of the commercially available recovery or recovery/ recycle stations.
The Low Side Gauge, registers both vacuum and pressure. The vacuum side of the scale is calibrated from 0 to 30 inches (0 to
762 mm) of mercury (in. Hg). The pressure side of the scale is calibrated to 150 psi (10.6 kg/cm²).
WARNING! Never open the hand valve to the high side at anytime when the air conditioning system is
operating. High side pressure, if allowed, may rupture charging containers and potentially
cause personal injury.
The High Side Gauge is used to measure pressure only on the discharge side of the compressor. The scale is calibrated from
0 to 500 psi (0 to 35.3 kg/cm²).
40-60 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
1. Be sure all valves on the manifold are closed all the way (turn them
clockwise).
3. Locate the low and high side system service fittings and remove
their protective caps.
4. Connect two service hoses from the manifold to the correct service
valves on the compressor. (High side to compressor discharge valve
and low side to compressor suction side.) Do not open service valves at this time.
This gauge hook-up process will be the same, regardless of the gauge set being installed. Whether it is a recovery station or
individual gauges, the connections are the same. The procedures performed next will vary depending what type of equipment
is being used. If a recovery/recycling station is being used, complete servicing can be accomplished. Using only a set of
gauges will limit the servicing to only adding refrigerant or observing pressures.
SK1026-5N 40-61
TROUBLESHOOTING AIR CONDITIONING SYSTEM
The purpose of this procedure is to remove all air trapped in the hoses prior to actual system testing. Environmental regulations
require that all service hoses have a shutoff valve within 12 inches (304.8 mm) of the service end. These valves are required to
ensure only a minimal amount of refrigerant is lost to the atmosphere. R-134a gauge sets have a combination quick disconnect
and shutoff valve on the high and low sides.
The center hose also requires a valve. Initial purging is best accomplished when connected to recovery or recycle equipment.
With the center hose connected to the recovery station, service hoses connected to the high and low sides of the system, we can
begin purging.
The manifold valves and service valves should be closed. Activating the vacuum pump will now pull any air or moisture out of
the center hose. This will require only a few minutes of time. The hose is the only area that is being placed in a vacuum and
this will not require a lengthy process. Closing the valve will then insure the hose is purged.
40-62 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
2. Start the engine and set the idle at 1200 to 1500 RPM and then turn on the air conditioning.
3. Open the refrigerant dispensing valve on the container and then the low pressure hand valve on the manifold. This will
allow the refrigerant to enter the system as a gas on the low pressure or suction side of the compressor. The compressor
will pull refrigerant into the system.
4. Continue adding refrigerant until the gauge reads in the normal range. Gauge readings will fluctuate as the compressor
cycles on and off. Pressures within the air conditioning system vary with ambient temperature. A normal pressure range is
defined as follows:
Low side 15 - 30 psi (1.1 - 2.1 kg/cm²)
High side 170 - 300 psi (12.0 - 21.1 kg/cm²)
5. When the gauges show a normal reading, close the hand valve on the refrigerant container.
WARNING! During this stabilization period, do not open hand valves on manifold for any reason.
Equipment damage and personal injury may result.
1. Start the engine and return to an idle speed of 1200 to 1500 rpm. Turn on the air conditioner.
2. After a performance check of the control functions, blower speeds and air flow, set the AC system controls to maximum
cooling and blower speed on high. All windows must be closed. If the cab temperature is hot, open the windows long
enough to allow the hot air to move out of the cab.
3. Run the engine and air conditioner about 5 minutes for the system to stabilize.
4. If humidity is high it will be necessary to place a fan in front of the AC condenser to help air flow across the condenser.
This helps to stabilize the system by simulating normal operating conditions.
5. It is then possible to observe the gauge readings and the temperature coming out of the air ducts with a thermometer.
Remark
If low refrigerant is indicated by lower than normal pressure readings, add refrigerant to enable adequate
system testing.
SK1026-5N 40-63
TROUBLESHOOTING AIR CONDITIONING SYSTEM
WARNING! Do not open high side hand valve. High side system pressure is greater than refrigerant
container. Serious personal injury may result if the container explodes.
WARNING! Use hand valve to regulate low side reading during charging. DO NOT EXCEED 40 psi
(2.8 kg/cm²) maximum. Exceeding this pressure may cause compressor failure.
1. Place the power switch and the controller on the recovery unit in the OFF position.
3. Drain the recovered oil through the valve marked OIL DRAIN on the front of the machine.
4. Place the controller knob in the ON position. The low pressure gauge will show a rise.
5. Immediately switch to the OFF position and allow the pressure to stabilize. If the pressure does not rise to between 5 psi
and 10 psi (0.35 and 0.70 kg/cm²), switch the controller ON and OFF again.
6. When the pressure reaches 5 to 10 psi (0.35 to 0.70 kg/cm²), open the OIL DRAIN valve, collect the oil in an appropriate
container, and dispose of container as indicated by local, state or Federal Regulation.
Remark
The oil is not reusable, due to contaminants absorbed during its previous use.
1. Be sure the equipment being used is designed for the refrigerant you intend to recover.
2. Observe the sight glass oil level. Having drained it, it should be zero.
3. Check the cylinder refrigerant level before beginning recovery to make sure you have enough capacity.
4. Confirm that all shut-off valves are closed before connecting to the AC system.
6. Start the recovery process by operating the equipment as per the manufacturer’s instructions.
8. If an abnormal amount of time elapses after the system reaches 0 psi (0 kg/cm²) and does not drop steadily into the
vacuum range, close the manifold valves and check the system pressure. If it rises to 0 psi (0 kg/cm²) and stops, there is a
major leak.
40-64 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
9. Check the system pressure after the recovery equipment stops. After five minutes, system pressure should not rise above
“0” gauge pressure. If the pressure continues to rise, restart and begin the recovery sequence again. This cycle should
continue until the system is void of refrigerant.
10. Check the sight glass oil level to determine the amount of oil that needs to be replaced. (The amount of oil that was lost
during the recovery cycle must be replaced back into the system).
11. Mark the cylinder with a RECOVERED (red) magnetic label to reduce the chance of charging a system with
contaminated refrigerant. Record the amount of refrigerant recovered.
1. Attach the high and low side hoses to the appropriate connections.
3. Check the gauge readings for five minutes. If the gauge needle moves up, the system is not sealed. The vacuum that was
just created did not hold, air and moisture are being sucked into the system by that same vacuum.
4. Tighten any loose connections. Re-start the pump, and open the hand valves on the gauges again. Repeat the vacuum test.
5. If the leak has been repaired, run the vacuum pump for at least an hour to remove any moisture from the system.
Remark
The moisture must turn to gas before the pump can pull it out. The moisture takes time to boil away, so that it can be
drawn out of the system. The vacuum pump can draw most of the air out quickly, but a deep vacuum requires more
time; the deeper the vacuum the more time required.
When adding a full charge of refrigerant, it is possible to put it in as a gas or as a liquid. Adding refrigerant as a liquid is faster
but can damage the compressor if not done correctly. The procedure used, and where the refrigerant is added in the AC system
makes a difference. When using refrigerant as a liquid, never add more than two thirds of system requirements as a liquid.
Finish charging the system using gas.
SK1026-5N 40-65
TROUBLESHOOTING AIR CONDITIONING SYSTEM
2. Place fan in front of condenser to simulate normal ram air flow and allow system to stabilize.
4. Evaluate the readings obtained from the gauges to see if they match the readings for the ambient temperature.
B. Set air conditioning system at maximum cooling and blower speed operation.
C. Readings on the two manifold gauges should be within normal range, adjust for ambient temperature.
D. Compare evaporator discharge air temperature reading to see if it matches the recommended temperature for the
ambient temperature and gauge readings obtained.
E. Carefully feel the hoses and components on the high side. All should be warm-hot to the touch. Check the inlet and
outlet of receiver-drier for even temperatures, if outlet is cooler than inlet, a restriction is indicated.
WARNING! Use extreme caution when placing hands on high side components and hoses. Under
certain conditions these items can be extremely hot.
F. Feel the hoses and components on the low side. They should be cool to the touch. Check connections near the
expansion valve, inlet side should be warm and cold-cool on the outlet side.
G. If these conditions are met, the system is considered normal. Shut down engine. Remove gauges and install the caps
on the service valves.
40-66 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
WARNING! Use extreme caution leak testing a system while the engine is running.
In its natural state, refrigerant is a harmless, colorless gas, but when combined with an
open flame, it will generate toxic fumes (phosgene gas), which can cause serious injuries
or death.
Refrigerant leaks are probably the most common cause of air conditioning problems, resulting from improper or no cooling, to
major internal component damage. Leaks most commonly develop in two or three places. The first is around the compressor
shaft seal, often accompanied by an indication of fresh refrigerant oil. If a system is not operated for a while (winter months),
the shaft seal may dry out and leak slightly. The centrifugal force of the clutch pulley spinning can also cause the problem.
When the system is operated and lubricant wets the seal, the leak may stop. Such leaks can often be located visually, or by
feeling with your fingers around the shaft for traces of oil. (The R-134a itself is invisible, odorless, and leaves no trace when it
leaks, but has a great affinity for refrigerant oil.)
A second common place for leaks is the nylon and rubber hoses where they are crimped or clamped to the fittings, or where
routing allows abrasion. Other threaded joints or areas where gaskets are used should be visually and physically examined.
Moving your fingers along the bottom of the condenser and evaporator, particularly near the drain hole for the condensate will
quickly indicate the condition of the evaporator. Any trace of fresh oil here is a clear indication of a leak.
Usually, a 50% charged system is enough to find most leaks. If the system is empty, connect manifold gauge set to the system
and charge at least one (1) lb. (0.45 kg) of refrigerant into the system.
Remark
The refrigerant is heavier than air and will move down when it leaks. Apply pickup hose or test probe on
the undersurface of all components to locate leak.
Tracer Dyes
Tracer dyes are available that can be added to the system as refrigerant is added. The system is then operated to thoroughly
circulate the dye. As refrigerant escapes, it leaves a trace of the dye at the point of leakage, which is then detected using an
ultraviolet light (black light), revealing a bright fluorescent glow.
SK1026-5N 40-67
TROUBLESHOOTING AIR CONDITIONING SYSTEM
System Repair
WARNING! Before system assembly, check the compressor oil level and fill to manufacturer
specifications.
WARNING! All of the service procedures described are only performed after the system has been
discharged. Never use any lubricant or joint compound to lubricate or seal any AC
connections.
The following service and repair procedures are not any different than typical vehicle service work. However, AC system
components are made of soft metals (copper, aluminum, brass, etc.). Comments and tips that follow will make the job easier
and reduce unnecessary component replacement.
Remark
To help prevent air, moisture or debris from entering an open system, cap or plug open lines, fittings or
components and lubricant containers until connected and as soon as they are disconnected.
Keep all connections clean (also caps and plugs used) so debris can’t enter accidentally.
Lines
Always use two wrenches when disconnecting or connecting AC fittings attached to metal lines. You are working with copper
and aluminum tubing which can kink or break easily. Tube O-ring type fittings require only 18 ft. lbs. (24.4 N.m) {2.5 kgf.m}
of torque for correct sealing. When grommets or clamps are used to prevent line vibration, be certain these are in place and
secured.
Expansion Valve
When removing the expansion valve from the system, remove the insulation, clean the area and disconnect the line from the
receiver-drier. Detach the capillary (bulb) and external equalizer tube (if present) from their mounting locations. Remove the
expansion valve from the evaporator inlet. Expansion valve service is limited to cleaning or replacing the filter screen. If this is
not the problem, replace the valve. Secure the capillary and equalizer, if used, to clean surfaces and replace or attach any
insulating material.
Receiver-Drier
The receiver-drier can not be serviced or repaired. It should be replaced whenever the system is opened for any service. If the
receiver-drier has a pressure switch to control the clutch, it should be removed and installed on the new unit.
Thermostat
A thermostat can be stuck open or closed due to contact point wear or fusion. The thermostat temperature sensing element
(capillary tube) may be broken or kinked closed and therefore unable to sense evaporator temperature.
When thermostat contact points are stuck open or the sensing element can not sense temperature in the evaporator, the clutch
will not engage (no AC system operation). Causes are a loss of charge in the capillary tube or a kink, burned thermostat contact
or just no contact. When troubleshooting, bypass the thermostat by hot wiring the clutch coil with a fused lead. If the clutch
engages, replace the thermostat.
Thermostat contact points may be fused (burned) closed and the clutch will not disengage. Causes are a faulty switch that
could be due to fatigue. The thermostat must be replaced. When the clutch will not disengage you may also note that
condensate has frozen on the evaporator fins and blocked air flow. There will also be below normal pressure on the low side of
the system. Side effects can be compressor damage caused by oil accumulation (refrigeration oil tends to accumulate at the
coolest spot inside the system) and lower than normal suction pressure that can starve the compressor of oil.
40-68 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Clutch
Clutch problems include electrical failure in the clutch coil or lead wire, clutch pulley bearing failure, worn or warped clutch
plate or loss of clutch plate spring temper. Defective clutch assembly parts may be replaced or the whole assembly replaced. If
the clutch shows obvious signs of excessive heat damage, replace the whole assembly.
The fast way to check electrical failure in the lead wire or clutch coil is to hot wire the coil with a fused lead. This procedure
enables you to bypass clutch circuit control devices.
Clutch pulley bearing failure is indicated by bearing noise when the AC system is off or the clutch is not engaged. Premature
bearing failure may be caused by poor alignment of the clutch and clutch drive pulley. Sometimes it may be necessary to use
shims or enlarge the slots in the compressor mounting bracket to achieve proper alignment.
Excessive clutch plate wear is caused by the plate rubbing on the clutch pulley when the clutch is not engaged or the clutch
plate slipping when the clutch coil is energized. A gap that is too small or too large between the plate and clutch pulley or a
loss of clutch plate spring temper are possible causes. The ideal air gap between the clutch pulley and the clutch plate is 0.022
to 0.057 in. If the gap is too wide, the magnetic field created when the clutch coil is energized will not be strong enough to pull
and lock the clutch plate to the clutch pulley.
Compressor
The compressor can fail due to shaft seal leaks (no refrigerant in the system), defective valve plates, bearings, other internal
parts or problems associated with high or low pressure, heat or lack of lubrication. Be sure the compressor is securely mounted
and the clutch pulley is properly aligned with the drive pulley.
Refrigerant oil is a synthetic oil very susceptible to high levels of water absorbtion. Always be sure the oil is an approved type
for use in the air conditioner compressor.
Refrigerant oil, under normal circumstances inside the sealed system, cannot go anywhere, and there is no need to check the
oil at such times. Always keep a cap on an oil container except when in use. Moisture is quickly absorbed by the oil.
Whenever a system is opened for service, the compressor oil level should be checked and clean refrigeration oil added as
required by the manufacturer’s specifications (usually located on compressor).
SK1026-5N 40-69
TROUBLESHOOTING AIR CONDITIONING SYSTEM
WARNING! Do not use the air conditioning compressor as a vacuum pump or the compressor will be
damaged.
Evacuating the complete air conditioning system is required in all new system installations, and when repairs are made on
systems requiring a component replacement (system opened), or a major loss of refrigerant has occurred. All these conditions
will require that a vacuum be pulled using a vacuum pump that completely removes any moisture from the system.
Once properly evacuated, the system can be recharged again.
Using a pump to create a vacuum in the air conditioning system effectively vaporizes any moisture, allowing the water vapor
to be easily drawn out by the pump. The pump does this by reducing the point at which water boils (212°F {100° C}) at sea
level with 15 psi {1.05 kg/cm²}). In a vacuum, water will boil at a lower temperature depending upon how much of a vacuum
is created.
As an example, if the ambient air outside the vehicle is 75°F (23° C) at sea level, by creating a vacuum in the system so that the
pressure is below that of the outside air (in this case, at least 29.5 inches {749.3 mm} of vacuum is needed), the boiling point
of water will be lowered to 72°F (22° C). Thus any moisture in the system will vaporize and be drawn out by the pump if the
pump is run for approximately an hour. The following steps indicate the proper procedure for evacuating all moisture from the
heavy duty air conditioning systems.
Remark
Lower the vacuum requirement 1 inch (25.4 mm) for every 1000 feet (304.8 m) above sea level at your
location.
1. With the manifold gauge set still connected (after discharging the
system), connect the center hose to the inlet fitting of the vacuum
pump. Then open the low side hand valves to maximum.
2. Open the discharge valve on the vacuum pump or remove the dust
cap from the discharge outlet. Turn the pump on and watch the low
side gauge. The pump should pull the system into a vacuum (if not,
the system has a leak).
3. Run the pump for five minutes and close the hand valves and shut
off the pump.
6. Close the manifold hand valves and turn off vacuum pump, watching the low side gauge reading. If vacuum remains for a
few minutes, the system is ready for charging.
Remark
If using a recycling and charging machine, the vacuum pump is built into the unit. Separate hook-up is not
required.
40-70 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
MEMORANDUM
SK1026-5N 40-71
TROUBLESHOOTING AIR CONDITIONING SYSTEM
A good working knowledge of the manifold gauge set is required to correctly test and diagnose an air conditioning system. An
accurate testing sequence is usually the quickest way to diagnose an internal problem. When correctly done, diagnosis
becomes an accurate procedure rather than guesswork.
• Compressor Belt - Must be tight, and aligned.
• Compressor Clutch - The clutch must engage. If it does not, check fuses, wiring, and switches.
• Oil Leaks - Inspect all connection or components for refrigeration oil leaks (especially in the area of the compressor
shaft). A leak indicates a refrigerant leak.
• Electrical Check - Check all wires and connections for possible open circuits or shorts. Check all system fuses.
• Cooling System - Check for correct cooling system operation. Inspect the radiator hoses, heater hoses, clamps, belts,
water pump, thermostat and radiator for condition or proper operation.
• Radiator Shutters - Inspect for correct operation and controls, if equipped.
• Fan and Shroud - Check for proper operation of fan clutch. Check installation of fan and shroud.
• Heater/Water Valve - Check for malfunction or leaking.
• System Ducts and Doors - Check the ducts and doors for proper function.
• Refrigerant Charge - Make sure system is properly charged with the correct amount of refrigerant.
Remark
Some systems use different safety devices in the compressor circuit to protect the compressor. Check the
thermal fuse, low pressure cutout switch, high pressure cutout switch, or trinary pressure switch if
equipped.
Preliminary Steps
The following steps outline the correct procedures necessary to prepare the vehicle and the system for testing and diagnosis:
1. Correctly connect the manifold gauge set to the system. Refer to the connection and purging procedures outlined in this
section.
2. Run the engine with the air conditioning system on for five to ten minutes to stabilize the system.
3. With the engine and the system at normal operating temperature, conduct a Performance Test.
2. Place fan in front of condenser to simulate normal ram air flow and allow system to stabilize.
4. Evaluate the readings obtained from the gauges to see if they match the readings for the ambient temperature.
40-72 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
As preliminary steps to begin checkout of the system, perform the following:
B. Set air conditioning system at maximum cooling and blower speed operation.
C. Readings on the two manifold gauges should be within normal range, adjust for ambient temperature.
D. Compare evaporator discharge air temperature reading to see if it matches the recommended temperature for the
ambient temperature and gauge readings obtained.
E. Carefully feel the hoses and components on the high side. All should be warm-hot to the touch. Check the inlet and
outlet of receiver-drier for even temperatures, if outlet is cooler than inlet, a restriction is indicated.
WARNING! Use extreme caution when placing hands on high side components and hoses. Under
certain conditions these items can be extremely hot.
F. Feel the hoses and components on the low side. They should be cool to the touch. Check connections near the
expansion valve, inlet side should be warm and cold-cool on the outlet side.
G. If these conditions are met, the system is considered normal. Shut down engine. Remove gauges and install the caps
on the service valves.
SK1026-5N 40-73
TROUBLESHOOTING AIR CONDITIONING SYSTEM
12
Troubleshooting by Manifold Gauge Set Readings
Indications:
• Low side pressure LOW.
Check for leaks by perfoming leak test.
• High side pressure LOW.
• Discharge air is only slightly cool.
1. Charge system.
No leaks found:
2. Performance test system.
Indications: 1. Add refrigerant (make sure system has at least 50% of its
• Low side pressure VERY LOW. normal amount) and leak test system.
• High side pressure VERY LOW. 2. It may be necessary to use a jumper wire to enable the
• Discharge air warm compressor to operate, if the compressor has shut down
• No bubbles observed in sight glass, may show oil due to faulty pressure sensing switch.
streaks. 3. If a leak is present at a connection, tighten the
• Pressure sensing switch may have compressor clutch connection, then add refrigerant as required.
disengaged. 4. If a system component needs to be replaced, recover all
• Refrigerant excessively low; leak in system. refrigerant from the system. Replace the defective part,
then check the compressor oil level; refill compressor oil
as necessary.
5. Evacuate system.
6. Charge system with new / recycled refrigerant.
7. Check A/C operation and do system performance test.
Indications:
• Low side pressure LOW.
• High Side Pressure LOW.
• Air from vents in the cab seems warm. If there is a low
pressure switch in the system, it may have shut off the Check for leaks by performing leak test.
compressor clutch.
40-74 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
SK1026-5N 40-75
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Indications: Test:
• Gauge Reading - Low Side Low or Vacuum. Warm diaphragm and valve body with your hand, or very
• High Side High. carefully with a heat gun. Activate system and watch to
• Air from vents in the cab is only slightly cool. see if the low pressure gauge rises.
• The expansion valve body is frosted or sweating.
Next, carefully spray a little nitrogen, or any substance
Cause: below 32° F (0° C), on the capillary coil (bulb) or valve
• An expansion valve malfunction could mean the valve diaphragm. The low side gauge needle should drop and
is stuck in the closed position. read at a lower (suction) pressure on the gauge. This
• The filter screen is clogged (block expansion valves do indicates the valve was part way open and that your
not have filter screens). action closed it. Repeat the test, but first warm the valve
• Moisture in the system has frozen at expansion valve diaphragm or capillary with your hand. If the low side
orifice. gauge drops again, the valve is not stuck.
• Sensing bulb is not operating.
Repair Procedure:
If the sensing bulb is accessible, perform the following test. Inspect the expansion valve screen (except block type
If not then proceed to the Repair Procedure. valves). To do this, remove all refrigerant from system.
Disconnect the inlet hose fitting from the expansion
valve. Remove, clean and replace the screen, then
reconnect the hose. Replace the receiver-drier. Then
evacuate and recharge the system with refrigerant, and
check AC operation and performance. If the expansion
valve tests did not cause the low pressure gauge needle
to rise and drop, and if the other procedure described did
not correct the problem, the expansion valve is defective.
Follow the procedure for component replacement.
Indications: Test:
• Gauge Reading- Low Side High. Operate the AC system on it’s coldest setting for a few
• High Side Normal. minutes. Carefully spray a little nitrogen or other cold
• Air from vents in cab is warm or only slightly cool. substance, on the capillary tube coil (bulb) or head of the
valve. The low pressure (suction) side gauge needle
Cause: should now drop on the gauge. This indicates the valve
• Expansion valve is stuck open and/or the capillary tube has closed and is not stuck open. Repeat the test, but
(bulb) is not making proper contact with the evaporator first warm the valve diaphragm by warming with hands.
outlet tube. If the low side gauge shows a drop again, the valve is not
• Liquid refrigerant may be flooding evaporator making it stuck. Clean the surfaces of the evaporator outlet and the
impossible for the refrigerant to vaporize and absorb capillary coil or bulb. Make sure the coil or bulb is
heat normally. securely fastened to the evaporator outlet and covered
• In vehicles where the expansion valve sensing bulb is with insulation material. Operate the system and check
accessible, check the capillary tube for proper mounting performance.
and contact with the evaporator outlet tube.
• Perform the following test if the valve is accessible. If it Repair Procedure:
is not, proceed to the Repair Procedure. If the test did not result in proper operation of expansion
valve, the valve is defective and must be replaced.
Recover all refrigerant from the system and replace the
expansion valve and the receiver-drier. Evacuate and
recharge the system with refrigerant, then check AC
operation and performance.
40-76 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Cause:
• There could be a kink in a line, or other restriction in the
high side of the system.
Compressor Malfunction
SK1026-5N 40-77
TROUBLESHOOTING AIR CONDITIONING SYSTEM
40-78 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
MEMORANDUM
SK1026-5N 40-79
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Remark
Compressor should be run at least 5 minutes (40° F {4° C}) minimum ambient temperature) every month,
in order to circulate oil and lubricate components.
Maintenance Interval
Component (Months)
3 6 12 Done
Compressor
1 Check belt tension: 80 - 100 lbf (356 - 445 N) (11.1 - 13.8 kgf.m) V-belt •
Check alignment of clutch w/crankshaft pulley (within 0.06 in. {1.5 mm}) •
Condenser
Receiver - Drier
Expansion Valve
4 Inspect capillary tube (if used) for leakage, damage, or
•
looseness)
40-80 SK1026-5N
TROUBLESHOOTING AIR CONDITIONING SYSTEM
Maintenance Interval
Component (Months)
3 6 12 Done
Evaporator
Other (Components)
SK1026-5N 40-81
TROUBLESHOOTING AIR CONDITIONING SYSTEM
MEMORANDUM
40-82 SK1026-5N
50 DISASSEMBLY AND ASSEMBLY
SK1026-5N 50-1
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
50-2 SK1026-5N
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
SK1026-5N 50-3
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS SECTION
A. Necessity
■: Special tools that cannot be substituted and should always be used (installed).
●: Special tools that will be useful if available and are substitutable with commercially available tools.
Removal
• The [Removal] section contains procedures and precautions for implementing the work, expertise, and the amount of oil
or coolant to be drained.
• General tools that are necessary for removal are described as [1], [2]•••etc. and their part names, part numbers and
quantities are not described.
• Various symbols used in the Removal Section are explained and listed below.
WARNING! This mark indicates safety-related precautions that must be followed when
implementing the work.
Installation
• Except where otherwise instructed, installation of parts is done in the reverse order of removal.
• Instructions and precautions for installing parts are shown with [*1] mark in the Installation Section, identifying which
step the instructions are intended for.
• General tools that are necessary for installation are described as [1], [2]•••etc. and their part names, part numbers and
quantities are not described.
• Marks shown in the Installation Section stand for the following.
50-4 SK1026-5N
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS SECTION
★ :This mark gives guidance or precautions when doing the procedure.
Tightening torque.
A. Necessity
■ : Special tools that cannot be substituted and should always be used (installed).
• : Special tools that will be useful if available and are substitutable with commercially available tools.
WARNING! This mark indicates safety-related precautions that must be followed when implementing
the work.
Assembly
• In Assembly section, the work procedures, precautions and expertise for performing those procedures, and quantity of the
oil and coolant added are described.
• General tools that are necessary for assembly are described as [1], [2]•••etc. and their part names, part numbers and
quantities are not described.
SK1026-5N 50-5
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS SECTION
• The meanings of the symbols used in Assembly section are as follows.
Tightening torque.
50-6 SK1026-5N
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS SECTION
MEMORANDUM
SK1026-5N 50-7
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
3. If the part is not under hydraulic pressure, the following corks can be used:
Dimensions
Nominal number Part 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
50-8 SK1026-5N
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
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
SK1026-5N 50-9
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
Other Precautions
• To maintain performance of the machine and to prevent failures, it is particularly important to pay attention to the degree
of cleanliness of oil in the hydraulic circuits. When adding or changing the oil, or when replacing the filters, check that the
oil container and area around the filler of the hydraulic tank are clean.
• To keep the hydraulic circuits clean and to protect hydraulic equipment, be careful of the following when disassembling or
assembling:
★ Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be
disassembled.
★ Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
★ Perform thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that
have failed.
★ When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
★ Do not use seal tape for the thread of plug mounts or connections.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, always
thoroughly flush the hydraulic circuits.
• When changing oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the air
before starting the engine to prevent seizure of the pump. For details, see “Bleeding Air From the Pump” on page 30-31.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without going
to the end of this stroke. (Stop approximate 100 mm (4 in.) before the end of the stroke.)
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of its stroke, the air inside the
cylinder will cause damage to the piston packing.
2. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step B to bleed the air. Repeat this procedure until no more air comes out from the
plugs.
4. After completing bleeding the air, tighten the plugs.
50-10 SK1026-5N
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
Stripping Insulation
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the table below.
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)
Wire Inspection
After stripping insulation from wire, inspect wire strands for:
• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause high
resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire strand
breakage during the crimping process.
SK1026-5N 50-11
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
Remark
Using a removal tool that is too large or too small will hinder
wire removal and may damage the connector or removal
tool. Always use the correct removal tool size for the wire
gauge you are servicing.
3. In a straight line, carefully slide the removal tool along the wire and
into the grommet until a contact resistance is felt.
Remark
Do not pull on the wire or twist the tool when inserting
removal tool into the grommet. Damage to tool or connector
may result.
4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.
5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.
50-12 SK1026-5N
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
3. Insert contact terminal with barrel up. Turn the adjusting screw
counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
SK1026-5N 50-13
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
50-14 SK1026-5N
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.
SK1026-5N 50-15
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
3. Insert the contact terminal with barrel up. Turn adjusting screw
counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
50-16 SK1026-5N
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
2. Hold the connector with the rear grommet facing you and insert the
completed wire into the connector.
3. Push the contact terminal straight into the connector until a "click"
is felt. A slight tug will confirm that the contact terminal is properly
locked in place.
4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The wedge
lock will snap into place. Rectangular wedges are not oriented and
may fit either way.
Remark
As the connector receptacle is shown - use the same
procedures for a plug.
SK1026-5N 50-17
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
MEMORANDUM
50-18 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
ENGINE
Remark
For disassembly and assembly of the following components, see the ENGINE SHOP MANUAL.
SK1026-5N 50-19
DISASSEMBLY AND ASSEMBLY ENGINE
Removal
1. Tilt the cab until it is resting on a support.
(For details, see “Tilting the Cab” on page 30-38). [*1]
6. Disconnect connectors X10 (4), X01 (5), X42 (6) and X02 (7) that
connect control unit (1) to the engine and frame wiring harness.
50-20 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
8. Disconnect fuel level sensor (11) and connector (10).
11. Disconnect the heating system supply (15) and return (16) hoses
from the engine and drain any engine coolant from the hoses.
★ Mark the lines to avoid mixing them up during reassembly.
12. Remove clamp (17), disconnect line (19) and connector (20) from
tank (18).
SK1026-5N 50-21
DISASSEMBLY AND ASSEMBLY ENGINE
13. Disconnect throttle cable (22) from engine (21).
14. Disconnect the sensor connector on the accelerator cable support.
15. Disconnect delivery (25) and return (26) lines from container (23)
and filter (24).
16. Disconnect lines (28), (29) and (30) from pump (27).
★ Mark the lines to avoid mixing them up during reassembly.
17. Disconnect pipes (31), (32), (33) and (34) from the pump.
★ Mark the lines to avoid mixing them up during reassembly.
50-22 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
18. Attach a hoist and tackle to the engine assembly and apply slight
tension to the cables.
19. Loosen the four nuts (35) that secure the engine and remove the
complete assembly. [*3]
Installation
• To install, reverse removal procedure. [*1]
1. Adjust the accelerator cables.
(For details, see “Adjusting the Stroke of the Accelerator Cables” on page 30-13)
2. Fill the hydraulic oil tank up to maximum level. [*2]
3. While filling the tank, bleed the air from the pump.
(For details, see “Bleeding Air From the Pump” on page 30-31).
5. Fill the fuel tank and bleed the air from the system.
(For details, see “Bleeding Air From Fuel System” on page 30-4).
6. Start the engine to circulate the oil and coolant and check for leaks.
7. Stop the engine, check the levels and, if necessary, top them off.
8. Bleed the air from the hydraulic circuits and pressurize the tank.
(For details, see “BLEEDING HYDRAULIC CIRCUITS” on page 30-31).
[*3]
SK1026-5N 50-23
DISASSEMBLY AND ASSEMBLY ENGINE
Valve Cover
Removal
WARNING! Disconnect the negative terminal cable (-)
from the battery.
50-24 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
7. Loosen two screws (11), remove the four centering bushings (12)
and valve cover (13). [*2]
Installation
• To install, reverse the removal procedure.
[*1]
[*2]
★ Check the condition of cover gasket and if necessary replace it.
SK1026-5N 50-25
DISASSEMBLY AND ASSEMBLY ENGINE
Nozzle Holder
Remark
For disassembly and assembly of the nozzle holder, see the ENGINE SHOP MANUAL.
Removal
1. Remove the air filter (1).
(For detail see “AIR CLEANER ASSEMBLY” on page 30-45).
2. Remove the valve cover (1).
(For detail see “Valve Cover” on page 30-24).
3. Loosen the five screws (1) and remove the fuel pipe (2). [*1]
★ Take care to not damage the five gaskets (3).
4. Loosen the screws (4) and remove the four bracket (5). [*2]
Installation
To install, reverse the removal procedure.
[*1]
[*2]
Screws (4): 22.6 - 28.4 N•m (200 - 251 lbf in) {17 - 21 lbf ft}
50-26 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
Removal
WARNING! Disconnect the negative terminal cable
(-) from the battery. Close the cock of the
water separator to prevent fuel leakage.
4. Disconnect from injection pump (4) fuel feeding pipes (5), return
pipes (6), feedback pipe (7) and the coolant pipes (8) and (9).
5. Disconnect high pressure pipes (10) from injection pump (4). [*2]
SK1026-5N 50-27
DISASSEMBLY AND ASSEMBLY ENGINE
7. Remove fan (12) and cover (13). [*3]
8. Loosen and remove nut (14) and lock washer (15) of pump driving
gear. [*4]
★ Be careful not let nut (14) and lock washer drop in the housing.
50-28 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
11. Loosen screws (18) (No. 3) and remove injection pump (4) with
O-rings (19). [*6]
Installation
• To install, reverse the removal procedure.
★ Check accelerator stroke lever. (For details, see “Adjusting the Stroke of the Accelerator Cables” on page 30-13).
[*1]
[*2]
[*3]
★ Align marks among gears before to install pump and nut. [*4]
SK1026-5N 50-29
DISASSEMBLY AND ASSEMBLY ENGINE
Cylinder Head
Remark
For disassembly and assembly of the cylinder head, see the ENGINE SHOP MANUAL.
Removal
WARNING! Disconnect the negative terminal cable
(-) from the battery.
50-30 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
8. Remove the rocker-arm shaft (8).[*2]
★ Loosen the lock nuts and unscrew the valve tappets by 2-3
turns. [*3]
9. Take out the rocker-arm control rods (9).
10. Take out the screws (10) in the sequence indicated and remove the
complete cylinder head (11).[*4]
★ The cylinder head gasket (12) must be substituted every time it
is dismantled.
SK1026-5N 50-31
DISASSEMBLY AND ASSEMBLY ENGINE
Installation
• To install, reverse the removal procedure.
[*1]
1. Fill up the cooling circuit.
2. Start the engine to circulate the liquid through all circuits. Stop the engine and check the level.
3. Pressurize the hydraulic tank and bleed air from the hydraulic circuits.
(For details, see “BLEEDING HYDRAULIC CIRCUITS” on page 30-31).
[*2]
Second step:
Screw: 22.6 - 28.4 N•m (17 - 21 lbf ft)
[*3]
★ Adjust valve clearance. (For details, see “Adjustment of Valve Clearance” on page 30-6).
[*4]
★ Raise the cylinder head, keeping it horizontal, and place it on the
gasket without shifting anything.
★ Lubricate the screw-threads with engine oil.
★ Tighten screws in two steps in the sequence given. (See illustration
on the right).
First step:
Screw: 49.0 - 58.8 N•m (36 - 43 lbf ft)
Second step:
Screw: 103.1 - 112.9 N•m (76 - 83 lbf ft)
50-32 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
Water Pump
Remark
For disassembly and assembly of the cylinder head, see the ENGINE SHOP MANUAL.
Removal
WARNING! Disconnect the negative terminal cable
(-) from the battery.
3. Loosen screws (5) and remove the complete pump (6) and gasket
(7). [*3]
Installation
• To install, reverse removal procedure.
[*1]
1. Fill up the coolant circuit.
2. Start the engine and idle for a few minutes; re-check the coolant
level again and add coolant if necessary before replacing radiator
cap.
[*2]
★ Adjust the belt tension. (For details, see “Control and Adjustment of the Fan Belt Tension” on page 30-9).
[*3]
★ A new gasket (7) must be fitted each time the pump is removed.
SK1026-5N 50-33
DISASSEMBLY AND ASSEMBLY ENGINE
Starter Motor
Remark
For disassembly and assembly of the starter motor, see the ENGINE SHOP MANUAL.
Removal
1. Tilt the cab and secure it in its safety position. (For details, see
“Tilting the Cab” on page 30-38.)
2. Remove battery (1). (For details, see “BATTERY” on page 30-44).
Remark
Do not allow the starter motor to hang from the cables,
damage to the cables may result.
4. Loosen the bolts (4) and remove the starting motor (5).
Installation
• To install, reverse removal procedure.
50-34 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
Turbocharger
Remark
For disassembly and assembly of the turbocharger, see the ENGINE SHOP MANUAL.
Removal
1. Remove the muffler.
(For details see “MUFFLER ASSEMBLY” on page 30-46).
2. Loosen clamps (1), (2) and disconnect intake hose (4) and supply
hose (5) from turbocharger (3).
3. Loosen fitting (6) and disconnect upper lubrication pipe (7) from
turbocharger (3).
★ Seals (8) must be replaced at each disassembly.
4. Loosen clamp (9) and remove the lower lubrication pipe (10).
Installation
• To install, reverse removal procedure.
SK1026-5N 50-35
DISASSEMBLY AND ASSEMBLY ENGINE
Alternator
Remark
For disassembly and assembly of the alternator, see the ENGINE SHOP MANUAL.
Removal
1. Tilt the cab and secure it in its safety position. (For details, see
“Tilting the Cab” on page 30-38.)
2. Remove battery (1). (For details, see “BATTERY” on page 30-44).
3. Disconnect the cable (1) and (2), then connectors (3).
4. Loosen fasteners (4) and (5) to allow the alternator to move freely.
5. Remove fan belt (6) from the pulley and remove the alternator (7).
Installation
• To install, reverse removal procedure.
• Adjust the tension of the fan-belt. (For details, see “Control and Adjustment of the Fan Belt Tension” on page 30-9).
50-36 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY
1. Remove the retaining fasteners (1) from hinges (2) and (3).
2. While lifting the hood, remove the retaining nut (4) from the shock
strut (5). [*1]
Installation
1. To install, reverse removal procedure. [*1]
2. Check and centre the lock engagement.
SK1026-5N 50-37
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
Remark
Only if the engine or the complete pump are to be
removed, remove the engine hood. For removal details
see “ENGINE HOOD ASSEMBLY” on page 30-37.
4. Loosen the fasteners (5) (two to each side) and raise the cab as far
as the safety cables allow. [*1]
5. Insert the safety pin
50-38 SK1026-5N
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
6. Disconnect cable (12) from the accelerator lever and from the
engine (11).
10. Disconnect the heating system supply (16) and return (17) hoses
from the engine.
• Mark the lines to avoid exchanging them during reassembly.
11. Attach the cab (18) to a hoist. Be sure the hook and straps are in
place
SK1026-5N 50-39
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
12. Remove pin (19) and the washers (20).
13. Remove the safety pin.
14. Push cab (18) gently towards ”its at rest” position to relieve tension
on the safety cables (21), and disconnect them from the pins (22).
15. Tilt the cab (18) slowly until the distance between the centers of the
hooks (23) is 1100 mm (43 in).
★ The distance of 1100 mm (43 in) corresponds to the maximum
stretch of the dumper hooks.
16. Remove pins (22) from the dumper hooks (23).
17. Position a stand “A”, about 1200 mm (48 in) high, and tilt the cab
(18) until it is resting on the stand.
★ Make sure that the connecting cables between the cab and the
engine are not being strained.
50-40 SK1026-5N
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
3. Disconnect connectors (3) from the cab cabling (4) and release the
engine cable (5) from its retaining clamps.
4. Tilt the cab. (For details, see“Tilting the Cab” on page 30-38).
5. Disconnect the four lines (6) on the RH side, the two servo-control
feed-lines (7) and the four lines (8) on the LH side.
★ To disconnect the lines, remove the retainer (9) push line (6)
completely inside the union (10) and extract line (6).
★ Mark all hoses to avoid any mix-up during reassembly. [*1]
SK1026-5N 50-41
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
With Front Door
7. Loosen fastener (11) and remove clamp (12).
8. Remove clamps (13) that secure the lines.
9. Disconnect the heating systems supply (14) and return (15) hoses
from the engine and drain any engine coolant from the hoses.
★ Mark the hoses to avoid mixing them during installation.
10. Remove clamp (16) and disconnect the line (18) from washer tank
(17).
11. Disconnect the accelerator lever cable (20) from the engine (19).
[*2]
50-42 SK1026-5N
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
12. Connect the cab (21) to hoist and tackle.
13. Remove the safety pins (22) and the washers (23).
14. Push the cab slightly towards its “at rest” position to relieve the
strain on the safety cables (24), and disconnect the cables from the
pins (25).
15. Tilt the cab (21) slowly until the distance between the centres of the
hooks is 1100 mm (43 in)
★ The distance of 1100 mm (43 in) corresponds to the maximum
stretch of the hooks.
16. Remove the pins (25) from the hooks (26).
17. Loosen nuts (27) and remove the fasteners (28) and washers (29).
18. Remove the complete cab assembly (21).
SK1026-5N 50-43
DISASSEMBLY AND ASSEMBLY BATTERY
BATTERY
WARNING! When handling batteries always wear
personal protective equipment including
face shield, rubber gloves and apron.
Never allow an open flame or smoke
around batteries, explosive gasses may
be present.
Removal
1. Loosen screws (1) and remove cover (2).
2. Disconnect the negative cable (-) (3) first and the positive cable (+)
(4) next from the battery (5) in that sequence.
3. Loosen the nuts (6) that secure battery clamp (7) and remove the tie
rods (8) of the battery support.
★ Disconnect battery clamp (7)
4. Tilt battery clamp (7) towards the front of the machine and lift out
and remove the battery (5).
Installation
• To replace, reverse removal procedure.
50-44 SK1026-5N
DISASSEMBLY AND ASSEMBLY AIR CLEANER ASSEMBLY
1. Loosen the clamp (1) and remove the suction elbow (2).
2. Disconnect the connector (3).
Installation
• To install, reverse removal procedure.
SK1026-5N 50-45
DISASSEMBLY AND ASSEMBLY MUFFLER ASSEMBLY
MUFFLER ASSEMBLY
Removal
1. Loosen clamp (1) and remove inlet hose (2).
5. Remove four nuts (9) that secure muffler (8) to turbocharger (10).
50-46 SK1026-5N
DISASSEMBLY AND ASSEMBLY MUFFLER ASSEMBLY
6. Remove muffler (8).
★ A new gasket (11) should be installed each time the muffler is
removed.
Installation
• To install, reverse removal procedure.
SK1026-5N 50-47
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
RADIATOR ASSEMBLY
Removal
1. Completely raise the working equipment and tilt the cab. (For
details, see “Tilting the Cab” on page 30-38). [*1]
2. Drain the hydraulic oil.
50-48 SK1026-5N
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
Installation
[*1]
★ To install, reverse removal procedure.
1. Fill the hydraulic oil to maximum level.
3. Start the engine to circulate the oil and coolant, and check for leaks.
[*2]
4. Stop the engine, check the levels and, if necessary, top them off.
5. Pressurizes the tank and bleed the air from all circuits.
(For details, see “BLEEDING HYDRAULIC CIRCUITS” on page 30-31).
SK1026-5N 50-49
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
1. Remove fasteners (1) and loosen the fastener (2), leaving them in
place.
4. Disconnect the return (7) line from filter (6) and the delivery line
(9) from bottle (8).
50-50 SK1026-5N
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
6. Loosen fastener (12) that secure the rear bracket (13).
7. Disconnect wire connector (14) from the level sensor.
8. Raise the tank (15) and move it towards the front of the machine.
Installation
• To install, reverse removal procedure.
SK1026-5N 50-51
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
2. Disconnect lines (5), (6), (7), and (8) from the pump.
★ Mark all lines to avoid mixing them up during reassembly.
50-52 SK1026-5N
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
4. Attach the pump (1) to a hoist tackle and apply a slight tension to
the cables.
5. Loosen the eight fasteners (12) and remove the pump (1) complete
with bell housing (13). [*1]
6. Loosen fastener (14) and disconnect pump (1) from bell housing
(13). [*2]
SK1026-5N 50-53
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
Installation
• To install, reverse removal procedure.
[*1]
[*2]
2. Bleed the air from the pump. (For details, see “Bleeding Air From the Pump” on page 30-31).
3. Fill the coolant to maximum level.
4. Start the engine to circulate the oil and check that there are no leaks.
5. Stop the engine, check the levels and, if necessary, top them up.
6. Bleed the air from the hydraulic circuits and pressurizes the tank. (For details, see “Bleeding Air From the Cylinders” on
page 30-31 and “Bleeding Air From Optional Equipment” on page 30-31).
50-54 SK1026-5N
DISASSEMBLY AND ASSEMBLY GEAR PUMP ASSEMBLY
3. Disconnect from pump (1) the suction line (2) and (3) (one for the
normal version, two for the HIGHFLOW version).
4. Loosen the two fasteners (4) and remove the pump (1) complete
with the O-ring (5).
Installation
• To install, reverse removal procedure.
SK1026-5N 50-55
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP COUPLING
ENGINE-PUMP COUPLING
Removal
1. Fully raise the working equipment and tilt the cab. (For details, see
“Tilting the Cab” on page 30-38).
2. Remove the pump. (For details, see “HYDRAULIC PUMP
ASSEMBLY” on page 30-52).
Half-coupling On Pump
3. Loosen dowel (1) that secures the coupling (2). [*1]
★ Heat the dowel at 85-100°C (185-212°F) temperature.
4. Remove the pump coupling (2).
★ Use an extractor if necessary.
Half-coupling On Flywheel
5. Remove fastener (3) and the flange (4). [*2]
Installation
• To install, reverse the removal procedure.
[*1]
[*2]
1. Fill the tank up to maximum level bleed the air from piston pump and pressurize the tank. (For details, see “Bleeding Air
From the Pump” on page 30-31).
2. Start the engine to circulate the oil and check for leaks.
3. Stop the engine, check the levels and, if necessary, top them up.
50-56 SK1026-5N
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
Removal
WARNING! Fully raise the working equipment and tilt the cab. (For details, see “Tilting the Cab” on
page 30-38).
WARNING! Release residual pressures from all hydraulic circuits and the tank. (For details, see
“Elimination of Pressure” on page 30-30).
2. Loosen three fasteners (4) and remove the control valve (1).
Installation
1. To install, reverse removal procedure.
3. Start the engine and run at low idle to circulate the oil throughout the system.
4. Pressurize the tank and bleed the air from all circuits.
(For details, see “Bleeding Air From the Pump” on page 30-31).
SK1026-5N 50-57
DISASSEMBLY AND ASSEMBLY PPC VALVES
PPC VALVES
Removal
1. Lower the working equipment until it is resting on the ground, stop
the engine and remove the ignition key.
2. Release residual pressures from all circuits and from the tank.
Installation
• To install, reverse removal procedure.
Left Hand PPC Valve
Position
P T P1 P2 P3 P4
M S A R L R
White White Yellow Yellow Blue Blue
Position
P T P1 P2 P3 P4
M S D S C A
White White Red Red Yellow Yellow
• If the unions are removed from the PPC valves, make sure that a
union with a filter is mounted at the “P” inlet.
• Check the positions for the line connections carefully.
50-58 SK1026-5N
DISASSEMBLY AND ASSEMBLY PPC VALVES
MEMORANDUM
SK1026-5N 50-59
DISASSEMBLY AND ASSEMBLY CAB HEATER ASSEMBLY
3. Disconnect the heating systems supply (4) and return (5) hoses
from the engine and drain any engine coolant from the hoses.
★ Mark the hoses to avoid mixing them up during reassembly.
4. Loosen the fastener (6) and remove the front part of the air intake
line (7).
5. Remove the upper retaining fastener (8) from the heater assembly.
50-60 SK1026-5N
DISASSEMBLY AND ASSEMBLY CAB HEATER ASSEMBLY
6. Remove the lower retaining screws (9) from the heater assembly.
7. Rotate the heater assembly (10) towards the inside of the machine
and remove the retainer clamp (11) from the washer pipe (12).
8. Disconnect the connector (13) and remove the heater assembly (10)
together with the supply and return hoses.
Installation
• To install, reverse removal procedure.
1. Fill the cooling system with engine coolant.
2. Start the engine to let the coolant circulate.
3. Stop the engine and top off.
SK1026-5N 50-61
DISASSEMBLY AND ASSEMBLY WHEEL HUB ASSEMBLY
2. Loosen the nuts (1) and take off the tire (2). [*1]
3. Loosen the drain plug (3) in order to drain the chain and gearing
lube oil.
5. Loosen the nuts (5) and take off the cover (6). [*2]
★ Check condition of seal (7) and install a new one if necessary.
50-62 SK1026-5N
DISASSEMBLY AND ASSEMBLY WHEEL HUB ASSEMBLY
6. Start the engine and allow the pinion (8) to turn slowly until the
master links (9) are both positioned on the upper section of the
chain.
7. Remove the pins (10) and pull out the master link (9). [*3]
Installation
[*1]
• To install, reverse removal procedure.
[*2]
[*3]
1. Make sure that the master link is in the correct position with respect
to the pinion.
2. Adjust the tension of the chains.
(For details, see “CHAIN TENSION” on page 30-18).
3. Fill the oil up to maximum level.
[*4]
SK1026-5N 50-63
DISASSEMBLY AND ASSEMBLY WHEEL HUB ASSEMBLY
Disassembly
1. Remove the wheel hub (1).
(For details, see “Removal” on page 30-62).
2. Place the wheel hub (1) in a vice and loosen the fastener (2). [*1]
3. Remove the disk (3) and the shims (4). [*2]
★ Make a note of the number and positions of the shims (4).
5. Position the wheel hub (1) beneath a press and slowly extract the
axle shaft (6) until it is released from the inner ring (7).
★ Place the wheel hub (1) on two supports “A” about 520 mm
(20.4 in) high.
6. Remove the inner bearing (7).
7. Proceed with the removal of the axle shaft (6) until it is fully
removed from the bearing (8). [*3]
50-64 SK1026-5N
DISASSEMBLY AND ASSEMBLY WHEEL HUB ASSEMBLY
8. Place the hub (1) in a vice and extract the seal ring (9).
9. Mount a new seal ring (9) each time the hub is dismantled.
10. Extract the outer rings (7) and (8). [*4]
Assembly
• To install, reverse removal procedure.
[*1]
[*2]
1. Take the existing measurement “X” between the axle shaft (6) and
the ring bevel gear (5).
2. Calculate the thickness of shims that should be inserted between the
disc (3) and the ring bevel gear (5) using the following formula:
S=X-Z
• S = the shim pack
• X = the measurement taken
• Z = residual clearance [0.05-0.125]
★ For example: clearance measured X = 0.570 Addition of two shims of 0.2 and one of 0.1
3. Check that the measurement X lies within the permissible limits.
[*3]
4. Grease bearings (7) and (8).
[*4]
5. Grease the lip of the seal ring (9).
SK1026-5N 50-65
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
3. Disconnect from the final drive (2) the supply pipes (3), the speed
increment pipe (4) and the drainage pipe (5).
★ Cap all lines to prevent entry of impurities.
4. Attach the final drive (2) to some type of hoist and tackle and apply
a slight tension to the chains.
5. Loosen the 10 fastener (6) and remove the complete final drive
assembly (2). [*1]
★ Check the condition of the O-ring (7) and replace it with a new
one if necessary.
50-66 SK1026-5N
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
Installation
• To install, reverse removal procedure.
Grease the O-ring. [*1]
SK1026-5N 50-67
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
CYLINDER ASSEMBLIES
Lift Cylinder Assembly
Removal
WARNING! Lower the working equipment until it is resting on the ground. Release residual pressures
from all circuits. (For details, see “Elimination of Pressure” on page 30-30).
4. Push the cylinder (4) towards the front of the machine, loosen the
screws (5), remove the rear bracket (6) retaining the plate (3) and
remove the plate.
50-68 SK1026-5N
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
6. Remove the clamps (9); disconnect the hoses (10) from the fittings
(11).
★ Mark the hoses for position to avoid mixing them during
installation.
★ Plug the hoses (10) and fittings (11) to prevent foreign material
and dirt from entering.
7. Connect the cylinder (4) to a hoist, tension the belt, loosen the
screw (12) and remove the pin (13). [*1], [*2]
8. Remove the cylinder (4) together with the hoses (10).
Installation
• To install, reverse removal procedure.
[*1]
[*2]
WARNING! When the positions of hole and pin line up, idle the engine. Do not insert fingers into the
holes to check alignment.
1. Start the engine and bleed air from the cylinder. (For details see “Bleeding Air From the Cylinders” on page 30-31).
★ When air bleeding is complete, check the oil level in the tank.
SK1026-5N 50-69
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
1. Remove pin (1) and fully retract the piston rod (2). [*1], [*2]
★ Make a note as to the position of the adjustments and given
clearance.
3. Remove pin (6) and lift off cylinder (3). [*1], [*3]
★ Make a note as to the position of the adjustments in relation to
the given clearance.
50-70 SK1026-5N
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
Installation
• To install, reverse removal procedure.
WARNING! When aligning the positions between the hole and the pin, do not insert fingers into the
holes to check alignment.
[*1]
[*2]
1. Insert the removed shims and, if necessary, add more until the
residual clearance is about 1 mm (0.039 in).
[*3]
2. Insert the removed shims and, if necessary, add more until the
residual clearance is about 1 mm (0.039 in).
3. Start the engine and bleed the air from the cylinder. (For details, see
“Bleeding Air From the Cylinders” on page 30-31).
★ After bleeding the air, check the level of oil in the tank
SK1026-5N 50-71
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
3. Attach special wrench “C” (adjusted to fit the cylinder) to head (3)
and apply dynamometric tool “D”.
4. Unscrew head (3) and completely remove it from the cylinder (2).
50-72 SK1026-5N
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
5. Raise the cylinder, and hook the piston rod to the mobile group of
tool “A”.
6. Extract the piston rod assembly (4) from the cylinder.
7. Remove cylinder (2) and the piston rod assembly.
SK1026-5N 50-73
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
4. Install O-ring (10), the anti-extrusion ring (11), and O-ring (12) on
to the cylinder head (3).
50-74 SK1026-5N
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
Piston Assembly
1. Using tool “H”, install the piston seal. Install in sequence rubber
ring (13), outer seal (14), and anti-extrusion rings (15).
3. Install pilot boss “L” set to the diameter onto the outside of the
piston rod.
4. Slide head (3) onto the piston rod (4).
5. Remove pilot boss “L” from the outside of the piston rod.
SK1026-5N 50-75
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
6. Install the complete piston (6).
7. Install nut (5) that secures the piston and tighten it with socket
wrench “E” and the dynamometric tool with a multiplier “D”.
Cylinder Assembly
1. Set tools “A” onto apparatus “B”.
2. Position bushing (20) and install it onto cylinder (2).
★ Leave the cylinder in position, ready for the next assembly
operation.
4. Place the two halves of tool “M”, set to the diameter, onto the end
of cylinder (2).
50-76 SK1026-5N
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
5. Install the piston rod group (4) onto tool “A” and raise the movable
part up to the end of its stroke.
6. Position cylinder (2) into a vertical position and guide the piston
into tool “M”.
7. Lower the apparatus supporting piston rod (4) in order to insert the
piston into the cylinder liner (2).
8. Remove tool “M” from the cylinder and then lower apparatus “A”
even further, until head (3) and the piston rod reach the cylinder.
9. Place cylinder (2) in position for installing the head (3).
10. Insert the head (3) into the cylinder and screw it in by hand for a
few turns.
11. Attach special wrench “C” to the impact tool “D” and screw head
(3) into the cylinder.
12. Install guard rings (1) on both sides of the cylinder and piston rod.
SK1026-5N 50-77
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
3. Connect the complete arm (1) to a hoist and tension the cables.
★ Cable length: approximately 2 m (6.5 ft)
50-78 SK1026-5N
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
4. Remove snap ring (7) and 6 shims (8).
5. Loosen screw (10) and remove pin (11).
★ Check for a damaged seal (9), replace if necessary.
6. Introduce wooden shims "A" between lift lever (12) and fulcrum
lever (13).
7. Lift the arm until the tool holder frame fulcrum pin and arm
fulcrum pin line up.
8. Loosen screw (14), remove pin (15) and remove the work
equipment.
SK1026-5N 50-79
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
[*2]
★ Introduce shims between arm and frame until residual clearance is
less than 1 mm (0.039 in).
1. Start the engine and bleed the air from the cylinder. (For details, see
“Bleeding Air From the Cylinders” on page 30-31).
★ After bleeding the air, check the level of oil in the tank
50-80 SK1026-5N
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
WARNING! When aligning the positions between the hole and the pin, do not insert fingers into the
holes to check alignment.
[*1]
[*2]
★ Introduce shims between the fulcrum lever and frame until the
residual clearance is less than 1 mm (0.039 in).
SK1026-5N 50-81
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
4. Hoist lift lever (1) until the center hole on the lever and the fulcrum
hole on the frame line up.
50-82 SK1026-5N
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
5. Remove bolt (4) and lock pin (5) and remove lift lever (1).
WARNING! When aligning the positions between the hole and the pin, do not insert fingers into the
holes to check alignment.
[*1]
[*2]
★ Introduce shims between the lift lever and frame until the residual
clearance is less than 1 mm (0.039 in).
SK1026-5N 50-83
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
2. Remove the pins (1) and retract the cylinder piston rods (2).
Check and make a note of the positions of the adjustments to a
given clearance. [*1], [*2]
3. Remove the pins (3) and take off the complete working equipment
support frame (4). [*2]
WARNING! When aligning the positions between the hole and the pin, run the engine at loe idle.
ATTENTION! DO NOT insert fingers into the holes to check alignment.
50-84 SK1026-5N
90 DIAGRAMS AND SCHEMATICS
SK1026-5N 90-1 1
DIAGRAMS AND SCHEMATICS
12
90-21 SK1026-5N
DIAGRAMS AND SCHEMATICS
100 100
MESH P1 P2 P3 P4 MESH
UNLOAD VALVE
Ø0.5 P
HYDRAULIC CIRCUIT DIAGRAM PORT
T T
Ø6.41=1550
(9/16-18 JIC)
Ø7.3
Ø6.51=500 Ø15.91=1100 (1”3/16-12 ORFS) +40cm 2 /rev +40cm 2 /rev
(9/16-18 JIC) E
Ø15.91=1100 (1”3/16-12 ORFS)
ENGINE
B A S4D98E-2NFE
PP1 PP2 84.2/2500 PS/rpm
(61.9/2500 Kw/rpm
PB1 T5 PB2 S3 S4
Ø24.6~26.21=1000
Ø32.1=620
Ø19.11=900 (1”5/8-12 JIC)
(1”1/16-12 JIC) Ø9.51=1000 (9/16-18 JIC)
Ø6.51=350 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
RED
Ø191=1650 Ø16 Ø191=1450
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)
CVSM0362
T
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
P
LIFT ARM CYLINDER L.H.
Ø6.51=400 (1/2-20 JIC)
100 100
P1 P2 P3 P4 MESH P1 P2 P3 P4 MESH
Ø9.51=1200 (13/16-16 ORFS)
PORT
Ø9.51=530 (13/16-16 ORFS)
PA1
LIFT ARM
Ø9.51=530 (13/16-16 ORFS) LOWER
UNLOAD VALVE
P3 OUT P2 IN
Ø6.41=1550
(9/16-18 JIC)
P2 OUT P1 IN
PP2 A B PP1 PA1 DA1 DB1 DB2 DA2 PA2 P4
P1 OUT P3 IN
P5 OUT P5 IN
33.2 cm 2 /rev
Ø15.91=1100 (1”3/16-12 ORFS)
28 cm 2/rev
Ø6.51=600 P6 OUT P6 IN
(9/16-18 JIC) Ø15.91=1100 (1”3/16-12 ORFS)
Ø24.6~26.21=1000
Ø32.1=620 P
(1”5/8-12 JIC)
Ø9.5=1150 (9/16-18 JIC)
T
Ø19.11=900
(1”1/16-12 JIC) Ø9.51=1000 (9/16-18 JIC)
Ø6.51=350 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
RED
Ø191=1650 Ø16 Ø191=1450
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)
CVSM0363
FEMALE 1/2
Ø16 t=2 Ø12.71=3700 (13/16-16 ORFS)
PORT
B3
PORT PORT Ø6.51=400 (1/2-20 JIC)
Ø9.51=1200 (13/16-16 ORFS) PB3 PA3
PORT
Ø9.51=530 (13/16-16 ORFS) PB1
LIFT ARM A1
Ø9.51=530 (13/16-16 ORFS) RAISE B1
P4 OUT P4 IN
P6 OUT P6 IN
Ø15.91=1100 (1”3/16-12 ORFS)
33.2 cm 2 /rev
23.7 cm 2 /rev
28 cm 2/rev
Ø6.51=600
Ø15.91=1100 (1”3/16-12 ORFS)
(9/16-18 JIC) OPTION PATTERN (CASE)
PP1 B A PP2
ENGINE
Ø6.41=1550 S4D98E-2NFE
(9/16-18 JIC) 84.2/2500 PS/rpm
(61.9/2500 Kw/rpm
PB1 T5 PB2 S3 S4 S5
(1”5/16-12 JIC)
(1”5/8-12 JIC)
Ø25.41=800
Ø32.1=620
Ø24.6~26.21=1000 SV1 SPEED SV2 PPC SV3 BRAKE
A B C
Ø9.5=1150 (9/16-18 JIC)
Ø25.41=430
TRAVEL MOTOR R.H. DR (1”5/16-12 JIC)
Ø191=850
Ø9.51=1300 (9/16-18 JIC) (1”1/16-12 JIC)
Ø42
Ø9.51=1300 (9/16-18 JIC)
CVSM0364
ARM FLOAT
UNLOAD VALVE
CONNECTOR
12V CN-A
TRAVEL MOTOR L.H. ISO PATTERN (KOMATSU)
DR OUTPUT INPUT
PORT PA1
PORT
P Ø6.41=650 (1/2-20 JIC) P4 OUT P4 IN
RED
PORT LIFT ARM LOWER
TS Ø6.41=850 (1/2-20 JIC) P3 OUT P2 IN
Ø0.5
Ø6.41=650 (1/2-20 JIC) P2 OUT P1 IN
HYDRAULIC CIRCUIT DIAGRAM PORT
T
Ø6.41=950 (1/2-20 JIC) P1 OUT P3 IN
RELIEF VALVE
20.6MPa Ø6.41=1500 (1/2-20 JIC) P5 OUT P5 IN
(210kg/cm 2 )
Ø6.41=950 (1/2-20 JIC) P6 OUT P6 IN
P5 OUT P5 IN
33.2 cm 2 /rev
Ø15.91=1100 (1”3/16-12 ORFS)
28 cm 2/rev
Ø6.51=600 P6 OUT P6 IN
(9/16-18 JIC) Ø15.91=1100 (1”3/16-12 ORFS)
Ø24.6~26.21=1000
Ø32.1=620 P
(1”5/8-12 JIC)
Ø9.5=1150 (9/16-18 JIC)
T
Ø19.11=900
(1”1/16-12 JIC) Ø9.51=1000 (9/16-18 JIC)
Ø6.51=350 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
RED
Ø191=1650 Ø16 Ø191=1450
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)
CVSM0365
LIFT ARM A1
RAISE
BUCKET CYLINDER R.H. B1
ARM FLOAT
UNLOAD VALVE
CONNECTOR
12V CN-A
TRAVEL MOTOR L.H.
DR
PORT PA1
PORT
P
RED
PORT LIFT ARM LOWER
TS
Ø0.5
HYDRAULIC CIRCUIT DIAGRAM PORT
T
RELIEF VALVE Ø101=850 Ø101=950 Ø101=650 Ø101=650
20.6MPa (9/16-18 JIC) (9/16-18 JIC) (9/16-18 JIC) (9/16-18 JIC)
(210kg/cm 2 )
33.2 cm 2 /rev
Ø15.91=1100 (1”3/16-12 ORFS)
28 cm 2/rev
Ø6.51=600
(9/16-18 JIC) Ø15.91=1100 (1”3/16-12 ORFS)
Ø7.3
Ø6.51=500 Ø15.91=1100 (1”3/16-12 ORFS) +40cm 2 /rev +40cm 2 /rev
(9/16-18 JIC) E
Ø15.91=1100 (1”3/16-12 ORFS)
ENGINE
B A S4D98E-2NFE
PP1 PP2 84.2/2500 PS/rpm
Ø6.41=1550
(9/16-18 JIC) (61.9/2500 Kw/rpm
SV1 SPEED SV2 PPC SV3 BRAKE
A B C
PB1 T5 PB2 S3 S4
Ø24.6~26.21=1000
Ø32.1=620 P
(1”5/8-12 JIC)
Ø9.5=1150 (9/16-18 JIC)
T
Ø19.11=900
(1”1/16-12 JIC) Ø9.51=1000 (9/16-18 JIC)
Ø6.51=350 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
RED
Ø191=1650 Ø16 Ø191=1450
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)
CVSM0366
T
Ø6.51=670 (9/16-18 JIC) P1 P2 P4 P3
PPC VALVE R.H.
PORT 2 LS PRESSURE PORT
P P
PRESSURE
CHECK PORT P T
Ø4.71=1570
(1/2-20 JIC)
MALE 3/4 Ø6.51=400 (1/2-20 JIC)
B3 1 3 2 4
Ø20 t=2 Ø16 (5/8) 1=3700 (1”14 ORFS)
A2
PORT
PB2 B2
Ø6.41=1500 (1/2-20 JIC)
BUCKET DUMP BUCKET CURL
LIFT ARM CYLINDER L.H.
PORT
PA2
PORT
BUCKET CYLINDER R.H. PORT PA1
P
PORT LIFT ARM LOWER
TS
Ø9.51=530 (13/16-16 ORFS)
RED
Ø12.71=1950 (13/16-16 ORFS)
Ø12.71=1950 (13/16-16 ORFS) Ø101=850 (9/16-18 JIC)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
Ø12.71=1350 (1”-14 ORFS) Ø101=950 (9/16-18 JIC)
33.2 cm 2 /rev
23.7 cm 2 /rev
cm 2/rev
Ø6.51=600
(9/16-18 JIC) Ø15.91=1100 (1”3/16-12 ORFS)
28
Ø6.51=500 Ø15.91=1100 (1”3/16-12 ORFS) Ø7.3
(9/16-18 JIC) +40cm 2 /rev +40cm 2 /rev
Ø15.91=1100 (1”3/16-12 ORFS) E
PP1 B A PP2
ENGINE
Ø6.41=1550 S4D98E-2NFE
(9/16-18 JIC) 84.2/2500 PS/rpm
(61.9/2500 Kw/rpm
PB1 T5 PB2 S3 S4 S5
(1”5/16-12 JIC)
(1”5/8-12 JIC)
Ø25.41=800
Ø32.1=620
Ø24.6~26.21=1000 SV1 SPEED SV2 PPC SV3 BRAKE
A B C
Ø9.5=1150 (9/16-18 JIC)
Ø25.41=430
TRAVEL MOTOR R.H. DR (1”5/16-12 JIC)
Ø191=850
Ø9.51=1300 (9/16-18 JIC) (1”1/16-12 JIC)
Ø42
Ø9.51=1300 (9/16-18 JIC)
CVSM0367
R-N2.5
X01
V1 K02 K03 4
M2.5
X01
SAFETY RELAY 3
POWER K01 86 87 R4
X01
BOX 2
R4
R-B1
85 30 X01
G1
R1
N1
1
SOLENOID
X03 X03 X03 X03 X06 X06 X07 X07 X07 X07 XS1 XS1 X08 X08 X08 X08 N4 RELAY
GND. 5 AIR FILTER FUEL-STOP FUEL LEVEL BACK-UP
86 85 30 87 I - 4 3 2 1 A B 1 3 5 6 X03 SWITCH PREHEATING SOLENOID SENSOR ALARM
R-N2.5 XS R4 S25 R1 X13 X17 X29
R-N1.5
R-N1.5
R-N1.5
X02
M-V1
M-V1
R-G1
S-N1
L/B1
L/B1
B2.5
I
N1
N1
B2
B1
L-R1
X02
SAFETY RELAY
R10
-
R-N1.5
X08 ENGINE OIL
X10 PERSURE SWITCH
13 S31
X10
12
R2.5
X10 SAFETY RELAY
11 XS1
R-V1
X10
B1 10
X10
9 INSULATOR
S1 XS
X10
8
C-N1
X10
7
C-L1 ENGINE STOP
X10 TIMER
S-G1 6
X10 X07 STOP LIGHT
5 PRESSURE SWITCH 2
X10 X20
4 DIODE
B-N1
X10 X06
3 GROUND
R-G1
X10
1
ENGINE COOLANT GND
8
2
2 BACK-UP
9
R10
3
TEMPERATURE
10
GND. B-G1
4
X10 FRAME SENSOR PRESSURE SWITCH 2
5
11
6
1 CABLE
1
1 X18 X23
2
7
13
1
X10
XF X28
+ FRAME
STOP LIGHT
CABLE
S31 PRESSURE SWITCH 2
FG1 X01
80A p>
HA3 - FRAME
START (+50) X21
CABLE BACK-UP
GROUND
X02 XM FUEL PRESSURE SWITCH 1
GND5 PUMP
XF GENERATOR X22
X11 X14
2 X29 X29
2 1
HYDRAULIC
Z-N1
OIL FILTER
N1
SWITCH
R10 R10
S26
GENERATOR
G2
R-N1.5
R-G1
R-G1
C-N1
S-G1
S-N1
B-N1
R-V1
M2.5
Z-N1
C-L1
L-R1
L-R1
L-R1
B2.5
N1
N1
N1
N1
S1
B2
CONNECT WITH XS
1 2 1 3 3 1 2 - + 1 2 1 C A - + 1 1 2 1 2 1 2 1 2
XS*
G1 +
1
X09 X11 X11 X11 X13 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 X20 X20 X21 X21 X22 X22 X23 X23
1 STARTER GENERAL
R-1.5
B2.5
12Vcc XB XM R1 R2 R3
M2 S25 S26 S27 S28 S29 S30 XB FG1
M1 50 G2 D+ Y0 M
M 30
G W p> p> p> p> p> p>
- 3
t
U
N50
31
COMPONENTS
FG1 General Fuse 80A X06 Diode 2 Way Connector
G1 Battery 100Ah X07 Pool Solenoid Timer 4 Way Connector
G2 Generator X08 Safety Relay 6 Way Connector
GND C8 Ground Terminal X09 C6 Generator Terminal
GND5 C6 Ground Terminal X10 Frame Line Mark 13 Way Connector
HA3 Back-Up Alarm X11 Generator 3 Way Connector
K01 Fuel Solenoid Valve Relay X13 Fuel Pool-Stop Solenoid 3 Way Connector
K02 Fuel Pull Solenoid Valve Timer 1 Second X14 Fuel Pump 2 Way Connector
K03 Safety Relay X15 Preheating Start C6 Terminal
M1 Starter Motor X16 Air Filter Blocked Switch 2 Way Connector
M2 Fuel Pump X17 Fuel Level Sender 3 Way Connector
R1 Preheating Starter X18 Engine Water Temperature Sender 2 Way Connector
R2 Fuel Level Sender X19 Hydraulic Oil Filter Blocked Switch C5 Terminal
R3 Engine Water Temperature Sender X20 Stop Light Pressure 1 Switch 2 Way Connector
S25 Air Filter Blocked Switch X21 Stop Light Pressure 2 Switch 2 Way Connector
S26 Hydraulic Oil Filter Blocked Switch X22 Back-Up Pressure 1 Switch 2 Way Connector
S27 Stop Lights Pressure Switch X23 Back-Up Pressure 2 Switch 2 Way Connector
S28 Stop Lights Pressure Switch X28 Engine Min. Pressure Switch Terminal
S29 Back-Up Alarm Pressure Switch X29 Back-Up Alarm 2 Way Connector
S30 Back-Up Alarm Pressure Switch XB C8 Start Motor Terminal
S31 Engine Oil Min. Pressure Switch XF General Fuse 2 Way Connector
V1 Diode 1A XM C4 Start Motor Terminal
X01 Frame Line 3 Way Connector XS Safety Relay 2 Way Connector
X02 2 Way Connector XS1 Insulator
X03 Fuel Solenoid Relay Connector Y0 Stop Fuel Solenoid Valve CVSM0352
X01.1 R-N2.5 M1
X48 TO
1 TO
X01.1 4 M2.5 M-V1 ENGINE CABLE
X48 CABIN CABLE
X01.1 3 2
X46 X01.1
R4 R-V1 TO
X48
2 3 ENGINE CABLE
X01.1 R4 L-G1
X48 X02.1
1 4 TO
ENGINE CABLE
8 9
1 2
X10.1
10
3
R-N2.5
4 5
X46
11 1
GND. 5 4 TO
M2.5
2 13
6 7
X46 CABIN CABLE
3
R4 X47
X02.1 X46
2
R4
FROM ENGINE LINE STD/OPT
X02.1 I L-R1.5
X46
1
- GND 5
X10.1 R-N1.5
X10.1 13 R-N1.5
X45
8 9 10
1 2 3
M-B1
X45 TO
X10.1 10 11
B1 L-R1.5 CABIN CABLE GND 2
4
X45
X45
11 12 13
5 6 7
X10.1 9 10
S1 B1
X45
X10.1 8 C-N1 M-N1
9
X45
X10.1 7 8
C-L1 R-G1
X45
X10.1 6 S-G1 S1
7
X45
X10.1 5 C-N1
6
X45
X10.1 4 B-N1 C-L1 5
X45 PPC SAFETY
X10.1 3 4
R-G1 S-G1 PRESSURE SWITCH
X45
1
X10.1 2 3 X32
2
B-G1 B-N1
X45 TO
3
5
1 2 CABIN CABLE
B-G1
X45 X48 BRAKE PRESSURE
1 SWITCH
X37
N2.5
M-B1
M-N1
M-V1
L-G1
V-N1
M1
R1
N1
N1
N1
N1
1 1 1 2 1 2 1 2 1 2 1
S32 S33
Y1 Y2 Y6 Y3 GND 2 C8 Ground Terminal
p> p>
GND 5 C6 Ground Terminal
S32 PPC Safety Pressure Switch
GND. 2 S33 Brake Valve Pressure Switch
X01.1 Engine Line 4 Way Connector
X02.1 Engine Line 2 Way Connector
X10.1 Engine Line 13 Way Connector
X32 PPC Safety Pressure Switch 1 Way Connector
X32A PPC Safety Pressure Switch 1 Way Connector
X33 PPC Valve 2 Way Connector
X34 Float Valve 2 Way Connector
X35 Brake Valve 2 Way Connector
X36 Second Speed Valve 2 Way Connector
X37 Brake Pressure Switch 1 Way Connector
X45 Cabin Line 13 Way Connector
X46 Cabin Line 4 Way Connector
X47 Ground 2 Way Connector
X48 Cabin Line 5 Way Connector
Y1 PPC Valve
Y2 Float Valve
Y3 Second Speed Valve
Y6 Brake Valve
CVSM0353
TO
ENGINE CABLE
X42
TO
X01.1 ENGINE CABLE
4
R-N2.5 M1 5
X48
1 2
X01.1
3
1 TO
X01.1 4 M2.5 M-V1 TO
X48 CABIN CABLE ENGINE CABLE
2 TO
X01.1 3 R4 R-V1 X46 ENGINE CABLE X43 TO
X48
2 3 X41 ENGINE CABLE
X01.1 R4 L-G1
X48 X02.1
1 4 TO
ENGINE CABLE
8 9
1 2
X10.1
10
N4
3
R-N2.5
4 5
X46
11 1
GND. 5 4 TO
M2.5
2 13
6 7
X46 CABIN CABLE
3
R4 X47
X02.1 X46
2
R4
X02.1 I X46
TO ENGINE LINE STD/OPT
L-R1.5 1
- GND. 5
X10.1 R-N1.5
X10.1 13 R-N1.5
X45
X10.1 12 R2.5 V-N1 13
X45
X10.1 11 12
8 9 10
1 2 3
RV.1 M-B1
X45 TO
X10.1 10 11
B1 L-R1.5 CABIN CABLE GND. 2
4
X45
X45
11 12 13
5 6 7
X10.1 9 10
S1 B1
X45
X10.1 8 C-N1 M-N1
9
X45
X10.1 7 8
C-L1 R-G1 GND. 1
X45
X10.1 6 S-G1 S1
7
X45
X10.1 5 C-N1
6
X45
X10.1 4 B-N1 C-L1 5
X45 PPC SAFETY
PRESSURE
1
X10.1 3 4
4
R-G1 S-G1
2
X45 TO SWITCH
3
X32
5
X10.1 2 3 CABIN CABLE
B-G1 B-N1
X45 X48
1 2
B-G1
X45
1
C-B1
X41
4 1 PPC SERV. BRAKE
C1 7
2
VALVE 2nd VALVE
X41 8 3
4
SPEED
3 9
HI-FLOW HI-FLOW X35 BRAKE
V-B1 10
5
6
X32A X33 VALVE PRESSURE
(POWER BOX ATTACH. LINE)
M-V1
M-B1
L-G1
V-N1
Z-N1
A-V1
R2.5
X41
M1
N1
N1
N1
N1
N1
CVSM0354
H-R1
HA1 LEFT LEVER RIGHT LEVER
+ G1.5
R-N2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
S13 S14 S15
R2.5
X50 -
BRAKE P.B. IN L/B1
X52 X53 1 1 1 1 1 1 1
H-R2.5
1 1 1 1
X50 23
M2.5
HI SPEED P.B. IN A/B1
K04
B1
1 1 X64 X66 X68 X70 X72 X74 X76 85 87
X56 X58 X60 X62
R-N0.5
R-N0.5
X50 22
V/B0.5
L/G0.5
L/G0.5
FLOAT P.B. IN L/G1
R/N1
Z-B1
OFF ACC
21 R1 ST R1 ACC BR R2 C
SAF. BAR. SWITCH IN X50 C/N1 FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01 86 30 X83 X83 X83 X83 X84 X84 X84
20
SEAT SWITCH IN X50 C-B1 30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A
B-R1
B/R1
A/B1
N1
B-R1
L/G1
EV BRAKE OUT H-L1
N1
17 S12 1 1 1 1 1 1 1 1 1 1 1
1 1 85 86 30 87
STOP ENGINE OUT X50 R-N1.5
M-N1
B-N1
B-R1
B-R1
H/R1
N1
ELECTRONIC UNIT
H/R1
B-R1
A-R1.5
G/R1
G-N1
G-N1
R-N2.5
R-G1
L-R1.5
H/R1
H-R1.5
G1
+ -
SAF. BAR. LED OUT X50 15 B/N1
R4
14
SEAT LED OUT X50 G/N1 X55 X55
X54 X54 X54
13
WARNING LED OUT X50 M/B1
C A B 2 1
12
FLOAT OUT X50 B-N1
N1
H-R1
C-B1
H-R1
C/N1
BUZZER OUT (-) X50 11 Z-B1
G/R1 X85
10
Hi-SPEED OUT X50 M-B1 9
A-R1.5 X85
9 1
GROUND X50 N1.5
8 1 9
HORN OUT X50 C1 1 0
X50 7
START SIGN IN B1
6
+12V HORN X50 H-R1.5
5
S01 5 10
HORN PUSH B. IN X50 B/R1 A-G1.5 X85
4 5
PPC SAF. SWITCH IN X50 L-G1 N1 X85
X50 3 10
EV PPC OUT V-N1
2
BUZZER OUT (+) X50 R/N1
1
K06
G/R1 X86
G1.5 9 X86
8
H-N1 X86
1
1 6 9
1
X48.1 M1 0 2
1
X48.1 M-V1
X48.1 2
S02 3 2 10
X48.1 3 L-G1 H-R1.5 X86
4 3
H-R1 X86
N1 2 X86
10
X44 86
X46.1 R-N2.5
M1 X44 87a
4
X46.1 M2.5 S/N1 X87
X46.1 3 R4 H-R1
6
X87
K14 86 87a 87
3
X46.1 2 R4
FROM FRAME LINE STANDARD
A-G1.5
M-N1
G-N1
M-V1
M-B1
G-N1
H-G1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
H-N1
H-N1
B-N1
B/N1
Z-B1
C-L1
H0.5
N1.5
M1
N1
C1
B1
S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
P1
CONTROL PANEL (UNIDECK) GND. 3
TO TOP CAB IN LINE STD.
CVSM0355A
SK1026-5 Turbo 90-12j
DIAGRAMS AND SCHEMATICS
PARKING
SAFETY CONTROL BOX RELAY
X50 K14 FLOAT RELAY
BUZZER FUSE BOX SOCKET
X52-X53 CIGARETTE X56-X77 K04
CONTROL PANEL (EXTERNAL VIEW) INTERNAL CONECTION CONTROL PANEL LIGHTER
X78-X79 01171077
X80-15
X80-16
X80-12
X80-14
X80-11
X80-8
+ FROM
L1 L2 L3 L4 L5 C2 C3 FRAME LINE
X48.1
4
1
FUEL WATER TEMP.
2
LEVEL INDICATOR
1
H F
3
L1 L2 L3 L4 L5
C2
C1 00000 00 h PROXIMITY
BAR 3 WAY
C E X54
C1 FROM
HOUR COUNTER C3 FRAME LINE
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
STARTING RIGHT LEVER X83
1
SWITCH X84
8
2
9
S10
11 4 3
10
L6 L7 L8 L9 L10 DL2 DL1 DL3 X80-9
X80-2 X80-3
13 6 5
FROM
12
7
FRAME LINE
X45.1
SAFETY SEAT
SWITCH
GROUND
X47.1 X55
REAR FRONT
WIRE WIRE GROUND WORK LIGHTS WORK LIGHTS
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR GND. 3 SWITCH SWITCH CONTROL
1
2 PANEL
7
8
3
4 X85 X86
9
10
5
6 X80
X80-1 X80-9 INTERNAL LIGHTS (+LUCI) POSITIVE G-N1 11
C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1 CABIN LINE
X82 BRAKE BEACON LIGHT
C3 X80-3 WATER TEMPERATURE INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1 CONTROL
PANEL BUTTON SWITCH
X80-4 PREHEATING LAMP X81 X87 X88
+50 START SIGNAL +50 B1 L2 X80-12 POSITIVE M1
GND. X80-5 GROUND GND. X80-13
GND. X80-6 GROUND GND. N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1
COMPONENTS
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 GND3 C6 Ground Terminal X54 Proximity Bar 3 Way Connector
FU01 Fuse 3A Left Side Lights X55 Safety Seat Switch 3 Way Connector
FU02 Fuse 3A Control Panel Lights X56 Fuse 1 Way Connector
FU03 Fuse 15A Horn, Front Work Lights X57 Fuse 1 Way Connector
FU04 Fuse 7.5A Switch Lights X58 Fuse 1 Way Connector
FU05 Fuse 15A Rear Work Light X59 Fuse 1 Way Connector
FU06 Fuse 10A Lever Switch Power Supply, Float X60 Fuse 1 Way Connector
WIRE WIRE FU07 Fuse 10A Current Intake 12V, Beacon Light X61 Fuse 1 Way Connector
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR FU08 Fuse 10A Control Panel, Electronic Unit, Fuel Shut Off, Safety Bar Proximity, Seat Safety Switch and Brake Switch X62 Fuse 1 Way Connector
FU09 Fuse 7.5A Back-Up Alarm X63 Fuse 1 Way Connector
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 FU10 Fuse 7.5A Fuel Pump, Safety Engine Relay, Generator X64 Fuse 1 Way Connector
FU11 Fuse 30A Pull Solenoid, PPC Safety Pressure Switch X65 Fuse 1 Way Connector
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5 HA1 Warning Buzzer X66 Fuse 1 Way Connector
L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1 K04 Float Relay X67 Fuse 1 Way Connector
K06 Electronic Unit X68 Fuse 1 Way Connector
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 K14 Brake Relay X69 Fuse 1 Way Connector
P1 Control Panel X70 Fuse 1 Way Connector
S01 Rear Work Lights Switch X71 Fuse 1 Way Connector
S02 Panel Lights and Low Beam Lights Switch X72 Fuse 1 Way Connector
S07 Beacon Light Switch X73 Fuse 1 Way Connector
S08 Brake Switch X74 Fuse 1 Way Connector
S10 Starting Switch X75 Fuse 1 Way Connector
S11 Safety Seat Switch X76 Fuse 1 Way Connector
S12 Bar PNP Safety Sensor X77 Fuse 1 Way Connector
S13 Horn Push Button X78 Current Intake 1 Way Connector
S14 Second Speed Push Button X79 Current Intake 1 Way Connector
S15 Float Push Button X80 Control Panel 16 Way Connector
X44 Brake Relay Connector X81 Control Panel 8 Way Connector
X45.1 From Frame Line 13 Way Connector X82 Lights Line 11 Way Connector
X46.1 From Frame Line 4 Way Connector X83 Left Lever 12 Way Connector
X47.1 From Frame Line 2 Way Ground Connector X84 Right Lever 12 Way Connector
X48.1 From Frame Line 5 Way Connector X85 Rear Work Lights SWF Switch
X50 Electronic Unit 23 Way Connector X86 Panel and Front Lights SWF Switch Connector
X52 Buzzer 1 Way Connector X87 Brake Switch Connector
X53 Buzzer 1 Way Connector X88 Beacon Light Switch Connector
X89 Float Relay Connector
CVSM0355B
H-R1
HA1 G1.5
+
TO TOP CAB IN LINE OMOLOG./STD
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
R-N2.5
R2.5
- K04 K95 1 2 3 4 5 6 7 8 9 10 11
BRAKE P.B. IN X50 L/B1
X52 X53 1 1 1 1 1 1 1 85 87a 87
H-R2.5
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
1 1 1 1 85 87
X50 23
M2.5
HI SPEED P.B. IN A/B1
B1
1 1 X64 X66 X68 X70 X72 X74 X76
X56 X58 X60 X62
X50 22
H-N1
A1
L1
G1
G-N1
R/N1
H-N1
A-G1.5
C1
N1.5
H-G1
FLOAT P.B. IN L/G1
R/N1
Z-B1
OFF ACC 85 30
R1 ACC BR R2 C 86 30
21 R1 ST
SAF. BAR. SWITCH IN X50 C/N1 FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01
20 X95 X95 X95 X95
SEAT SWITCH IN X50 C-B1 30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A
X89 X89 X89 X89
POWER SUPPLY +12V X50 19 H-R1 S10 B
X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77 86 85 30 87a
EV BRAKE OUT X50 18 H-L1
X78 X79 85 86 30 87
R-V1
S12
L-R1
M1
N1
17 1 1 1 1 1 1 1 1 1 1 1 1 1
STOP ENGINE OUT X50 R-N1.5
X50 16
M-N1
B-N1
B-R1
B-R1
S/N1 S11
H/R1
B-R1
A-R1.5
G/R1
G-N1
G-N1
BRAKE LIGHT OUT
R-N2.5
R-G1
L-R1.5
H/R1
H/R1
N1
+ -
SAF. BAR. LED OUT X50 15 B/N1
R4
14
SEAT LED OUT X50 G/N1 X55 X55
X54 X54 X54
13
WARNING LED OUT X50 M/B1
C A B 2 1
12
FLOAT OUT X50 B-N1
N1
H-R1
C-B1
H-R1
C/N1
BUZZER OUT (-) X50 11 Z-B1
10
Hi-SPEED OUT X50 M-B1
9
GROUND OUT X50 N1.5
8 G/R1 X85
HORN OUT X50 C1
9
7 A-R1.5 X85
START SIGN IN X50 B1 1
6
+12V HORN X50 H-R1.5 1 9
5 1 0
HORN PUSH B. IN X50 B/R1
4
PPC SAF. SWITCH IN X50 L-G1
2 G-N1.5 X85
BUZZER OUT (+) X50 R/N1 5
1 N1 X85
K06 10
G/R1 X86
G1.5 9 X86
8
H-N1 X86
1
X48.1 M1 1 6 9
1
0 2
X48.1 1 M-V1
X48.1 2 R-V1
X48.1 3
L-G1 S02 3 2 10
4 H-R1.5 X86
3
H-R1 X86
N1 2 X86
10
X46.1 86 X44
R-N2.5
4 X44
X46.1 M2.5 M1 87a
S/N1 X87
X46.1 3 R4
K14 86 87a 87 H-R1
6
X87
X46.1 2 R4 3
FROM FRAME LINE OPTION
1
85 30 15/1 30/3 L/6
0 1
X45.1 R-N1.5 H-L1 30 X44
13
X45.1 V-N1 X44
B-G1 85
49/4 30b/2 R/7
X45.1
12
M-B1
S08
11 L/B1 X87
X45.1 L-R1.5
H-R1 2
10 X87
X45.1 B1
7
X45.1 9 M-N1
8
X45.1 R-G1
7
X45.1 S1 G/R1 X88
6 9
X45.1 C-N1 H/R1 X88
5 1
X45.1 C-L1
4 1 9
X45.1 S-G1 1 0
3
X45.1 B-N1
2
X45.1 B-G1
S07 5 10
1
H-G1 X88
N1 5
X47.1 X88
2 10
X47.1 N4
1
M-N1
G-N1
M-V1
M-B1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
B-N1
B/N1
Z-B1
C-L1
H0.5
M1
N1
B1
S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
A-R1.5
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
L-R1.5
L-R1.5
G/R1
H/R1
B-R1
R-V1
R/N1
B/R1
L-N1
L/G1
A/B1
N1.5
N1
A1
L1
= Parts are Not Includes in the Wiring
P1
CONTROL PANEL (UNIDECK) GND. 3
CONTINUED ON PAGE 90-15 (CVSM0356B)
CVSM0356A
RELAYS UNIT
85 30 86 87 86 87 85 30
K10
K07 K13
FROM PAGE 90-14 (CVSM0356A) 85 30
+
R CL(T)
53M
53S
86 87
31
15
T
-(53S)
H/R1
L-N1
B-R1
L1
A1
R-V1
L/G1
L-R1.5
A/B1
L-R1.5
B/R1
R/N1
N1
N1.5
A-R1.5
G/R1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
K05
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
A-V1
C/B1
L-R1.5
A/N1
L-N1
A/V1
R/N1
R-V1
L/N1
Z-N1
N1.5
A-N1
V/B1
L/R1
A-G1
Z/N1
A-B1
A-R1.5
A1 X104
2
L1 X104
1
0
S03 1 2
1 2
54
A/N1 X104
54
N1 X105
A/N1 10 X105
5
G/R1 X105
8
H/R1 X105
2
S09 2 8 5 10
1 0
4 6 3 1 7
L/R1 X105
4
A1 X105
L1 3 X105
1
G/R1 X105
X49.1 7
C-B1
X49.1 11 C1 G/R1 X106
9
X49.1 10 V-B1 V-B1 X106
7
X49.1 9 V1
V1 X106
1
X49.1 8 A-N1 S05
0 1 7 9
X49.1 7 A-B1 1 2
X49.1 6
A-G1
B-R1
B-R1
A-N1
B/R1
C/B1
Z-N1
A-B1
A/B1
V/B1
L/G1
A/V1
Z/N1
L/N1
A-G1
N1
N1
X49.1 5 Z-N1
L-R1.5
1 2 3 4 5 6 11 1 2 3 4 5 6 7 8 9 11 3 10
G/R1
S-N1
X49.1 4
N1
AV1 L-R1.5 X106
X49.1 3 S-N1 5 1 9 10 3
X83
X83
X83
X83
X83
X83
X83
X84
X84
X84
X84
X84
X84
X84
X84
X84
X84
N1 X106
X49.1 2 L-R1.5 10
LEFT LEVER RIGHT LEVER
R-N0.8
R-N0.8
A-G0.5
A-N0.5
A-B0.5
A-B0.5
Z-N0.5
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
1
N0.8
N0.8
G/R1 X107
SWITCH EV ENPI C-B1 9 X107
7
C1 X107
1
0 S06 1 7 9
1 2
3 10
S13 S14 S36 S37 HL1 S15 S38 HL2 S39 HL3 S40 HL4 HL5
L-R1.5 X107
N1 3
X107
10
CVSM0356B
BUZZER
FROM X52-X53
FRAME LINE PARKING STOP LIGHT OFF
X49.1 SAFETY CONTROL BOX RELAY RELAY
7 X50 K14 FLOAT RELAY S K95 COMAND UNIT
9
8
1 CURRENT INTAKE SOCKET RELAY
2 FUSE BOX
SOLDER JOINT 10 4
11 5
3
X78-X79 X56-X77 K04 K90
6
SAL ENPI VALVE
11 10 9 8 7 6 5 4 3 2 1
SWITCH
21 20 19 18 17
01171077
X91
16 15 14 13 12
FRAME LINE
X80-15
X80-16
X80-12
X80-14
X80-11
X80-8
+ X48.1
4
1
L1 L2 L3 L4 L5 C2 C3
2
1
3
FUEL WATER TEMP. PROXIMITY
LEVEL INDICATOR BAR 3 WAY
H F
L1 L2 L3 L4 L5 X54
C2 FROM
C1 00000 00 h FRAME LINE
X46.1
C E
RIGHT LEVER
C1 X84
C3 LEFT LEVER
HOUR COUNTER
DL1 DL2 DL3 STARTING X83
1
SWITCH
8
2
X80-6 L6 L7 L8 L9 L10
9
S10
11 4 3
10
P
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
13 6 5
FROM
12
7
FRAME LINE
X45.1 HAZARD
L6 L7 L8 L9 L10 DL2 DL1 DL3 X80-9
SWITCH
X80-2 X80-3
X105
LEFT STAB. SWITCH
SAFETY SEAT
SWITCH X106
GROUND X55
X47.1
FRONT
WORK LIGHTS
SWITCH
REAR STAB. DX SWITCH
GROUND X86
WORK LIGHTS X107
1
GND. 3 SWITCH CONTROL
2
3 PANEL
7
8 4 X85
9
10
5
6 X80
WIRE WIRE
11
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR CABIN LINE
X82 BRAKE
DIRECTION LIGHTS CONTROL
X80-1 X80-9 INTERNAL LIGHTS (+LUCI) POSITIVE G-N1 SWITCH PANEL BUTTON
X104 X81 X87 BEACON LIGHT SWITCH
C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1
X88
C3 X80-3 WATER TEMPERATURE INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
+50 X80-4 START SIGNAL +50 B1 L2 X80-12 PREHEATING LAMP POSITIVE M1
GND. X80-5 GROUND GND. X80-13 COMPONENTS
GND. X80-6 GROUND GND. N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1
GND3 C6 Ground Terminal S01 Rear Work Lights Switch X59 Fuse 1 Way Connector X104 Direction Lights Switch Connector
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1
FU01 Fuse 3A Left Side Lights, Plate Light S02 Panel Lights and Low Beam Lights Switch X60 Fuse 1 Way Connector X105 SWF Hazard Connector
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 FU02 Fuse 3A Control Panel Lights, Right Side Lights S03 Direction Lights Switch X61 Fuse 1 Way Connector X106 Stabilizer Push Button Connector
FU03 Fuse 15A Horn, Low Beam or Front Work Lights S05 Up-Down Left Stabilizer Button X62 Fuse 1 Way Connector X107 Stabilizer Push Button Connector
FU04 Fuse 10A Switch Lights, Direction Lights S06 Up-Down Right Stabilizer Button X63 Fuse 1 Way Connector
FU05 Fuse 15A Rear Work Light, Stop Light S07 Beacon Light Switch X64 Fuse 1 Way Connector
FU06 Fuse 10A Lever Switch Power Supply, Float S08 Brake Switch X65 Fuse 1 Way Connector
FU07 Fuse 10A Current Intake 12V, Hazard, Beacon Light S09 Hazard Switch X66 Fuse 1 Way Connector
FU08 Fuse 10A Control Panel, Electronic Unit, Fuel Shut Off, S10 Starting Switch X67 Fuse 1 Way Connector
WIRE WIRE Safety Bar Proximity, Seat Safety Switch and Brake Switch S11 Safety Seat Switch X68 Fuse 1 Way Connector
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR FU09 Fuse 10A Back-Up Alarm, Attachment 3 Way, Hi-Flow, S12 Bar PNP Safety Sensor X69 Fuse 1 Way Connector
Stabilizer, ENPI Valve S13 Horn Push Button X70 Fuse 1 Way Connector
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 FU10 Fuse 7.5A Fuel Pump, Safety Engine Relay, Generator S14 Second Speed Push Button X71 Fuse 1 Way Connector
FU11 Fuse 30A Pull Solenoid, PPC Safety Pressure Switch S15 Float Push Button X72 Fuse 1 Way Connector
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5 HA1 Warning Buzzer S36 Reverse Hi-Flow Momentary Push Button X73 Fuse 1 Way Connector
X81-3 DL1 X81-7 WARNING LED NEGATIVE M/B1 HL1 Super-Flow LED Diode S37 Super-Flow Detent Push Button X74 Fuse 1 Way Connector
L6 PARKING BRAKE LAMP NEGATIVE M-V1
HL2 “C” Way LED Diode S38 “C” Way Push Button X75 Fuse 1 Way Connector
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 HL3 “A” Way LED Diode S39 “A” Way Push Button X76 Fuse 1 Way Connector
HL4 “B” Way LED Diode S40 “B” Way Push Button X77 Fuse 1 Way Connector
HL5 Optional LED Diode X44 Parking Brake Relay Connector X78 Current Intake 1 Way Connector
K04 Float Relay X45.1 From Frame Line Mark 13 Way Connector X79 Current Intake 1 Way Connector
K05 Relays Box (Without Relays) X46.1 From Frame Line 4 Way Connector X80 Control Panel 16 Way Connector
K06 Electronic Unit X47.1 Ground 2 Way Connector X81 Control Panel 8 Way Connector
K07 “B” Way Relay X48.1 From Frame Line Mark 5 Way Connector X82 Lights Line 11 Way Connector
K08 “A” Way Relay X49.1 From Frame Line Mark 11 Way Connector X83 Left Lever 12 Way Connector
K09 “C” Way Relay X50 Safety Control Box 23 Way Connector X84 Right Lever 12 Way Connector
K10 Super-Flow Detent Step By Step Relay X52 Buzzer 1 Way Connector X85 Rear Work Lights SWF Switch
K11 Reverse Hi-Flow Momentary Relay X53 Buzzer 1 Way Connector X86 Panel and Front Lights SWF Switch Connector
K12 Stop Lights Relay X54 Proximity Bar 3 Way Connector X87 Brake Push Button Connector
K13 Flasher Unit X55 Safety Seat Switch 2 Way Connector X88 Beacon Light Switch Connector
K14 Brake Relay X56 Fuse 1 Way Connector X89 Float Relay Connector
K95 Stop Light Relay X57 Fuse 1 Way Connector X90 Relays Box 21 Way Connector
P1 Control Panel X58 Fuse 1 Way Connector X91 ENPI Valve SWF Connector
CVSM0356C
B
A A B
X82.1 H-G1
11
X82.1 N1.5
10
X82.1 C1
9
X82.1 A-G1
FROM CABIN LINE
8
X82.1 H-N1 FRONT LEFT
7 WORKING LIGHT
X82.1 H-N1 H4
GND. 4
6
9 8 7
3 2 1
X82.1
FROM
5 DASHBOARD
A B
X82.1 CABLE
6 5 4
4 X82.1
11 10
X82.1
X82.1 3
2
X82.1
1
1 2 1 2 A B A B 2 1
HORN
X108 X108 X109 X109 X110 X110 X111 X111 XP1 XP1A CURRENT
INTAKE (12V) HA 2
XP1
H-N1
N1
H-N1
N1
A-G1
N1
A-G1
N1
N1
H-G1
B A
GROUND
GND. 4
FRONT RIGHT
WORKING LIGHT
H6
HORN
GROUND
GND. 6 GND. 6
X113 H1
H4 H6 H10 H11
M
HA2
COMPONENTS
CVSM0357
REAR LEFT
WORKING LIGHT
H10
G1
TO REAR LIGHT LINE
5 6
1
L1
X130
2
FRONT LEFT
3
1
7
4
MAIN BEAM
H4
X82.1 H-G1
11
X82.1
A
N1.5
B
10
X82.1 C1
9 8 7
3 2 1
9 FROM
X82.1 A-G1 DASHBOARD
FROM CABIN LINE
8 CABLE
6 5 4
X82.1 H-N1 X82.1
11 10
7
X82.1 H-N1
6
X82.1 R-N1.5
5
X82.1 G-N1
GND. 4
4
X82.1 G1
3
X82.1 L1
2
X82.1 A1 HORN
1 HA 2
CURRENT
INTAKE (12V)
A B 1 1 1 A B 1 1 1 A B A B 1 1
XP1
1
B A
X113 X108 X108 X115 X116 X117 X109 X109 X118 X119 X120 X110 X110 X111 X111 XP1 XP1A GROUND
GND. 4 FRONT RIGHT
LIGHT
H-N1
N1
L1
G1
N1
N1
H-N1
G-N1
A1
N1
A-G1
N1
A-G1
N1
N1
H-G1
FRONT RIGHT
H7
MAIN BEAM
HORN H6
GROUND
GND. 6
GND. 6
HA2
H5 H7 H1
L
58L
58R
H4 H6 H10 H11
M
COMPONENTS
31
31
CVSM0358
REAR LEFT
WORKING LIGHT
H10
REAR RIGHT
WORKING LIGHT
H11 FRONT LEFT
A B
LIGHT
= Parts are not included on the wiring H5
REAR LIGHT B
CONNECTOR A
X130
5 6
1
2
FRONT LEFT
3
7
4
MAIN BEAM
H4
X130.1 G1 X132 X132.1 G1
FROM CABIN LINE
X130.1 7 X132.1 7
R-N1.5 X132
A
B
X130.1 G-N1 6 X132.1 6 G-N1
X132
9 8 7
5 X132.1 5
3 2 1
X130.1 A1 X132 A1 FROM
X130.1 4 4 DASHBOARD
N1.5 X132 X132.1
CABLE
6 5 4
X130.1 3 X132.1 3 X82.1
11 10
X132
2 2
X130.1 L1 X132 X132.1 L1
1 1
X131
X131
1 2
HORN
HA 2
1 2
X131.1
X131.1
CURRENT
INTAKE (12V) B A
XP1 GROUND
FRONT RIGHT
GND. 4 LIGHT
G1
N1
FRONT RIGHT
H7
1 2 1 1 1 1 1 1 1 1
MAIN BEAM
HORN H6
X121 X122 X123 X124 X115 X116 X117 GROUND
GND. 6
X129.1
X129
N1
L1
G1
R-N1
R-N1
G-N1
A1
N1
G1
N1
H8 H9
L
58L
54
54
58R
H12
COMPONENTS
31
31
CVSM0359
R-N2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
S14
R2.5
K14, X18 X13
X50 -
BRAKE P.B. IN L/B1
H-R2.5
X52 X53 1 1 1 1 1 1 1 1 1 1 1
R-N0.5
R-N0.5
V/B0.5
L/G0.5
L/G0.5
M2.5
X50 23
1 2 HI SPEED P.B. IN A/B1 K04
B1
1 1 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76 85 87
22
FLOAT P.B. IN X50 L/G1
R/N1
Z-B1
X83 X83 X83 X83 X84 X84 X84
3 SAF. BAR. SWITCH IN X50
21
C/N1
OFF ACC
R1 ACC BR R2 C FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01
R1 ST 86 30
20 30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A 1 2 3 11 1 3 11
SEAT SWITCH IN X50 C-B1
K08 K07
B-R1
L/G1
B-R1
B/R1
A/B1
N1
X50 19
POWER SUPPLY +12V H-R1 S10 X89 X89 X89 X89
N1
18 B X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77
X78 X79
1 2 3 1 2 EV BRAKE OUT X50 H-L1
85 86 30 87
17 1 1 1 1 1 1 1 1 1 1 1 1 1
STOP ENGINE OUT X50 R-N1.5 S12
4 5 6 3 4 BRAKE LIGHT OUT X50 16
S/N1
H/R1
N1
M-N1
B-N1
B-R1
B-R1
ELECTRONIC UNIT
H-R1.5
H/R1
B-R1
A-R1.5
G/R1
G-N1
G-N1
G1
R-N2.5
R-G1
L-R1.5
H/R1
SAF. BAR. LED OUT X50 15
B/N1
S11
R4
+ -
14
SEAT LED OUT X50 G/N1
13 X54 X54 X54 X55 X55
WARNING LED OUT X50 M/B1
= Parts are not included on the wiring = Parts are not included on the wiring 12
WIRE POSITIONING ON CONNECTOR FLOAT OUT X50 B-N1 C A B 2 1
11
(WIRE SIDE VIEWING WIRING) X50 Z-B1
N1
H-R1
C-B1
H-R1
BUZZER OUT (-)
C/N1
G/R1 X85
10 9
Hi-SPEED OUT X50 M-B1 A-R1.5 X85
9 1
GROUND X50 N1.5
8 1 9
HORN OUT X50 C1 1 0
X50 7
START SIGN IN B1
6
+12V HORN X50 H-R1.5
R-N2.5 X01 X01.1 R-N2.5 S01 5 10
5
4 4 HORN PUSH B. IN X50 B/R1 A-G1.5 X85
M2.5 X01 X01.1 M2.5
X50 4 5
3 3 PPC SAF. SWITCH IN L-G1 N1 X85
R4 X01 X01.1 R4
V1 K02 K03 EV PPC OUT X50 3
V-N1 10
2 2
R4 X01 X01.1 R4 2
86 87 SAFETY RELAY BUZZER OUT (+) X50 R/N1
POWER K01 1 1
1
BOX K06
R-B1
N4
85 30
G1
R1
N1
N4 G/R1 X86
X03 X03 X03 X03 X06 X06 X07 X07 X07 X07 XS1 XS1 X08 X08 X08 X08
GND. 5 GND. 5 9
G1.5 X86
H-N1 8 X86
86 85 30 87 I - 4 3 2 1 A B 1 3 5 6
XS X02.1 1
R-N2.5
R-N1.5
R-N1.5
R-N1.5
R4 X02
M-V1
M-V1
R-G1
S-N1
L/B1
L/B1
B2.5
I I 1 6 9
N1
N1
N1
X02.1
B2
B1
L-R1 X02 L-R1.5
1
M1 X48 X48.1 M1 0 2
R10
- -
M-V1 1 1
R-N1.5 X10 X10.1 R-N1.5 X48 X48.1 M-V1
13 13 X10.1 2 2 X48.1
X10 R-V1 X48 S02 3 2 10
12 12 3 3
X10.1 R2.5 L-G1 X48 X48.1 L-G1 H-R1.5 X86
R2.5 X10
4 4 H-R1 3 X86
11 11
R-V1 X10 X10.1 R-V1
N1 2 X86
10 10
B1 X10 X10.1 B1 R-N2.5 X46 X46.1 R-N2.5 10
9 9 X10.1 H-L1 X44 86
S1 X10 S1 4 4 X46.1
M2.5 X46 M2.5
8 8 M1 X44 87a
C-N1 X10 X10.1 C-N1 3 3
R4 X46 X46.1 R4 S/N1 X87
7 7 X10.1 2 6
C-L1 X10 C-L1 2 X46.1 H-R1 X87
R4 X46 R4 K14 86 87a 87
6 6 X10.1 3
S-G1 X10 S-G1 1 1
5 5 X10.1 15/1 30/3 L/6
X10 0 1
85 30
4 4 X10.1
B-N1 X10 B-N1
R-N1.5 X45 X45.1 R-N1.5 H-L1 X44 30
3 3 X10.1
R-G1 X10 R-G1 13
2 2 X10.1 V-N1 X45 13 X45.1 V-N1 B-G1 X44 85 S08 49/4 30b/2 R/7
R10
Z-N1
4 4 1 0
N1
S-G1 X45 X45.1 S-G1
3 3
R10 R10 B-N1 X45 X45.1 B-N1
2 2 S07 5 10
B-G1 X45 X45.1 B-G1
1 1 H-G1 X88
R-N1.5
N1 5 X88
R-G1
R-G1
C-N1
S-G1
S-N1
B-N1
R-V1
M2.5
Z-N1
C-L1
L-R1
L-R1
L-R1
B2.5
R50 10
N2
N1
N1
N1
N1
S1
B2
N4 X47 X47.1 N4
1 2 1 3 3 1 2 - + 1 2 1 C A - + 1 1 2 1 2 1 2 1 2
2 2 X47.1 N4
G1 N4 X47
+ X09 X11 X11 X11 X13 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 X20 X20 X21 X21 X22 X22 X23 X23 1 1
1 1
R-1.5
G-N1
C-N1
H-R1
S-G1
B-G1
N2.5
B-N1
B2.5
M-N1
Z-B1
C-L1
M-V1
M-B1
M/B1
G/N1
B/N1
R1 R2 R3
H0.5
12Vcc XB XM
M1
N1
M2
B1
S1
S25 S26 S27 S28 S29 S30
A-G1.5
M1 50 G2 D+ Y0 M
G-N1
H-G1
H-N1
H-N1
M
N1.5
30 G W p> p> p> p> p> p> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
G1
C1
- 3
t INTERNAL CONECTION CONTROL PANEL
N50
X80-15
X80-16
X80-12
X80-14
X80-11
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
31
X80
X80-8
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
+
L1 L2 L3 L4 L5 C2 C3
ENGINE PARTS P1
GND. 3
L1 L2 L3 L4 L5 CONTROL PANEL (UNIDECK)
FUEL WATER TEMP.
LEVEL INDICATOR
N2.5
H F
1 2 3 4 5 6 7 8 9 10 11
M-B1
M-V1
M-N1
L-G1
V-N1
R2.5
C2
M1
N1
N1
C1
N1
N1
00000 00 h
DESCRIPTION
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
H-G1 X82.1
NAME SUPP. TYPE QTY. 1 1 1 2 1 2 1 2 1 2 1
C E
= Parts are not included on the wiring
X32 X32A X33 X33 X34 X34 X35 X35 X36 X36 X37 C1
H-N1
H-N1
A-G1
DESCRIPTION
N1.5
C3
FG1 General Fuse 80A CIAM 163028 HOUR
NAME SUPP. TYPE QTY.
C1
1 S32 S33 COUNTER
Y1 Y2 Y6 Y3 DL1 DL2 DL3
G1 Battery 100Ah FIAMM (KUE) L5 600 103 086 (37C-06-11110) 1 p> p> X80-6
L6 L7 L8 L9 L10
G2 Generator YANMAR (DENSO) 129423-77200 1 P
S07 Beacon Light Switch C1AM 106AA008 (KUE 885081160) 1
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
GND C8 Ground Terminal * * 1 GND. 2 X80-2 X80-3 S08 Brake Switch C1AM 0A003455 (KUE 37A-06-11410) 1
GND5 C6 Ground Terminal * * 1 S10 Starting Switch 1
L6 L7 L8 L9 L10 DL2 DL1 DL3 X80-9
HA3 Back-Up Alarm CIAM (KUE) 0A001357 (312612100) 1 S11 Safety Seat Switch 1
K01 Fuel Solenoid Valve Relay MATSUSHITA (KUE) CB1aH (885071022) 1 S12 Bar PNP Safety Sensor SAIET E-A1TMU/3AP (KUE 37A-06-11250) 1
K02 Fuel Pull Solenoid Valve Timer 1 Second 1 S13 Horn Push Button 1
K03 Safety Relay YANMAR (KUE) 119802-77200 1 S14 Second Speed Push Button 1 1 2 1 2 A B A B 2 1 GND. 4
WIRE WIRE
M1 Starter Motor YANMAR 123900-77010 1 POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR S15 Float Push Button 1
M2 Fuel Pump YANMAR 129612-52100 1 X44 Brake Relay Connector 1 X108 X108 X109 X109 X110 X110 X111 X111 XP1 XP1A
R1 Preheating Starter YANMAR 129100-77500 1 X80-1 X80-9 INTERNAL LIGHTS (+LUCI) POSITIVE G-N1
X45.1 From Frame Line 13 Way Connector AMP * 1
R2 Fuel Level Sender COBO (KUE) 29-0419-0000 (37A-04-11140)
H-N1
N1
H-N1
N1
A-G1
N1
A-G1
N1
N1
H-G1
1 C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1 X46.1 From Frame Line 4 Way Connector DEUTSCH DTP04-4P 1
R3 Engine Water Temperature Sender YANMAR (KUE) (7861-92-3320) 1 C3 X80-3 WATER TEMPERATURE INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1 X47.1 From Frame Line 2 Way Ground Connector DEUTSCH DTP04-2P 1
S25 Air Filter Blocked Switch DONALDSON (KUE) X770317 (37A-06-11960) 1 X48.1 From Frame Line 5 Way Connector AMP * 1
+50 X80-4 START SIGNAL +50 B1 L2 X80-12 PREHEATING LAMP POSITIVE M1 X113 GND. 6
S26 Hydraulic Oil Filter Blocked Switch FMDI (KUE) 11716/1 (885261034) 1 X50 Electronic Unit 23 Way Connector AMP * 1
H1
GND. X80-5 GROUND GND. X80-13
S27 Stop Lights Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1 X52 Buzzer 1 Way Connector AMP * 1 H4 H6 H10 H11
S28 Stop Lights Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1 GND. X80-6 GROUND GND. N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1 M
X53 Buzzer 1 Way Connector AMP * 1
S29 Back-Up Alarm Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1 X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1 X54 Proximity Bar 3 Way Connector DEUTSCH * 1 HA2
S30 Back-Up Alarm Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1 X55
S31 Engine Oil Min. Pressure Switch YANMAR *
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 Safety Seat Switch 3 Way Connector DEUTSCH * 1 WIRING COLORS
1 X56 Fuse 1 Way Connector AMP * 1
V1 Diode 1A CIAM 1A1N4007 1 X57 Fuse 1 Way Connector AMP * 1
A LIGHT BLUE
X01 Frame Line 3 Way Connector * * 1 WIRE WIRE X58 Fuse 1 Way Connector AMP * 1
POS. PIN FUNCTION SIGNAL POS. PIN FUNCTION SIGNAL B WHITE
X02 2 Way Connector * * 1 COLOR COLOR X59 Fuse 1 Way Connector AMP * 1
C ORANGE
X03 Fuel Solenoid Relay Connector * * 1 X60 Fuse 1 Way Connector AMP * 1
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 G YELLOW
X61 Fuse 1 Way Connector AMP * 1
H GRAY
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
X62 Fuse 1 Way Connector AMP * 1
L BLUE
X06 Diode 2 Way Connector * * 1 L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1
X63 Fuse 1 Way Connector * 1
X07 Pool Solenoid Timer 4 Way Connector * * 1
AMP
NAME DESCRIPTION SUPP. TYPE QTY. M BROWN
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 X64 Fuse 1 Way Connector AMP * 1
N BLACK
X08 Safety Relay 6 Way Connector SUMITOMO 6195-0021 1 X65 Fuse 1 Way Connector AMP * 1
R RED
X09 C6 Generator Terminal * * 1 X66 Fuse 1 Way Connector AMP * 1 GND. 4 C6 Ground Terminal AMP * 1
X10 Frame Line Mark 13 Way Connector * * 1 NAME DESCRIPTION SUPP. TYPE QTY. X67 Fuse 1 Way Connector * 1 GND. 6 C8 Horn Ground Terminal AMP * 1 S PINK
AMP V GREEN
X11 Generator 3 Way Connector SUMITOMO 6189-0442 1 NAME DESCRIPTION SUPP. TYPE QTY. X68 Fuse 1 Way Connector AMP * 1 H1 Beacon Light CIAM (KUE) 110450 (885111118) 1
Z VIOLET
GND 2 C8 Ground Terminal * * 1
X69 Fuse 1 Way Connector * 1 H4 Left Front Work Lamp COBO (KUE) 05-531-000 (885111132) 1
AMP
X13 Fuel Pool-Stop Solenoid 3 Way Connector DEUTSCH DT06-35 1 GND 5 C6 Ground Terminal 1
X70 H6 Right Front Work Lamp COBO (KUE) 05-531-000 (885111132) 1
FU01 Fuse 3A Left Side Lights 1 Fuse 1 Way Connector AMP * 1 EXAMPLE:
X14 Fuel Pump 2 Way Connector * * 1 S32 PPC Safety Pressure Switch FMDI (KUE) 11717.75 (37A-06-11670) 1
X71 H10 Left Rear Work Light COBO (KUE) 05-531-000 (885111132) 1
FU02 Fuse 3A Control Panel Lights 1 Fuse 1 Way Connector AMP * 1
X15 Preheating Start C6 Terminal * * 1 S33 Brake Valve Pressure Switch FMDI (KUE) * 1
X72 H11 Right Rear Work Light COBO (KUE) 05-531-000 (885111132) 1 G/V = YELLOW/GREEN
FU03 Fuse 15A Horn, Front Work Lights 1 Fuse 1 Way Connector AMP * 1
X16 Air Filter Blocked Switch 2 Way Connector AMP MINI TIMER 1 X01.1 Engine Line 4 Way Connector DEUTSCH DTP04-4P 1
X73 HA2 Horn CIAM (KUE) 112001 (885100005) 1 (TRANSVERSE MARKED)
FU04 Fuse 7.5A Switch Lights 1 Fuse 1 Way Connector AMP * 1
X17 Fuel Level Sender 3 Way Connector * * 1 X02.1 Engine Line 2 Way Connector * * 1
X74 X82.1 From Cabin Line 11 Way Connector AMP * 1 YELLOW GREEN
FU05 Fuse 15A Rear Work Light 1 Fuse 1 Way Connector AMP * 1
X18 Engine Water Temperature Sender 2 Way Connector * * 1 X10.1 Engine Line 13 Way Connector * * 1
X75 X108 Left Front Light 2 Way Connector PACKARD * 1
FU06 Fuse 10A Lever Switch Power Supply, Float Fuse 1 Way Connector AMP * 1
X19 Hydraulic Oil Filter Blocked Switch C5 Terminal * * 1 X32 PPC Safety Pressure Switch 1 Way Connector AMP SUPERSEAL 1
X76 X109 Right Front Light 2 Way Connector PACKARD * 1
FU07 Fuse 10A Current Intake 12V, Beacon Light 1 Fuse 1 Way Connector AMP * 1
X20 Stop Light Pressure 1 Switch 2 Way Connector DEUTSCH DT06-2S 1 X32A PPC Safety Pressure Switch 1 Way Connector AMP SUPERSEAL 1
X77 X110 Left Rear Work Lights 2 Way Connector DEUTSCH * 1
FU08 Fuse 10A Control Panel, Electronic Unit, Fuel Shut Off, 1 Fuse 1 Way Connector AMP * 1
X21 Stop Light Pressure 2 Switch 2 Way Connector DEUTSCH DT06-2S 1 X33 PPC Valve 2 Way Connector * * 1
X78 Current Intake 1 Way Connector * 1 X111 Right Rear Work Lights 2 Way Connector DEUTSCH * 1
Safety Bar Proximity, Seat Safety Switch and Brake Switch AMP G-V = YELLOW-GREEN
X22 Back-Up Pressure 1 Switch 2 Way Connector DEUTSCH DT06-2S 1 X34 Float Valve 2 Way Connector * * 1
X79 X113 Horn 1 Way Connector AMP * 1
FU09 Fuse 7.5A Back-Up Alarm 1 Current Intake 1 Way Connector AMP * 1 (LONGITUDINAL COLORS)
X23 Back-Up Pressure 2 Switch 2 Way Connector DEUTSCH DT06-2S 1 X35 Brake Valve 2 Way Connector * * 1
X80 XP1 12V Socket, Beacon Light 1 Way Connector AMP * 1
FU10 Fuse 7.5A Fuel Pump, Safety Engine Relay, Generator 1 Control Panel 16 Way Connector AMP * 1
X28 Engine Min. Pressure Switch Terminal * * 1 X36 Second Speed Valve 2 Way Connector * * 1 XP1A 12V Socket, Beacon Light 1 Way Connector AMP * 1 YELLOW GREEN
FU11 Fuse 30A Pull Solenoid, PPC Safety Pressure Switch 1 X81 Control Panel 8 Way Connector AMP * 1
X29 Back-Up Alarm 2 Way Connector * * 1 X37 Brake Pressure Switch 1 Way Connector * * 1
X82
GND3 C6 Ground Terminal AMP * 1 Lights Line 11 Way Connector AMP * 1
X45 Cabin Line 13 Way Connector * * 1
X83
HA1 Warning Buzzer 1 Left Lever 12 Way Connector DEUTSCH DT04-12P,DT06-12-S 1
XB C8 Start Motor Terminal * * 1 X46 Cabin Line 4 Way Connector DEUTSCH DTP-06-4S 1
X84
K04 Float Relay C1AM 157061 (KUE 88507 1043) 1 Right Lever 12 Way Connector DEUTSCH DT04-12P,DT06-12-S 1
XF General Fuse 2 Way Connector * * 1 X47 Ground 2 Way Connector DEUTSCH DTP06-2S 1
X85
K06 Electronic Unit C1AM 01171077 (KUE885070046) 1 Rear Work Lights SWF Switch SWF * 1
XM C4 Start Motor Terminal * * 1 X48 Cabin Line 5 Way Connector * * 1
X86
K14 Brake Relay C1AM * 1 Panel and Front Lights SWF Switch Connector SWF * 1
XS Safety Relay 2 Way Connector SUMITOMO 6195-0060 1 Y1 PPC Valve HYDRAFORCE * 1
X87
P1 Control Panel UNIDECK 04610027 (KUE 37A-54-14291) 1 Brake Switch Connector PNEUTRON * 1
XS1 Insulator * * 1 Y2 Float Valve HYDRAFORCE * 1
X88
S01 Rear Work Lights Switch C1AM 106AA008 (KUE 885081159) 1 Beacon Light Switch Connector SWF * 1
Y0 Stop Fuel Solenoid Valve YANMAR 129005-77950 1 Y3 Second Speed Valve HYDRAFORCE * 1
X89
S02 Panel Lights and Low Beam Lights Switch C1AM 106AA018 (KUE 885081160) 1 Float Relay Connector 1
Y6 Brake Valve HYDRAFORCE * 1 CVSM0360
SK1026-5 Turbo 90-20j
DIAGRAMS AND SCHEMATICS
C1
H8 Left Rear Lamp COBO (KUE 885111135) 1 + A17
X108 X108 X115 X116 X117 X109 X109 X118 X119 X120 X121 X122 X123 X124 X125 X126 X127 X128 X129 X130 X110 X110 X111 X111 XP1 XP1A
1 2 H9 Right Rear Lamp COBO (KUE 885111134) 1
H-N1
N1
L1
G1
N1
N1
H-N1
G-N1
A1
N1
N1
L1
G1
R/N1
R/N1
G-N1
A1
N1
G1
N1
A-G1
N1
A-G1
N1
N1
H-G1
H10 Left Rear Work Light COBO 05-531-000 (KUE 885111132) 1 X113 X50 23 L/B1
-
H-R2.5
R-N2.5
BRAKE P.B. IN
3 H11 X52 X53
M2.5
Right Rear Work Light COBO 05-531-000 (KUE 885111132) 1 IN X50 22 A/B1
HI SPEED P.B.
B1
H12 Plate Light COBO 02224-600 (KUE 885110052) 1 1 1
H1 FLOAT P.B. IN X50 21 L/G1 OFF ACC
58L
R
X82.1
58R
58L
54
58R
K08 K07
54
R
11 Way Connector AMP 1
R/N1
Z-B1
HA2 SAF. BAR. SWITCH IN X50 20 C/N1 R1 ST R1 ACC BR R2 C
X108 & X109 Front Low Beam 2 Way Connector PACKARD 1 H4 H5 H6 H7 H8 H9 H12 H10 H11
1 2 3 1 2 X110 & X111 Rear Work Lights 2 Way Connector PACKARD 1 M SEAT SWITCH IN X50 19 C-B1
X113 Horn 1 Way Connector AMP 1 POWER SUPPLY +12V X50 18 H-R1 S10
4 5 6 3 4 B
X115, X116 & X117 Front Traffic Lights 1 Way Connector AMP 1 EV BRAKE OUT X50 17 H-L1
31
31
31
X118, X119 & X120
31
Front Traffic Lights 1 Way Connector AMP 1 STOP ENGINE OUT X50 16 R-N1.5 S12
X121, X122, X123 & X124 Rear Traffic Lights 1 Way Connector AMP 1 GND. 6
BRAKE LIGHT OUT X50 15 S/N1
ELECTRONIC UNIT
X125, X126, X127 & X128 Rear Traffic Lights 1 Way Connector AMP 1 X50 S11
SAF. BAR. LED OUT 14 B/N1
R4
XP1 & XP1A 12V Socket, Beacon Light 1 Way Connector AMP 1
+ -
N1
H-R1
C-B1
H-R1
C/N1
GND. 4 GND. 5 C6 GROUND TERMINAL Hi-SPEED OUT X50 9 M-B1 A18
= Parts are not included GROUND X50 8 N1.5 A19
on the wiring X129-X130 Plate Light Connection HORN OUT X50 7 C1
A20
KUE 37C-06-11312 A21
= Parts are not included on the wiring START SIGN IN X50 6 B1
85 30
G1
R1
N1
N4 K06 A24
X03 X03 X03 X03 X06 X06 X07 X07 X07 X07 XS1 XS1 X08 X08 X08 X08 N4
GND. 5 GND. 5
A25
86 85 30 87 I - 4 3 2 1 A B 1 3 5 6
XS R4 X02 X02.1
R-N2.5
R-N1.5
R-N1.5
R-N1.5
R-G1
S-N1
B2.5
M-V1
M-V1
I I
L/B1
L/B1
A26
N1
N1
B2
- M1 X48 X48.1 M1
-
R10
2 2 X10.1
B-G1 X10 B-G1 12
M-B1 X45 12 X45.1 M-B1
1 1 1
1 GND. X45 11 11 X45.1 L-R1.5
L-R1.5 A32
XF X28 + B1 X45
10 10 X45.1 B1
S31 9
FG1 HA3 - M-N1 X45 9 X45.1 M-N1
80A p> A33
R-G1 8 8 X45.1 R-G1
X45 A34
S1 X45 7 7 X45.1 S1
XF X29 X29
2 C-N1 X45 6 6 X45.1 C-N1
2 1 C-L1 X45 5 5 X45.1 C-L1
Z-N1
4 4
N1
A35
R-G1
R-G1
C-N1
S-G1
S-N1
B-N1
R-V1
M2.5
Z-N1
C-L1
L-R1
L-R1
L-R1
B2.5
N1
N1
N1
N1
S1
B2
A36
1 2 1 3 3 1 2 - + 1 2 1 C A - + 1 1 2 1 2 1 2 1 2 N4 2 2 X47.1 N4
X47 A37
G1 + 1 1
1 X09 X11 X11 X11 X13 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 X20 X20 X21 X21 X22 X22 X23 X23 A38
1
X49 X49.1 C-B1
R-1.5
C-B1
N2.5
B2.5
12Vcc XB XM R1 R2 R3 A39
M2 S25 S26 S27 S28 S29 S30 C1 X49 11 11 X49.1 C1
M1 50 G2 D+ Y0 M A40
M 30 G W p> p> p> p> p> p>
V-B1 X49 10 10 X49.1 V-B1
- 3
t V1 X49 9 9 X49.1 V1
N50
U
A-N1 X49 8 8 X49.1 A-N1
31
A-B1 X49 7 7 X49.1 A-B1
A-G1 X49 6 6 X49.1 A-G1
ENGINE PARTS
G-N1
C-N1
H-R1
S-G1
B-G1
B-N1
M-N1
M-V1
M-B1
Z-B1
C-L1
M/B1
G/N1
B/N1
L-N1
H0.5
Z-N1 X49 5 5 X49.1 Z-N1
M1
N1
B1
S1
4 4
N2.5
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
M-N1
M-V1
M-B1
L-G1
Z-N1
A-V1
V-N1
R2.5
M1
N1
N1
N1
N1
N1
N1
1 1 1 2 1 2 1 2 1 2 1 2 1 2 1 P1
CONTROL PANEL (UNIDECK)
X32 X32A X33 X33 X34 X34 X39 X39 X40 X40 X35 X35 X36 X36 X37
S32 S33
Y1 Y2 Y5 Y4 Y6 Y3
p> p>
A41
X41 S-N1.5
X41 L-R1.5
X41 A-G1
X41 C-B1
X41 A-N1
X41 A-B1
X41 V-B1
X41 N1.5
GND. 2 GND. 1 KUE 37C-06-11331 A42
NAME DESCRIPTION SUPP. TYPE QTY.
X41 C1
X41 V1
A43
A44
FG1 General Fuse 80A CIAM 163028 1 A45
G1 Battery 100Ah FIAMM (KUE) L5 600 103 086 (37C-06-11110) 1 A46
G2 Generator YANMAR (DENSO) 129423-77200 1 A47
GND C8 Ground Terminal * * 1 KUE 37A-06-11460
GND5 C6 Ground Terminal * * 1 a c A48
A49
HA3 Back-Up Alarm CIAM (KUE) 0A001357 (312612100) 1 DESCRIPTION
NAME SUPP. TYPE QTY. b WAY A50
K01 Fuel Solenoid Valve Relay MATSUSHITA (KUE) CB1aH (885071022) 1
A51
N1.5
N1.5
R1.5
A-N1.5
A-B1.5
A-G1.5
K02 Fuel Pull Solenoid Valve Timer 1 Second YANMAR (KUE) 1
X121 Attachment 8 Way Connector DEUTSCH HD34 18-8PN 1
X121
H
WAY A
K03 Safety Relay YANMAR (KUE) 119802-77200 1
M1 Starter Motor YANMAR 1
X121 Nut DEUTSCH 114020-90 1
A
X121
G C
A-B1.5
M2 Fuel Pump YANMAR 129612-52100 1
X121 Washer DEUTSCH 114021 1 B N1.5
X121
F “B” Way Attachment C D E (-)
X121 Male Pin DEUTSCH D460-204-12141 6 X121
R1 Preheating Starter YANMAR 129100-77500 1
X121 Plug DEUTSCH HDC36-18 1 C A-G1.5 X121
E Ground
(+12V) B A
R2 Fuel Level Sender COBO (KUE) 29-0419-0000 (37A-04-11140) 1 D “A” Way Attachment H G F
R3 Engine Water Temperature Sender YANMAR (KUE) (7861-92-3320) 1
X8 5 Way Female Mark II Connector CIAM (AMP) 125216 1 A-N1.5 X121
C “C” Way Attachment KEY
S25 Air Filter Blocked Switch DONALDSON (KUE) X770317 (37A-06-11960) 1
X8 Male Pin CIAM (AMP) 120072 5 R1.5 X121
B +15 WAY
S26 Hydraulic Oil Filter Blocked Switch FMDI (KUE) 11716/1 (885261034) 1 RIGHT LEVER N1.5 X121
A Ground
B
S27 Stop Lights Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1
S28 Stop Lights Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1
S29 Back-Up Alarm Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1
S30 Back-Up Alarm Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1
S31 Engine Oil Min. Pressure Switch YANMAR * 1
V1 DESCRIPTION SUPP. TYPE QTY. NAME DESCRIPTION SUPP. TYPE QTY.
Diode 1A CIAM 1A1N4007 1 NAME
X01 Frame Line 3 Way Connector * * 1
X02 2 Way Connector * * 1 X107 Stabilizer Push Button Connector SWF 1
X03 Fuel Solenoid Relay Connector * *
GND. 1 C8 Ground Terminal AMP * 1 NAME DESCRIPTION SUPP. TYPE QTY. NAME DESCRIPTION SUPP. TYPE QTY. X44 Parking Brake Relay Connector BOSCH 1 WIRING COLORS
1 GND. 2 C8 Ground Terminal AMP * 1
X45.1 From Frame Line Mark 13 Way Connector AMP 1
GND. 5 C6 Ground Terminal AMP * 1 FU01 Fuse 3A Left Side Lights 1 K13 Flasher Unit CIAM 00105013 (KUE 885151012) 1
X46.1 From Frame Line 4 Way Connector DEUTSCH DTP04-4P 1 LIGHT BLUE
A
S32 PPC Safety Pressure Switch 1 Way Connector FMDI 11717.75 (37A-06-11670) 1 FU02 Fuse 3A Control Panel Lights 1 K14 Brake Relay CIAM 157061 (KUE 885071043) 1
X47.1 Ground 2 Way Connector DEUTSCH DTP04-2P 1 WHITE
X06 Diode 2 Way Connector * * 1 B
S33 Brake Valve Pressure Switch FMDI (KUE) * 1 FU03 Fuse 15A Horn, Front Work Lights 1 K95 Stop Lights Relay CIAM 157061 (KUE 885071043) 1
X48.1 From Frame Line Mark 6 VIE Connection 1
X07 Pool Solenoid Timer 4 Way Connector * * 1 AMP C ORANGE
X01.1 Engine Line 4 Way Connector DEUTSCH DTP04-4P 1 FU04 Fuse 7.5A Switch Lights 1 P1 Control Panel UNIDECK 04810027 (KUE 37A-54-14291) 1
X49.1 From Frame Line Mark 11 VIE Connector 1
X08 Safety Relay 6 Way Connector SUMITOMO 6195-0021 1 AMP G YELLOW
X02.1 Engine Line 2 Way Connector AMP * 1 FU05 Fuse 15A Rear Work Light 1 S01 Rear Worklights Switch CIAM 106AA008 (KUE 885081160) 1
X50 Safety Control Box 23 Way Connector 1
X09 C6 Generator Terminal * * 1 AMP H GRAY
X10.1 Engine Line 13 Way Connector AMP * 1 FU06 Fuse 10A Lever Switch Power Supply, Float S02 Panel Lights and Low Beam Lights Switch CIAM 106AA018 (KUE 885081159) 1
X52 Buzzer One Way Connector 1
X10 Frame Line Mark 13 Way Connector * * 1 AMP L BLUE
X32 PPC Safety Pressure Switch 1 Way Connector AMP SUPERSEAL 1 FU07 Fuse 10A Current Intake 12V, Beacon Light 1 S03 Direction Lights Switch CIAM 116003 (KUE 885081161) 1
X53 Buzzer One Way Connector 1
X11 Generator 3 Way Connector SUMITOMO 6189-0442 1 AMP M BROWN
X32A PPC Safety Pressure Switch 1 Way Connector AMP SUPERSEAL 1 FU08 Fuse 10A Control Panel, Electronic Unit, Fuel Shut Off, 1 S05 Up-Down Left Stabilizer Button CIAM 108AA002 (KUE885081163) 1
X54 Proximity Bar 3 Way Connector 1
DEUTSCH N BLACK
X33 PPC Valve 2 Way Connector DEUTSCH DT06-2S 1 Safety Bar Proximity, Seat Safety Switch and Brake Switch S06 Up-Down Right Stabilizer Button CIAM 108AA002 (KUE885081163) 1
X55 Safety Seat Switch 3 Way Connector 1
X13 Fuel Pool-Stop Solenoid 3 Way Connector DEUTSCH DT06-35 1 DEUTSCH R RED
X34 Float Valve 2 Way Connector DEUTSCH DT06-2S 1 FU09 Fuse 7.5A Back-Up Alarm 1 S07 Beacon Light Switch CIAM 106AA008 (KUE 885081160) 1
X56 Through X60 Fuse 1 Way Connector 5
X14 Fuel Pump 2 Way Connector * * 1 AMP S PINK
X35 Brake Valve 2 Way Connector DEUTSCH DT06-2S 1 FU10 Fuse 7.5A Fuel Pump, Safety Engine Relay, Generator 1 S08 Brake Switch CIAM 0A003455 (KUE 37A-06-11411) 1
X61 Through X65 Fuse 1 Way Connector 5
X15 Preheating Start C6 Terminal * * 1 AMP V GREEN
X36 Second Speed Valve 2 Way Connector DEUTSCH DT06-2S 1 FU11 Fuse 30A Pull Solenoid, PPC Safety Pressure Switch 1 S09 Hazard Switch CIAM 106AA014 (KUE 885081162) 1
X66 Through X70 Fuse 1 Way Connector 5
X16 Air Filter Blocked Switch 2 Way Connector AMP MINI TIMER 1 AMP Z VIOLET
X37 Brake Pressure Switch 1 Way Connector AMP * 1 GND. 3 C6 Ground Terminal SWF 1 S10 Starting Switch 1
X71 Through X75 Fuse 1 Way Connector AMP 5
X17 Fuel Level Sender 3 Way Connector * * 1 X39 Hight Flow Detent Valve 2 Way Connector DEUTSCH * 1 HA1 Warning Buzzer 1 S11 Safety Seat Switch 1
X76 & X77 Fuse 1 Way Connector AMP 2 EXAMPLE:
X18 Engine Water Temperature Sender 2 Way Connector * * 1 X40 Hight Flow Momentary Valve 2 Way Connector DEUTSCH * 1 HL1 Super Flow LED Diode 1 S12 Bar PNP Safety Sensor SAIET E-A1TMU3AP (KUE 37A-06-1250) 1
X78 & X79 Current Intake 1 Way Connector AMP 2
X19 Hydraulic Oil Filter Blocked Switch C5 Terminal * * 1 G/V = YELLOW/GREEN
X41 Stabilizer 5 Way Connector AMP * 1 HL2 “C” Way LED Diode 1 S13 Horn Push Button 1
X80 Control Panel 16 Way Connector AMP 1 (TRANSVERSE MARKED)
X20 Stop Light Pressure 1 Switch 2 Way Connector DEUTSCH DT06-2S 1 X42 1 S14 Second Speed Push Button 1
Attachment 5 Way Connector AMP * HL3 “A” Way LED Diode 1
X21 Stop Light Pressure 2 Switch 2 Way Connector DEUTSCH DT06-2S 1 X81 Control Panel 8 Way Connector AMP 1 YELLOW GREEN
X43 ENPI Valve 1 Way Connector AMP * 1 HL4 “B” Way LED Diode 1 S15 Float Push Button 1
X82 Lights Line 11 Way Connector 1
X22 Back-Up Pressure 1 Switch 2 Way Connector DEUTSCH DT06-2S 1 AMP
X45 Cabin Line 13 Way Connector AMP * 1 HL5 Optional LED Diode 1 S32 PPC Safety Pressure Switch FMDI (KUE) 11717.75 (37A-06-11670) 1
X83 Left Lever 12 Way Connector DT04-12P, DT06-12S 1
X23 Back-Up Pressure 2 Switch 2 Way Connector DEUTSCH DT06-2S 1 DEUTSCH
X46 Cabin Line 4 Way Connector DEUTSCH DTP06-4S 1 K04 Float Relay C1AM 01170922 (KUE 885070040) 1 S33 Brake Valve Pressure Switch FMDI (KUE) 11717.15 (885411439) 1
X84 Right Lever 12 Way Connector DT04-12P, DT06-12S 1
X28 Engine Min. Pressure Switch Terminal * * 1 DEUTSCH
X47 Ground 2 Way Connector DEUTSCH DTP06-2S 1 K05 Relays Box (Without Relays) C1AM 122010 (KUE 885411196) 1 S36 Reverse HI-Flow Momentary Push Button 1
X85 Rear Work Lights SWF Switch 1 G-V = YELLOW-GREEN
X29 Back-Up Alarm 2 Way Connector * * 1 SWF
X48 Cabin Line 5 Way Connector AMP * 1 K06 Electronic Unit C1AM 01171077 (KUE 885070046) 1 S37 Super-Flow Detent Push Button 1
X86 Panel & Front Lights SWF Switch Connector 1 (LONGITUDINAL COLORS)
SWF
X49 Cabin Line 11 Way Connector AMP * 1 K07 “B” Way Relay KUE 885071044 1 S38 “C” Way Push Button 1
X87 Brake Switch Connector 1
XB C8 Start Motor Terminal * * 1 PNEUTRON
Y1 PPC Valve HYDRAFORCE * 1 K08 “A” Way Relay KUE 885071044 1 S39 “A” Way Push Button 1
X88 Beacon Light Switch Connector 1 YELLOW GREEN
XF General Fuse 2 Way Connector * * 1 SWF
Y2 Float Valve HYDRAFORCE * 1 K09 “C” Way Relay KUE 885071044 1 S40 “B” Way Push Button 1
X89 Float Relay Connector 1
XM C4 Start Motor Terminal * * 1 BOSCH
Y3 Second Speed Valve HYDRAFORCE * 1 K10 Super-Flow Detent Step By Step Relay CIAM 01170923 (KUE 37A-06-11430 1 X104 Direction Lights Switch Connector 1
X90 Relays Box 21 Way Connector 1
XS Safety Relay 2 Way Connector SUMITOMO 6195-0060 1 AMP
Y4 Reverse HI-Flow Momentary Valve HYDRAFORCE * 1 K11 Reverse HI-Flow Momentary Relay CIAM 157061 (KUE 885071043) 1 X105 SWF Hazad Connector SWF 1
X91 ENPI Valve SWF Connector 1
XS1 Insulator * * 1 CEMBRE
Y5 Super-Flow Detent Valve HYDRAFORCE * 1 K12 Stop Lights Relay CIAM 157061 (KUE 885071043) 1 X106 Stabilizer Push Button Connector SWF 1
X95 Stop Light Relay Connector 1
Y0 Stop Fuel Solenoid Valve YANMAR 129005-77950 1 AMP
Y6 Brake Valve HYDRAFORCE * 1
CVSM0361A
SK1026-5 Turbo 90-21j
DIAGRAMS AND SCHEMATICS
X82.1 G-N1
10 X82.1 H-G1
X82.1 H-N1
X82.1 H-N1
X82.1 A-G1
X82.1 R/N1
A13
X82.1 N1.5
G/R1 X86
X82.1 G1
X82.1 C1
X82.1 A1
X82.1 L1
G1.5 X86 9
A14
8
A15 H-N1 X86
H-R1
A16 KUE 37A-06-11391 1
11
7
1
2
3
4
5
6
8
9
A17 G1.5 1 6 9
1
0 2
R-N2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
R2.5
H-G1 X82 10
11
L1 X82 1
G1 X82 2
G-N1 X82 3
R/N1 X82 4
H-N1 X82 5
H-N1 X82 6
A-G1.5 X82 7
C1 X82 8
9
S02 3 2 10
1 1 1 1 1 1 1 1 1 1 1 K04 85 87
A1 X82
N1.5 X82
86 87a 87 H-R1.5 X86
K95
X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76 3
H-R1 X86
86 30 2
FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01 N1 X86
85 30
30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A 10
X89 X89 X89 X89
X78 X79
X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77 86 85 30 87a
1 1 85 86 30 87
1 1 1 1 1 1 1 1 1 1 1
X95 X95 X95 X95
H/R1
N1
M-N1
B-N1
B-R1
B-R1
M1
N1
L-R1
R-V1
H-R1.5
H/R1
B-R1
A-R1.5
G/R1
G-N1
G-N1
G1
R-N2.5
R-G1
L-R1.5
H/R1
S/N1 X87
6
H-R1 X87
3
15/1 30/3 L/6
0 1
A18
A19 R/7
S08 49/4 30b/2
A20
L/B1 X87
A21
2
H-R1 X87
7
A22
A23
G/R1 X88
9
A24 H/R1 X88
1
A25 1 9
1 0
A26 S07 5 10
H-G1 X88
A27 5
N1 X88
A28
10
A29
A30
A31
RELAYS UNIT
85 30 86 87 86 87 85 30
A32
A33
A34
KUE 37A-06-11363
K07 85 30 K10
K13 +
R CL (T)
53M
53S
86 87
31
15
T
- (53S)
A35
A36
A37
A38
A39
A40
A1 X104 2
L1 X104 1
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
K05 0 1 2
1 2
GND. 3
10
12
13
14
15
16
17
18
19
20
21
11
S03 54
1
2
3
4
5
6
7
8
9
A/N1 X104 54
A-R1.5
L-R1.5
A-G1
R/N1
R-V1
A-N1
A-V1
C/B1
A/N1
Z-N1
Z-N1
A-B1
L-N1
A/V1
V/B1
L/N1
N1.5
L/R1
N1 X105 10
A/N1 X105 5
X80-16
X80-12
X80-14
X80-11
L1 L2 L3 L4 L5 C2 C3 X80-8 0
+ 1 2 1 7 9
H F L1 L2 L3 L4 L5
FUEL WATER TEMP.
LEVEL INDICATOR
S05 3 10
C1 00000 00 h C2
L-R1.5 X106 3
C E
N1 X106 10
C1
HOUR C3
COUNTER
DL1 DL2 DL3
X80-6
P L6 L7 L8 L9 L10 G/R1 X107 9
C-B1
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
X107 7
X80-2 X80-3
C1 X107 1
L6 L7 L8 L9 L10 DL2 DL1 DL3 X80-9
0
1 2 1 7 9
WIRE WIRE
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR S05 3 10
L-R1.5 X107 3
B-R1
B/R1
C/B1
Z-N1
A/B1
A-G1
L/N1
B-R1
A-N1
A-B1
V/B1
L/G1
A/V1
Z/N1
X80-1 X80-9 INTERNAL LIGHTS (+LUCI) POSITIVE
N1
G-N1
N1
N1 X107 10
C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1 1 2 3 4 5 6 11 1 2 3 4 5 6 7 8 9 11
C3 X80-3 WATER TEMPERATURE INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
+50 X80-4 START SIGNAL +50 L2 X80-12 PREHEATING LAMP POSITIVE HL3 HL2
B1 M1
LEFT LEVER RIGHT LEVER
X83
X83
X83
X83
X83
X83
X83
X84
X84
X84
X84
X84
X84
X84
X84
X84
X84
GND. X80-5 GROUND GND. X80-13 HL4
S-N1.5
L-R1.5
HL1
G/R1
R-N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
A-B0.6
N0.8
GND. X80-6 GROUND GND. N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1
R-N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
A-B0.5
A-G0.5
A-N0.6
Z-N0.6
N0.8
N1
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1 5 1 9 10
S13 S38 S15
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 S14
X91
X91
X91
X91
S36 S39 S40
S37
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 S13 S14 S36 S37 HL1 S15 S38 HL2 S39 HL3 S40 HL4 HL5
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 LEFT LEVER RIGHT LEVER
CVSM0361B