Komatsu Wheel Loaders WA450-3 Shop Manual

SEBM009904
1
LL
LOG LOADER
MACHINE MODEL
SERIAL NUMBER
WA450-3LL
50305 and up
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
WA450-3LL mount the S6D125 engine.

For details of the engine, see the 125 Series Engine Shop Manual.
2000 1
All Rights Reserved
Printed in Japan 08-00(01)
00-1
r
CONTENTS
01
GENERAL ........................................................................
01-1
10
STRUCTURE AND FUNCTION ......................................
10-1
20
TESTING AND ADJUSTING ..........................................
20-1
30
DISASSEMBLY AND ASSEMBLY .................................
30-1
40
MAINTENANCE STANDARD .........................................
40-1
90
OTHERS...........................................................................
90-1
00-2
w
U42103
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SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol

is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
Always wear safety glasses when hitting

parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a

trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the negative () terminal first.
14.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.
15.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.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places.

Replace any damaged parts 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.
20.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.
21.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.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.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.
FOREWORD
GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
(
....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all
models
REVISIONS
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5
00-6
123
Revised pages are shown in the LIST OF REVISED

PAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol
Item
Remarks
Safety
Special safety precautions

are necessary when performing the work.
Caution
Special technical precautions or other precautions

for preserving standards
are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary

when selecting hoisting
wire, or when working posture is important, etc.
Tightening
torque
Places that require special

attention for the tightening
torque during assembly.
Coat
Places to be coated with

adhesives and lubricants,
etc.
Oil, water
Places where oil, water or

fuel must be added, and
the capacity.
Drain
Places where oil or water

m u s t b e d r a i n e d , a nd
quantity to be drained.
4
3
2
5
6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted

with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol
If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter
Allowable load
mm
kN
tons
10
11.5
12.5
14
16
18
20
22.4
30
40
50
60
9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
Slinging near the edge of the hook may cause

the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41%
SAD00479
3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically
wound onto the load.
Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a

wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
lifting angle of 150.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Before carrying out the following work, release

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
Even if the residual pressure is released from
the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),
press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.
(See Fig. 3)
Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (See Fig. 5)
When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
Type 1
FOREWORD
Type 3
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.
1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push

until cover (3) contacts contact surface a of
3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.
Disassembly
Type 2
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
LT-2
09940-00030
50 g
Polyethylene
container
LT-3
790-129-9060
(Set of
adhesive and
hardening
agent)
Adhesive:
1 kg
Hardenin
g
agent:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three bond
1735
790-129-9140
50 g
Polyethylene
container
2g
Polyethylene
container
Adhesives
Aron-alpha
201
790-129-9130
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr
Used to prevent rubber gaskets,

rubber cushions, and cock plug
from coming out.
Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
Features: Resistance to heat and

chemicals
Used for anti-loosening and sealant purpose for bolts and plugs.
Used as adhesive or sealant for

metal, glass and plastic.
Used as sealant for machined

holes.
Used as heat-resisting sealant for

repairing engine.
Quick hardening type adhesive

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals, rubbers, plastics and woods.
Quick hardening type adhesive

Quick cure type (max. strength after 30 minutes)
Used mainly for adhesion of rubbers, plastics and metals.
Resistance to heat, chemicals

Used at joint portions subject to
high temperatures.
Used as adhesive or sealant for

gaskets and packing of power
train case, etc.
Used as sealant for various

threads, pipe joints, flanges.
Used as sealant for tapered
plugs, elbows, nipples of hydraulic piping.
Gasket
sealant
LG-6
790-129-9020
200 g
Tube
00-10
Features: Silicon based, resistance to heat, cold

Used as sealant for flange surface, tread.
mab Used as sealant for oil pan,
final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr
LG-7
790-129-9070
1g
Tube
Three bond
1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
Adhesives
Molybdenum
disulphide
lubricant
LM-P
09940-00040
200 g
Used as heat-resisting sealant for

repairing engine.
Used as lubricant for sliding portion (to prevent from squeaking).
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting.
Used as lubricant for linkage,
bearings, etc.
Tube
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various
Various
Molybdenum
disulphide
lubricant
SYG2-400M
400 g
(10 per
case)
Belows type
Grease
Various
Ftures: Silicon based, quick hardening type

Used as sealant for flywheel
housing, intake manifold, oil an,
thermostat housing, etc.
General purpose type
Used for normal temperature,

light load bearing at places in contact with water or steam.
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter
of bolt
Width across
flats
mm
mm
6
8
10
12
14
10
13
17
19
22
16
18
20
22
24
24
27
30
32
36
27
30
33
36
39
41
46
50
55
60
Thread diameter
of bolt
Width across
flats
mm
mm
Nm
6
8
10
12
10
13
14
27
7.85 1.95
18.6 4.9
40.2 5.9
82.35 7.85
Nm
kgm
0 0.15
0 0.3
0 0.7
01
02
28.5 0 3
39 0 4
56 0 6
76 0 8.5
94.5 0 10.5
135 0 15
175 0 20
225 0 25
280 0 30
335 0 35
0 1.4
03
07
0 10
0 19
279 0 30
382 0 39
549 0 59
745 0 83
927 0 103
1320 0 140
1720 0 190
2210 0 240
2750 0 290
3290 0 340
1.35
3.2
6.7
11.5
18
13.2
31
66
113
177
kgm
0
0
0
0
0.8
1.9
4.1
8.4
0 0.2
0 0.5
0 0.6
0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14
18
22
24
30
33
36
42
19
24
27
32
36
41
46
55
24.5 4.9
49 19.6
78.5 19.6
137.3 29.4
176.5 29.4
196.1 49
245.2 49
294.2 49
2.5 0.5
5 2
8 2
14 3
18 3
20 5
25 5
30 5
00-12
Tightening torque
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FOREWORD
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10
12
16
14
17
22
65.7 6.8
112 9.8
279 29
0
0
0
6.7 0.7
11.5 1
28.5 3
0
0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
14
20
24
33
42
Varies depending
on type of
connector.
34.3 4.9
93.1 9.8
142.1 19.6
421.4 58.8
877.1 132.3
Norminal No.
02
03, 04
05, 06
10, 12
14
kgm
0
0
0
0
0
0 0.5
01
02
06
0 13.5
3.5
9.5
14.5
43
89.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08
10
12
14
16
18
20
24
30
33
36
42
52
14
17
19
22
24
27
30
32
32
n
36
n
n
7.35 1.47
11.27 1.47
17.64 1.96
22.54 1.96
29.4 4.9
39.2 4.9
49 4.9
68.6 9.8
107.8 14.7
127.4 19.6
151.9 24.5
210.7 29.4
323.4 44.1
0
0
0
0
0
0
0
0
0
0
0
0
0
0.75 0.15
1.15 0.15
1.8 0.2
2.3 0.2
3 0.5
4 0.5
5 0.5
7 1
11 1.5
13 2
15.5 2.5
21.5 3
33 4.5
Norminal No.
08
10
12
14
16
18
20
24
30
33
36
42
52
0
0
0
0
0
0
0
0
0
0
0
0
0
00-13
FOREWORD
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
10 2
24 4
43 6
77 12
kgm
0
0
0
0
1.02
2.45
4.38
7.85
0 0.20
0 0.41
0 0.61
0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
14
8 2
10 2
12 2
24 4
36 5
kgm
0
0
0
0
0
0.81
1.02
1.22
2.45
3.67
0 0.20
0 0.20
0 0.20
0 0.41
0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter
Tightening torque
inch
Nm
1 / 16
1/8
1/4
3/8
1/2
3/4
1
3 1
8 2
12 2
15 2
24 4
36 5
60 9
kgm
0
0
0
0
0
0
0
0.31
0.81
1.22
1.53
2.45
3.67
6.12
0 0.10
0 0.20
0 0.20
0 0.41
0 0.41
0 0.51
0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
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.
Tightening torque (Nm {kgm})
Nominal size Width across
of hose
flats
Taper seal
type
Face seal type
Nominal thread
Thread size size - Threads per
Root diameter
(mm)
(mm) (Reference)
inch, Thread series
Range
Target
19
35 - 63 {3.5 - 6.5}
44 {4.5}
14
9
- 18UNF
16
14.3
22
54 - 93 {5.5 - 9.5}
74 {4.5}
11
- 16UN
16
17.5
24
59 - 98 {6.0 - 10.0}
78 {8.0}
18
04
27
84 - 132 {8.5 - 13.5}
103 {10.5}
22
13
- 16UN
16
20.7
05
32
128 - 186 {13.0 - 19.0}
157 {16.0}
24
1 - 14UNS
25.4
06
36
177 - 245 {18.0 - 25.0}
216 {22.0}
30
3
1 - 12UNF
16
30.3
(10)
41
177 - 245 {18.0 - 25.0}
216 {22.0}
33
(12)
46
197 - 294 {20.0 - 30.0}
245 {25.0}
36
(14)
55
246 - 343 {25.0 - 35.0}
294 {30.0}
42
02
03
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Cable O.D.
(mm)
Current
rating
(A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal

etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (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
Norminal
number
Number of
strands
Dia. of
strands
(mm2)
Cross
section
(mm 2)
0.85
11
0.32
26
CLASSIFICATION BY COLOR AND CODE

Circuits
Priority
Classification
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2
Color White & Red
Code
WB
3
Color White & Black
Code
4
Auxiliary
WL
Color White & Blue

Code
WG
5
Color White & Green
Code
6
Color
n
n
n
n
n
n
n
n
n
n
n
n
White & Black Red & White Rellow & Red Green & White Blue & White
BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR
RY
Black & Red Red & Yellow
n
n
n
n
RG
YG
GY
LY
Yellow &
Green
Green &
Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
Red & Blue Yellow & White Green & Blue
n
n
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
from .
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
from .
(3) Take the point where the two lines cross as . This point
gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
A
B
B
Millimeters to inches
1 mm = 0.03937 in
00-16
0
10
20
30
40
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.197
0.591
0.984
1.378
1.772
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 kg = 2.2046 lb
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
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
00-20
FOREWORD
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice 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.
1C = 33.8F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
117.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
0
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
00-21
FOREWORD
UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses {
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
}.
01
GENERAL
U42103
General assembly drawing ........................... 01-2

Specifications .................................................. 01-4
Weight table ................................................... 01-7
List of lubricant and water ............................ 01-9
01-1
e
GENERAL
GENERAL ASSEMBLY DRAWING
U42103
Serial No.: 50305 52999
01-2
e
GENERAL
Serial No.: 53001 53999
U42103
Serial No.: 54001 and up
01-3
e
r
GENERAL
SPECIFICATIONS
SPECIFICATIONS
WA450-3LL
Weight
Serial No.
kg
22,750
23,440
Distribution (front)
kg
11,510
11,420
Distribution (rear)
kg
11,240
12,020
Rated load
kg
8,600
8,600
FORWARD 1st
km/h
6.6
6.6
FORWARD 2nd
km/h
12.3
12.3
FORWARD 3rd
km/h
21.8
21.8
FORWARD 4th
km/h
34.0
34.0
REVERSE 1st
km/h
6.8
6.8
REVERSE 2nd
km/h
12.8
12.8
REVERSE 3rd
km/h
22.7
22.7
REVERSE 4th
km/h
36.0
36.0
Max. rimpull
kN
{kg}
188.1
{19,180}
188.1
{19,180}
Gradeability
deg
25.0
25.0
Center of outside wheel
mm
5,820
5,820
Outside portion of
chassis
mm
6,905
6,950
Overall length
mm
9,365
9,510
Overall width (chassis)
mm
3,000
3,000
Log grapple width
mm
2,685
2,685
Overall height (top of exhaust pipe)
mm
3,450
3,450
mm
7,005
7,130
Wheelbase
mm
3,400
3,400
Tread
mm
2,300
2,300
Min. ground clearance
mm
525
525
Height of grapple hinge pin
mm
4,235
4,360
Dumping clearance (30)
mm
3,255
3,380
Dumping reach
mm
1,900
1,915
Grapple dump angle
deg
45
45
Grapple tilt angle (travel posture)
deg
19
19
Performance
Min. turning
radius
Dimensions
(Grapple arm open)
e
r
53001 53999
54001 and up
Operating weight
Travel speed
01-4
50305 52999
U42103
Machine model
GENERAL
SPECIFICATIONS
Machine model
WA450-3LL
Serial No.
Model
Komatsu S6D125
4-cycle, water-cooled, in-line,
6-cylinder, direct injection, with turbocharger
Type
No. of cylinders bore x stroke
mm
6 125 x 150
{cc}
11.04 {11,040}
Flywheel horsepower
kW {HP}/rpm
196 {259}/2,200
Maximum torque
Nm {kgm}/rpm
1,050 {107}/1,400
Fuel consumption ratio
g/kWh {g/HPh}
224 {169}
High idling speed
rpm
2,400 50
Low idling speed
rpm
700 750
Engine
Piston displacement
Starting motor
24 V
Alternator
12 V
Axle, wheel
Power train
Torque converter
Brakes
150 Ah x 2
3-element, 1-stage, single-phase (Komatsu TCA38-8A)

Spur gear, constant-mesh multiple-disc,
hydraulically actuated, modulation type
Transmission
Reduction gear
Spiral bevel gear, splash lubrication
Differential
Straight bevel gear, torque proportioning
Final drive
Planetary gear single stage, splash lubrication
Drive type
Front-, rear-wheel drive
Front axle
Fixed frame, full-floating type
Rear axle
Center pin support full-floating type
Tire
26.5-25-24PR
Wheel rim
Inflation pressure
Brake cooling
system
7.5 kW
24 V 50 A
Battery
U42103
53001 53999
54001 and up
50305 52999
22.00 x 25TB (for water ballast)

Front tire
kMPa {kg/cm2}
392 {4.0}
Rear tire
kMPa {kg/cm2}
343 {3.5}
Front-, rear-wheel independent system control,
sealed multiple-disc wet-type disc brake
With hydraulic booster
Service brake
Parking brake
Drive shaft, wet type disc brake

Hydraulically released spring type
Cooling type
Oil circulating
Brake cooling pump
Gear pump
Capacity
Brake tank capacity
/min
55
22.5
01-5
e
r
GENERAL
SPECIFICATIONS
Machine model
WA450-3LL
Type
Articulated steering
Structure
Fully hydraulic power steering
Hydraulic pump type
Gear pump
Hydraulic pump
302
Switch pump
Delivery
122
/min
Control valve
Work
equipment
e
r
168
PPC pump
Cylinder
Hydraulic system
Steering pump
01-6
53001 53999
54001 and up
50305 52999
62
Set pressure for work equipment
MPa
{kg/cm2}
3-spool type
20.58 {210}
Set pressure for steering
MPa
{kg/cm2}
Spool type
20.58 {210}
Lift arm cylinder

No. bore x stroke
mm
Reciprocating piston
2 180 x 764
Fork cylinder
No. bore x stroke
mm
1 200 x 550
Log grapple cylinder

No. bore x stroke
mm
2 130 x 411
Steering cylinder
No. bore x stroke
mm
2 100 x 440
Link type
Single link
U42103
Steering
system
Serial No.
GENERAL
WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model
50305 52999
53001 53999
54001 and up
1120
1120
168
168
1000
1000
Center drive shaft
36
36
Front drive shaft
40
40
Rear drive shaft
19
19
Front axle
1455
1455
Rear axle
1466
1466
Front differential
235
235
Rear differential
244
244
Planetary carrier and brake assembly (each)
685
685
Axle pivot (rear axle)
148
148
Wheel (each)
240
240
Tire (each)
421
421
Steering valve
24
24
Steering cylinder (each)
38
38
Serial No.
Engine
Radiator
Transmission (including torque converter)
U42103
WA450-3LL
Brake valve (R.H.)

Hydraulic tank
8.5
8.5
231
231
Hydraulic, PPC and brake cooling pump (tandem pump)
33
33
Steering, switch pump (tandem pump)
20
20
Main control valve
90
90
Lift cylinder (each)
192
192
Fork cylinder
222
222
78
78
Engine hood
184
184
Front frame
1830
1830
Rear frame
1420
1586
Bucket link
89
89
415
415
Lift arm (including bushing)
1440
1540
Log grapple
1772
1772
PPC valve
Log grapple cylinder (each)
Bellcrank
01-7
e
r
GENERAL
WEIGHT TABLE
Unit: kg
Machine model
WA450-3LL
50305 52999
53001 53999
54001 and up
1200
1600
292
292
Battery (each)
45
45
Operators seat
38
38
Floor board
140
140
Counterweight, Rear (for Log)
400
400
Counterweight, R.H. (for Log)
282.5
278
Counterweight, L.H. (for Log)
373.5
365
Serial No.
Counterweight
U42103
Fuel tank
01-8
e
r
GENERAL
LIST OF LUBRICANT AND WATER

RESERVOIR
KIND OF
FLUID
AMBIENT TEMPERATURE
22 4
30 20
14
10
32
0
50
10
68
20
86
30
CAPACITY
104122F
40 50C
Specified
Refill
47
38
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Engine oil
Transmission case
SAE 10W
65
60
Hydraulic system
SAE 10W
280
192
Axle oil
See Note 1
57
57
Engine oil
SAE 10W
60
52
Grease
NLGI No. 2
390
68
U42103
Axle (with standard

differential)
(Front and rear)
(Each)
Brake cooling
system
Pins
ASTM D975 No.2

Fuel tank
Cooling system
Diesel fuel
Water
Add antifreeze
ASTM D975 No. 1

Note 1: For axle oil, use only recommended oil as follows.
SHELL:
DONAX TT or TD
CALTEX:
RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL:
MOBILAND SUPER UNIVERSAL
It is possible to substitute engine oil CLASS-CD SAE30 for axle oil.
If noise comes from the brake, it is no problem of durability.
01-9
e
r
GENERAL
Fuel sulphur content
Change interval of oil in

engin oil pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
When starting the engine in an atmospheric temperature of lower than 0C, be sure to use engine
oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up to
10C more or less in the day time.
Use API classification CD as engine oil and if API classification CC, reduce the engine oil change
interval to half.
There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be
sure to add single grade oil that matches the temperature in the table.
We recommend Komatsu genuine oil which has been specifically formulated and approved for use
in engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API: American Petroleum Institute
01-10
e
U42103
REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
U42103
10
Power train ...............................................

Power train system ..................................
Torque converter, transmission
piping ..................................................
Transmission hydraulic system
diagram ...............................................
Transmission hydraulic circuit
diagram ...............................................
Torque converter ......................................
Torque converter oil filter .......................
Transmission ............................................
Transmission control valve .....................
Transmission solenoid valve ..................
Pilot oil filter .............................................
Drive shaft .................................................
Axle ............................................................
Differential.................................................
Final drive .................................................
Axle mount, center hinge pin .................
Steering piping .........................................
Steering column .......................................
Steering valve ...........................................
Orbit-roll valve ..........................................
Stop valve .................................................
Emergency steering pump (option) .......
Diverter valve (option) .............................
Brake piping ..............................................
Brake circuit diagram ...............................
Brake valve ...............................................
Charge valve .............................................
Accumulator (for brake) ..........................
Slack adjuster ...........................................
Brake cooling piping ................................
Brake cooling circuit diagram .................
Brake ..........................................................
Brake cooling ............................................
Parking brake control ...............................
1010-
3
4
10-
10-
10- 9
10- 10
10- 13
10- 14
10- 25
10- 47
10- 48
10- 49
10- 50
10- 52
10- 56
10- 57
10- 58
10- 59
10- 60
10- 74
10- 78
10- 79
10- 80
10- 84
10-84-2
10- 86
10- 92
10- 96
10- 97
10-100
10-101
10-102
10-104
10-105
Parking brake ............................................

Parking brake solenoid valve ..................
Parking brake valve ..................................
Parking brake emergency release
solenoid valve ....................................
Hydraulic piping .......................................
Work equipment hydraulic
system diagram .................................
Work equipment hydraulic circuit
diagram ...............................................
Work equipment lever linkage ................
Hydraulic tank ...........................................
PPC valve ..................................................
PPC relief valve ........................................
Accumulator (for PPC valve) ...................
Cut-off valve .............................................
Main control valve ...................................
Work equipment linkage .........................
Log grapple ...............................................
Fork positioner and lift arm kick-out ......
Cab (option) ..............................................
Air conditioner (option) ...........................
Electric circuit diagram ............................
Machine monitor system.........................
Main monitor ............................................
Maintenance monitor ...............................
E.C.S.S. ......................................................
Sensors .....................................................
Engine starting circuit ..............................
Engine stop circuit ...................................
Preheating circuit .....................................
Electric transmission control ...................
Kick-down switch .....................................
Kick-down electric circuit diagram .........
Transmission cut-off switch ....................
Transmission cut-off function .................
Electric parking brake control .................
10-106
10-107
10-108
10-109
10-111
10-112
10-114
10-115
10-116
10-118
10-123
10-124
10-125
10-128
10-142
10-144
10-145
10-151
10-152
10-153
10-155
10-156
10-161
10-163
10-167
10-172
10-173
10-174
10-175
10-178
10-179
10-184
10-185
10-187
10-1
e
POWER TRAIN
U42103
POWER TRAIN
1. Transmission (multiple shaft

type)
2. Torque converter
3. Engine (S6D125)
4. Rear axle
5. Rear drive shaft
6. Center drive shaft
Outline
The motive force from engine (3) passes
through the engine flywheel and is transmitted to torque converter (2), which is connected to the input shaft of transmission (1).
The transmission has six hydraulically actuated clutches, and these provide four speed
ranges for both FORWARD and REVERSE.
The transmission speed ranges are selected
manually.
7. Front drive shaft

8. Front axle
The motive force from the output shaft of

the transmission passes through center drive
shaft (6), front drive shaft (7) and rear drive
shaft (5), and is then transmitted to front
axle (8) and rear axle (4) to drive the wheels.
10-3
POWER TRAIN SYSTEM
U42103
POWER TRAIN SYSTEM
10-4
U42103
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Front axle
Differential
Front drive shaft
Center drive shaft
Parking brake (wet type multiple disc)
Rear drive shaft
Differential
Rear tire
Final drive
Wet type multiple disc brake
Rear axle
Engine (S6D125)
Torque converter
Hydraulic pump
PPC pump
Steering pump
Switch pump
Transmission, torque converter charging
pump
Transmission (multiple shaft type)
Flange bearing
Front tire
Final drive
Wet type multiple disc brake
Brake cooling pump
POWER TRAIN SYSTEM
Outline
The motive force from engine (12) passes
through the flywheel and is transmitted to
torque converter (13).
The torque converter uses oil as a medium.
It converts the transmitted torque in accordance with the change in the load, and transmits the motive force to the input shaft of
the transmission.
In addition, the motive force of the engine
passes through the pump drive gear of the
torque converter, and is transmitted to steering pump (16), switch pump (17), hydraulic
pump (14), PPC pump (15) and brake cooling pump (24) to drive each pump.
Transmission (19) operates the directional
spool and speed spool of the transmission
valve through the solenoid valves, and actuates the six hydraulically actuated clutches
to select one of the four FORWARD or REVERSE speeds.
The transmission speed range is selected
manually.
Parking brake (5) is installed to the front output shaft, and acts to stop the machine
through the solenoid valve and hydraulically
actuated clutches when the parking brake
switch is operated.
The output shaft of transmission (19) transmits the power to the front and rear axles.
At the front, the power is transmitted to front
axle (1) through center drive shaft (4), flange
bearing (20), and front drive shaft (3).
At the rear, the power is transmitted to rear
axle (11) through rear drive shaft (6).
The motive force transmitted to front axle
(1) and rear axle (11) has its speed reduced
by the bevel gear and pinion gear of differentials (2) and (7), and is then transmitted to
the sun gear shaft through the differential
mechanism.
The motive force of the sun gear is rduced
further by the planetary mechanism and is
transmitted to the wheels through the axle
shaft.
10-5
TORQUE CONVERTER, TRANSMISSION PIPING
U42103
TORQUE CONVERTER, TRANSMISSION PIPING
1.
2.
3.
4.
Torque converter charging pump

Torque converter
Radiator
Oil cooler
10-6
5.
6.
7.
8.
Pilot oil filter

Transmission control valve
Transmission
Oil filter
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
U42103
(Conditions: Engine at low idling, transmission shift lever at neutral)
10-8
r
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
U42103
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
1. Transmission case
2. Strainer
3. Torque converter charging
pump
4. Flow valve
5. Oil filter
6. Pilot reducing valve
7. Pilot oil filter
8. Priority valve
9. Modulation valve
10. Quick return valve
11. Main relief valve
12. Torque converter

13. Torque converter outlet
valve
14. Oil cooler
15. Transmission lubrication
16. Emergency manual spool
17. Solenoid valve (FORWARD)
18. Directional selector valve
19. Solenoid valve (REVERSE)
20. REVERSE clutch
21. FORWARD clutch
22. Solenoid valve (H-L selection)
23. H-L selector valve
24. Solenoid valve (range selection)

25. Range selector valve
26. Solenoid valve (parking
brake)
27. Parking brake valve
28. Parking brake
29. 4th clutch
30. 3rd clutch
31. 2nd clutch
32. 1st clutch
33. Accumulator
10-9
r
TORQUE CONVERTER
TORQUE CONVERTER
Z
SDW00010
1.
2.
3.
4.
Breather
Housing
Hydraulic, PPC, brake cooling pump mount
Steering, switch pump mount
10-10
r
Specifications
Model: TCA38-8A
Type: 3 element, 1 stage, 1 phase
Stall torque ratio: 3.19
U42103
TORQUE CONVERTER
9
B
10
U42103
11
SDW00011
5.
6.
7.
8.
Flywheel
Drive case
Turbine
Pump
9. Stator
10. Transmission input shaft
11. Housing
A. Inlet port
B. Outlet port
10-11
Path of motive force

The torque converter is installed between
the engine and the transmission.
The motive force from the engine enters
drive case (6) from flywheel (5).
Drive case (6), pump (8), and PTO gear (drive)
(12) are each secured by bolts and are rotated directly by the rotation of the engine.
The motive force of pump (8) uses oil as a
medium to rotate turbine (7) and transmit
the motive force to transmission input shaft
(10).
The motive force of drive case (6) is used as
the motive force to drive the gear pump
through PTO gear (drive) (12).
TORQUE CONVERTER
12
SDW00012
Flow of oil
The oil supplied from the torque converter charging pump enters inlet port A, passes through
the oil passage of stator shaft (13), and flows to
pump (8).
The oil is given centrifugal force by pump (8),
enters turbine (7), and transmits the energy of
the oil to the turbine. Turbine (7) is fixed to
transmission input shaft (10), so the motive force
is transmitted to the transmission input shaft.
The oil from turbine (7) is sent to stator (9), and
enters the pump again. However, part of the oil
is sent from the stator through outlet port B to
the cooler.
13
SDW00013
10-12
U42103
10
TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER

1.
2.
3.
4.
Relief valve
Element
Center bolt
Drain plug
Specifications
Filter mesh size: 10 microns
Filtering area:
8900 cm2
Relief pressure: 0.3 MPa {3.25 kg/cm2}
U42103
SEW00014
Operation
The oil from the torque converter charging
pump enters filter inlet port A. It is filtered
from the outside of element (2) to the inside, and flows to outlet port B.
To Transmission
control valve
SEW00015
1 A
If element (2) becomes clogged with dirt, or

the oil temperature is low and the pressure
rises at inlet port A, the oil from inlet port A
opens relief valve (1) and flows directly to
outlet port B in order to prevent damage to
the pump or element (2).
B
To Transmission
control valve
SEW00016
10-13
TRANSMISSION
U42103
TRANSMISSION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
10-14
r
Torque converter charging pump

Torque converter
Torque converter housing
Accumulator
Oil filter (pilot)
Rear output coupling
Transmission
Parking brake (wet type multiple disc)
Front output coupling
Oil filter
PTO
Transmission oil filler
PTO gear (No. of teeth: 65)
TRANSMISSION
U42103
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
1st clutch
FORWARD clutch
Input gear (No. of teeth: 30)
Torque converter
PTO drive gear (No. of teeth: 74)
FORWARD gear (No. of teeth: 48)
REVERSE gear (No. of teeth: 46)
3rd, 4th shaft (No. of teeth: 50)
4th gear (No. of teeth: 53)
Output shaft
Output gear (No. of teeth: 41)
3rd gear (No. of teeth: 49)
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
3rd clutch
4th clutch
REVERSE, 2nd shaft (No. of teeth: 51)
2nd gear (No. of teeth: 26)
2nd clutch
2nd gear (No. of teeth: 50)
REVERSE clutch
FORWARD, 1st shaft (No. of teeth: 50)
1st gear (No. of teeth: 26)
Countershaft
4th gear (No. of teeth: 27)
10-15
r
TRANSMISSION
Outline
The transmission is installed behind the
torque converter. The motive force from the
torque converter passes through the transmission input shaft and enters the transmission.
The transmission uses the combination of

the forward or reverse clutches and the four
speed clutches to shift to F1 4 or R1 4,
and transmits the motive force from the input shaft to the output shaft.
CLUTCH
FORWARD, 1ST CLUTCH
U42103
b
SDW00019
1.
2.
3.
4.
Spacer
Thrust washer
1st gear
1st clutch
10-16
5.
6.
7.
8.
FORWARD, 1st cylinder

FORWARD clutch
FORWARD gear
FORWARD, 1st shaft
a. 1st clutch oil port

b. FORWARD clutch oil port
c. Lubrication oil port
TRANSMISSION
REVERSE, 2ND CLUTCH

1
11
10
U42103
SDW00020
1.
2.
3.
4.
Spacer
Thrust washer
2nd gear
2nd gear
5. 2nd clutch
6. 2nd, REVERSE cylinder
7. REVERSE clutch
8. REVERSE gear
9. Thrust washer
10. Spacer
11. 2nd, REVERSE shaft
a. 2nd clutch oil port

b. REVERSE clutch
oil port
c. Lubrication oil
port
3RD, 4TH CLUTCH

1
11
10
b
SDW00021
1.
2.
3.
4.
Spacer
Thrust washer
3rd gear
3rd gear
5.
6.
7.
8.
3rd clutch
3rd, 4th cylinder
4th gear
4th clutch
9. Thrust washer
10. Spacer
11. 3rd, 4th shaft
a. 3rd clutch oil port

b. 4th clutch oil port
c. Lubrication oil port
10-17
TRANSMISSION
Operation of clutch
When operated
The oil sent from the transmission valve
passes through the oil passage inside shaft
(1), and goes to the rear face of piston (5) to
actuate the piston.
When piston (5) is actuated, separator plate
(2) is pressed against clutch disc (3) and
forms shaft (1) and clutch gear (4) into one
unit to transmit the motive force.
U42103
SDW00022
When not actuated

If the oil from the transmission valve is shut
off, the pressure of the oil acting on the rear
face of piston (5) drops.
The piston is returned to its original position
by wave spring (6), so shaft (1) and clutch
gear (4) are separated.
SDW00023
10-18
TRANSMISSION
FORWARD 1ST
38
17
18
19
35
22
33
U42103
28
27
26
SDW00024
Operation
In the case of FORWARD 1st, FORWARD
clutch (18) and 1st clutch (17) are engaged.
The motive force transmitted from the torque
converter to input shaft (2) is transmitted to
gear (19), which is installed to the input shaft.
Each clutch disc of FORWARD clutch (18)
and 1st clutch (17) is engaged by the oil
pressure applied to the piston.
The motive force from the torque converter
passes from input shaft (2) through gear (19)
and is transmitted to FORWARD gear (22).
When FORWARD clutch (18) is engaged, the
motive force is transmitted to the FORWARD
1st cylinder.
The 1st clutch is engaged, so the motive

force transmitted to the FORWARD 1st cylinder passes through 1st clutch (17) and is
transmitted from 1st gear (38) to 2nd clutch
gears (35, 33). It then passes through 3rd
clutch gear (28) and output gear (27) and is
transmitted to output shaft (26).
10-19
TRANSMISSION
FORWARD 2ND
42
18
19
34
33
22
43
32
U42103
28
27
26
SDW00025
Operation
In the case of FORWARD 2nd, FORWARD
clutch (18) and 2nd clutch (34) are engaged.
The clutch discs of FORWARD clutch (18)
and 2nd clutch (34) are engaged by the oil
FORWARD clutch (18) is engaged, so the
motive force is transmitted to FORWARD 1st
cylinder gear (42).
10-20
The motive force is transmitted to REVERSE

2nd cylinder gear (43) and REVERSE 2nd
shaft (32), which are meshed with the FORWARD 1st cylinder gear. 2nd clutch (34) is
engaged, so the motive force transmitted to
the REVERSE 2nd shaft passes through the
2nd clutch and goes from 2nd gear (33)
through 3rd gear (28) and output gear (27),
and is transmitted to output shaft (26).
TRANSMISSION
FORWARD 3RD
42
19
18
22
30
43
U42103
28
24
27
44
26
SDW00026
Operation
In the case of FORWARD 3rd, FORWARD
clutch (18) and 3rd clutch (30) are engaged.
and 3rd clutch (30) are engaged by the oil
cylinder gear (42).
The motive force is transmitted through REVERSE 2nd cylinder gear (43) and REVERSE
2nd shaft (32), which is meshed with the
FORWARD 1st cylinder gear, and is transmitted to 3rd, 4th cylinder gear (44) and 3rd,
4th shaft (24). 3rd clutch (30) is engaged, so
the motive force passes through the 3rd
clutch and goes from 3rd gear (28) through
output gear (27), and is transmitted to output shaft (26).
10-21
TRANSMISSION
FORWARD 4TH
42
18
19
22
29
43
31
40
39
41
28
27
U42103
24
a
b
25
44
26
25
SDW00027
Operation
In the case of FORWARD 4th, FORWARD
clutch (18) and 4th clutch (31) are engaged.
and 4th clutch (31) are engaged by the oil
cylinder gear (42).
10-22
The motive force is transmitted through REVERSE 2nd cylinder gear (43), which is
meshed with the FORWARD 1st cylinder
gear, and is transmitted to 3rd, 4th cylinder
gear (44) and 3rd, 4th shaft (24). 4th clutch
(31) is engaged, so the motive force transmitted to the 3rd, 4th shaft passes through
the 4th clutch and goes from 4th gear (25)
through 4th counter gear (41), countershaft
(40), and 3rd counter gear (39), is transmitted to 3rd gears (29) and (28), and then
passes through output gear (27), and is transmitted to output shaft (26).
TRANSMISSION
REVERSE 1ST
37 38 17
42
19
35
33
43
25
36
U42103
28
27
26
SDW00028
Operation
In the case of REVERSE 1st, REVERSE clutch
(36) and 1st clutch (17) are engaged. The
motive force transmitted from the torque
With reverse clutch (36) and 1st clutch (17),
each clutch disc is engaged by the oil pressure applied to the piston.
and is transmitted to REVERSE gear (25).
When REVERSE clutch (36) is engaged, the
motive force is transmitted to the REVERSE
2nd cylinder.
The motive force is transmitted to FORWARD

1st cylinder gear (42) and FORWARD 1st
shaft (37), which are meshed with REVERSE
2nd cylinder gear (43). 1st clutch (17) is engaged, so the motive force transmitted to
the FORWARD 1st shaft passes through 1st
clutch (17) and is transmitted from 1st gear
(38) to 2nd gears (35, 33), passes through
3rd gear (28) and output gear (27) and is
transmitted to output shaft (26).
10-23
TRANSMISSION CONTROL VALVE
C
A
5
B
3
B
g
a
2
d
A
C
f
U42103
SDW00029
1. Mechanical modulation
valve
2. Upper valve
3. Lower valve
4. Solenoid valve
5. Emergency manual spool
a. Torque converter inlet port

oil pressure measurement
port
b. Torque converter outlet port
oil pressure measurement
port
c. Clutch oil pressure measurement port
d. To oil cooler
Outline
The oil from the pump passes through the
flow valve and torque converter oil filter,
enters the transmission valve, and is divided
into the pilot circuit and clutch actuation circuit.
The priority valve adjusts the delivery pressure of the pump and ensures the pilot pressure and oil pressure used to release the
parking brake.
The pressure of the oil flowing to the clutch
actuation circuit is regulated by the main
relief valve, and actuates the clutch.
The oil relieved by the main relief valve is
supplied to the torque converter.
e. Parking brake oil pressure

measurement port (priority
measurement port)
f. From pump
g. Main oil pressure measurement port
h. Pilot oil pressure measurement port
The quick return valve and modulation valve

are interconnected when shifting gear. This
allows the clutch pressure to rise smoothly
and reduces the shock when shifting gear.
In addition, when the machine is traveling,
the clutch pressure is kept constant. The
pressure of the oil flowing to the pilot valve
is regulated by the pilot reducing valve, and
actuates the directional and range spools as
the solenoid valves are switched ON or OFF.
When the directional and range spools are
switched, the oil, whose pressure is regulated by the modulation valve, is supplied to
the selected clutch to provide the necessary
speed range.
10-25
UPPER VALVE
BB
7
1
U42103
AA
SDW00030
10-26
LOWER VALVE
9
11
10
11
11
16
11
U42103
12
15
13
14
CC
SDW00031
1.
2.
3.
4.
5.
6.
7.
8.
Upper valve body

Emergency manual spool
Quick return valve
Torque converter outlet port valve
Main relief valve
Pilot reducing valve
Accumulator
Fill valve
9.
10.
11.
12.
13.
14.
15.
16.
Lower valve body

Directional selector valve
Solenoid valve
Range selector valve
Priority valve
Parking brake valve
Parking brake solenoid valve
H-L selector valve
10-27
TRANSMISSION SOLENOID VALVE
1
2
5
1. Solenoid valve [1] for FORWARD selector

2. Solenoid valve [2] for REVERSE selector
3. Solenoid valve [5] for parking brake
U42103
SMW01268
4. Solenoid valve [4] for range selector

5. Solenoid valve [3] for H-L selector
Actuation table for solenoid valve and clutch

Solenoid valve
Structure
The transmission solenoid valve is installed
to the lower valve of the transmission valve.
When the speed lever is operated, the movement is converted to electricity, and this
opens or closes each solenoid valve to move
the spool inside the transmission valve.
The parking brake solenoid valve is installed
to the transmission lower valve. When the
parking brake switch is operated, the solenoid valve is opened or closed by an electric
signal to move the parking brake spool.
10-28
1 2 3 4 5
F1
F2
F3
F4
N
R1
R2
R3
R4
Parking brake operated

Parking brake released
Function
When the speed lever in the operators compartment is operated, the four solenoid
valves installed to the transmission control
valve are switched ON or OFF to actuate the
directional selector spool, H-L selector spool
and range selector spool`.
From pump
2
Lower valve
2nd clutch
U42103
4
Operation
1. Solenoid valve OFF
The oil from pilot reducing valve (1) flows to
ports a and b of H-L selector spool (2) and
range selector spool (3). The oil at a and b is
blocked by solenoid valves (4) and (5), so
selector spools (2) and (3) are moved to the
right in the direction of arrow.
As a result, the oil from the pump flows to
the 2nd clutch.
2. Solenoid valve ON
When the speed lever is operated, the drain
ports of solenoid valves (4) and (5) open.
The oil at ports a and b of selector spools (2)
and (3) flows from ports c and d to the drain
circuit. Therefore, the pressure in the circuits at ports a and b drops, and the spools
are moved to the left in the direction of the
arrow by return springs (6) and (7).
As a result, the oil at port e flows to the 4th
clutch and switches from 2nd to 4th.
Pilot filter
1
From pump
SEW00036
From pump
e
Lower valve
4th clutch
Pilot filter
From pump
SEW00037
10-29
FLOW VALVE
U42103
c
SDW00038
1. Valve body
2. Valve spool
Operation
The oil from the pump flows to the transmission valve circuit but when it becomes
greater than the specified flow, the flow valve
acts to send oil to the transmission lubrication circuit.
When the oil from the pump becomes
greater then the specified flow, valve spool
(2) moves and part of the oil from the oil
pump flows to the transmission lubrication
circuit.
10-30
r
a. To transmission valve circuit

b. From pump
c. To transmission lubrication circuit
ACCUMULATOR VALVE
A
U42103
10
AA
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Piston (FORWARD clutch)

Piston (1st clutch)
Piston (2nd clutch)
Body accumulator
Spring (2nd clutch)
Stopper (2nd clutch)
Stopper (1st clutch)
Stopper (FORWARD clutch)
Spring (FORWARD clutch)
Spring (1st clutch)
SDW00039
Outline
The accumulator valve is installed in the FORWARD, 1st, 2nd clutch circuit. When the
transmission shifts gear, the accumulator
valve slowly reduces the oil pressure to the
clutch that was first engaged in order to prevent loss of torque and to reduce the transmission shock when shifting gear. It temporarily stores the clutch oil pressure in order
to allow gear shifting to be carried out
smoothly without any time lag.
(To make it possible to reduce the oil pressure to the clutch slowly, there are throttles
installed in the directional spool and selector spool of the transmission control valve.)
10-31
2nd clutch oil pressure

Clutch oil pressure
Operation
1. Shifting down when digging (kick-down F2
F1)
When the transmission is in F2, oil pressure
is stored in the 2nd clutch accumulator.
When the kick-down is operated, the F1
clutch is engaged, but the oil pressure in the
accumulator is maintained for the 2nd clutch
until the torque is transmitted to the 1st
clutch. In this way, it is possible to shift gear
smoothly without losing the torque.
1st clutch oil pressure
Oil pressure
maintained so
remains of torque
Time
SDW00040
REVERSE clutch oil

pressure, 2nd clutch
oil pressure
U42103
FORWARD clutch oil

pressure, 1st clutch
oil pressure
Clutch oil pressure
Moving out after digging (F1 R2)

When the transmission is in F1, oil pressure
is stored in the accumulator for the FORWARD clutch and 1st clutch.
When shifting to R2 after completing digging operations, the R2 clutch is engaged,
but the oil pressure for the FORWARD clutch
and 1st clutch is maintained in the accumulator. This makes it possible to reduce the
loss of torque due to the reaction force to
the product being handled, and to move back
smoothly without shock.
Oil pressure
maintained so
torqe is lowered
smoothly
Time
SDW00041
10-32
TRANSMISSION OIL PRESSURE SYSTEM DIAGRAM
U42103
Operation of FORWARD 1st
10-34
r
U42103

filter, then passes through the pilot circuit
and priority valve, and is divided to the clutch
actuation circuit and the torque converter
circuit.
When the speed lever is operated to F1, FORWARD solenoid valve (1) is actuated. The oil
which was filling port a is drained, directional spool (4) is moved to the left, and
clutch oil pressure port b and FORWARD
clutch oil pressure port b are connected.
At the same time, oil fills the circuit and
pushes the H-L selector spool (5) fully to the
right to prevent H-L selector solenoid valve
(2) from being actuated. In addition, the oil
is drained and range selector spool (6) is
pushed fully to the left to actuate range selector solenoid valve (3).
In this condition, 1st clutch oil pressure port
d is connected to oil pressure port c of the
H-L selector valve and the range selector
valve.
At the same time, the oil flowing through
priority valve (7) to the clutch actuation circuit passes through the modulation valve,
and then flows to the FORWARD clutch and
1st clutch through directional spool (4), H-L
selector spool (5), and range selector spool
(6).
When the oil completely fills the clutch cylinder, the pressure rises gradually because
of the action of accumulator (8) and modulation valve (9). When it reaches the set pressure, the FORWARD and 1st clutches are
completely engaged.
10-35
DIRECTIONAL SELECTOR VALVE

Operation
1. When at neutral
Solenoid valves (4) and (5) are OFF and the
drain port is closed. The oil from the pilot
circuit passes through the oil hole in the
emergency manual spool and fills ports a
and b of the directional spool.
In this condition, P1 + spring force (1) = P2 +
spring force (2), so the balance is maintained.
Therefore, the oil at port c does not go to
the FORWARD or REVERSE clutch.
From pilot reducing valve

Accumulator
FORWARD clutch
4
OFF
REVERSE clutch
b
P2
OFF
P1
From
modulation
valve
U42103
SBW00468
2. When at FORWARD
When the directional lever is placed at the
FORWARD position, solenoid valve (4) is
switched ON and drain port d opens. The oil
which is filling port a is drained, so P1 +
spring force (1) < P2 + spring force (2). When
this happens, the directional spool moves to
the left, and the oil at port c flows to port e
and is supplied to the FORWARD clutch.
From pilot reducing valve

Accumulator
FORWARD clutch
REVERSE clutch
ON
1
b
P2
OFF
P1
2
From
modulation
valve
SBW00469
10-36
r
EMERGENCY MANUAL SPOOL

Function
If there should be a failure in the electrical
system and the directional solenoid valve
cannot be actuated, it is possible to actuate
the FORWARD or REVERSE clutch manually.
U42103
Operation
1. When the emergency manual spool is at
neutral (during normal operation)
The oil from the pilot valve flows through
the oil hole of emergency manual spool
(5) and fills ports a and b of the directional spool.
Under this condition, P1 + spring force
(1) = P2 + spring force (2). Accordingly,
the oil in port c does not flow to the
forward and reverse clutches.
2. When the emergency manual spool is

actuated (to the forward side)
When the emergency manual spool (5)
is pulled out, drain port d opens and the
oil filled in port a is drained. Accordingly, P1 + spring force (1) < P2 + spring
force (2). As a result, the directional
spool moves to the left and the oil in
port c flows through port e to the forward clutch.
10-37
r
MODULATION VALVE
Clutch pressure
MPa (kg/cm2)
2.3 0.2
(23.0 2)
Function
The modulation valve regulates the pressure
of the oil entering the accumulator and controls the oil flow to raise the clutch pressure.
A
Gear shift
D
C
0.34 0.05
(3.5 0.5)
Sec
(Clutch fully engaged)
B
Operation
1. Clutch fully engaged (point A)
SEW00047
Quick return valve
U42103
To clutch
Fill valve
Accumulator
From priority From torque converter

valve
outlet port valve
SEW00048
2. Transmission switched from FORWARD to

REVERSE (point B)
The oil inside the accumulator is drained by
the quick return valve, and accumulator piston (1) moves to the right in the direction of
the arrow. When this happens, the pressure
in chamber c and chamber d drops, and fill
valve (3) is moved to the left in the direction
of the arrow by spring (2) to open port a.
To clutch
From priority
valve
From torque converter

outlet port valve
SEW00049
10-38
U42103
3. Beginning of rise in clutch pressure (point

C Point D)
The pressure in the clutch circuit begins to
rise when the oil from the priority valve fills
the clutch piston.
Quick return valve (2) moves to the right,
and the drain circuit in the accumulator is
closed.
When the quick return valve's drain circuit
closes, the oil which has passed through port
d passes through fill vale (4) and enters port
b, and pressure P2 of chamber b begins to
rise. At this time, the relationship between
pressures P1 and P2 of the accumulator section is P2 > P1 + P3 (oil pressure equivalent
to spring (3) tension). Fill valve (4) moves to
the right, shutting off port d and preventing
the clutch pressure from rising suddenly.
The oil at port d flows into the clutch circuit,
and since P2 > P1 + P3, it simultaneously
passes through quick return valve (2) orifice
e and flows into accumulator chamber c.
Both pressures P1 and P2 increases. This
action is repeated, while maintaining the relationship P2 = P1 + P3 (oil pressure equivalent to spring (3) tension), and the clutch
pressure gradually rises.
The pressure at the torque converter outlet
is released to fill valve port f. The pressure
at the torque converter outlet changes according to the engine speed.
Thus, because of the relationship P2 = P1 +
P3 + P4 (the pressure at port f which varies
according to the engine speed), pressure P2
changes by the same amount as pressure
P4. Since pressure P2 increases by the
amount of increase of pressure P4, it is possible to create oil pressure characteristics
corresponding to the engine speed.
10-39
r
QUICK RETURN VALVE
Function
To allow the modulation valve to raise the
clutch pressure smoothly, the quick return
valve sends the pressure in the accumulator
acting on the modulation valve spool momentarily to the drain circuit when the transmission is shifted.
Operation
1. After engine is started, clutch completely
engaged (clutch pressure at point A)
U42103
(FORWARD 1st)
10-40
r
U42103
2. When switching from FORWARD to REVERSE (clutch pressure at point B)
When the directional lever is shifted from

FORWARD to REVERSE, FORWARD solenoid
(1) closes and REVERSE solenoid (2) opens.
Directional spool (3) is moved to the right in
the direction of the arrow and the oil at FORWARD clutch (4) is drained from the drain
circuit.
At the same time, the oil from the pump
flows to REVERSE clutch (5), but while the
oil is filling the inside of the clutch, the clutch
oil pressure drops.
As a result, the oil pressure at port a of
quick return valve (6) drops, check valve (7)
opens, and the oil at port b flows to port a.
At the same time, quick return valve (6) is
moved to the left in the direction of the ar-
row by the accumulator oil pressure, and

the oil in accumulator (8) is drained suddenly from port e.
Accumulator (8) is returned to the left end
by the force of spring (9).
10-41
r
U42103
3. Clutch pressure beginning to rise (clutch

pressure at point C)
The oil from the pump fills the REVERSE

clutch and the clutch circuit pressure starts
to rise.
As a result, the pressure at port b rises and
quick return valve (6) is moved to the right
in the direction of the arrow to close drain
port c.
10-42
r
U42103
4. Start of accumulator operation, clutch completely engaged (clutch pressure at point D)
Because of the differential pressure created

by modulation valve (11), the oil passing
through orifice (10) of the quick return valve
flows as a constant amount into accumulator (8). When this oil flows in, the accumulator moves to the left in the direction of the
arrow and compresses spring (9), so the accumulator pressure rises. The clutch oil pressure also rises because of this rise in the
accumulator pressure.
When the piston in accumulator (8) moves
to the end of its stroke, the rise in the oil
pressure at port d is completed and the specified pressure is maintained to completely
engage the REVERSE clutch.
10-43
r
MAIN RELIEF VALVE

Function
The main relief valve regulates the pressure
of the oil flowing to the clutch circuit and
distributes the oil flow between the clutch
circuit and the torque converter.
2. If the pressure is above the specified value,

the oil which has passed through main relief
valve (1) orifices c and d presses poppet (2),
moving main relief valve (1) to the right,
and is released to port E, maintaining the
pressure at the specified value. The oil released from port E flows to the torque converter.
10-43-1
r
U42103
Operation
1. The oil from the pump passes through the
priority valve, then through ports A and B of
main relief valve (1) until specified pressure
is reached, and flows to the clutch circuit.
PRIORITY VALVE
Function
The priority valve regulates the pump's discharge pressure and provides the pilot oil
pressure and parking brake release oil pressure.
If the pressure in the circuit reaches specified level, the priority valve acts as a relief
valve, releasing the pressure to protect the
hydraulic circuit.
2. The oil at port a flows through orifice b of

priority valve (2) to port c.
When the oil pressure at port a rises to the
set level, the oil pressure at port c overcomes the force of return spring (3), then
priority valve (2) moves to the left and the
oil flows to port d.
While the oil pressure at port a is below the
set level, the oil does not flow in port d.
Accordingly, the pilot oil pressure and parking brake release oil pressure are secured.
10-44
r
U42103
Operation
1. The oil from the pump enters port a, then
separates into the oil flowing to parking
brake valve (1), priority valve (2) and the
pilot circuit.
TORQUE CONVERTER OUTLET PORT VALVE

Function
The torque converter outlet port valve is installed in the outlet line of the torque converter and adjusts the maximum pressure of
the torque converter.
Operation
The oil at port a passes through the orifice
in spool (1) and flows to port c.
To cooler
U42103
1
SEW00058
When the pressure at port a rises, the pressure at port c also rises. This overcomes the
tension of spring (2) and moves spool (1) to
the left in the direction of the arrow to allow
oil to flow from port a to port b.
To cooler
SEW00059
If the pressure at port a becomes even

higher, spool (1) is moved further to the left
in the direction of the arrow, and the oil
flows from port a to port b and drain port d.
(Cold relief)
To cooler
c
SEW00060
10-45
PILOT REDUCING VALVE

Function
The pilot reducing valve controls the pressure used to actuate the directional selector
spool, H-L selector spool, range selector
spool, and parking brake spool.
From pump
Operation
The oil from the pump enters port a, passes
through port b of pilot reducing spool (1),
enters spools (2) and (3) in the lower valve,
and fills the pilot circuit.
The oil at port b passes through the orifice
and flows to port c.
Lower valve
Solenoid valve
Solenoid valve
Pilot filter
From pump
U42103
SEW00061
When the pressure in the pilot circuit rises,

the pressure at port c also rises. Then, pilot
reducing spool (1) moves in the direction of
the arrow to a position at which the pressure at c is balanced with the tension of
spring (4). Accordingly, the pressure at port
b is maintained at the specified level.
From pump
Lower valve
Solenoid valve
Solenoid valve
Pilot filter
a
From pump
10-46
r
SEW00062

1
10
2
3
4
5
6
7
8
SEW00064
9
Nut
Core assy
Coil assy
Plunger
Spring
6.
7.
8.
9.
10.
Pin
Spring
Valve seat
Body
Connector
U42103
1.
2.
3.
4.
5.
10-47
PILOT OIL FILTER
PILOT OIL FILTER

3
B
SEW00071
1. Oil filter heat

2. Element
3. Case
A. Inlet port
B. Outlet port
10-48
Specifications
Filtering area:
170 cm2
Filter mesh size: 105
U42103
DRIVE SHAFT
U42103
DRIVE SHAFT
SDW00072
1.
2.
3.
4.
Front drive shaft

Flange bearing
Center drive shaft
Rear drive shaft
Outline
The motive force from the engine passes
through the torque converter and the transmission. Some of it is transmitted from rear
drive shaft (4) to the rear axle, while the rest
goes from center drive shaft (3) through
flange bearing (2) and front drive shaft (1) to
the front axle.
The drive shaft has the following purpose in

addition to simply transmitting the power.
The drive shaft has a universal joint and
sliding joint to enable it to respond to
changes in the angle and length. This enables the drive shaft to transmit the motive
force when the machine is articulated and to
protect the components from damage from
shock when the machine is being operated
or shock from the road surface when the
machine is traveling.
10-49
AXLE
AXLE
U42103
FRONT AXLE
1.
2.
3.
4.
10-50
Brake
Final drive
Oil filler
Level plug
5. Differential
6. Breather
7. Drain plug
AXLE
U42103
REAR AXLE
1.
2.
3.
4.
Brake
Final drive
Oil filler
Level plug
5. Differential
6. Breather
7. Drain plug
10-51
DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
U42103
SDW00075
1.
2.
3.
4.
5.
Shaft
Bevel gear (No. of teeth: 42)
Bevel pinion (No. of teeth: 9)
Side gear (No. of teeth: 12)
Pinion (No. of teeth: 9)
10-52
Specifications
Type:

Reduction ratio: 4.667
Differential type: Torque proportioning, splash
lubrication
DIFFERENTIAL
REAR DIFFERENTIAL
U42103
SDW00076
1.
2.
3.
4.
5.
Shaft
Bevel gear (No. of teeth: 42)
Bevel pinion (No. of teeth: 9)
Side gear (No. of teeth: 12)
Pinion (No. of teeth: 9)
Specifications
Type:

Reduction ratio: 4.667
Differential type: Torque proportioning, splash
lubrication
10-53
DIFFERENTIAL
Outline
The motive force from the drive shaft passes
through bevel pinion (1) and is transmitted
to bevel gear (5). The bevel gear changes
the direction of the motive force by 90, and
at the same time reduces the speed. It then
transmits the motive force through differential (4) to sun gear shaft (2).
1
2
3
4
5
SEW00077
U42103
When driving straight forward

When the machine is driven straight forward,
the rotating speed of the left and right wheels
is the same, so pinion gear (4) inside the
differential assembly is sent through pinion
gear (4) and side gear (3) and is transmitted
equally to left and right sun gear shafts (2).
3
2
4
SEW00078
When turning
When turning, the rotating speed of the left
and right wheels is different, so pinion gear
(4) and side gear (3) inside the differential
assembly rotate in accordance with the difference between the rotating speed of the
left and right wheels. The motive force of
carrier (6) is then transmitted to sun gear
shafts (2).
3
2
4
SEW00079
10-54
TORQUE PROPORTIONING DIFFERENTIAL
U42103
Function
Because of the nature of their work, 4-wheeldrive loaders have to work in places where the
road surface is bad. In such places, if the tires
slip, the ability to work as a loader is reduced,
and also the life of the tire is reduced. The
torque proportioning differential is installed to
overcome this problem.
In structure it resembles the differential of an
automobile, but differential pinion gear (3) has
an odd number of teeth. Because of the difference in the resistance from the road surface,
the position of meshing of pinion gear (3) and
side gear (4) changes, and this changes the
traction of the left and right tires.
DIFFERENTIAL
Ordinary differential
SEW00080
Torque proportioning differential
Operation
When traveling straight (equal resistance from road
surface to left and right tires)
If the resistance from the road surface to the
left and right wheels is the same, the distance
between pinion gear (2) and meshing point
a of left side gear (1) is the same as the
distance between pinion gear (2) and meshing
point b of right side gear (3).
Therefore the left side traction TL and the right
side traction TR are balanced.
When traveling on soft ground (resistance from
road surface to left and right tires is different)
On soft ground, if the tire on one side slips,
the side gear of the tire on the side which has
least resistance from the road surface tries to
rotate forward. Because of this rotation, the
meshing of pinion gear (2) and side gear
changes.
If left side gear (1) rotates slightly forward, the
distance between the pinion gear and the
meshing point a of the left side gear becomes longer than the distance between the
pinion gear and the meshing port b of the
right side gear. The position is balanced as
follows.
a x TL = b x TR
The ratio between the distances to a and
b can change to 1 : 1.38.
Therefore when the ratio of the distances to
a and b is less than 1 : 1.38 (that is, the
difference between the resistance from the road
surface to the left and right tires is less than
38%), the pinion gear will not rotate freely, so
drive force will be given to both side gears,
and the tires will not slip.
Because of this effect, the tire life can be increased by 20 30%, and at the same the
operating efficiency is also increased.
SEW00081
Spider rotating direction
TL
TR
SEW00082
Spider rotating direction
2
TL
b
TR
SEW00083
10-55
FINAL DRIVE
1.
2.
3.
4.
5.
6.
Outline
The final drive uses a planetary gear mechanism to obtain a large drive force, and transmits the drive force to the tires.
Operation
The motive force transmitted to sun gear (5)
from the differential through axle shaft (1) is
transmitted to planet gear (3). The planet
gear rotates inside ring gear (2), which is
fixed, and transmits the motive force to
wheel (6), which is installed to the planetary
carrier.
10-56
Axle shaft
Ring gear (No. of teeth: 67)
Planet gear (No. of teeth: 24)
Planetary carrier
Sun gear (No. of teeth: 17)
Wheel
U42103
FINAL DRIVE
AXLE MOUNT, CENTER HINGE PIN

Serial No.: 50305 52999
A
B
U42103
3
7
AA
BB
CC
SDW00086
1.
2.
3.
4.
5.
6.
7.
Front axle
Front frame
Rear axle
Rear frame
Upper hinge pin
Lower hinge pin
Rear axle
Outline
Front frame (2) and rear frame (4) are joined
by hinge pins (5) and (6) through the bearings. In addition, the steering cylinders are
connected to the left and right front and rear
frames, and the angle of articulation of the
frame (the turning angle) is adjusted according to the movement of the cylinders.
10-57
e
U42103
1.
2.
3.
4.
5.
6.
7.
Front axle
Front frame
Rear axle
Rear frame
Upper hinge pin
Lower hinge pin
Rear axle
10-57-1
e
Outline
Front frame (2) and rear frame (4) are joined
by hinge pins (5) and (6) through the bearings. In addition, the steering cylinders are
connected to the left and right front and rear
frames, and the angle of articulation of the
frame (the turning angle) is adjusted according to the movement of the cylinders.
STEERING PIPING
U42103
STEERING PIPING
1.
2.
3.
4.
5.
6.
Main control valve

Steering valve
Steering cylinder (right)
Hydraulic tank
Switch pump
Steering pump
10-58
7.
8.
9.
10.
11.
12.
Hydraulic pump
PPC pump
Brake cooling pump
Stop valve
Orbit-roll valve
Steering cylinder (left)
STEERING COLUMN
STEERING COLUMN
U42103
SEW01221
1.
2.
3.
4.
Steering wheel
Steering column
Joint
Orbit-roll
10-59
STEERING VALVE
U42103
STEERING VALVE
1.
2.
3.
4.
5.
Safety valve (with suction)

Check valve
Steering spool
Relief valve
Demand spool
10-60
A: To steering cylinder
B: To steering cylinder
Pa: From orbit-roll
Pb: From orbit-roll
P1: From steering pump
P2: From switch pump
PB: To main control valve
T: Drain (to oil cooler)
STEERING VALVE
OPERATION OF DEMAND VALVE

STEERING SPOOL AT NEUTRAL
To Oribit-roll
valve
To Oribit-roll
valve
U42103
III
II
IV
I
To cut-off valve
(Main cotrol valve)
M M
Steering
pump
Switch
pump
SLW01223
The oil from the steering pump enters port

A, and the oil from the switch pump enters
port B.
When steering spool (2) is at neutral, pressure-receiving chamber (II) is connected to
the drain circuit through orifice (b), and notch
(c) is closed.
Notch (c) is closed, so the pressure of the oil
at port A and port B rises. This pressure
passes through orifice (a), goes to pressurereceiving chamber (I), and moves demand
spool (1) to the left in the direction of the
arrow.
When the pressure at pressure-receiving

chamber (I) reaches a certain value (set by
spring (5)), notch (f) opens, and the oil from
the steering pump flows to the drain circuit.
At the same time, notch (g) closes, and the
oil from the switch pump all flows to the
main control valve.
10-61
w
STEERING VALVE
STEERING SPOOL OPERATED
Engine at low speed
c
e
To Orbit-roll
valve
II
U42103
From Orbit-roll
valve
I
To cut-off valve
(Main control valve)
3
M M
Steering
pump
Switch
pump
SLW01224
When steering spool (2) is pressed (operated), pressure-receiving chamber (II) and the
drain circuit are shut off, and at the same
time notch (c) opens.
When this happens, the pressure in pressure-receiving chamber (II) rises, and demand spool (1) moves to the right in the
direction of the arrow until notch (h) closes.
The passage from port B to the main control
valve is shut off, so the oil from the switch
pump pushes up merge check valve (3), and
merges with the oil at port A from the steering pump.
10-62
w
The merged oil passes through notch (c) and

notch (d), pushes up load check valve (4),
and flows to the cylinder. The oil returning
from the cylinder passes through notch (e)
and enters the drain circuit.
In this condition, the pressure before passing through notch (c) goes to pressure-receiving chamber (I), and the pressure after
passing notch (c) goes to pressure-receiving
chamber (II). Demand spool (1) moves to
maintain the pressure difference on the two
sides of notch (c) at a constant value. Therefore, a flow corresponding to the amount of
opening notch (c) is discharged from the
cylinder port. These pressure differences
(control pressure) are set by spring (5).
STEERING VALVE
Engine at high speed
c
d
U42103
From Orbit-roll
valve
To Orbit-roll
valve
To cut-off valve
M M
Steering
pump
Switch
pump
SLW01225
The extra oil from the switch pump is not

needed, so the steering pump pressure rises
until notch (g) closes, and shuts off the merge
passage at port B.
The pressure difference on the two sides of
notch (c) is controlled only by notch (f), so
the excess oil from the steering pump is
drained from notch (f) to the drain circuit
(when this happens, notch (g) is completely
closed).
The oil from the steering pump passes

through notch (c) and notch (d), pushes up
load check valve (4), and flows to the cylinder. The oil returning from the cylinder
passes through notch (e) and flows to the
drain circuit.
Notch (g) is closed, so the oil from the switch
pump is sent from port B to the main control valve.
10-63
w
STEERING VALVE
FLOW AMP
C
Steering spool
Valve housing (body)
Spring seat
Return spring
5. Cap
6. Capscrew
7. Flow arm notch
Operation of flow amp

1. Spool at neutral (Orbit-roll valve not actuated)
A: From Orbit-roll valve

B: From Orbit-roll valve
C: Passage (inside housing)
PiB
PiA
Stop valve
Stop valve
Orbit-roll
Relief
valve
Switch pump
When the Orbit-roll valve is not actuated,

both pilot port PiA and pilot port PiB are
connected through the Orbit-roll to the drain
(return) circuit, so steering spool (1) is kept
at neutral by return spring (4).
10-64
SLW01226
U42103
1.
2.
3.
4.
SLW01227
STEERING VALVE
2. Spool actuated (oil flows to port PiA)
PiB
PiA
Stop valve
Stop valve
U42103
Orbit-roll
Relief
valve
Switch pump
When oil flows to port PiA, the pressure inside the cap at end A rises and moves steering spool (1) in the direction of the arrow.
The oil entering from port PiA passes
through the hole in spring seat (3), through
flow amp notch (7) in steering spool (1), and
then flows to the opposite end (B end).
SLW01228
Port PiB is connected to the drain circuit

through the Orbit-roll valve, so the oil flowing to end B is drained.
The pressure generated at port PiA is proportional to the amount of oil flowing in, so
steering spool (1) moves to a position where
the opening of the flow amp notch balances
the pressure generated with the force of return spring (4).
10-65
STEERING VALVE
3. Spool returning (steering wheel stopped,

flow of oil to port PiA cut)
PiB
PiA
Stop valve
Stop valve
U42103
Orbit-roll
Relief
valve
Switch pump
When the steering wheel (Orbit-roll valve) is

stopped, ports PiA and PiB are both connected to the drain circuit through the Orbitroll valve. For this reason, steering spool (1)
is returned to the neutral position by return
spring (4).
10-66
SLW01229
STEERING VALVE
OPERATION OF STEERING VALVE
U42103
NEUTRAL
The steering wheel is not being operated, so

steering spool (1) does not move.
A; the oil from the switch pump enters port
B.
When the pressure at ports A and B rises,

demand spool (4) moves to the left in the
direction of the arrow. The oil form the steering pump passes through port C of the spool
and is drained. The oil form the switch pump
passes through port D and all flows to the
main control valve.
10-67
w
STEERING VALVE
U42103
TURNING RIGHT
When the steering wheel is turned to the

right, the pressure oil from the Orbit-roll
valve acts on steering spool (1), and steering spool (1) moves to the left in the direction of the arrow.
A, passes through demand spool (2), and
flows to steering spool (1). It pushes open
load check valve (4) of the spool, and the oil
flows to the bottom end of the left cylinder
and the rod end of the right cylinder to turn
the machine to the right.
10-68
w
The oil from the left and right cylinders

passes through load check valve (3) of the
steering spool, and is drained.
The oil from the switch pump enters port B,
flows through demand spool (2), pushes
open check valve (5), and merges with the
oil form the steering pump.
STEERING VALVE
U42103
TURNING LEFT
When the steering wheel is turned to the

left, the pressure oil from the Orbit-roll valve
acts on steering spool (1), and steering spool
(1) moves to the right in the direction of the
arrow. The oil form the steering pump enters port A, passes through demand spool
(2), and flows to steering spool (1). It pushes
open load check valve (3) of the spool, and
the oil flows to the rod end of the left cylinder and the bottom end of the right cylinder
to turn the machine to the right.
The oil from the left and right cylinders

passes through load check valve (4) of the
steering spool, and is drained.
The oil from the switch pump enters port B,
flows through demand spool (2), pushes
open check valve (5), and merges with the
oil from the steering pump.
10-69
w
STEERING VALVE
STEERING RELIEF VALVE
1.
2.
3.
4.
5.
Adjustment screw
Spring
Plug
Pilot poppet
Valve seat
Function
The steering relief valve is inside the steering valve, and sets the maximum circuit pressure of the steering circuit when the steering valve is actuated. When the steering
valve is being actuated, if the steering circuit goes above the set pressure of this valve,
oil is relieved from this valve. When the oil
is relieved, the flow control spool of the demand valve is actuated, and the oil is drained
to the steering circuit.
10-70
U42103
SEW00097
STEERING VALVE
OPERATION OF RELIEF VALVE
To Orbit-roll
valve
U42103
From Orbit-roll
valve
II
To cut-off valve
M
Switch
pump
Steering
pump
SLW01233
When the pressure in the circuit rises, and it

reaches the pressure set by adjustment screw
(1) and spring (2), pilot poppet (4) opens,
and the oil is drained.
When this happens, the balance in pressure
between pressure-receiving chamber (I) and
pressure-receiving chamber (II) is lost, so
demand spool (6) moves to the left in the
direction of the arrow.
When demand spool (6) moves, the oil from

the steering pump is drained, and the oil
from the switch pump is released to the main
control valve. This prevents the pressure in
the steering circuit from going above the set
value.
10-71
STEERING VALVE
SAFETY VALVE (WITH SUCTION)
1.
2.
3.
4.
5.
SEW00091
Function
The overload relief valve is installed to the
steering valve. It has the following two functions: When the steering valve is at neutral,
if any shock is applied to the cylinder, and
an abnormal pressure is generated, the oil
is relieved from this valve. In this way, it
functions as a safety valve to prevent damage to the cylinder or hydraulic piping. On
the other hand, if negative pressure is generated at cylinder end, it functions as a suction valve to prevent a vacuum from forming.
Operation
Acting as relief valve
Port A is connected to the cylinder circuit
and port B is connected to the drain circuit.
Oil passes through the hole in poppet (1)
and acts on the different areas of diameters
d1 and d2, so check valve poppet (3) and
relief valve poppet (2) are firmly seated in
position.
When the pressure at port A reaches the set

pressure of the relief valve, pilot poppet (4)
opens. The oil flows around pilot poppet (4),
passes through the drill hole, and flows to
port B.
U42103
Poppet
Relief valve poppet
Check valve poppet
Pilot poppet
Spring
2
d1 A
d2
B
1
SEW00092
B
SEW00093
10-72
STEERING VALVE
When pilot poppet (4) opens, the pressure

at the back of poppet (1) drops, so poppet
(1) moves and is seated with pilot poppet
(4).
B
1
Compared with the pressure at port A, the

internal pressure is low, so relief valve poppet (2) opens. When this happens, the oil
flows from port A to port B, and prevents
any abnormal pressure from forming.
SEW00094
U42103
B
SEW00095
Acting as suction valve

When negative pressure is formed at port A,
the difference in area of diameters d3 and d4
causes check valve poppet (3) to open. When
this happens, the oil from port B flows to
port A, and prevents any vacuum from forming.
B
d3
d4
B
SEW00096
10-73
ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
12
A
AA
2
7
8
3
9
4
10
5
11
BB
SEW01234
1.
2.
3.
4.
Needle bearing
Center spring
Drive shaft
Valve body
10-74
5.
6.
7.
8.
Rotor
Cover
Center pin
Sleeve
9.
10.
11.
12.
Spool
Stator
Lower cover
Check valve
U42103
ORBIT-ROLL VALVE
U42103
Outline
The steering valve is connected directly to
the shaft of the steering wheel. It switches
the flow of oil from the steering pump to the
left and right steering cylinders to determine
the direction of travel of the machine.
The steering valve, broadly speaking, consists of the following components: rotary
type spool (3) and sleeve (5), which have the
function of selecting the direction, and the
Girotor set (a combination of rotor (8) and
stator (9)), which acts as a hydraulic motor
during normal steering operations, and as a
hand pump (in fact, the operating force of
the steering wheel is too high, so it cannot
be operated) when the steering pump or
engine have failed and the supply of oil has
stopped.
Structure
Spool (3) is directly connected to the drive
shaft of the steering wheel, and is connected
to sleeve (5) by center pin (4) (it does not
contact the spool when the steering wheel
is at neutral) and centering spring (12).
The top of drive shaft (6) is meshed with
center pin (4), and forms one unit with sleeve
(5), while the bottom of the drive shaft is
meshed with the spline of rotor (8) of the
Girotor.
There are four ports in valve body (2), and
they are connected to the pump circuit, tank
circuit, and the circuits at the head end and
bottom end of the steering cylinders. The
pump port and tank port are connected by
the check valve inside the body. If the pump
or engine fail, the oil can be sucked in directly from the tank by this check valve.
2
12
3
4
5
6
7
8
9
10
11
SBW00715
Connected to
steering
wheel shaft
3
12
5
SBW00716
SBW00717
Groove for meshing

with center pin
SBW00718
10-75
ORBIT-ROLL VALVE
CONNECTION BETWEEN HAND PUMP AND SLEEVE
7 1
6
5
2
g h i jk
f
l
e
dc ba
7 1
3
5
3
5
U42103
j k la
b
i
c
h
d
g
f e
7 1
SBW00725
SBW00726
The diagrams above show the connections

with the sleeve ports used to connect the
suction and discharge ports of the Girotor.
If the steering wheel has been turned to the
right, ports a, c, e, g, i, and k are connected
by the vertical grooves in the spool to the
pump side. At the same time, ports b, d, f,
h, j, and l are connected to the head end of
the left steering cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3
are the discharge ports of the Girotor set.
They are connected to ports l, b, and d, so
the oil is sent to the cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If the steering wheel is turned 90, the condition changes to the condition shown in
Fig. 2. In this case, ports 1, 2, and 3 are the
suction ports, and are connected to ports i,
k, and c. Ports 5, 6, and 7 are the discharge
ports, and are connected to ports d, f, and h.
Suction /
discharge port
SBW00727
SBW00728
10-76
U42103
ORBIT-ROLL VALVE
In this way, the ports of the Girotor acting

as delivery ports are connected to ports
which are connected to the end of the steering valve spool. The ports acting as suction
ports are connected to the pump circuit.
Adjusting delivery in accordance with angle
of steering wheel:
For every 1/7 turn of the steering wheel, the
inner teeth of the Girotor gear advance one
position so the oil flow from the pump is
adjusted by this movement. In this way, the
oil delivered from the pump is directly proportional to the amount the steering wheel
is turned.
FUNCTION OF CENTER SPRING

Centering spring (12) consists of four layers
of leaf springs crossed to form an X shape.
The springs are assembled in spool (3) and
sleeve (5) as shown in the diagram on the
right.
When the steering wheel is turned, the spring
is compressed and a difference in rotation
(angle variation) arises between the spool
and the sleeve.
Because of this, the ports in the spool and
sleeve are connected and oil is sent to the
cylinder. When the turning of the steering
wheel is stopped, the Girotor also stops turning, so no more oil is sent to the cylinder
and the oil pressure rises.
To prevent this, when the turning of the
steering wheel is stopped, the action of the
centering spring only allows it to turn by an
amount equal to the difference in angle of
rotation (angle variation) of the sleeve and
spool, so the steering wheel returns to the
NEUTRAL position.
SDW01236
3
Angle
Variation
12
SDW01237
10-77
STOP VALVE
STOP VALVE
A
B
DR
U42103
7
B
A
xx
1.
2.
3.
4.
5.
6.
7.
Boot
Wiper
Seal
Poppet
Spring
Spool
Spring
10-78
Circuit diagram
A: From orbit-roll
B: To steering valve
DR: To drain
DR
SEW01238
EMERGENCY STEERING PUMP
EMERGENCY STEERING PUMP (OPTION)
U42103
1.
2.
3.
4.
5.
AA
SEW01239
Drive gear (Teeth 12)

Front cover
Gear case
Rear cover
Driven gear (Teeth 12)
Specifications
Model: SAM (2)-050
Direction of revolution: Possible to rotate both direction
Theoretical delivery:
50.8 cc/rev
Max. delivery pressure: 20.6 MPa {210 kg/cm2}
10-79
DIVERTER VALVE
DIVERTER VALVE (OPTION)

G
U42103
1
B
YY
1.
2.
3.
4.
XX
Diverter valve
Valve body
Check valve
Check valve
FUNCTION
If the engine stops or the pump seizes during machine traveling, and it becomes impossible to steer, the rotation of the transmission is used to turn the emergency steering pump to make steering possible.
10-80
A.
B.
C.
D.
E.
F.
G.
From steering pump

To steering valve
To hydraulic tank
Sensor mounting port
Emergency pump port
Emergency pump port
From hydraulic
SEW01240
DIVERTER VALVE
OPERATION
Pump and engine are working normally.
When the steering pump and engine are

working normally, the hydraulic pump, steering pump, and switch pump are rotated by
the engine. Therefore, oil is sent to the steering valve, and the machine can be steered.
In addition, the emergency steering pump is
rotated by the transmission, so oil from port
A of the diverter valve pushes open check
valve (2) and enters port B.
Pressure oil from the steering pump is flowing to port D, so it pushes spool (3) in the
direction of the arrow.
As a result, the oil from port B flows to port
C and is drained to the hydraulic tank.
U42103
To steering cylinder
Diverter valve
Emergency
pump
To main control valve
Safety valve
(with suction)
Steering
spool
T/M
Demand
spool
Hydraulic
tank
S/T S/W
Oil cooler
SLW01242
10-81
e
DIVERTER VALVE
U42103
Failure in pump or engine when machine is traveling.
If there is a failure in the pump or engine when

the machine is traveling, the rotation of the
wheels is transmitted through the transfer to
rotate the emergency steering pump.
The steering pump is not rotating, so no pressure oil is formed at port D. As a result, spool
(3) is pushed in the direction of the arrow by
spring (4).
The oil from the emergency steering pump
passes from port A through port B and flows to
the steering valve to make steering possible.
The emergency steering pump is designed
so that it can rotate both directions.
10-82
e
U42103
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Brake valve (right)
Hydraulic tank
Parking brake switch
Parking brake emergency cancel switch
Rear brake
Charge valve
Accumulator
Slack adjuster
Rear brake
PPC, brake pump
Parking brake valve
Parking brake
Brake valve (left)
Front brake
Slack adjuster
Front brake
10-84
BRAKE PIPING
BRAKE PIPING
For details of this page, see 90-3 page.
BRAKE CIRCUIT DIAGRAM
U42103
10-84-2
e
U42103
1. Hydraulic pump
1A. Work equipment pump
1B. PPC and brake pump
2. Strainer
3. Accumulator charge valve
3A. Safety relief valve
3B. PPC relief valve
3C. Filter
4. Check valve
5. Low pressure switch
6. Rear brake accumulator
7. Front brake accumulator
8. Emergency brake switch
9. Left brake valve
10. Transmission cut-off switch
11. Right brake valve
12. Pilot lamp switch
13. Rear slack adjuster
14. Front slack adjuster
15. Emergency parking brake valve
15A. Parking brake emergency release
solenoid
16. Parking brake emergency release switch
17. Parking brake
18. Parking brake pilot lamp switch
19. Parking brake solenoid
20. Parking brake valve
21. Transmission pump
22. Parking brake switch
10-85
e
BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (RIGHT)
1
2
A
U42103
4
B
6
C
7
SDW00107
1.
2.
3.
4.
5.
6.
7.
8.
Brake pedal (left, right brake)

Rod (right brake)
Pilot piston (right brake)
Spool (right brake)
Upper cylinder (right brake)
Spool (right brake)
Lower cylinder (right brake)
Rod (left brake)
10-86
9. Spool (left brake)

10. Cylinder (left brake)
A.
B.
C.
D.
E.
Pilot port (right brake)

To rear brake (right brake)
To front brake (right brake)
Drain (left, right brake)
To pilot port (left brake)
BRAKE VALVE
BRAKE VALVE (LEFT)
U42103
D
9
E
10
SDW00108
Outline
There are two brake valves installed in parallel under the front of the operators cab,
and these are actuated by depressing the
pedal.
When the right pedal is depressed, oil is
sent to the brake cylinder to apply the brakes.
When the left pedal is depressed, oil is sent
to the right pedal to apply the brakes in the
same way as when the right pedal is depressed.
In addition, the left brake pedal operates the

transmission cut-off switch to actuate the
transmission solenoid valve electrically and
set the transmission to neutral.
10-87
BRAKE VALVE
Operation
Brake applied (right brake valve)
Upper portion
When brake pedal (1) is depressed, the operating force is transmitted to spool (3)
through rod (2) and spring (4). When spool
(3) goes down, drain port a is closed, and
the oil from the pump and accumulator flows
from port A to port C and actuates the rear
brake cylinders.
1
2
3
Drain
Brake applied (left brake pedal)

When pedal (7) is depressed, spool (10) is
pushed up by rod (8) and spring (9), and
drain port c is closed. The oil from the pump
and the accumulator flows from port E to
port F.
Port F of the left brake valve and port PP of
the right brake valve are connected by a
hose, so the oil flowing to port F flows to
pilot port PP of the right brake valve.
The oil entering pilot port PP enters port G
from orifice d, and pushes piston (11). The
spring pushes spool (3) down, so the operation is the same as when the right brake
valve is depressed.
Accumulator
A
To rear brake
cylinder
From pump
Accumulator
b
5
6
To front brake
cylinder
From pump
SED00109
U42103
Lower portion
When brake pedal (1) is depressed, the operating force is transmitted to spool (3)
through rod (2) and spring (4). When spool
(3) goes down, spool (5) is also pushed down
by plunger (6). When this happens, drain
port b is closed, and the oil from the pump
and accumulator flows from port B to port D
and actuates the front brake cylinders.
7
Left brake valve
8
9
C
10
F
E
Right brake
valve
d
G
PP
11
To rear brake
cylinder
From pump
3
From pump
To front brake
cylinder
SEW00110
10-88
BRAKE VALVE
U42103
Applying brake when upper valve fails (right

brake valve)
Even if there is leakage of oil in the upper
piping, spool (5) is moved down mechanically when pedal (1) is depressed, and the
lower portion is actuated normally.
The upper brake is not actuated.
Applying brake when lower valve fails (right
brake valve)
Even if there is leakage of oil in the lower
piping, the upper portion is actuated normally.
When actuation is balanced

Upper portion
When oil fills the rear brake cylinder and the
pressure between port A and port C becomes
high, the oil entering port H from orifice e of
spool (3) pushes against spring (4). It pushes
up spool (3) and shuts off the circuit between port A and port C. When this happens, drain port a stays closed, so the oil
entering the brake cylinder is held and the
brake remains applied.
Lower portion
When spool (3) in the upper portion moves
up and the circuit between port A and port C
is shut off, oil also fills the front brake cylinder at the same time, so the pressure in the
circuit between port B and port D rises. The
oil entering port J from orifice f of spool (5)
pushes up spool (5) by the same amount
that spool (3) moves, and shuts off port B
and port D. Drain port b is closed, so the oil
entering the brake cylinder is held, and the
brake is applied.
The pressure in the space in the upper portion is balanced with the operating force of
the pedal, and the pressure in the space in
the lower portion is balanced with the pressure in the space in the upper portion. When
spools (3) and (5) move to the end of their
stroke, the circuits between ports A and C
and between ports B and D are fully opened,
so the pressure in the space in the upper
and lower portions and the pressure in the
left and right brake cylinders is the same as
the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of
the brake can be adjusted by the amount
that the pedal is depressed.
From pump
To fear brake
cylinder
From pump
To front brake
cylinder
From pump
3
e
A
f
From pump
SEW00111
4
a
H
To rear brake
C cylinder
5
b To front brake
Dcylinder
J
SEW00112
10-89
BRAKE VALVE
Brake released (right brake valve)

Upper portion
When pedal (1) is released and the operating force is removed from the top of the
spool, the back pressure from the brake cylinder and the force of the spool return spring
move spool (3) up. Drain port a is opened
and the oil from the brake cylinder flows to
the hydraulic tank return circuit to release
the rear brake.
3
a
From pump
From pump
From rear brake

cylinder
b From front brake

5 cylinder
SEW00113
U42103
Lower portion
When the pedal is released, spool (3) in the
upper portion moves up. At the same time,
the back pressure from the brake cylinder
and the force of the spool return spring move
spool (5) up. Drain port b is opened and the
oil from the brake cylinder flows to the hydraulic tank return circuit to release the front
brake.
10-90
CHARGE VALVE
U42103
CHARGE VALVE
A. To PPC valve
ACC. To brake valve
PP. To brake valve
P. From pump
T. Drain
10-92
e
Function
The charge valve is actuated to maintain the
oil pressure from the pump at the specified
pressure and to store it in the accumulator.
When the oil pressure reaches the specified
pressure, the oil from the pump is connected
to the drain circuit to reduce the load on the
pump.
CHARGE VALVE
U42103
1.
2.
3.
4.
5.
6.
Valve body
Main relief valve (R3)
Relief valve (R1)
PPC relief valve (R2)
Relief valve (H1)
Filter
10-93
e
CHARGE VALVE
Operation
1. When no oil is being supplied to accumulator (cut-out condition)
The pressure at port B is higher than the set

pressure of the relief valve (R1), so piston
(8) is forcibly pushed up by the oil pressure
at port B. Poppet (6) is opened, so port C
and port T are short circuited.
The spring chamber at the right end of spool
(15) is connected to port C of the relief valve
(R1), so the pressure becomes the tank pressure. The oil from the pump enters port P,
pushes spool (15) to the right at a low pressure equivalent to the load on spring (14),
and flows from port A to the PPC valve.
At the same time, it also passes through
orifices (17), (18), and (16), and flows to the
tank.
C T
R3
R1
6
8
Front accumulator
pilot pressure
B
16
To front, rear
accumulator 18
A
To
PPC
valve
R2
H1
17
15
SDW00116
2. When oil is supplied to accumulator

1) Cut-in condition
When the pressure at port B is lower than
the set pressure of the relief valve (R1), piston (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought
into tight contact, and port C and port T are
shut off.
(15) is also shut off from port T, so the pressure rises, and the pressure at port P also
rises in the same way.
When the pressure at port P goes above the
pressure at port B (accumulator pressure),
the supply of oil to the accumulator starts
immediately. In this case, it is decided by
the size (area) of orifice (17) and the pressure difference (equivalent to the load on
spring (14)) generated on both sides of the
orifice. A fixed amount is supplied regardless of the engine speed, and the remaining
oil flows to port A.
C T
R1
R3
5
6
7
8
Front accumulator
pilot pressure
B
16
To front, rear
accumulator 18
A
To
PPC
valve
R2
H1
14
P
17
15
SDW00117
10-94
U42103
14
2) When cut-out pressure is reached

When the pressure at port B (accumulator
pressure) reaches the set pressure of the
relief valve (R1), poppet (6) separates from
valve seat (7), so an oil flow is generated
and the circuit is relieved.
When the circuit is relieved, a pressure difference is generated above and below piston (8), so piston (8) moves up, poppet (6) is
forcibly opened, and port C and port T are
short circuited.
(15) is connected to port C of the relief valve
(R1), so the pressure becomes the tank pressure.
The pressure at port P drops in the same
way to a pressure equivalent to the load on
spring (14), so the supply of oil to port B is
stopped.
CHARGE VALVE
C T
R3
R1
6
7
8
Front accumulator
pilot pressure
B
16
To front, rear
accumulator 18
A
To
PPC
valve
R2
H1
14
17
15
U42103
SDW00118
3. Safety relief valve (R3)

If the pressure at port P (pump pressure)
goes above the set pressure of the relief
valve (R3), the oil from the pump pushes
spring (3). Ball (11) is pushed up and the oil
flows to the tank circuit, so this sets the
maximum pressure in the brake circuit and
protects the circuit.
R3
R1
11
Front accumulator
pilot pressure
To front, rear
accumulator
To
PPC
valve
R2
H1
P
SDW00119
10-95
ACCUMULATOR (FOR BRAKE)
ACCUMULATOR (FOR BRAKE)
1
2
1.
2.
3.
4.
Valve
Top cover
Cylinder
Piston
U42103
SEW00120
Function
The accumulator is installed between the
charge valve and the brake valve. It is
charged with nitrogen gas between cylinder
(3) and free piston (4), and uses the
compressibility of the gas to absorb the pulse
of the hydraulic pump or to maintain the
braking force and to make it possible to operate the machine if the engine should stop.
10-96
Specifications
Gas used:
Nitrogen gas
Charge amount:
3000 cc
Charging pressure: 3.4 0.15 MPa
{35 1.5 kg/cm2} (at 50C)
SLACK ADJUSTER
SLACK ADJUSTER
SEW00121
U42103
1.
2.
3.
4.
5.
Bleeder
Cylinder
Check valve
Piston
Spring
A. Inlet port
B. Outlet port
Function
The slack adjuster is installed in the brake
oil line from the brake valve to the brake
piston. It acts to provide a fixed time lag
when the brake is applied.
Specifications
Piston actuation pressure:
+0.1
2
0.01 +0.01
0 MPa {0.1 0 kg/cm }
Check valve cracking pressure:
0.93 0.05 MPa {9.5 0.5 kg/cm2}
Check valve closing pressure:
0.6 0.05 MPa {6.0 0.5 kg/cm2}
10-97
Operation
1. When brake pedal is depressed
Before the brake is depressed, piston (4) is
returned by the distance of stoke S (full
stroke). When the brake pedal is depressed,
the oil discharged from the brake valve flows
from port P of the slack adjuster and is divided to left and right cylinders (2), where it
moves piston (4) by stroke S to the left and
right.
SLACK ADJUSTER
P 2 4
Right brake
To left
brake
S
From brake valve
SEW00122
C
When this is done, brake piston (7) moves
by a distance of stroke S. In this condition,
the closer the clearance between the brake
piston and disc is to 0, the greater the braking force becomes.
C
7
Right brake
U42103
To left
brake
From brake valve
If the brake pedal is depressed further, and

the oil pressure discharged from the brake
valve goes above the set pressure, check
valve (3) opens and the pressure is applied
to port C to act as the braking force.
Therefore, when the brake is applied, the
time lag is a fixed value.
C
Right brake
To left
brake
From brake valve
10-98
SEW00123
SEW00124
7
Right
brake
To left
brake
S
From brake valve
T
SEW00125
U42103
2. When brake pedal is released

When the brake is released, piston (4) is returned by brake return spring (8) by an
amount equivalent to the oil for stroke S,
and the brake is released.
In other words, return stroke T of brake piston (7) is determined by the amount of oil
for stroke S of the slack adjuster. The time
lag of the brake is always kept constant regardless of the wear of the brake disc.
SLACK ADJUSTER
10-99
BRAKE COOLING PIPING
U42103
BRAKE COOLING PIPING
1.
2.
3.
4.
5.
10-100
Front brake (R.H.)

Oil filter
Rear brake (R.H.)
Brake cooling oil tank
Breather
6.
7.
8.
9.
10.
Oil cooler
Rear brake (L.H.)
Brake cooling pump
Check valve
Front brake (L.H.)
BRAKE COOLING CIRCUIT DIAGRAM
U42103
BRAKE COOLING CIRCUIT DIAGRAM
1.
2.
3.
4.

Breather
Brake cooling pump
Front brake
5.
6.
7.
8.
Rear brake
Check valve
Oil cooler
Oil filter
10-101
BRAKE
U42103
BRAKE
1.
2.
3.
4.
5.
6.
7.
8.
10-102
Guide pin
Return spring
Cylinder
Brake piston
Outer gear (No. of teeth: 138)
Inner gear (No. of teeth: 105)
Plate
Disc
BRAKE
Function
Service brakes are wet-type multiple-disc
brakes and are installed to all four wheels.
U42103
Operation
When the brake pedal is depressed, the pressure oil from the brake valve moves brake
piston (4) to the right in the direction of the
arrow. This brings disc (8) and plate (7) into
contact, and friction is generated between
the disc and plate. The wheel is rotating together with the disc, so the machine speed
is reduced and the machine is stopped by
this friction.
When the brake pedal is released, the pressure at the back face of brake piston (4) is
released, so the piston is moved to the left
in the direction of the arrow by the force of
return spring (2), and the brake is released.
10-103
BRAKE COOLING
U42103
BRAKE COOLING
1.
2.
3.
4.

Breather
Brake cooling pump
Front brake
5.
6.
7.
8.
Rear brake
Check valve
Oil cooler
Oil filter
Function
The brake oil cooling system is installed to
all four wheels. It consists of a brake cooling
pump which circulates the oil inside the
brake chamber continuously.
Operation
When the engine is started, brake cooling
pump (3) rotates, and the oil sent under pressure enters axle brake chamber A, circulates
between brake disc (9) and plate (10) inside
brake chamber A, and then flows out of the
chamber.
The oil leaving the brake chamber goes
through oil cooler (7) and oil filter (8), and
then returns to brake cooling oil tank (1).
Check valve (6) is installed in the cooling
circuit and acts to return the oil to the tank if
the oil goes above the specified pressure.
10-104
9. Brake disc
10. Plate
PARKING BRAKE CONTROL
PARKING BRAKE CONTROL

2
U42103
3
4
5
1. Parking brake switch

2. Parking brake emergency release switch
3. Transmission control valve
Outline
The parking brake is a wet-type multipledisc brake built into the transmission. It is
installed to the output shaft bearing, and
uses the pushing force of a spring to apply
the brake mechanically and hydraulic power
to release the brake.
When parking brake switch (1) installed in
the operators compartment is switched ON,
parking brake solenoid valve (4) installed to
transmission control valve (3) shuts off the
oil pressure and applies the parking brake.
When the parking brake switch is turned OFF,
the oil pressure in the cylinder releases the
parking brake.
SEW00129
4. Parking brake solenoid valve

5. Transmission (built-in parking brake)
When the parking brake is applied, the neutralizer relay shuts off the electric current to
the transmission solenoid valve and keeps
the transmission at neutral.
Emergency release switch (2) for the parking brake is installed for use when moving
the machine if the machine has stopped (the
parking brake is automatically applied) because of trouble in the engine or drive system.
10-105
PARKING BRAKE
PARKING BRAKE
2
SDW00130
1.
2.
3.
4.
5.
Output shaft
Disc
Plate
Piston
Spring
10-106
Outline
The parking brake is a wet-type multipledisc brake. It is actuated mechanically by a
spring and applies the braking force to output shaft (1) of the transmission.
The pushing force of spring (5) pushes piston (4) and plate (3) and disc (2) into contact
and applies the braking force to stop output
shaft (1).
U42103
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
Coil
Valve assy
Body
IN port
OUT port
U42103
1.
2.
3.
A.
B.
Function
This solenoid valve is controlled by the parking brake switch in the operators compartment and acts to switch the flow of oil to the
parking brake.
Operation
Parking brake applied
When the parking brake switch in the operators compartment is turned ON, the solenoid valve is turned OFF (electric current is
cut), and the oil in the pilot circuit from the
transmission pump flows from the IN port
to the OUT port and opens the drain circuit.
Parking brake released

When the parking brake switch in the operators compartment is turned OFF, the solenoid valve is turned ON (electric current
flows). The valve closes and the flow of oil
in the pilot circuit to the drain circuit is shut
off.
10-107
r
PARKING BRAKE VALVE
PARKING BRAKE VALVE

Function
The parking brake valve is installed inside
the transmission control valve and lower
valve, and controls the parking brake cylinder.
Operation
1. Parking brake applied
When the parking brake switch is turned ON,
solenoid valve (1) is turned OFF and the drain
circuit is opened. The oil in the pilot circuit
from the pump then flows to drain circuit.
The oil in the main circuit is shut off by
spool (2), and the oil in the brake cylinder
flows to the drain circuit. Therefore, the parking brake is applied by the force of the spring
in the parking brake cylinder.
From main circuit
From
pilot
circuit
2
1
Parking brake springs
U42103
SEW00132
2. Parking brake released

When the parking brake switch is turned OFF,
solenoid valve (1) is turned ON, and the drain
circuit is closed.
When the oil pressure at port a rises, it
pushes against spring (3) and moves spool
(2) to the right in the direction of the arrow.
This shuts off the drain circuit of the brake
cylinder, so the oil from the main circuit flows
from port b to port c to actuate the brake
cylinder and release the parking brake.
From main circuit
b
a
From
pilot
circuit
2
c
Parking brake springs
SDW00133
10-108
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE

1. Valve assy
2. Solenoid valve
A:
B:
C:
T:
P:
U42103
To parking brake
From parking brake valve
From pilot circuit
Drain
From brake (accumulator circuit)
SEW00134
Function
The emergency release solenoid valve is installed between the transmission and the
transmission control valve. If the engine
breaks down and no oil pressure is supplied
from the transmission pump, it is possible
to actuate the solenoid for the parking brake
release switch in the operators compartment. This allows the accumulator charge
pressure in the brake circuit to flow to the
parking brake cylinder.
From pilot circuit
To parking
brake
From parking
brake valve
A
Operation
When parking brake emergency release
switch 1 is turned ON, solenoid valve 2 is
actuated and the pressure stored in accumulator 3 enters from port P. The circuit is
switched by the pilot pressure, so the oil
flows from port A to the parking brake to
release the parking brake.
C
B
Parking brake
emergency
release
solenoid
Parking brake
emergency release
switch
From brake
circuit
SEW00135
10-109
U42103
1.
2.
3.
4.
5.
6.
7.
8.
9.
Main control valve

Fork cylinder
Steering valve
Hydraulic tank
PPC valve
Solenoid valve
Switch pump
Steering pump
Check valve
10. Accumulator
11. Radiator
12. Hydraulic pump
13. PPC, brake pump
14. Brake cooling pump
15. Steering cylinder
16. Lift arm cylinder
17. Grapple arm cylinder
Outline
The hydraulic system consists of the work equipment circuit and the steering circuit. The work
equipment circuit controls the actuation of the
grapple and attachments.
The oil in hydraulic tank (4) is sent to main control valve (1) by hydraulic pump (12). If the spools
for the fork, grapple arm and lift arm in the main
control valve are at the HOLD position, the oil
flows to the drain circuit of the main control
valve, is filtered by the filter inside the hydraulic
tank, and then returns to the tank.
When the work equipment control levers are operated, the PPC valve, fork spool or grapple arm
spool or lift arm spool is actuated, and the spools
of the main control valve are actuated by hydraulic pressure to send the oil from the main
control valve to lift arm cylinder (16) or fork cylinder (2) or grapple arm cylinder (17) to operate
the lift arm or grapple.
Control of the maximum pressure in the hydraulic circuit is carried out by the relief valve inside
the main control valve. A safety valve (with suction) is installed in the fork and grapple arm
cylinder circuit to protect the circuit.
Accumulator (10) is installed in the PPC pilot
circuit, and makes it possible to lower the lift
arm to the ground even when the engine has
stopped.
Hydraulic tank (4) is a pressurized sealed type
and has a breather equipped with a relief valve.
This makes it possible to pressurize the inside of
the tank and also to prevent any negative pressure, thereby preventing any cavitation of the
pump.

HYDRAULIC PIPING
HYDRAULIC PIPING
10-111
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
U42103
(Conditions: Engine at low idling, work equipment control levers at HOLD)
10-112
U42103
1.
2.
3.
4.
5.
6
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Hydraulic tank
Oil filter
Breather
Hydraulic pump
PPC, brake pump
Brake cooling pump
Steering pump
Switch pump
Filter
Accumulator charge valve
Accumulator
L.H. PPC valve
R.H PPC valve
Orbit-roll valve
Stop valve
Steering valve assembly
Flow control valve
Relief valve
Steering spool
Overload relief valve with suction
Steering cylinder
Cut-off valve
Main control valve
Main relief valve
Grapple arm control spool
Fork control spool
Lift arm control spool
Suction valve
Unloader valve
Float selector valve
Slow return valve
Lift arm cylinder
Fork cylinder
Grapple arm cylinder
Oil cooler
10-113
U42103
1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. PPC, brake pump
6. Brake cooling pump
7. T/C, T/M pump
8. Steering pump
9. Switch pump
10. Filter
11. Accumulator charge valve
12. Accumulator
13. L.H. PPC valve
14. R.H. PPC valve
15. Orbit-roll valve
16. Stop valve
17. Steering valve assembly
18. Flow control valve
19. Relief valve
20. Steering spool
21. Overload relief valve with
suction
23. Cut-off valve
24. Main control valve
25. Main relief valve
26. Grapple arm control spool
27. Safety valve (with suction)
28. Fork control spool
29. Safety valve (with suction)
30. Lift arm control spool
31. Suction valve
32. Unloader valve
33. Float selector valve
34. Slow return valve
36. Fork cylinder
38. Oil cooler
10-114
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT LEVER LINKAGE
U42103
WORK EQUIPMENT LEVER LINKAGE
1.
2.
3.
4.
Grapple arm control lever

Lift arm control lever
Kick-down switch
Fork control lever
5.
6.
7.
8.
9.
Solenoid valve for fork control

L.H. PPC valve
R.H. PPC valve
Solenoid valve for lift arm control
Safety lever
10-115
HYDRAULIC TANK
HYDRAULIC TANK
AA
U42103
SDW00140
1. Oil filler
2. Breather
3. Sight gauge
10-116
4. Filter suction valve

5. Oil filter
6. Hydraulic tank
HYDRAULIC TANK
BREATHER
1.
2.
3.
4.
Body
Filter element
Poppet
Sleeve
Preventing rise in pressure inside tank

If the pressure in the circuit rises above the
set pressure during operations because of
the change in the oil level in the hydraulic
cylinders or the rise in the temperature, the
sleeve is actuated to release the pressure
inside the hydraulic tank.
U42103
SEW00141
Preventing negative pressure inside tank

The tank is a pressurized sealed type, so if
the oil level inside the hydraulic tank goes
down, there will be negative pressure in the
tank. If this happens, a poppet is opened by
the difference between the pressure inside
the tank and the atmospheric pressure, and
air is let in to prevent negative pressure from
forming inside the tank.
10-117
PPC VALVE
PPC VALVE
U42103
T
D
B
P2
P.
P1 .
P2 .
P3 .
P4 .
T.
From PPC pump

To fork cylinder bottom end
To lift arm cylinder head end
To lift arm cylinder bottom end
To fork cylinder head end
Drain
10-118
r
P3
P4
P1
SEW00142
PPC VALVE
3
4
5
6
7
8
9
AA
U42103
BB
1.
2.
3.
4.
5.
6.
7.
8.
9.
Bolt
Piston
Plate
Collar
Retainer
Centering spring
Metering spring
Valve
Body
DD
SEW00143
CC
Function
The PPC valve is installed at the bottom of
the work equipment control lever and is connected by a linkage to the control lever.
The oil from the PPC pump is supplied to
the end of each spool of the main control
valve in accordance with the movement of
the control lever, and this actuates the spool.
For this reason, the operating force of the
control lever is small and this helps to reduce operator fatigue.
10-119
PPC VALVE
OPERATION OF PPC VALVE

[At neutral]
To cylinder
To tank
To cylinder
PA1
PB1
From pump
Charge valve
Accumulator
Filter
f
T
P
Check valve
10
P4
P1
PPC pump
Hydraulic tank
SEW00144
The oil from the pump enters port P. The

circuit is closed by spool (8), so the oil is
drained from relief valve (1).
At the same time, the oil at port PA1 of the
main control valve is drained from port f of
spool (8).
In addition, the oil at port PB1 is drained
from port g of spool (10).
10-120
U42103
PPC VALVE
FUNCTION OF PPC VALVE

The PPC valve supplies pressure oil from the
charging pump to the side face of the spool of
each control valve according to the amount of
travel of the control lever.
This pressure oil actuates the spool.
Operation
1. Control lever at hold (Fig. 1)
Ports PA1, P4, PB1 and P1 are connected to
drain chamber D through fine control hole
(f) in valve (8).
U42103
f
2. Control lever operated slightly (fine control)
(Fig. 2):
When piston (2) starts to be pushed by plate
(10), retainer (5) is pushed. Valve (8) is also
pushed by spring (7) and moves down.
When this happens, fine control hole (f) is
shut off from drain chamber D. At almost
the same time it is connected to pump pressure chamber PP, and the pilot pressure of
the control valve is sent through fine control
hole (f) to port P4. When the pressure at port
P4 rises, valve (8) is pushed back. Fine control hole (f) is shut off from pump pressure
chamber PP. At almost the same time it is
connected to drain chamber D, so the pressure at port P4 escapes to drain chamber D.
Valve (8) moves up and down until the force
of spring (7) is balanced with the pressure
of port P4.
The position of valve (8) and body (9) (when
fine control hold (f) is midway between drain
chamber D and pump pressure chamber PP)
does not change until the head of valve (8)
contacts the bottom of piston (2).
Therefore, spring (7) is compressed in proportion to the travel of the control lever, so
the pressure at port P4 also rises in proportion to the travel of the control lever. The
spool of the control valve moves to a position where the pressure of port PA1 (same
as pressure at port P4) and the force of the
return spring of the control valve are balanced.
T
P
8
P4
P1
PA1
PB1
Control valve
SEW00145
(Fig. 1)
10
2
5
D
7
T
PP
8
P4
P1
PB1
PA1
Control valve
(Fig. 2)
SEW00146
10-121
3.
Control lever moved back from slightly operated position to hold (Fine control) (Fig. 3):
When plate (10) starts to be pushed back,
piston (2) is pushed up by a force corresponding to the force of centering spring (6)
and the pressure at port P4.
At the same time, fine control hole (f) of
valve (8) is connected to drain chamber D,
so the oil at port P4 escapes.
If the pressure at port P4 drops too far, valve
(8) is pushed down by spring (7). Fine control hole (f) is shut off from drain chamber
D, and at almost the same time it is connected to pump pressure chamber PP. The
pump pressure is supplied until the pressure at port PA1 returns to a pressure equivalent to the position of the lever.
When the spool of the control valve returns,
the oil in drain chamber D flows in from fine
control hole (f) of the valve which has not
moved. The extra oil then flows through port
P1 to chamber PB1.
PPC VALVE
10
2
6
D
7
f
f'
T
8
P4
PP
P1
PB1
PA1
SEW00147
(Fig. 3)
4.
Control lever operated to end of travel (Fig. 4):

Plate (10) pushes piston (2) down, and piston (2) forcibly pushes in valve (8).
Fine control hole (f) is shut off from drain
chamber D, and is connected to pump pressure chamber PP.
Therefore, pressure oil from the charging
pump passes through fine control hole (f),
and flows from port P4 to chamber PA1 to
push the spool of the control valve.
The oil returning from chamber PB1 flows
from port P1 through fine control hole (f) to
drain chamber D.
10
2
D
f
f'
8
P4
PP
P1
PA1
PB1
Control valve
(Fig. 4)
10-122
SEW00148
U42103
Control valve
PPC RELIEF VALVE
PPC RELIEF VALVE

R2
1.
2.
3.
4.
5.
6.
Main valve
Spring
Valve seat
Pilot poppet
Spring
Screw
U42103
SDW00149
Function
The PPC relief valve is between the PPC,
brake pump and the PPC valve. When the
PPC pump is not being actuated, or when
any abnormal pressure is generated, the oil
sent from the pump is relieved from this
valve to prevent any damage to the pump
or circuit.
Operation
The relief valve is installed to the charge
valve. Port A is connected to the pump circuit and port C is connected to the drain
circuit.
The oil passes through the orifice in main
valve (1) and fills port B.
In addition, pilot poppet (4) is seated in valve
seat (3).
When the pressure at port A and port B
reaches the set pressure, pilot poppet (4)
opens and the oil pressure at port B escapes
from port D to port C to lower the pressure
at port B.
When the pressure at port B goes down, a
difference in pressure is generated at ports
A and B by the orifice of main valve (1).
Main valve (1) is opened by the pressure at
port A and the oil at port A is drained to port
C to relieve the circuit.
R2
To PPC
valve
SDW00150
R2
To PPC
valve
SDW00151
10-123
ACCUMULATOR (FOR PPC VALVE)
ACCUMULATOR (FOR PPC VALVE)

1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
2
Specifications
Type of gas: Nitrogen gas
Gas amount: 500 cc
Max. actuation pressure: 3.4 MPa {35 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
3
4
5
U42103
SEW00152
Function
The accumulator is installed between the hydraulic pump and the PPC valve. Even if the
engine stops when the boom is raised, it is
possible to lower the boom and bucket under their own weight by using the pressure
of the nitrogen gas compressed inside the
accumulator to send the pilot oil pressure to
the main control valve to actuate it.
Operation
After the engine stops, if the PPC valve is at
hold, chamber A inside the bladder is compressed by the oil pressure in chamber B.
When the PPC valve is operated, the oil pressure in chamber B goes below 2.9 MPa {30
kg/cm2}. When this happens, the bladder is
expanded by the pressure of the nitrogen
gas in chamber A, and the oil inside chamber B is used as the pilot pressure to actuate
the main control valve.
B
SEW00153
10-124
CUT-OFF VALVE
CUT-OFF VALVE
3
2
AA
D
B
B
C
BB
U42103
CC
T1
DD
SDW00154
1.
2.
3.
4.
C.
P.
T1.
T2.
Unload valve
Check valve
Cut-off relief valve
Screen
Port C (from hydraulic pump)
Port P (from steering valve)
Port T1 (to tank)
Port T2 (to tank)
Function
The cut-off valve is installed between the
switch pump and the main control valve.
Depending on the operating condition, it
switches the oil from the switch pump to
the main control valve or to the drain circuit.
The cut-off valve is operated by hydraulic
pressure on the standard specification machine and by the engine throttle controller
on the HYPER specification machine.
10-125
CUT-OFF VALVE
OPERATION OF CUT-OFF VALVE
Cut-off operation conditions

: Cut-off (drain)
x: Not actuated (to main control valve)
More than
13.6 MPa
{140 kg/cm2}
Less than
13.6 MPa
{140 kg/cm2}
1. Main control valve at HOLD

The oil from the switch pump (the oil from
the steering valve) pushes up check valve
(2), merges with the oil from the hydraulic
pump, and flows to the main control valve.
Main
control
valve
U42103
2. Main control valve operated

1) When hydraulic pump pressure is lower than
cut-off pressure
In the same way as when the main control
valve is at HOLD, the oil from the switch
pump (the oil from the steering valve) pushes
up check valve (2), merges with the oil from
the hydraulic pump, and flows to the main
control valve.
Hydraulic pump
2
Steering
valve
M
Steering
pump
Switch
pump
SNW01280
10-126
2) When hydraulic pump pressure is higher

than cut-off pressure
Cut-off relief valve (3) opens and the pilot oil
flows in the direction shown by the arrow.
When this happens, a difference in pressure
is generated between P2 and P1, so unload
valve (1) opens. Therefore, the oil from the
switch pump (the oil from the steering valve)
is drained.
CUT-OFF VALVE
Main
control
valve
Hydraulic pump
P1
P2
Steering
valve
M
SNW01281
U42103
Steering Switch
pump
pump
10-127
MAIN CONTROL VALVE
MAIN CONTROL VALVE

3-SPOOL
MA1
MA2
MA3
A
A
A1
A2
A1
A3
B3
U42103
B2
D2
B1
D1
B
D
E
MB1
MA1:
MA2:
MA3:
MB1:
MB2:
MB3:
From
From
From
From
From
From
10-128
PPC
PPC
PPC
PPC
PPC
PPC
valve
valve
valve
valve
valve
valve
A1: To
A2: To
A3: To
B1: To
B2: To
B3: To
MB2
MB3
fork cylinder bottom end

lift arm cylinder bottom end
grapple arm cylinder
fork cylinder head end
lift arm cylinder head end
grapple arm cylinder
SDW00160
P: Pump port
T: Drain port (to hydraulic tank)
D1: Drain port
D2: Drain port
MAIN CONTROL VALVE
U42103
AA
BB
10
7
8
DD
11
CC
EE
SDW00161
1.
2.
3.
4.
5.
6.
Main relief valve

Grapple arm spool
Fork spool
Lift arm spool
Return spring
Body
7.
8.
9.
10.
11.
Check valve
Unload valve
Suction valve
Safety valve with suction
Float selector valve
10-129
MAIN CONTROL VALVE
RELIEF VALVE
1
1.
2.
3.
4.
5.
6.
Main valve
Valve seat
Pilot poppet
Spring
Adjustment screw
Locknut
SEW00162
Operation
Port A is connected to the pump circuit and
port C is connected to the drain circuit. The
oil passes through the orifice in main valve
(1), and fills port B. Pilot poppet (3) is seated
in valve seat (2).
If the pressure inside ports A and B reaches
the set pressure of pilot poppet spring (4),
pilot poppet (3) opens and the oil pressure at
port B escapes from port D to port C, so the
pressure at port B drops.
When the pressure at port B drops, a difference in pressure between ports A and B is
created by the orifice of main valve (1). The
main valve is pushed open and the oil at port
A passes through port C, and the abnormal
pressure is released to the drain circuit.
The set pressure can be changed by adjusting the tension of pilot poppet spring (4). To
change the set pressure, remove the cap nut,
loosen the locknut, then turn adjustment screw
(5) to adjust the set pressure as follows.
TIGHTEN to INCREASE pressure
LOOSEN to DECREASE pressure
SEW00164
10-130
SEW00163
SEW00165
U42103
Function
The relief valve is installed to the inlet portion of the main control valve. If the oil goes
above the set pressure, the relief valve drains
the oil to the tank to set the maximum pressure for the work equipment circuit, and to
protect the circuit.
MAIN CONTROL VALVE
SAFETY VALVE (WITH SUCTION)

1
1.
2.
3.
4.
5.
6.
Suction valve
Main valve
Main valve spring
Pilot piston
Suction valve spring
Valve body
SEW00166
U42103
Function
The safety valve is in the bucket cylinder
circuit inside the main control valve. If any
abnormal pressure is generated by any shock
to the cylinder when the main control valve
is at the neutral position, this valve relieves
the abnormal pressure to prevent damage
to the cylinder.
Operation
Operation as safety valve
Port A is connected to the cylinder circuit
and port B is connected to the drain circuit.
The oil pressure at port A is sent to port D
from the hole in pilot piston (4). It is also
sent to port C by the orifice formed from
main valve (2) and pilot piston (4).
Pilot piston (4) is secured to the safety valve,
and the size of the cross-sectional surface
(cross-sectional area) has the following relationship: d2 > d1 > d3 > d4.
If abnormal pressure is created at port A,
suction valve (1) is not actuated because of
relationship d2 > d1 >, but relationship between port A and port C is d3 > d4, so main
valve (2) receives oil pressure equivalent to
the difference between the areas of d3 and
d4. If the oil pressure reaches the force (set
pressure) of main valve spring (3), main valve
(2) is actuated, and the oil from port A flows
to port B.
d1 d3 d4
B 1
d2
SEW00167
SEW00168
10-131
MAIN CONTROL VALVE
Operation as suction valve

If any negative pressure is generated at port
A, port D is connected with port A, so there
is also negative pressure at port D. The tank
pressure of port B is applied to port E, so
the safety valve receives oil pressure a, which
is equal to the difference in the area of d2
and d1 because of the tank pressure at port
E. Therefore, oil pressure e moves the valve
in the direction of opening, and oil pressure
a acts to move suction valve (1) in the direction of closing.
When the pressure at port A drops (and
comes close to negative pressure), it becomes lower than hydraulic pressure e. The
relationship becomes oil pressure e > oil
pressure a + force of valve spring (5), and
suction valve (1) opens to let the oil from
port B flow into port A and prevent any negative pressure from forming at port A.
SEW00170
Function
This valve acts to prevent any negative pressure from forming in the circuit.
Operation
If any negative pressure is generated at port
A (boom cylinder rod end) (when a pressure
lower than tank circuit port B is generated),
main poppet (1) is opened because of the
difference in area between d1 and d2, and oil
flows from port B at the tank end to port A
at the cylinder port end.
10-132
1. Main poppet
2. Sleeve
3. Spring
U42103
SUCTION VALVE
MAIN CONTROL VALVE
FLOAT SELECTOR VALVE AND UNLOAD VALVE
U42103
Function
The float selector valve and unload valve
are inside the main control valve. When the
lift arm control lever is operated to the
FLOAT position, the float selector valve detects this, and it is actuated to actuate the
unload valve and set the lift arm to the
FLOAT position.
Operation
If the lift arm control lever is pushed further
from the LOWER position, it is set to the
FLOAT position and the PPC valve is set to
the same condition as for the LOWER position.
The pressure at port A becomes high pressure and the pressure at port B becomes
low pressure.
The oil from the steering valve fills chamber
F and chamber E.
If the difference in pressure between port A

and port B becomes greater than the specified pressure, float selector valve (2) is
moved to the right, and port C and port D
open.
When port C is opened, the oil pressure in
chamber E drops, unload valve (4) is moved
up in the direction of the arrow, and the oil
from the steering valve flows to the drain
circuit, and also flows to the rod end of the
lift arm cylinder.
The oil at the bottom end of the lift arm
cylinder is connected to the drain circuit and
forms the FLOAT position.
10-133
MAIN CONTROL VALVE
U42103
GRAPPLE ARM, FORK AND LIFT ARM SPOOL HOLD POSITION
Operation
The oil enters port A from the pump, and
the maximum pressure is set by relief valve
(7).
Grapple arm spool (1) and fork spool (2) are
at the HOLD position, so the bypass circuit
is open and the oil at port A passes around
the spool and flows to port B. Lift arm spool
(3) is also at HOLD, so the bypass circuit is
open and the oil at port B passes around the
spool, enters port C of the drain circuit,
passes through the filter, and returns to the
tank.
10-134
The oil from the PPC pump passes through

check valve (9), and enters port L of the PPC
valve. However, the fork and lift arm levers
are at the HOLD position, so the oil returns
to the hydraulic tank from PCC relief valve
(8).
MAIN CONTROL VALVE
U42103
LIFT ARM SPOOL AT RAISE POSITION
Operation
When lift arm lever (5) is pulled, the oil flows
from port L of the PPC valve to port N and
port S. In addition, the oil at port T passes
through port M and flows to the drain circuit.
The oil pressure at port S pushes lift arm
spool (3) and moves it to the RAISE position.
bypass circuit of the grapple arm and fork
spools and flows to the bypass circuit of lift

arm spool (3). The bypass circuit is closed
by the spool, so the oil pushes open check
valve (10). The oil flows from port H to port
I, and flows to the cylinder bottom.
At the same time, the oil at the cylinder rod
end enters drain port C from port K and
returns to the tank. Therefore, the lift arm
rises.
10-135
MAIN CONTROL VALVE
U42103
LIFT ARM SPOOL AT LOWER POSITION
Operation
When lift arm lever (5) is pushed, the oil
flows from port L of the PPC valve to port M
and port T. In addition, the oil at port S
flows to the drain circuit.
The oil pressure at port T pushes lift arm
spool (3) and moves it to the LOWER position.
bypass circuit of the grapple arm and fork
spools and flows to the bypass circuit of lift
10-136
arm spool (3). The bypass circuit is closed

by the spool, so the oil pushes open check
valve (10). The oil flows from port J to port
K, and flows to the cylinder rod end.
At the same time, the oil at the cylinder
bottom enters drain port C from port I and
returns to the tank. Therefore, the lift arm
goes down.
MAIN CONTROL VALVE
U42103
LIFT ARM SPOOL AT FLOAT POSITION
Operation
When lift arm lever (5) is pushed to the
FLOAT position, the PPC valve spool moves
beyond the LOWER position to the FLOAT
position. The pressure oil at port L flows to
port M, and at the same time, it also flows
to port T and port W. In addition, the pressurized oil at port S flows to port N.
The pressurized oil at port T pushes lift arm
spool (3) to the LOWER position.
If a difference in pressure greater than the
specified pressure is generated at port W
and port X, valve (11) moves to the right,
opens port C1 and port C, and connects to

the drain circuit. When port C1 is connected
to the drain circuit, unload valve (12) moves
up and the oil from the pump flows to the
drain circuit.
Therefore, the oil at the cylinder rod end
passes from port K through unload valve
(12) and flows to the drain circuit. The oil at
the cylinder bottom flows from port I to port
C, and then flows to the drain circuit. Therefore, the lift arm is set to the FLOAT condition.
10-137
MAIN CONTROL VALVE
U42103
FORK SPOOL AT DUMP POSITION
Operation
When fork lever (6) is pushed, the pressure
oil at port L of the PPC valve flows from port
Q to port V. In addition, the oil at port R
flows to the drain circuit. The pressure oil at
port V moves fork spool (2) to the DUMP
position.
The bypass circuit is closed by fork spool
(2), so the oil from port A pushes open check
10-138
valve (13). The oil from check valve (13) flows

from port F to port G, and then flows to the
cylinder rod end.
bottom flows from port D to drain port C,
and returns to the tank, so the fork is
dumped.
MAIN CONTROL VALVE
U42103
FORK SPOOL AT TILT POSITION
Operation
When fork lever (6) is pulled, the pressure
oil at port L of the PPC valve flows from port
P to port R. In addition, the oil at port V
flows to the drain circuit. The pressure oil at
port R moves fork spool (2) to the TILT position.
The bypass circuit is closed by fork spool

(2), so the oil from port A pushes open check
valve (13). The oil from check valve (13) flows
from port D to port E, and then flows to the
cylinder bottom.
end flows from port G to drain port C, and
returns to the tank, so the fork is tilted.
10-139
MAIN CONTROL VALVE
U42103
GRAPPLE ARM SPOOL AT OPEN POSITION
Operation
When grapple arm lever (4) is pushed, the
pressure oil at port L of the PPC valve flows
from port Q to port V. In addition, the oil at
port R flows to the drain circuit. The pressure oil at port V moves grapple arm spool
(1) to the OPEN position.
The bypass circuit is closed by grapple arm
spool (1), so the oil from port A pushes open
10-140
check valve (14). The oil from check valve

(14) flows from port F to port G, and then
flows to the cylinder rod end.
bottom flows from port D to drain port C,
and returns to the tank, so the grapple arm
is opened.
MAIN CONTROL VALVE
U42103
GRAPPLE ARM SPOOL AT CLOSE POSITION
Operation
When grapple arm lever (4) is pulled, the
pressure oil at port L of the PPC valve flows
from port P to port R. In addition, the oil at
port V flows to the drain circuit. The pressure oil at port R moves grapple arm spool
(1) to the closed position.
The bypass circuit is closed by grapple arm

spool (1), so the oil from port A pushes open
check valve (14). The oil from check valve
(14) flows from port D to port E, and then
flows to the cylinder bottom.
end flows from port G to drain port C, and
returns to the tank, so the grapple arm is
closed.
10-141
WORK EQUIPMENT LINKAGE
U42103
1.
2.
3.
4.
Grapple arm
Bellcrank
Fork cylinder
Lift arm cylinder
10-142
5. Lift arm
7. Fork
U42103
10-143
LOG GRAPPLE
U42103
LOG GRAPPLE
1. Fork
2. Grapple arm
10-144
FORK POSITIONER AND LIFT ARM KICK-OUT
1
4
U42103
AA
1.
2.
3.
4.
5.
SEW00183
Proximity switch
Proximity switch
Fork cylinder rod
Lever
Plate
10-145
FORK POSITIONER
1
4
SEW00184
U42103
The fork positioner is an electrically actuated system which is used to set the fork to
the desired angle when the fork is moved
from the DUMP position to the TILT position. When the fork reaches the desired position, the fork lever is returned from the
TILT position to the HOLD position, and the
fork is automatically set to the suitable digging angle.
Lever (4) is secured to fork cylinder rod (3)
by bolts. In addition, proximity switch (1)
fixed to the cylinder by bolts.
When the fork is moved from the DUMP
position to the TILT position, the fork cylinder rod moves to the left, and at the same
time, lever (4) also moves to the left. Proximity switch (1) separates from lever (4) at
the desired position, and the fork lever is
returned to neutral.
LIFT ARM KICK-OUT
The lift arm kick-out is an electrically actuated system. It acts to move the lift arm
lever to the HOLD position and stop the lift
arm at the desired position before the lift
arm reaches the maximum height.
Plate (5) is fixed to the lift arm. In addition,
proximity switch (2) is fixed to the frame.
When the lift arm is moved from the LOWER
position to the RAISE position, the lift arm
rises, and when it reaches the desired position, the proximity switch and lever come
together and the system is actuated to return the lift arm lever to the HOLD position.
SEW00185
10-146
Operation of proximity switch
U42103
Lift arm RAISE

When the lift arm is lower than the set position for the kick-out, the detector (steel plate)
is not above the detection surface of the
proximity switch, so the proximity switch
load circuit is shut off.
The relay switch is turned OFF and the current for the solenoid is shut off.
When the lift arm lever is moved to the

RAISE position, the lift arm spool is held at
the RAISE position by the cam follower and
cam on the lever, and the lift arm rises.
10-147
When the lift arm rises and reaches the set

position for the kick-out, in other words, the
detector (steel plate) is in position on the
detection surface of the proximity switch, an
electric current is sent to the solenoid by the
action of the proximity switch and relay circuit. As a result, the solenoid is actuated,
and the cam is pulled away from the cam
detent, so the lift arm spool is returned to
the HOLD position by the return spring.
U42103
Action of proximity switch

When detector is in position
at detection surface of
proximity switch
When detector is separated

from detection surface of
proximity switch
Lights up
Goes out
Proximity switch load circuit

(relay switch circuit)
Current flows
Current is shut off
Relay switch load circuit

(solenoid circuit)
Current flows
Current is shut off
Position
Proximity switch
actuation display
10-148
Operation of proximity switch
U42103
Fork TILT
When the fork is lower than the set position
for the auto-leveler, the detector (steel plate)
is not above the detection surface of the
fork proximity switch, so electric current
flows in the proximity switch load circuit.
The relay switch is turned OFF and the current for the solenoid is shut off.
When the fork lever is moved to the TILT

position, the DUMP spool is held at the TILT
position by the cam follower and cam on
the lever, and the fork tilts.
10-149
r
When the fork tilts and reaches the set position for the fork leveler, in other words, the
detector (steel plate) separates from the detection surface of the proximity switch, electric current is sent to the solenoid by the
action of the proximity switch and relay circuit.
As a result, the solenoid is actuated, and the
cam is pulled away from the cam detent, so
the FORK spool is returned to the HOLD position by the return spring.
U42103
Action of proximity switch
Position
Proximity switch
actuation display
Proximity switch load circuit
(relay switch circuit)
Relay switch load circuit
(solenoid circuit)
10-150
When detector is in position

at detection surface of
proximity switch
When detector is separated

from detection surface of
proximity switch
Lights up
Goes out
Current flows
Current is shut off
Current is shut off
Current flows
CAB
CAB (OPTION)
U42103
4
SEW00198
1.
2.
3.
4.
Front glass
Front wiper
Rear wiper
Door
10-151
AIR CONDITIONER
AIR CONDITIONER (OPTION)
U42103
AIR CONDITIONER PIPING
1.
2.
3.
4.
Vent
Window defroster
Vent
Dry receiver
10-152
e
5.
6.
7.
8.
Air conditioner condenser

Compressor
Air conditioner condenser
Air conditioner unit
AIR CONDITIONER
ELECTRIC CIRCUIT DIAGRAM
U42103
For details of this page, see 90-9 90-15.
10-153

E.C.S.S. (OPTION)
U42103
10-154
MACHINE MONITOR SYSTEM
U42103
MACHINE MONITOR SYSTEM
Outline
The machine monitor system uses the sensors and other devices installed to various
parts of the machine to observe the condition of the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator of the condition of the machine.
The machine monitor system consists of the
main monitor, maintenance monitor, sensors, switches, relays, alarm buzzer, and
power source.
The displays can be broadly divided into the
following: Cautions displayed on the monitors (abnormalities in the machine where an
alarm is given) and normal conditions which
are always displayed on the instrument panel
(pilot lamps and readings for the gauges,
speedometer, and service meter).
There are also various switches built into

the monitor panel which function to operate
the machine.
When the optional controller are installed,

the main monitor communicates with the
controller through the network wiring and
functions to display the controller failure
action code and failure code together with
the time elapsed since the failure (trouble
data display mode).
10-155
r
MAIN MONITOR
U42103
MAIN MONITOR
1. CHECK lamp
2. CAUTION lamp
3. Pilot item
3A. Turn signal (left)
3B. Turn signal (right)
3C. Hi beam
3D. Shift indicator
3E. Speedometer
Outline
The main motor has a display function for
the speedometer and other gauges and a
switching function to control the electric components and controllers.
There is one CPU (Central Processing Unit)
installed internally, and this processes the
10-156
r
3F. Parking brake

3G. Preheating
3H. Failure action code
4. Switches
4A. Working lamp (front) switch (option)
4B. Working lamp (rear) switch
4C. Transmission cut-off switch
signals from the sensors and outputs the

display.
A liquid crystal display and LEDs are used
for the display. The switches are embossed
sheet switches.
MAIN MONITOR
MAIN MONITOR DISPLAY FUNCTION

Display
category
Symbol
Display item
Display range
Display method
When there is
abnormality display on
maintenance monitor
Display flashes (for details, see

MAINTENANCE MONITOR
DISPLAY FUNCTION)
Parking brake actuated,

transmission not at
neutral
Display flashes and buzzer

sounds
When there is
abnormality display on
maintenance monitor
Display flashes (buzzer may

also sound) (for details, see
MAINTENANCE MONITOR
DISPLAY FUNCTION)
Hi beam
When operated
Display lights up
Turn signal
(left, right)
When operated
Display lights up
When operated
Display lights up
Buzzer sounds when parking
brake is applied and shift lever
is not at N
Preheating
When preheating
Lights up
Lighting up time changes
according to engine water
temperature when starting
switch is turned ON (for details,
see PREHEATING OUTPUT
FUNCTION)
Speedometer
Travel speed
0 99 km/h
Digital display (display switches

between tachometer and
speedometer)
Shift
indicator
Shift indicator
14N
Digital display
Failure action code
When controller detects

failure and action by
operator is needed,
CALL is displayed,
or CALL and E
(action code) are
displayed in turn
Digital display
Buzzer sounds
(For details of the travel data
display mode, see TROUBLE
DATA DISPLAY MODE)
Check
Caution
CAUTION
Parking
brake
Check
Caution
Parking brake
U42103
Pilot
CHECK
Failure
action
code
10-157
r
MAIN MONITOR
MAIN MONITOR SWITCH FUNCTION

Item
Working lamp
(front)
Function
Front working lamp lights up
or goes out each time switch is
pressed when side lamps are
lighted up
Rear working lamp lights up or
goes out each time switch is
pressed when side lamps are
lighted up
Transmission
cut-off
Transmission cut-off function is

actuated or stopped each time
switch is pressed
Actuation
Lights up
Front working lamp lights up
Goes out
Front working lamp goes out
Lights up
Rear working lamp lights up
Goes out
Rear working lamp goes out
Lights up
Cut-off function actuated
Goes out
Cut-off function stopped
U42103
Working lamp
(rear)
Display
10-158
r
MAIN MONITOR
PREHEATING OUTPUT FUNCTION

Item
Actuation
Electrical intake
air heater
Power
source
ON
OFF
Starting
ON
signal
(terminal C)
OFF
ON
Display
OFF
T1
U42103
ON
Output
OFF
T2
Relationship between engine water temperature and display and output time
Display time:
T1 (sec)
Output time:
T2 (sec)
45
30
Engine water temperature (C)
10-159
10-159
r
MAIN MONITOR
TROUBLE DATA DISPLAY MODE (when optional controller are installed)

Switch operation
Method of switching to
trouble data display
mode
With engine stopped and starting

switch turned ON, press 2nd switch
from top on left side of main
monitor and working lamp (front)
switch simultaneously for at least 5
seconds.
ON
SDW00241
Method of sending
failure code
Press working lamp (front) switch
Actuation
All switch displays (LEDs) go out, and
failure code is displayed on speedometer
display and time elapsed since failure is
displayed on failure action code display.
(1) Failure code is a two-digit display
given in numbers or letters.
The display for the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
(000 is displayed for time elapsed
since failure)
(2) The time elapsed since failure is
displayed as a three-digit number
to show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
999H is displayed as 999H).
(3) A maximum of 9 items are stored
in memory for the failure code.
Failure code and time elapsed since
failure change to next item.
ON
Failure code
SPEED
x 100
RPM
km/h
MPH
Time elapsed
since failure
SDW01254
SDW00242
Clearing failure code
Press working lamp (rear) switch

for at least 2 seconds
ON
Failure code and time elapsed since

failure being displayed are cleared.
Failure code for problem now occurring
(flashing display) cannot be cleared.
SDW00243
Resetting from travel

data display mode
10-160
10-160
r
Press 2nd switch from top on left

side of main monitor and working
lamp (front) switch simultaneously
for at least 5 seconds, or start the
engine.
Changes to normal display
U42103
Item
MAINTENANCE MONITOR
U42103
MAINTENANCE MONITOR
1. Check items (Checks

before starting)
1A. Engine water level
1B. Engine oil level
2. Caution items (warning
items)
2A. Engine oil pressure
2B. Battery charge
2C. Brake oil pressure
2D. Air cleaner
(1A. Engine water level)
2E. Brake oil temperature
3. Gauge items
3A. Fuel level
3B. Engine water temperature
3C. Torque converter oil
temperature
Outline
The maintenance monitor has a display function for the caution items and gauges, and
switch functions to control the work equipment controller.
The maintenance monitor consists of the
monitor module, switch module, service
meter, case, and other mechanisms.
5. Service meter
5A. Service meter numeric
display
5B. Service meter RUN
pilot lamp
6. Monitor module
7. Switch module
The monitor module has a built-in CPU (Central Processing Unit). It processes the signal
from the sensors, and carries out the display and output.
A liquid crystal display and LEDs are used
for the display portions. The switches are
embossed sheet switches.
10-161
MAINTENANCE MONITOR
MAINTENANCE MONITOR DISPLAY FUNCTION

Display
category
Symbol
Display item
Display range
Engine water level
Below low level
Engine oil level
Below low level
Engine water level
Below low level
Engine oil pressure
Below specified
pressure
Brake oil pressure
Below specified
pressure
Check
Display method
Displays when engine is stopped and
starting switch is ON
Display when normal: OFF
Display when abnormal: Flashes
CHECK lamp flashes
Displays when engine is running
CAUTION lamp flashes
Buzzer sounds
Engine water temperature Above 102C
Buzzer sounds if above 105C
Torque converter oil

temperature
Above 120C
Buzzer sounds if above 130C
Fuel level
Below low level

CAUTION lamp flashes
Battery charge
When charge is
defective
Air cleaner
Above specified
negative pressure

CHECK lamp flashes
Brake oil temperature
Above 120C
Maintenance monitor pilot lamp

flashes, main monitor CAUTION lamp
flashes, buzzer sounds intermittently
Service meter
0 9999.9h
Actuated when charge is normal

Advances 1 for every hour
Service
meter
Service meter indicator

Fuel level
Lights up when service meter is

running
EMPTY
FULL
1 2 3 4 5 6 7
E
Red
Engine water temperature
F
Green
67 80 90 97 102 105C
Gauges
1 2 3 4 5 6 7
White Green

temperature
1 2 3 4 5 6 7
10-162
Green
Red
One place lights up to show

applicable level
Flashes when level is 6 or 7
Red
50 70 90 110 120 130C
All lamps light up below applicable

level
Flashes when level is 1
One place lights up to show

applicable level
Flashes when level is 6 or 7
U42103
Caution
E.C.S.S.
U42103
E.C.S.S. (Electronic Controlled

Suspension System) (Option)
1. E.C.S.S. (Electronic Controlled Suspension
System)
This system uses a combination of relieving
the hydraulic oil from the work equipment
and switching ON/OFF an accumulator which
is charged with high pressure gas. The controller carries out automatic control of these
in accordance with the travel condition of
the machine to give resilience to the up and
down movement of the work equipment and
to suppress the vibration of the chassis when
traveling at high speed. In this way, it improves the ride for the operator, prevents
spillage of the load, and improves the operating efficiency.
Special solenoid valves (ON-OFF valves) are
used to control the ON-OFF switching of the
accumulator (high pressure, low pressure)
and the opening and closing of the relief
valves.
With this system, it is possible to handle
four models (WA320, WA380, WA420, and
WA470) with the same system simply by
changing the connections of the model selection wiring harness.
2. Structure of system
The E.C.S.S. consists of the following electronic devices.
1) E.C.S.S controller (M type controller)
2) Input devices: E.C.S.S switch (system
switch), pressure switch (boom cylinder
bottom pressure), travel speed sensor,
model selection wiring harness, speed
range selection wiring harness
3) Output devices: solenoid valves (relief
valve, high pressure accumulator, low
pressure accumulator)
Main
monitor
Serial communication
+24V
Solenoid
(relief)
Solenoid
Travel speed sensor

+
Pressure switch
(High pressure accumulator)
solenoid
E.C.S.S
(low
pressure
controller accumulator
Speed range selection
Serial
communication
to main monitor
Model selection
wiring harness
SEW00268
10-163
E.C.S.S.
3. Content of control
In response to the input on the left side of
the table below, the controller carries out
the output on the right side to control the
system.
: ON
x: OFF
Input
OFF
ON
4
5
Speed range [Note 2]

H-L
Speed
Travel
speed
[Note 3]
OFF
OFF
OFF
ON
Min. 5 km/h
ON
ON
ON
OFF
OFF
OFF
ON
Min. 5 km/h
OFF
ON
ON
ON
OFF
Min. 5 km/h
[Note 4]
Note 1: The E.C.S.S system is switched ON-OFF

by operating the E.C.S.S switch on the
main monitor.
When the system is ON, the E.C.S.S
LED display on the main monitor lights
up.
The ON-OFF condition of the system is
retained even after the engine stops or
the starting switch is turned OFF. The
next time that the starting switch is
turned ON, the system is set to the
same condition as before it was turned
OFF.
(Main monitor function)
Starting switch OFF Machine stops
Starting switch ON
When system is ON System ON
When system is OFF System OFF
Note 2: Relationship between speed range signal and shift position
Shift position
1st
2nd
3rd
4th
Speed range
H-L
Speed
OFF
ON
OFF
OFF
ON
OFF
ON
ON
ON: +24V,
10-164
OFF: OPEN
Pressure
switch
Solenoid
(1)
(relief)
Solenoid Solenoid
(2) (high
(3) (low
pressure) pressure)
Note 3: Input pulse frequency when travel

speed is 1 km/h
Model
WA320
WA380
WA420
WA450
WA470
Pulse frequency (Hz)

54.41
47.70
40.96
44.46
44.46
Note 4: If the travel speed exceeds 5 km/h when

the output is OFF, the output is turned
ON.
When the output is ON, the output stays
ON until the travel speed reaches 3 km/h,
and when the travel speed goes below 3
km/h, the output is turned OFF.
Output ON
Output OFF
3km/ 5km/h
Travel speed
SEW00269
U42103
E.C.S.S switch
(system ON-OFF)
[Note 1]
Output
E.C.S.S.
4. Self-diagnostic function
This system always observes the condition
of the system, and displays the condition of
the system (LED code, see table below) in
the controller self-diagnostic display portion.
If there is any abnormality in the controller
itself or in the input or output devices, the
controller carries out troubleshooting of the
abnormality. It turns all the output OFF and
displays the error code (failure code) in the
self- diagnostic display portion and the main
monitor.
LED codes
LED
display
01
02
03
04
55
U42103
d0
d1
Error
code
d2
d3
d4
Content
Condition
of system
Selects model as WA320

Normal
Pressure switch ON
(displays only when ON)
Error in solenoid (relief)
system
Error in solenoid
(high pressure) system
Error in solenoid
Abnormal
(low pressure) system
Abnormality in travel speed
sensor system
Abnormality in model
selection (non-available
combination is selected)
1) Displays on controller
Error code displays [E] [dx] (where x
is a numeral from 0 to 4 in the table
above) repeatedly in turn.
If more than one abnormality occurs at
the same time, all the appropriate error
codes are displayed in turn.
When the starting switch is turned OFF
(controller power OFF, the error codes
are reset and not written to memory.
When checking the LED display, read the
code with the connector facing down.
2) Displays on main monitor
For details, see MAIN MONITOR TROUBLE DATA DISPLAY.
10-165
E.C.S.S.
5. Controller
1. Controller
2. Self-diagnostic display
CN1
CN2
CN3
U42103
SDW00270
Input/output signals
CN1
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Name of signal
Serial signal
Power source input (+24V)

GND
Solenoid (low pressure)

Serial signal
Solenoid power source

input (+24V)
Power source input (+24V)
GND
Solenoid (high pressure)
Solenoid (relief)
CN2
Input/
output
Output
Output
Output
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
CN3
Name of signal
Model
Model
Model
Model
selection
selection
selection
selection (Parity)
Pressure switch
Travel speed H-L

Travel speed SPEED
SAS SW
Model selection table

WA320
WA380
WA420
WA470
10-166
CN2-1
CN2-2
CN2-3
CN2-4
x
x
x
x
x
x
x
x
: GND
x: OPEN
Input/
output
Input
Input
Input
Input
Input
Input
Input
Input
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Name of signal
Travel speed sensor (+)
Travel speed sensor ()
Input/
output
Input
Input
SENSORS
SENSORS
Function
U42103
The sensors are a contact type sensor with

one end grounded to the chassis. The signal
from the sensor is input directly to the monitor panel, and when the contacts are closed,
the panel judges the signal to be normal.
However, the engine oil pressure uses a relay to reverse the sensor signal.
Sensor detection
item
Sensor
method
When
When
normal abnormal
Speed sensor
Electromagnetic
Engine oil level
Contact
ON
OFF
Radiator water
level
Contact
ON
OFF
Engine oil
pressure
Contact
OFF
ON
Engine water
temperature
Resistance
Torque converter
oil temperature
Resistance
Engine speed
sensor
Electromagnetic
Fuel level sensor
Resistance
Brake oil temperature sensor
Resistance
SPEEDOMETER SENSOR
Function
The speedometer sensor is installed to the
transmission output gear. A pulse voltage is
generated by the rotation of the gear teeth,
and the signal is sent to the machine monitor to display the travel speed.
AA
1. Connector
2. Magnet
3. Case
A
2
1
2
Structure of circuit
SEW00288
10-167
SENSORS
ENGINE SPEED SENSOR

1
2
1
5
0.85fG
0.85fG
1
2
SEW00289
1.
2.
3.
4.
5.
Magnet
Terminal
Case
Boot
Connector
Function
The engine speed sensor is installed to the
ring gear portion of the flywheel housing. A
pulse voltage is generated by the rotation of
the gear teeth, and a signal is sent to the
controller and monitor panel.
U42103
ENGINE OIL PRESSURE SENSOR

6
SEW00290
1.
2.
3.
4.
5.
6.
Plug
Contact ring
Contact
Diaphragm
Spring
Terminal
10-168
Function
This sensor is installed to the engine block
and the diaphragm detects the oil pressure.
If the pressure goes below the specified pressure, the switch is turned ON, and a relay is
actuated to turn the output OFF. This makes
the maintenance monitor flash to warn of
the abnormality. The caution lamp and alarm
buzzer are also actuated at the same time to
warn of the abnormality.
SENSORS
RADIATOR WATER LEVEL SENSOR
1
2
1. Float
2. Sensor
3. Connector
SEW00291
Function
This sensor is installed to the top of the
radiator. If the coolant goes below the specified level, the float goes down and the switch
is turned OFF. The caution lamp and alarm
buzzer are also actuated at the same time to
warn of the abnormality.
ENGINE OIL LEVEL SENSOR
U42103
SEW00292
1.
2.
3.
4.
Connector
Bracket
Float
Switch
Function
This sensor is installed to the side face of
the oil pan. When the oil goes below the
specified level, the float goes down and the
switch is turned OFF. This makes the maintenance monitor flash to warn of the abnormality. The check lamp also lights up at the
same time to warn of the abnormality.
10-169
SENSORS
FUEL LEVEL SENSOR
U42103
1
6
AA
E
Y
SEW00293
1.
2.
3.
4.
5.
6.
7.
Connector
Float
Arm
Body
Spring
Contact
Spacer
10-170
Function
The fuel level sensor is installed to the side
face of the fuel tank. The float moves up
and down as the level of the fuel changes.
As the float moves up and down, the arm
actuates a variable resistance, and this sends
a signal to the sub monitor to display the
fuel level. When the display on the maintenance monitor reaches the specified level,
the warning lamp flashes.
SENSORS
ENGINE WATER TEMPERATURE SENSOR

TORQUE CONVERTER OIL TEMPERATURE SENSOR
1
2
1
1
2
SEW00294
U42103
1. Connector
2. Plug
3. Thermistor
Function
These sensors are installed to the engine
cylinder block and transmission case. The
change in the temperature changes the resistance of the thermistor, and a signal is
sent to the maintenance monitor to display
the temperature. If the display on the sub
monitor reaches the specified position, the
lamp flashes and the buzzer sounds to warn
of the abnormality.
BRAKE OIL TEMPERATURE SENSOR
1. Thermistor
2. Plug
3. Connector
Function
This sensor is installed to the axle brake
chamber. The change in the temperature
changes the resistance of the thermistor, and
a signal is sent to the maintenance monitor
and main monitor to make the pilot lamp
flash and to sound the buzzer intermittently
to warn of the abnormality.
10-171
ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT

Engine stop
motor relay
CNL62
End
Start
D
1
2
3
4
5
6
7
8
6
5
3
2
1
Shift lever
N
A
C
B
M
Engine stop motor
A
C
B
M
Non-continuous
portion
(hatched portion)
Neutral relay
CNL57
Alternator
B
R
E
6
5
3
2
1
Heater signal
1
2
3
4
5
6
7
8
Starting
switch
B
10 A
Starting motor
E
C 24V
R 7.5KW
B
C
BR
5A
30 A
24V
50A
+
Battery relay
Battery
80 A
Electrical intake
air heater
Slow blow fuse
Function
There is neutral safety circuit which prevents
the engine from being started if the directional lever is not at the N position. This is
to ensure safety when starting the engine.
Operation
When the directional lever is placed at the N
position, the neutral contacts of the directional lever switch are closed. In this condition, if the starting switch is turned to the
START position, electric current flows in circuit 1 from the battery + starting switch
terminal B starting switch terminal C
starting motor terminal C starting motor
terminal E directional lever switch terminal N ground.
In addition, electric current flows from starting switch terminal BR stop motor relay
terminal 1 2 ground, and the relay coil
is excited.
The electric current from the battery flows
from engine stop motor terminal A B
relay terminal 5 3 terminal motor,
and rotates the motor. (The cable extends)
10-172
SDW00295
When the motor rotates, terminal D also rotates at the same time. When the non-continuous portion of terminal D reaches terminal B, the circuit from terminal A to B opens,
and the current from the battery to the motor is shut off. The motor attempts to continue rotating under inertia, but when the
continuous portion of terminal D contacts
terminal B, both poles of the motor are connected to the ground, and the motor stops
rotating.
In this condition, the stop motor cable is
completely extended, and the fuel injection
pump lever is set to the FULL position to
place it in the operating condition.
In addition, the current flows from starting
switch terminal BR battery relay coil
ground, and the battery relay switch is
closed.
A circuit is formed from the battery battery relay starting motor terminal B, so
the engine starts. If the directional lever is
not at the N position, circuit 1 is not formed,
so the engine does not start.
U42103
120 A
ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT

End
Start
Engine stop
motor relay
CNL62
1
2
3
4
5
6
7
8
6
5
3
2
1
D
A
C
B
+
1
2
3
4
5
6
7
8
D
A
C
B
+
Shift lever
Engine stop motor
Non-continuous
portion
(hatched portion)
Neutral relay
CNL57
Alternator
B
R
E
6
5
3
2
1
Heater signal
Starting
switch
BR
Starting motor
24V
7.5KW
B
5A
10A
U42103
C
R
24V
50A
30A
Battery relay
Battery
120A
80A
Electrical intake
air heater
Slow blow fuse
Function
The system is equipped with an electrical
fuel cut device (engine stop motor) which
makes it possible to start or stop the engine
by turning the starting switch ON or OFF.
This improves the ease of operation.
Operation
When the starting switch is turned OFF, starting switch terminals B, BR and C are opened.
The current in the stop motor relay is shut
off by the starting switch, so the coil is not
excited. Therefore, terminals 3 and 6 are
closed.
The current from the battery flows from engine stop motor terminals A C relay
terminals 6 3 motor to rotate the motor. (The cable is pulled in)
SDW00297
When the motor rotates, terminal D also rotates at the same time. When the non-continuous portion of terminal D reaches terminal C, the circuit from terminal A to C opens,
and the current from the battery to the motor is shut off. The motor attempts to continue rotating under inertia, but when the
continuous portion of terminal D contacts
terminal C, both poles of the motor are connected to the ground, and the motor stops
rotating.
In this condition, the stop motor cable is
completely pulled in, and the fuel injection
pump lever is set to the STOP position to
stop the engine.
10-173
PREHEATING CIRCUIT
PREHEATING CIRCUIT
(AUTOMATIC PREHEATING SYSTEM)
Neutral relay
CNL57
6
5
3
2
1
Starting switch
E
R2
C
R
Starting motor
24V
7.5KW
B
B
BR
Shift lever
N
Battery relay
30A
Preheating relay
120A
CNL56
6
5
3
2
1
80A
To alternator
Slow blow fuse
Battery
Heater relay
Electrical intake
air heater
U42103
10 12
Starting switch
terminal BR
Main monitor
Outline
To improve the ease of starting in cold areas, an automatic preheating system is installed. This system helps to reduce the
preheating time and also automatically sets
the preheating time to match the engine
water temperature when the starting switch
is operated.
When the starting switch is turned to the
ON (ACC) position, the preheating pilot lamp
on the main monitor lights up and preheating
is carried out on the intake air for the electric intake air heater.
The engine water temperature is detected
by the water temperature sensor, and the
preheating time is set by the controller built
into the main monitor.
While the pilot lamp is lighted up, preheating
is being carried out, so the starting switch
must be kept at the ON position. If the starting switch is turned to the START position
while the pilot lamp is ON, the preheating is
canceled.
10-174
16
CNL07
1 4
Preheating
output
CNL06
19 20
Preheating ON
1 4 7
Starting switch
terminal C
Water temerature
signal
CNL05
Engine water
temperature sensor
SDW00299
Operation
When the starting switch is turned to the
ON (ACC) position, a circuit is formed from
starting switch terminal BR controller inside main motor preheating output
ground.
The preheating relay coil is excited, so the
preheating relay is actuated to actuate the
heater relay.
Current flow from the battery battery relay heater relay electrical intake air
heater to carry out preheating. When the
preheating completion signal is sent from
the controller, the preheating relay and
heater relay are turned OFF and the
preheating is completed.
ELECTRIC TRANSMISSION CONTROL
U42103
1.
2.
3.
4.
5.
6.
7.
Transmission cut-off selector switch

Directional lever
Speed lever
Kick-down switch
Maintenance monitor
Relays
8.
9.
10.
11.
12.
13.
Fuse boxes
Speed sensor
Transmission cut-off switch
Brake valve (left)
Brake valve (right)
Function
1
2
Selection of F, R, and N positions

Selection of speed range
Kick-down switch
Transmission cut-off function
Transmission cut-off selector function
Neutralizer
Neutral safety function
Warning function
Using directional lever

Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch
without using the speed lever. If directional lever is operated to R or N,
speed range automatically returned to 2nd.
Transmission is shifted to neutral when left brake is operated
It is possible to select whether to actuate or not actuate the
transmission cut-off function. In this way, it is possible to obtain the
same or greater ease of operation as on conventional loaders with the
left brake when carrying out scooping work or when loading or unloading
the machine from a trailer.
To prevent seizure of the parking brake when traveling with the parking
brake applied, the transmission is shifted to neutral when the parking
brake is applied.
If the directional lever is not at the N position, the engine will not start
when the starting switch is turned. This prevents the machine from
starting suddenly. (For details, see STARTING CIRCUIT.)
When traveling in reverse, the backup lamp lights up and the backup
horn sounds to warn people in the area.
10-175
COMBINATION SWITCH
7
10
SDW00301
Outline
The directional lever has three positions and
the speed lever switch has four positions. As
an individual part, the switch does not have
a detent mechanism; the detent mechanism
is in the combination switch. Each switch is
positioned by two pins, and is secured to the
body by three screws. When each lever is

operated to the desired position, the switch,
which is interconnected by a shaft, acts to
allow electric current to flow to that circuit
only.
General locations, function

1
Directional lever switch
Switches between F, R, and N
Speed lever switch
Selects speed range
Speed lever stopper
Stopper used to prevent speed lever from entering 3rd or 4th during
operations
Turn signal indicators
Direction indicator lamps used when turning left or right
Self cancel
Turn signal indicator lever automatically returns to central position

after machines turns left or right
Lamp switch
Switches on clearance lamp, head lamp, parking lamp, etc.
Dimmer switch
Selects high beam for travel and low beam for passing
Hazard switch
Makes both left and right turn signal indicator lamps flash at the
same time
Emergency flashing pilot lamp
Flashes at the same time as the emergency flashing lamp flashes
Applies or releases parking brake
10
10-176
U42103
Operation
Directional lever (1) and shaft (2) of the
speed lever of the combination switch form
one unit with magnet (3), and magnet (3)
also moves together with lever (1).
Control switch (5) with built-in hole IC (4) is
installed at the bottom of magnet (3), and
hole IC (4) is positioned on the board to
match each position.
When directional lever (1) is operated to the
F position, magnet (3) is immediately above
hole IC (4) for the F position of the control
switch. The magnetism from magnet (3)
passes through the gap and case (6), and
magnetism is applied to hole IC (4).
When this happens, hole IC (4) is inside a
magnetism detection circuit, so it detects the
magnetism of magnet (3) and sends the F
position signal to the electric current amplification circuit. In the electric current amplification circuit, a signal is output to actuate
the transmission.
N
R
3
4
U42103
SEW00302
10-177
KICK-DOWN SWITCH
KICK-DOWN SWITCH
1.
2.
3.
4.
Kick-down switch
Spring
Side cap
Wiring harness
U42103
SEW00303
Operation
The kick-down (shifting down from 2nd

1st) is actuated only when traveling in F2.
When traveling in F2, if it is desired to shift
down to 1st without operating the speed
lever, operate the kick-down switch on the
boom lever to ON to shift down to F1.
After this, even if the kick-down switch is
pressed, the transmission is kept at F1.
Cancellation (or not actuated)

When directional lever is at N
When directional lever is at R
When speed lever is not at 2nd
When starting switch is OFF
10-178
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM

Normal operation
(directional lever at F, speed lever at 2)
Speed lever
HL
Speed
R
F
solenoid solenoid solenoid solenoid
(3)
(4)
(2)
(1)
2 1
2 1
1 2
1 2
CNT3
1
Neutral 8
1st signal 12
2nd signal 13
20
1 2
1 2
1 2
1 2
CNL06
Transmission
cut-off
switch
1
3
Stop lamp
15
CNL08
1
7
8
20A
CNL39
1 2
5 6 1 2 3 4
5 6 1 2 3 4
5 6 1 2 3 4
Back up
lamp
F signal
R signal
6 5 3 2 1
6 5 3 2 1
Starting switch
terminal C
Starting motor
terminal C
Main monitor
1 2 3 4 5 6
1 2
CNL05
U42103
CNT15 CNT16 CNT17
CNT1
CN37 CN38
10
CNT2
1
2
3
4
Parking switch
(Released) (Applied)
OFF
ON
CNT4
F
N
R
Battery
+
1
2
3
4
5
6
7
8
6 5 3 2 1
Backup
Kick-down
switch
CNL68
Kick-down
relay
CNL67
CNL66 buzzer
CNL65
CNL58 CNL53
REVERSE FORWARD
Transmission Neutralizer Stop
relay
relay
cut-off relay relay
lamp
relay
1) Directional lever set to F

When the directional lever is set to the F
position, electric current flows from the battery + directional lever switch terminal 1
2 FORWARD relay terminal 5 6
ground.
As a result, the FORWARD relay is actuated
and terminals 1 and 2 and terminals 3 and 4
are connected.
Next, the current flows from the battery +
parking brake safety relay terminal 5 3
parking brake switch terminal 3 2
neutralizer relay terminal 1 2 ground,
and neutralizer relay terminal 3 5 are connected. In addition, electric current flows
from the battery + transmission cut-off
relay terminal 1 2 monitor, and transmission cut-off relay terminals 3 5 are connected.
Parking
brake
solenoid
valve
6 5 3 2 1
6 5 3 2 1
CNL57 Stop lamp Transmission CNL59

switch
cut-off switch
Neutral
Parking brake
relay
safety relay
SDW00305
Electric current flows from the battery +

neutralizer terminal 3 5 transmission
cut-off relay terminal 3 5 FORWARD
relay terminal 1 2 solenoid 1 ground,
and solenoid (1) is actuated.
2) Speed lever set to 2
When the speed lever is at position 2, no
electric current flows to solenoids (2), (3), or
(4). In this condition, the transmission valve
is set to F2 by the action of solenoid (1).
No current flows to the coil (relay terminals
5 6) of the kick-down relay if the kick-down
is not pressed. Therefore, the kick-down relay is not actuated, and the transmission is
held in F2.
Solenoid actuation table
Solenoid
F1
FORWARD
(1)
REVERSE
(2)
H-L select
(3)
Speed select (4)
F2
F3
F4
R1
R2
R3 R4
10-179
Kick-down switch operated (case I)

(When operating or traveling in F2)
(When kick-down switch is pressed ON)
Speed lever
1
2
3
4
5
6
7
8
2 1
2 1
1 2
1 2
1 2 3 4 5 6
1 2
CNT3
CNL05
1
Neutral 8
1st signal 12
2nd signal 13
20
1 2
1 2
1 2
1 2
CNL06
1
3
Stop lamp
15
CNL08
1
7
8
20A
CNL39
1 2
5 6 1 2 3 4
Press
Kick-down
switch
5 6 1 2 3 4
5 6 1 2 3 4
Back up
lamp
F signal
R signal
6 5 3 2 1
6 5 3 2 1
6 5 3 2 1
Backup
CNL68
Kick-down
relay
CNL67
CNL66 buzzer
CNL65
CNL58 CNL53
REVERSE FORWARD
relay
relay
cut-off relay relay
lamp
relay
Parking
brake
solenoid
valve
6 5 3 2 1
6 5 3 2 1

switch
cut-off switch
Neutral
Parking brake
relay
safety relay
SDW00306
When the kick-down switch is pressed, electric current flows from the battery (+)
speed lever 2 FORWARD relay terminal 3
4 kick-down switch kick-down relay
terminal 5 6 ground.
As a result, the kick-down is actuated, and
kick-down relay terminals 1 and 2 and terminals 3 and 4 are closed. A circuit from
kick-down relay terminal 1 2 kick-down
relay terminal 5 6 ground is formed, so
the kick-down relay continues to be actuated even if the kick-down switch is returned.
(Self-hold circuit of kick-down relay)
When the kick-down relay is actuated and

terminals 3 and 4 are closed, electric current flows from the battery (+) kick-down
relay terminal 3 4 solenoid 4 ground,
and solenoid (4) is actuated. Solenoids (1)
and (4) are actuated, so the transmission is
set to F1.
In this way, if the kick-down switch is pressed
when the speed lever is at F2, the transmission
will shift to F1. At the same time, it will be held
in F1 by the self-hold function of the kick-down
relay even when the kick-down switch is released. However many times the kick-down
switch is pressed, the transmission will stay in
F1.
Solenoid
F1
FORWARD
(1)
REVERSE
(2)
H-L select
(3)
Speed select (4)
10-180
F2
F3
F4
R1
R2
R3 R4
U42103
Transmission
cut-off
switch
Starting switch
terminal C
Starting motor
terminal C
Main monitor
CNT15 CNT16 CNT17
CNT1
CN37 CN38
10
HL
Speed
R
F
(3)
(4)
(2)
(1)
CNT2
1
2
3
4
Parking switch
OFF
ON
CNT4
F
N
R
Battery
+
Canceling actuation of kick-down switch (Case I)

(Directional lever moved to N or R)
Speed lever
1
2
3
4
5
6
7
8
HL
Speed
R
F
(3)
(4)
(2)
(1)
2 1
2 1
1 2
1 2
CNT3
1
Neutral 8
1st signal 12
2nd signal 13
20
1 2
1 2
1 2
1 2
CNL06
Transmission
cut-off
switch
1
3
Stop lamp
15
CNL08
1
7
8
20A
CNL39
1 2
5 6 1 2 3 4
5 6 1 2 3 4
5 6 1 2 3 4
Back up
lamp
F signal
R signal
6 5 3 2 1
6 5 3 2 1
Starting switch
terminal C
Starting motor
terminal C
Main monitor
1 2 3 4 5 6
1 2
CNL05
U42103
CNT15 CNT16 CNT17
CNT1
CN37 CN38
10
CNT2
1
2
3
4
Parking switch
OFF
ON
CNT4
F
N
R
Battery
+
6 5 3 2 1
Backup
Kick-down
switch
CNL68
Kick-down
relay
CNL67
CNL66 buzzer
CNL65
CNL58 CNL53
REVERSE FORWARD
relay
relay
cut-off relay relay
lamp
relay
Parking
brake
solenoid
valve
6 5 3 2 1
6 5 3 2 1

switch
cut-off switch
Neutral
Parking brake
relay
safety relay
SDW00307
When the directional lever is moved to the R

position, the F terminal contacts are turned
OFF, so the electric current stops flowing
from the battery (+) directional lever F
FORWARD relay terminal 5 6 ground,
and the FORWARD relay is reset.
FORWARD relay terminals 1 and 2 and terminals 3 and 4 are opened, so the electric
current stops flowing to the solenoid of the
kick-down relay, and the kick-down relay is
reset.
In this way, the self-hold circuit of the kickdown relay is canceled, and terminals 3 and
4 are opened, so solenoid (4) is no longer
actuated. (When the directional lever is
moved to the N position, the actuation is the
same as above and the kick-down relay is
canceled.)
In addition, FORWARD relay terminal 1 and
2 are opened, so solenoid (1) is no longer
actuated.
When the directional lever is moved to the

R position, current flows from the battery
(+) directional lever R REVERSE relay
terminal 5 6 ground, so the REVERSE
relay is actuated and REVERSE terminals 1
and 2 and terminals 3 and 4 are closed.
As a result, electric current flows from the
battery (+) REVERSE relay terminal 1 2
solenoid 2 ground, and solenoid (2) is
actuated. Therefore, only solenoid (2) is actuated, and the transmission is set to the R2
position.
Solenoid
F1
FORWARD
(1)
REVERSE
(2)
H-L select
(3)
Speed select (4)
F2
F3
F4
R1
R2
R3 R4
10-181
Canceling actuation of kick-down switch (Case II)

(speed lever moved to position other than 2)
Speed lever
1
2
3
4
5
6
7
8
HL
Speed
R
F
(3)
(4)
(2)
(1)
2 1
2 1
1 2
1 2
1 2 3 4 5 6
1 2
CNT3
CNL05
1
Neutral 8
1st signal 12
2nd signal 13
20
1 2
1 2
1 2
1 2
CNL06
1
3
Stop lamp
15
CNL08
1
7
8
20A
CNL39
1 2
5 6 1 2 3 4
5 6 1 2 3 4
5 6 1 2 3 4
Back up
lamp
F signal
R signal
6 5 3 2 1
6 5 3 2 1
6 5 3 2 1
Backup
Kick-down
switch
CNL68
Kick-down
relay
CNL67
CNL66 buzzer
CNL65
CNL58 CNL53
REVERSE FORWARD
relay
relay
cut-off relay relay
lamp
relay
Parking
brake
solenoid
valve
6 5 3 2 1
U42103
Transmission
cut-off
switch
Starting switch
terminal C
Starting motor
terminal C
Main monitor
CNT15 CNT16 CNT17
CNT1
CN37 CN38
10
CNT2
1
2
3
4
Parking switch
OFF
ON
CNT4
F
N
R
Battery
+
6 5 3 2 1

switch
cut-off switch
Neutral
Parking brake
relay
safety relay
SDW00308
If the speed lever is moved to any position

other than 2, the electric current stops flowing from the battery (+) speed lever 2
FORWARD relay terminals 3 4, and the
current to the kick-down relay is also shut
off.
Therefore, the kick-down relay is canceled,
and solenoid (4) is no longer actuated.
If the speed lever is moved to 3, solenoid (3)
is actuated. In addition, the directional lever
is at the F position, so solenoid (1) is actuated. Therefore, solenoids (1) and (3) are
actuated and the transmission is set to F3.
10-182

Solenoid
F1
FORWARD
(1)
REVERSE
(2)
H-L select
(3)
Speed select (4)
F2
F3
F4
R1
R2
R3 R4
Canceling actuation of kick-down switch (Case

III)
(starting switch turned OFF)
U42103
When the starting switch is turned OFF, the

electric current stops flowing from the battery (+) speed lever 2 FORWARD relay
terminal 5 6 ground, and the kick-down
relay is reset.
Therefore, the kick-down relay is canceled.
If the starting switch is turned ON again, the
self-hold circuit of the kick-down relay has
been canceled, so the transmission will work
as normal.
10-183
TRANSMISSION CUT-OFF SWITCH
TRANSMISSION CUT-OFF SWITCH
1
2
7
B
B
1
2
U42103
SDW00313
1.
2.
3.
4.
Case
Seal film
Disc
Vinyl tape (Green)
Outline
When the left brake pedal is operated, the
switch detects the oil pressure in the brake
circuit, shuts off the electric power to the
solenoid valve circuit for the directional
clutch, and shifts the transmission to neutral.
10-184
5.
6.
7.
8.
Tube
Connector
Cover
Spring
Specifications
Voltage value
Current value
Min.
Max.
Min.
Max.
18 V
32 V
10 mA
2.3 A
TRANSMISSION CUT-OFF FUNCTION
CNL06
Transmission
cut-off
switch
1
3
16
20A
U42103
Transmission
combination
switch 1
Transmission
combination
switch
Transmission
cut-off switch
Transmission
combination
switch 2
F
N
R
10A
Starting switch
terminal C
main monitor
CNL15
1 2
Kick-down
switch
5 6 1 2 3 4
5 6 1 2 3 4
5 6 1 2 3 4
CNL68
Kick-down
relay
CNL67
REVERSE
relay
CNL66
FORWARD
relay
6 5 3 2 1
CNL65
Transmission
cut - off relay
6 5 3 2 1
6 5 3 2 1
CNL58
Neutralizer
relay
CNL57
Neutral
relay
From parking
brake switch
(battery power)
SDW00314
Outline
If the transmission cut-off selector switch on
the main monitor is turned ON (pilot lamp
lights up), the transmission cut-off switch
installed to the left brake pedal is actuated.
When the left brake pedal is operated, the
brakes are applied, and the transmission is
shifted to neutral at the same time. If the
transmission cut-off selector switch is set to
the OFF position (pilot lamp goes out), the
transmission is not shifted to neutral even
when the brake is operated, so the left brake
functions only as a brake in the same way
as the right brake.
Operation
1. Transmission cut-off selector switch ON
If the transmission cut-off selector switch is
turned ON, the transmission cut-off relay
solenoid is not excited, so transmission cutoff relay terminals 3 5 are not connected.
In this condition, +24V voltage is applied
through only the transmission cut-off switch
to transmission control valve solenoids R
and F.
When the left brake pedal is depressed, the
contacts of the transmission cut-off switch
are opened, so the voltage to solenoids R
and F is shut off. As a result, the brakes are
applied as normal, and the transmission is
also shifted to neutral at the same time.
10-185
CNL06
1
3
16
20A
Transmission
combination
switch 1
Transmission
combination
switch
Transmission
cut-off switch
Transmission
combination
switch 2
F
N
R
10A
CNL15
1 2
Kick-down
switch
5 6 1 2 3 4
5 6 1 2 3 4
5 6 1 2 3 4
CNL68
Kick-down
relay
CNL67
REVERSE
relay
CNL66
FORWARD
relay
6 5 3 2 1
CNL65
Transmission
cut - off relay
6 5 3 2 1
6 5 3 2 1
CNL58
Neutralizer
relay
CNL57
Neutral
relay
From parking
brake switch
(battery power)
SDW00315
2. Transmission cut-off selector switch OFF

If the transmission cut-off selector switch is
turned OFF, the transmission cut-off relay
solenoid is excited, and transmission cut-off
relay terminals 3 5 are connected. In this
condition, +24V voltage is applied to transmission solenoids R and F regardless of the
position of the transmission cut-off switch.
As a result, even when the left brake pedal
is depressed, the transmission is not shifted
to neutral.
10-186
U42103
Transmission
cut-off
switch
Starting switch
terminal C
main monitor
ELECTRIC PARKING BRAKE CONTROL
3,4,5
6
U42103
11
Outline
The parking brake is a wet-type multipledisc brake built into the transmission. When
an electric current flows to the parking brake
valve (solenoid valve), the oil pressure from
the transmission pump is applied to the parking brake cylinder and the parking brake is
released.
When the electric current is cut, the oil pressure from the transmission pump is shut
off, and the oil pressure inside the parking
brake cylinder passes through the parking
brake valve and is drained. The parking brake
is then applied by the force of the brake
spring.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
10
SEW00318

Parking brake emergency release switch
Parking brake safety switch
Neutralizer relay
Parking brake emergency release relay
Accumulator
Charge valve
Parking brake emergency release valve
Parking brake solenoid valve
Parking brake
10-187
Function
1. Applying and releasing parking brake
The parking brake is applied or released by
using the parking brake switch (combination
switch).
2. Automatic parking brake
When the engine stops (when the starting
switch is OFF), the parking brake is automatically applied to prevent the machine
from running away when the operator is
away from his seat.
6. Parking brake emergency release solenoid

valve
If the supply of pressure oil from the transmission pump should stop because of some
failure, it is possible to actuate the emergency relief solenoid valve with the parking
brake emergency release switch in the operators compartment. This sends the accumulator charge pressure in the brake piping
to the parking brake cylinder to release the
parking brake.
4. Parking brake safety

It is dangerous if the parking brake can be
released simply by turning the starting switch
ON after the automatic parking brake has
been applied. Therefore, to ensure safety,
the system is designed so the brake cannot
be released unless the starting switch is
turned ON and then the parking brake switch
is also turned ON.
5. Neutralizer
The parking brake may seize if the machine
is driven with the parking brake still applied.
To prevent this problem, the caution lamp
lights up and the alarm buzzer sounds to
warn the operator of the mistaken operation. In addition to this, when the parking
brake is applied, the transmission is forcibly
shifted to neutral to make it impossible to
drive the machine. However, the braking distance will become longer if the transmission
is shifted to neutral when the emergency
brake is applied. It may also be necessary to
move the machine if it stops in places where
it is prohibited to stop (such as on railway
crossings). To overcome this, the circuit is
designed so that the transmission is not
shifted to neutral when the emergency brake
is applied.
10-188
U42103
3. Emergency brake
If the pressure in the oil pump should drop
because of damage to the hydraulic circuit
and the braking force can not be ensured,
the parking brake is applied automatically to
act as an emergency brake.
PARKING BRAKE EMERGENCY RELEASE SWITCH
Connection table
Terminal No.
Lever position
OFF
ON
U42103
SEW00319
EMERGENCY BRAKE SWITCH
1
2
1.
2.
3.
4.
5.
6.
7.
8.
Case
Seal film
Disc
Vinyl tape
Tube
Connector
Cover
Spring
7
B
B
1
2
SDW00320
10-189
PARKING SAFETY RELAY

NEUTRALIZER RELAY
Relay actuation table
Terminal No.
Current
between 1 and 2
ON
OFF
q
6
5
1. Case
2. Base
2
Internal connection diagram
SEW00321
10-190
U42103
3
1
OPERATION
1. Starting switch OFF
(manual)
OFF
(Released)
ON
(Applied)
Parking brake
safety relay
Neutralizer relay
1 2 3 5 6
1 2 3 5 6
1 2 3 4 5 6
Battery relay
Battery
Starting switch
B
Alternator
terminal R
U42103
BR
To transmission
directional circuit
To transmission
speed circuit
Parking
brake
solenoid
valve
Emergency brake switch
(installed to accmulator)
SDW00322
When the starting switch is turned OFF, the

battery relay is opened, so electricity does
not flow to the parking brake circuit. For
this reason, if the starting switch is at the
OFF position, no electric current flows to
the parking brake solenoid valve, regardless of whether the parking brake switch is
ON (applied) or OFF (released), so the parking brake is actuated. (Automatic parking
brake)
10-191
2. Starting switch ON
2-1 When parking brake switch is ON (actuated) before starting switch is turned ON

(manual)
OFF
(Released)
ON
(Applied)
Parking brake
safety relay
Neutralizer relay
1 2 3 5 6
1 2 3 5 6
1 2 3 4 5 6
Battery relay
Battery
Starting switch
B
To transmission
directional circuit
Parking
brake
solenoid
valve
To transmission
speed circuit
SDW00323
The electric current flows in circuit 1 from

the battery + starting switch battery
relay coil ground, so the battery relay is
closed. When this happens, electric current
flows in circuit 2 from the battery +
battery relay parking brake switch terminal 1 3 parking brake safety relay terminal 1 2 ground. In this way, the parking safety relay is actuated and safety relay
terminals 3 5 are closed.
When this happens, circuit 3 is formed from
the battery + battery relay parking
safety relay terminal 5 3 parking safety
relay terminal 1 2 ground. From this
point, the parking safety relay is in the condition of circuit 3 until the starting switch is
turned OFF.
10-192
In this condition, electric current does not

flow to the parking brake solenoid valve, so
the parking brake is actuated.
In addition, in this condition, neutralizer relay terminals 3 and 5 are open, so electric
current does not flow to the transmission
directional circuit, and the transmission is
shifted to neutral.
U42103
Alternator
terminal R
BR
2-2 When parking brake switch is OFF (actuated) before starting switch is turned ON

(manual)
OFF
(Released)
ON
(Applied)
Parking brake
safety relay
Neutralizer relay
1 2 3 5 6
1 2 3 5 6
1 2 3 4 5 6
Battery relay
Battery
Starting switch
B
Alternator
terminal R
U42103
BR
To transmission
directional circuit
Parking
brake
solenoid
valve
To transmission
speed circuit
SDW00324
Electric current flows in circuit 1 from the

battery + starting switch battery relay
coil ground, so the battery relay is closed.
However, in this case, the parking brake
switch is OFF (released), so the parking safety
relay is not actuated. For this reason, the
electric current does not flow to the parking
brake solenoid valve, so after the automatic
parking brake is applied, the parking brake
is not released automatically even when the
starting switch is turned ON.
In addition, the electric current does not flow

to the transmission directional circuit, so the
machine does not move.
10-193
3. Parking brake switch OFF (released)

When the parking brake switch is turned from ON to OFF after the starting switch is turned ON

(manual)
OFF
(Released)
ON
(Applied)
Parking brake
safety relay
Neutralizer relay
1 2 3 5 6
1 2 3 5 6
1 2 3 4 5 6
Battery relay
Battery
Starting switch
B
To transmission
directional circuit
To transmission
speed circuit
Parking
brake
solenoid
valve
SDW00325
If the parking brake switch is turned from

ON (actuated) to OFF (released), the circuit
for terminals 2 and 3 of the parking brake
switch is connected, and the parking brake
safety relay is also actuated. For this reason, electric current flows in circuit 1 from
the battery + battery relay parking
brake safety relay parking brake switch,
and then flows to circuits 2 and 3 given
below.
10-194
2 This circuit is formed from the emergency brake switch parking brake solenoid valve ground, and the parking brake
is released.
3 This circuit is formed from the battery +
battery relay neutralizer relay terminal
3 5 transmission directional circuit, so
when the directional lever is operated, the
machine will move.
U42103
Alternator
terminal R
BR
4. Parking brake switch ON (actuated)

(manual)
OFF
(Released)
ON
(Applied)
Parking brake
safety relay
Neutralizer relay
1 2 3 5 6
1 2 3 5 6
1 2 3 4 5 6
Battery relay
Battery
Starting switch
B
Alternator
terminal R
U42103
BR
To transmission
directional circuit
Parking
brake
solenoid
valve
To transmission
speed circuit
SDW00326
If the parking brake switch is turned ON (applied) after carrying out operations with the
parking brake switch OFF (released), the circuit in the diagram above is formed.
Electric current does not flow to the parking
brake solenoid valve, so the oil pressure from
the transmission pump to the parking brake
cylinder is shut off. At the same time, the oil
pressure inside the parking brake cylinder
passes through the parking brake valve and
is drained, so the parking brake is applied
by the force of the spring.
In addition, at the same time, the neutralizer

relay is reset, so the circuit between terminals 3 and 5 is opened, and no electricity
flows to the transmission directional circuit,
so the transmission is shifted to neutral. This
kind of neutralizer relay shuts off the electric current going to the transmission solenoid valve when the parking brake is applied and shifts the transmission to neutral
to prevent seizure of the parking brake if the
operator should drive the machine with the
parking brake still applied.
10-195
5. When main brake oil pressure drops (emergency brake actuated)

(manual)
OFF
(Released)
ON
(Applied)
Parking brake
safety relay
Neutralizer relay
1 2 3 5 6
1 2 3 5 6
1 2 3 4 5 6
Battery relay
Battery
Starting switch
B
To transmission
directional circuit
Parking
brake
solenoid
valve
To transmission
speed circuit
SDW00327
Operation
If the oil pressure in the main brake line
drops, the emergency brake switch installed
to the accumulator is opened.
For this reason, the electric current stops
flowing to the parking brake solenoid valve,
so the oil pressure inside the parking brake
cylinder is drained and the parking brake is
applied. However, in this case, the condition is different from the case where the
parking brake switch is ON (applied), because there is electric current flowing to the
neutralizer relay coil.
10-196
For this reason, electric current flows to the

transmission directional circuit, and it is possible to engage the transmission clutch. In
this way, it is possible to use the engine
brake when the emergency brake is applied,
so the braking distance becomes shorter. At
the same time, if the emergency brake has
been applied and it is necessary to move
the machine (for example, if the emergency
brake is applied when the machine is on a
railway crossing), it is possible to move the
machine by operating the transmission lever.
U42103
Alternator
terminal R
BR
6. Parking brake emergency release
(Released)
ON
Parking brake emergency

release switch
Maintenance monitor
Brake oil
pressure
Buzzer
output
OFF
CNL18
1 2 3 4
Battery relay
Battery
U42103
CNL19
Buzzer
Starting switch
B
BR
Alternator
terminal R
Brake ACC
low pressure switch
Parking brake
emergency release
solenoid valve
SDW00328
Operation
If the machine should stop because of engine trouble, the oil pressure from the transmission pump to the parking brake cylinder
is shut off and the parking brake is applied.
When this happens, the oil pressure in the
main brake line is stored in the accumulator.
When the emergency release switch is turned
on (released), the buzzer sounds, and at the
same time, electric current flows to the emergency parking brake release solenoid valve.
The oil pressure stored in the accumulator

in the main brake line then flows to the
parking brake cylinder to release the parking brake.
The emergency release switch should normally be kept at the OFF position and should
be returned to the OFF position after the
emergency release.
10-197
FUNCTION OF PARKING BRAKE NEUTRALIZER RELAY
Main monitor
Outline
When the parking brake is applied, this relay
keeps the transmission at neutral to prevent
dragging of the parking brake due to mistaken operation.

(Released)
(Applied)
OFF
ON
CNL06
Transmission 1
cut-off 3
switch 16
20A
10A
Transmission
cut-off switch
1 2 3 4 5 6
To battey power source
Starting switch
terminal C
U42103
Transmission
combination
switch
Transmission
combination
switch 1
F
N
R
Transmission
combination
switch 2
CNL15
1 2
5 6 1 2 3 4
5 6 1 2 3 4
5 6 1 2 3 4
CNL68
CNL67
CNL66
Kick-down Kick-down REVERSE FORWARD
switch
relay
relay
relay
6 5 3 2 1
6 5 3 2 1
CNL65
CNL58
Transmission Neutralizer
cut-off relay relay
To parking brake
solenoid valve
6 5 3 2 1
6 5 3 2 1
CNL57
Neutral
relay
CNL59
Parking brake
safety relay
SDW00329
Operation
1. When the parking brake is actuated (ON),
electric current flows from the battery relay
parking brake switch terminal 1 3
parking brake safety relay terminal 1
ground. For this reason, the safety relay coil
is actuated, terminals 3 and 5 of the safety
relay are connected, and this circuit is
formed.
2. When the parking brake is actuated, no electric current flows to the neutralizer relay coil,
so terminal 3 and terminal 5 of the neutralizer relay are separated. No electric current
flows to the transmission directional circuit,
so when the parking brake is applied, the
transmission is kept at neutral.
10-198
3. When the engine is started with the parking

brake switch OFF (released), the circuit in
Item 1 is not formed, so it is necessary to
turn the parking brake switch ON to form
the circuit.
U42103
20
Standard value table for engine ......................... 20- 2

Standard value table for chassis......................... 20- 3
Standard value table for electrical system ........ 20- 6
Tools for testing, adjusting,
and troubleshooting .................................... 20-101
Measuring engine speed.................................... 20-102
Measuring intake air pressure
(boost pressure) ........................................... 20-103
Adjusting valve clearance .................................. 20-104
Measuring exhaust color ................................... 20-105
Measuring exhaust gas temperature ................ 20-106
Measuring blow-by pressure ............................. 20-107
Measuring compression pressure ..................... 20-108
Measuring engine oil pressure ......................... 20-109
Testing and adjusting fuel injection timing ..... 20-110
Method for adjusting engine stop motor
cable .............................................................. 20-112
Testing and adjusting fan belt tension ............ 20-114
Measuring accelerator pedal ............................. 20-115
Measuring operating force, travel of
speed lever ................................................... 20-117
Measuring stall speed ........................................ 20-118
Measuring torque converter, transmission,
parking brake oil pressure .......................... 20-120
Method of operating emergency
manual spool ............................................... 20-122
Measuring clearance between tire and wheel .. 20-124

Testing and adjusting steering wheel .............. 20-125
Testing and adjusting steering control ............ 20-128
Measuring steering oil pressure ....................... 20-129
Measuring operating force, travel of
brake pedal ................................................... 20-131
Measuring brake performance .......................... 20-132
Testing brake oil pressure ................................. 20-133
Measuring brake disc wear ............................... 20-134
Bleeding air from brake system ........................ 20-135
Bleeding air from brake cooling oil line ....... 20-135-1
Measuring parking brake performance ............ 20-136
Manual release method for parking brake ...... 20-137
Testing wear of parking brake disc .................. 20-138
Measuring work equipment control lever ........ 20-139
Measuring work equipment
hydraulic pressure ....................................... 20-141
Measuring work equipment ............................... 20-145
Testing and adjusting fork positioner .............. 20-147
Testing and adjusting lift arm kick-out ............ 20-148
Adjusting main monitor
(speedometer module) ................................ 20-150
Checking for abnormality in
fuel level sensor ........................................... 20-151
TROUBLESHOOTING .......................................... 20-201
When using the standard value table to make judgement for testing and adjusting, and troubleshooting, the
following precautions are necessary.
1.
The standard values in the table are the values for a new machine and are given as reference values for the
time when the machine is shipped from the factory. These values should be used as a guide when estimating
wear and tear after the machine is operated, and when carrying out repairs.
2.
The permissible values given in the table are values estimated based on the results of various tests carried
out on the machines shipped from the factory, so they should be used together with the information on the
repair condition and other information such as the operating history of the machine when judging the
condition of the machine.
3.
These standard values do not form a basis for judging claims.
When
carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the
safety pins and blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-1
w
STANDARD VALUE TABLE FOR ENGINE

Machine model
WA450-3LL
Engine
S6D125-1
Measurement conditions
Unit
High idling
Engine speed
2,400 50
Low idling
rpm
2,200
Max. 6.0
8.0
Max. 1.0
2.0
0.33
0.71
MPa
{kg/cm2}
Min. 3.1
{Min. 32}
2.2
{22}
(Water temperature:
Operating range) mmH2O
Max. 80
160
(SAE30)
0.3 0.5
{3.0 5.0}
0.21
{2.1}
MPa
(SAE30) {kg/cm2}
Min. 0.14
{Min. 1.5}
0.07
{0.7}
At high idling
(SAE10W)
0.25 0.44
{2.5 4.5}
0.18
{1.8}
At low idling
Min. 0.1
{Min. 1.0}
0.07
{0.7}
80 110
120
At sudden acceleration
At high idling
Blowby pressure
(SAE30 oil)
2,400 100
725 50
Exhaust gas color
Compression pressure
(SAE30 oil)
Permissible value
725 25
Rated speed
Valve clearance
(cold)
Standard value
Bosch
index
Intake valve
mm
Exhaust valve
Oil temperature:
40 60C
(engine speed:
200 250 rpm)
At rated output
(Water temperature:
Operating range)
At high idling
Oil pressure
At low idling
(SAE10W)
Oil temperature
Whole speed range

(inside oil pan)
Fuel injection timing
Before top dead cente r
(degree)
24 1
24 1
Belt tension
Deflection when pressed

with finger force of
approx. 58.8 N {6 kg.}
mm
10
7 13
20-2
q
U42103
Item
STANDARD VALUE TABLE FOR CHASSIS
Directional lever
Accelerator pedal
Category
Unit
Standard value
Permissible
value
N
{kg}
68.6 73.6
{7 7.5}
Max. 112.8
{Max. 11.5}
48
30
49.5 5
+0.5
5.9 +5
3 {0.60.3 }
Max. 16.7 {Max.1.7}
+0.5
5.9 +5
3 {0.60.3 }
Max. 16.7 {Max.1.7}
35 10
35 20
35 10
35 20
+0.5
5.9 +5
3 {0.60.3 }
Max. 16.7 {Max.1.7}
+0.5
5.9 +5
3 {0.60.3 }
Max. 16.7 {Max.1.7}
3rd 4th
Max. 10.8 {Max. 1.1}
Max. 16.7 {Max.1.7}
1st 2nd
35 10
35 20
35 10
35 20
35 10
35 20
2,250 100
2,250 200
2,260 100
2,260 200
1,970 200
2.8 0.15
{29 1.5}
2.5 0.15
{25 1.5}
0.44 0.05
{4.5 0.5}
0.34 0.05
{3.5 0.5}
1.0 0.1
{10.0 1.0}
2.3 0.2
{23 2.0}
2.8 0.15
{29 1.5}
2.5 0.15
{25 1.5}
1,970 300
Item
Operating force
1
2
1
Operating angle
2
Stopper height
Operating
force
deg.
TEW00002
N FORWARD
mm
N
{kg}
N REVERSE
N FORWARD
Travel
mm
N REVERSE
Speed lever
Operating
force
Travel
Engine stopped
temperature: 60 80C
2nd 3rd
2nd 3rd
N
{kg}
mm
Engine
3rd 4th
Engine water temperature
gauge: Green range
temperature: 60 80C
Hydraulic oil
temperature: 45 55C
Torque converter stall

Hydraulic stall
Transmission valve
Full stall
Priority
pressure
Rated speed
Torque
converter
outlet port
pressure
Rated speed
rpm
Low idling
Low idling

temperature: 60 80C
Pilot pressure
MPa
{kg/cm2}
Clutch pressure
Parking
brake
pressure
Tire
U42103
1st 2nd
Rated speed
Low idling
Fitting of wheel
lock ring
A
B
Tire inflation pressure:

Specified pressure
Lock ring
B
Clearance of wheel
lock ring
TEW00003
mm
+1.5
2.8 +0.15
0.44 {294.5 }
+1.5
2.5 +0.15
0.39 {254.0 }
+0.5
0.44 +0.05
0.1 {4.51.0 }
+0.5
0.34 +0.05
0.09 {3.50.9 }
+0.1 {10.0 +1.0 }
1.0 0.2
2.0
+2.0
2.3 +0.2
0.39 {234.0 }
+1.5
2.8 +0.15
0.44 {294.5 }
+0.15 {25+1.5 }
2.5 0.39
4.0
Max. 2.5
Max. 4.0
2 10
C
TEW00004
20-3
q
Steering wheel
Category
Unit
Standard value
Permissible
value
Play
Engine stopped, machine

facing straight to front
mm
Max. 20
Max. 50
Operating force
Flat, horizontal, straight,

dry paved road surface
N
{kg}
11.8 19.6
{1.2 2.0}
Max. 34.3
{Max. 3.5}
Max. 3.7
Max. 5.6
Hydraulic oil
temperature: 45 55C
Sec.
Max. 2.5
Max. 3.8
mm
40 5
MPa
{kg/cm2}
+0.5
+5
20.580.4
{2104
}
+10
20.58+1.0
0.6 {210 6 }
N
{kg}
294.2 29.4
{30 3}
Max. 421.7
{Max. 43}
45
15+1
0
5 0.5
Item
Low idling
Operating
time
Steering
valve Frame
High idling
Clearance between front
frame and rear frame
Relief pressure
Operating force
1
Operating angle
Hydraulic oil
temperature: 45 55C
Engine speed: 1200 rpm
Engine speed: High idling
Hydraulic oil
temperature: 45 55C
Engine speed: Low idling
Hydraulic oil
temperature: 45 55C
g
m
0m
15
tin
era
Op int
po
2
3
TEW00005
Performance
Max. 5
Max. 5
Drop in hydraulic pressure
4.9 MPa {50 kg/cm2} in 5 minutes
MPa
{kg/cm2}
Max. 0.5
{Max. 5}
Max. 0.5
{Max. 5}
Disc wear
Piston stroke
mm
1.2 4.7
Max. 6.2
Performance

Specified pressure
Flat paved road
with 1/5 (1120) grade
Dry road surface
Machine at operating condition
Stopped
mm
3.2 0.08
Max. 2.83
Max. 23.5
{Max. 2.4}
Max. 15.7
{Max. 1.6}
Max. 35.3
{Max. 3.6}
Max. 23.5
{Max. 2.4}
Max. 24.5
{Max. 2.5}
Max. 37.3
{Max. 3.8}
Max. 34.3
{Max. 3.5}
Max. 14.7
{Max. 1.5}
Max. 60.0
{Max. 5.3}
Max. 22.6
{Max. 2.3}
Disc thickness
HOLD RAISE
RAISE HOLD
HOLD LOWER
LIift
arm
LOWER HOLD
LOWER FLOAT
FLOAT HOLD
20-4
q
1 deg.
Flat, horizontal, straight, dry

paved road surface
Speed when applying brake:
20 km/h, braking delay: 0.1 sec.
Brake pedal operating force:
Specified operating force
Specified pressure
Operating force
Work equipment control

lever
Parking brake
Brakes
Play
3 2

Hydraulic oil
temperature: 45 55C
N
{kg}
U42103
Proximity
switch
Standard value
Permissible
value
Max. 23.5
{Max. 2.4}
Max. 35.3
{Max. 3.6}
Max. 23.5
{Max. 2.4}
Max. 14.7
{Max. 1.5}
Max. 35.3
{Max. 3.6}
Max. 22.6
{Max. 2.3}
67 15
67 30
53 15
53 30
67 15
67 30
HOLD DUMP
60 15
60 30
HOLD TILT
60 15
60 30
Operating
force
Item
Travel
Unit
HOLD DUMP
Fork
N
{kg}
HOLD TILT
TILT HOLD
HOLD RAISE
Lift
arm
HOLD LOWER

Hydraulic oil
temperature: 45 55C
HOLD FLOAT
mm
Fork
Relief pressure
Relief pressure
Hydraulic drift Work equipment speed
Lift arm, fork
U42103
PPC Main
valve control valve
Work equipment control lever
Category
Hydraulic oil
temperature: 45 55C
Hydraulic oil
temperature: 45 55C
+1.0
+10
MPa
{kg/cm2} 20.58 0.3 {210 3 }
MPa
{kg/cm2}
Lift arm lifting time

Lift arm lowering time
Fork dumping time
Fork
tilting
time
At full stroke
Hydraulic oil
temperature: 45 55C
Steering valve: Neutral
No load
Sec.
Fork horizontal
Retraction of lift arm

cylinder rod
Retraction of fork
cylinder rod
Clearance of fork
positioner switch
Clearance of lift arm
kick-out switch
Hydraulic oil
temperature: 45 55C
Leave for 5 minutes after
stopping engine then
mm
measure for next 15 minutes
Fork empty, lift arm, fork
horizontal
Hydraulic oil
temperature: 45 55C
+0.2
3.7 0
{38
+2
0}
+1.0
+10
20.58 1.3 {210 13 }

+0.4
+4
3.70.2 {382 }
5.5 0.3
Max. 7.0
3.7 0.3
Max. 5.1
1.4 0.3
Max. 2.1
1.9 0.3
Max. 2.7
1.2 0.3
Max. 1.8
Max. 30
Max. 36
Max. 20
Max. 24
37
37
mm
20-5
q
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Measurement
conditions
Short connector
If the condition is as shown in the table

below, the sensor is defective.
Check continuity
Judgment table

below, the sensor is normal.
Connect to
chassis ground


Short connector
connected
CN R06
disconnected
Turn starting
switch ON.
Monitor goes off

Monitor lights up
CN R06
Oil level,
water level normal
Oil level,
water level abnormal
Chassis ground
connected
CN E10
disconnected
Turn starting
switch OFF.
Continuity
No continuity
Turn starting
switch ON.
Monitor goes off

Monitor lights up
Engine water
temperature sensor
CN E06
Fuel level sensor
Alternator
20-6
q
CN R07
Measure
resistance
CN T07
Measure
voltage

temperature sensor
Measure
resistance
Engine oil level sensor CN E10
Engine oil level

normal
Engine oil level
abnormal
Turn starting
switch OFF.
Continuity
No continuity

Turn starting
switch OFF.
Normal temperature Approx. 38 48 k

(25C)
100C
Approx. 3.6 3.9 k

Turn starting
switch OFF.
+1
Full
Approx. 10 3
Empty
Approx. 85 95 k
When engine is running

Start engine
(half throttle or above) 27.5 29.5 V
If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
U42103
Radiator water level

sensor
Connector Inspection
No.
method
Check continuity
Name of component
Brake ACC
Low pressure switch
Emergency brake
switch
CN B08
CN B13
CN B09
CN B10
Connect to
chassis ground
CN T08
U42103
Judgment table
Short connector Check continuity Short connector Check continuity Short connector Check continuity
Engine oil pressure

sensor
No.
method

Check continuity
Name of component

Measurement
conditions
Turn starting
switch ON.
Terminal wiring
Monitor goes off
harness disconnected
Connected to
Monitor lights up
chassis ground
Oil pressure above

70 KPa {0.7 kg/cm2}
Oil pressure below
30 KPa {0.3 kg/cm2}
No continuity
Continuity

Short connector
connected
CN T08
disconnected
Start engine.
Turn starting
switch ON.
Monitor goes off

Monitor lights up

Turn starting
switch OFF.
Oil pressure above

Continuity
0.6 MPa {6.1 kg/cm2}
Oil pressure below
0.34 MPa {3.5 kg/cm2} No continuity
Short connector
connected
CN B08, CN B13
disconnected
Monitor goes off

Monitor lights up

Oil
5.9
Oil
3.9
pressure above
MPa {60 kg/cm2}
pressure below
MPa {40 kg/cm2}
Oil
4.3
Oil
3.1
pressure above
MPa {45 kg/cm2}
pressure below
MPa {32 kg/cm2}
Turn starting
switch OFF.
Continuity
No continuity

Short connector
connected
CN B09, CN B10
disconnected
Turn starting
switch ON.
Turn starting
switch ON.
Monitor goes off

Monitor lights up
Turn starting
switch OFF.
Continuity
No continuity
20-7
q
Name of
component
CNE 05
(male)
Speed sensor
CNT06
(male)
Judgment table
Measurement
conditions
When engine is running

(half throttle or above) 27.5 29.5 V
If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
1) Start engine.

below, it is normal.
1) Turn starting
switch OFF.
2) Disconnect
CNE05.
Normal temApprox. 2 k
perature (25C) Between CNE05
(male) GND
5C
Approx. 4 k
below, it is normal.
Between (1) (2)
500 1000
1) Turn starting
switch OFF.
2) Disconnect
CNE06.
U42103
Engine water
temperature sensor
Measure
resistance
Between
alternator
terminal R
and chassis
Measure
resistance
Main monitor
Alternator
No.
method
Measure
voltage
System
20-8
q
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Check or measurement item Symbol
Engine speed
Oil pressure
Part Name
Remarks
Digital display
L: 60 2,000 rpm
H: 60 19,999 rpm
Pressure gauge
2.45, 5.88, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge
49.0 MPa {500 kg/cm2}
7992039000
Multi-tachometer
7991015002
Analog hydraulic tester
7902611203
Digital hydraulic tester
7994012320
Hydraulic gauge
1.0 MPa {10 kg/cm2}

0.15 MPa {1,500 mmAq}
Intake air pressure
7994012310
Pressure gauge
Valve clearance
Commercially
available
Feeler gauge
7992019000
Handy smoke checker
Commercially
available
Smoke meter
7991011502
Digital temperature gauge
7992011511
Tool
7992011541
Gauge
Kit Part No.
7992011571
Tube
7992011504
7992011450
Adapter
7955021590
Compression gauge
7955021360
Adapter
79A2640090
Push-pull scale
0 6.9 MPa {0 70 kg/cm2}

Kit Part No. 7955021205
79A2640020
Push-pull scale
0 490 N {0 50 kg}
Scale
0 294 N {0 30 kg}
Exhaust color
Coolant, oil, and exhaust

temperatures
U42103
Part No.
Blowby pressure
Compression pressure
Operating force
Stroke, hydraulic drift
Work equipment speed
Troubleshooting of wiring
harnesses and sensors
Measuring voltage and
resistance values
Adjusting fuel injection
timing
Clearance
Wear of parking brake
Brake oil pressure

Lift arm drop prevention
tool
Commercially
available
Commercially
available
Discoloration 0 70% (with

standard color)
(Discoloration % x 1/10 = Bosch
index)
99.9 1,299C
Stop watch
Gauge assy
7996018000
Commercially
available
T-adapter
795-471-1200
Gauge Assy
Commercially
available
Commercially
available
Calipers
7935201803
Brake test kit
1702111190
Nipple
7934631100
Stopper
Q
R
Feeler gauge
20-101
q
MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

When
removing or installing the measuring

equipment, be careful not to touch any high
temperature parts.
Measure the engine speed under the following

conditions.
1) Coolant temperature: Within operating range
2) Power train oil temperature : 70 90C
3) Hydraulic oil temperature : 45 55C
TEW00010
TEW00011
2. Connect tachometer A and the adapter with the

cable.
When
carrying out the measurement, be

careful not to touch any high temperature
parts or rotating parts.
3. Start the engine, and measure the engine speed

when the engine is at low idling and high idling.
When measuring items other than the above
(during torque converter stall), see Mthe procedure for each item.
20-102
q
TEW00012
U42103
1. Remove cap (1) from speed pick-up port, then

install adapter 1 of tachometer A.
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR

PRESSURE (BOOST PRESSURE)
1
When
removing or installing the measuring

equipment, be careful not to touch any high
temperature parts.
1. Remove intake air pressure measurement plug

(1) (PT 1/8) and install coupler (2) of oil pressure
gauge kit B.
TEW00013
U42103
TEW00014
2. Connect oil pressure measurement hose (3) to

coupler (2) and pressure gauge C (0.15 MPa {1500
mmAq}).
When
carrying out the measurement, be

Note:
Run the engine at a mid-range speed or above,
and use the self-seal portion of the gauge to
bleed the oil from inside the hose.
Insert the gauge about half way, and repeatedly open the self-seal portion to bleed the
oil.
TEW00015
The gauge does not work if there is any oil

inside the hose, so always be sure to bleed
all the oil.
3. Run the engine at the rated speed and measure
the pressure indicated by the gauge.
20-103
q
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1
When adjusting the valve clearance, use the following procedure to adjust the clearance between the valve and rocker lever to the value.
1. Remove cylinder head cover (1).
2. Rotate the crankshaft in the normal direction to
align the TOP 1.6 line on the crankshaft pulley
with pointer (2) when No. 1 cylinder is at top
dead center. When rotating, check the movement of the valves.
TEW00016
3. When No. 1 cylinder is at compression top dead

center, adjust the valves marked ; when No. 6
cylinder is at compression top dead center, adjust the valves marked .
Valve arrangement
Intake valve
Exhaust valve
4. To adjust the valve clearance, loosen locknut

(6), then insert feeler gauge D between rocker
lever (3) and crosshead (4), and turn adjustment
screw (5) until the clearance is a sliding fit.
Then tighten locknut (6) to hold the adjustment
screw in position.
3 Locknut : 66.7 7.9 Nm {6.8 0.8 kgm}
5. Next, rotate the crankshaft one turn (360) in the
normal direction and adjust the valve clearance
of the remaining valves marked .
After adjusting No. 1 cylinder at compression top dead center, it is also possible to
turn the crankshaft 120 each time and adjust the valve clearance of each cylinder according to the firing order.
Firing order : 1 5 3 6 2 4
After tightening the locknut, check the valve
clearance again.
TEW00017
TEW00018
TEW00019
20-104
q
U42103
Cylinder No.
MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

When measuring in the field when there is no
air or power supply, use smoker the checker;
when recording official data, use the smoke
meter.
Measuring with handy smoke checker E1
When measuring the exhaust gas color, be care-
E1
ful not to touch the exhaust pipe or any other

high temperature part.
Warm up the engine (oil temperature: 60C) before measuring the exhaust gas color.
1) Fit filter paper in tool E1.
2) Insert the exhaust gas intake port into the
exhaust pipe, accelerate the engine suddenly,
and at the same time operate the handle to
catch the exhaust gas on the filter paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
TEW00020
SMOKE SCALE
U42103
Measuring with smoke meter E2
When measuring the exhaust gas color, be careful not to touch the exhaust pipe or any other
high temperature part.
Warm up the engine (oil temperature: 60C) before measuring the exhaust gas color.
1) Insert the probe into the outlet port of the
exhaust pipe, then tighten the clip to secure
it to the exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to tool E2.
The pressure of the air supply should be
less than 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC100V outlet.
When connecting the cord, check first
that the power switch is OFF.
4) Loosen the cap nut of the suction pump,
then fit the filter paper.
Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal and
operate the relief valve to catch the exhaust
gas color on the filter paper.
7) Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (10 sheets or more) inside the filter paper holder, and read the indicated value.
TEW00021
E2
TEW00022
20-105
q
MEASURING EXHAUST GAS TEMPERATURE
MEASURING EXHAUST GAS

TEMPERATURE
The
temperature sensor is installed to the exhaust manifold, so if the machine has been operated, wait for the manifold to cool down before installing the sensor.
Raise the coolant temperature to the operating

range before measuring.
1. Remove plug (1) from the exhaust manifold, then

install temperature sensor (2).
Temperature sensor : 6215-11-8180 (cable
length: 610 mm), or 6215-11-8170 (cable
length: 490 mm)
TEW00023
Measurement procedure
1) Measuring at torque converter stall
If the exhaust gas temperature is measured
only at torque converter stall, and this is
continued until the sensor core heats up and
a stable value is obtained, the torque converter will overheat.
(i) Use the full stall (torque converter stall +
hydraulic relief) to raise the exhaust gas temperature (see standard value).
(ii) From the above condition, cancel the hydraulic relief, and carry out only torque converter stall.
(The temperature will start to go down. If it
does not go down and continues to go up,
make the temperature setting at (i) higher.)
(iii) When the temperature starts to go down,
record the stable temperature.
2) When measuring maximum value for exhaust gas temperature
Carry out actual work and measure the maximum value when operating.
Use the PEAK mode function (the maximum value can be recorded) of the temperature gauge.
TEW00024
PT1/8
(male)
X type connector (2-pin) Temperature sensor

(female)
F2
TEW00025
F1
TEW00026
20-106
q
U42103
2. Connect to digital temperature gauge F1 with

wiring harness F2.
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
Raise the coolant temperature to the operating
range before measuring the blow-by pressure.
1. Install tools G4 and G1 to the tip of engine

breather hose (1), then connect tools G2 and G3.
2. Run the engine at the rated output and measure
the blow-by pressure.
When
U42103
measuring the blow-by pressure, be

The blow-by should be measured with the

engine running at rated output.
When measuring in the field, a similar value
can be obtained at stall speed.
If it is impossible to check at rated output or
stall speed, measure at high idling. In this
case, the blow-by value will be about 80% of
the value at rated output.
Blow-by varies greatly according to the condition of the engine. Therefore, if the blowby value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defective exhaust gas color, and prematurely dirty
or deteriorated oil.
TEW00027
G2
1
G4
G3
G1
TEW00029
20-107
q
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
1
When measuring the compression pressure, be

careful not to touch the exhaust manifold or
muffler, or to get your clothes caught in the fan,
fan belt or other rotating parts.
Warm up the engine (oil temperature: 40 60C)
before measuring the compression pressure.
1. Adjust the valve clearance.
For details, see ADJUSTING VALVE CLEARANCE.
2. Remove spill tube (1) and disconnect fuel injection pipe (2).
TEW00030
4. Install adapter H2 in the mount of the nozzle

holder of the cylinder to be measured, and
tighten to the specified torque.
3 Torque : 21.6 2.9 Nm {2.2 0.3 kgm}
TEW00031
5. Connect compression gauge H1 to adapter H2.

6. Disconnect connector (5) of stop motor (4), set
to the NO INJECTION position, then crank the
engine with the starting motor and measure the
compression pressure at the point where the
pressure gauge indicator remains steady.
If the fuel control lever is not set to the NO
INJECTION position, fuel will spurt out.
If the adapter mount is coated with a small
amount of oil, it will reduce leakage.
For details of the standard value for the compression pressure, see STANDARD VALUE
TABLE FOR ENGINE.
If the measurement is carried out with the
manual emergency stop cable disconnected,
an error message will light up on the monitor panel, so delete the error message after
measuring.
H1
H2
TEW00032
TEW00033
20-108
q
U42103
3. Remove nozzle holder assembly (3) from each

cylinder to be measured.
When removing nozzle holder assembly (3),
assemble bolt 1 to the spill tube mount and
twist with bar 2 to remove.
Be careful not to let dirt or dust get in.
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
1
When
measuring, be careful not to let your

clothes get caught in any rotating part.
Always stop the engine before removing or installing any oil pressure sensor or oil pressure
gauge.
When measuring the oil pressure, always measure at the specified oil temperature.
1) Remove oil pressure sensor (1).
2) Install tool B (gauge: 1.0 MPa {10 kg/cm2}).
3) Start the engine, and measure the oil pressure.
TEW00034
U42103
TEW00035
20-109
q
TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
The following methods can be used for testing and
adjusting the fuel injection timing of the injection
pump.
Match mark alignment method
This method is used when assembling the injection pump to the original engine without making any repairs.
Delivery valve method
This method is used when assembling and injection pump that has been repaired or replaced.
Set the No. 1 cylinder to the compression top
dead center position before carrying out testing
and adjusting.
For details, see ADJUSTING VALVE CLEARANCE.
2. Rotate the crankshaft slowly in the normal direction to align pointer (2) with the injection
timing line on crankshaft damper (1).
TEW00036
3. Check that line a on the injection pump and line

b on the coupling are aligned.
If the lines are not aligned, loosen nut (3),
move the coupling to align the lines, then
tighten the nut.
3 Nut: 60.8 2 Nm {6.2 0.2 kgm}
TEW00037
Testing and adjusting using delivery valve method

1. Disconnect fuel injection pipe (4) of No. 1 cylinder.
2. Remove delivery valve holder (5).
TEW00038
20-110
q
U42103
Testing and adjusting using match mark alignment

method
1. Rotate the crankshaft 30 40 in the reverse
direction from the No. 1 cylinder TOP position.
TESTING AND ADJUSTING FUEL INJECTION TIMING
3. Take out delivery valve stopper spring (6) and

delivery valve (7) from the delivery valve holder,
then install the delivery valve holder again.
4. Place the fuel control lever at the FULL position,

then rotate the crankshaft in the normal direction while operating the priming pump, and stop
at the point where the fuel stops flowing from
the delivery valve holder.
5. Check that the pointer and the injection timing

line on the crankshaft damper are aligned at the
point where the fuel stops flowing.
Beyond injection timing line: Injection timing is retarded
Before injection timing line: Injection timing
is advanced
TEW00039
If the check shows that the injection timing is

not correct, adjust the fuel injection timing as
follows.
U42103
After testing and adjusting, do not forget to assemble the spring and delivery valve again.
1) Rotate the crankshaft 30 40 in the reverse
direction from the No. 1 cylinder TOP position.
2) Rotate the crankshaft slowly in the normal
direction to align pointer (2) with the injection timing line on crankshaft damper (1).
TEW00036
3) Loosen nut (3) in the oblong hole of the

injection pump mounting flange, then rotate
the flange at the pump end a little at a time
while operating the priming pump, and stop
at the point where the fuel stops flowing
from the delivery valve holder.
TEW00037
4) Tighten the nut in the oblong hole of the

injection pump mount flange.
Check the injection timing again to confirm that the injection timing is correctly
adjusted.
3 Nut: 60.8 2 Nm {6.2 0.2 kgm}
5) Align match mark a with match mark b and
cut a line.
20-111
q
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
METHOD FOR ADJUSTING

ENGINE STOP MOTOR CABLE
1
TEW00043
2. Pull stop lever (4) of the injection pump by hand

to the engine stop position (no injection of fuel),
and temporarily assemble the cable to the
bracket.
When this is done, secure the cable at a point
where stop lever (4) contacts engine STOP stopper (5), and temporarily assemble to the bracket
with locknut (6).
Engine stop motor (1) is at the engine STOP
position with cable (2) pulled.
Stop lever (4) of the fuel injection pump is at
the RUN position when the lever is free (it is
pulled by a spring to the RUN side).
U42103
1. Temporarily install ball joint (3) to cable (2) of

engine stop motor (1) (screw in fully, then turn
back approx. 1/2 turns), then install the ball joint
to the stop lever of the injection pump.
3
6
Bracket
TEW00044
3. Adjust stop lever (4) of the injection pump and

STOP stopper (5) at the stop end so that clearance a is 1 2 mm.
Adjust with nut (6) which secures the cable to
the bracket or carry out fine adjustment by
changing the depth that ball joint (3) is screwed
in.
a
5
20-112
q
4
TEW00045
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
4. Tighten all nuts and bolts.

5. Turn the engine starting switch repeatedly
to the ON and OFF positions, and check that
the engine stop motor and cable work
smoothly, then carry out the following checks
again.
1) Check visually that there is slack in the
engine stop motor cable when the engine is running, and that the stop lever
of the fuel injection pump has returned
fully to the RUN position.
Problems caused by improper adjustment

of engine stop motor cable
When engine stop mo- Engine does not
tor cable is pulled and stop
clearance between stop
lever and STOP stopper
is too large
When cable is free and Engine does not
clearance between stop give full output belever and RUN stopper cause of drop in
is too large
amount of fuel injected
2) Check that the clearance between the

stop lever and stopper at the STOP end
is 1 2 mm when the engine is stopped.
U42103
With the engine stop motor, there are

built-in limit switches at both ends of
the cable stroke.
Engine stop motor stroke: 35 mm
Fuel injection pump stop lever stroke:
30 mm
When the engine is running, there is slack
in the engine stop motor cable, and the
RUN position is maintained by the action of a spring (this is frequently built
into the fuel injection pump).
There is a loose spring inside the engine
stop motor, and this absorbs the error in
the stop motor when the engine is
stopped.
However, if this is absorbed by the loose
spring in the engine stop motor, force is
brought to bear on the injection pump,
so depending on the machine model, this
system may not be possible to use.
With such models, there is a danger of
problems arising with the injection pump
if the clearance between the stop lever
and the stopper at the STOP end is set
to 0 when the engine is stopped.
20-113
q
TESTING AND ADJUSTING FAN BELT TENSION

FAN BELT TENSION
Approx. 10mm
1. Testing fan belt tension

Measure the deflection of the belt when it is
pushed with a finger force (approx. 58.8 N {6
kg}) at point a midway between the fan pulley
and the alternator pulley.
Deflection of V-belt: Approx. 10 mm
Fan pulley
a
Alternator
pulley
TEW00046
2. Adjusting belt
1) Loosen alternator mount bolt (1) and adjust
plate mounting bolt (2).
2) Loosen the locknut, then tighten adjustment
nut (3) to adjust the tension of the belt.
3) After adjusting the belt tension to the standard value, tighten the locknut, then tighten
adjust plate mounting bolt (2) and alternator
mount bolt (1).
TEW00047
20-114
q
U42103
MEASURING ACCELERATOR PEDAL
0m
MEASURING ACCELERATOR
PEDAL
15
Engine water temperature: Within green range
on engine water temperature gauge
OPERATING FORCE OF ACCELERATOR PEDAL
Top surface of floor
Measuring
1. Set push-pull scale I2 at a position 150 mm from
pedal fulcrum a.
Put the center of push-pull scale I2 in contact
with a point 150 mm from the pedal fulcrum.
TEW00048
U42103
2. Start the engine, then measure the maximum

value when the pedal is moved from the pushed
position (low idling) to the end of its travel (high
idling).
Testing and adjusting

1. Stop the engine.
2. Remove cable (1) at the bottom of the accelerator pedal, and check that there is no stiffness in
plate (2) or any other part under the pedal.
3. Connect cable (1) at the bottom of the pedal,

disconnect it again at the injection pump connection, and check that there is no stiffness in
rod (3) or ball joint (4).
Carry out the above inspection, and adjust
or replace parts if necessary. Then carry out
the measurement of the operating force
again to check that it is within the standard
value.
TEW00050
3
4
TEW00051
20-115
q
OPERATING ANGLE OF ACCELERATOR PEDAL
MEASURING ACCELERATOR PEDAL
1. Measuring
1) Stop the engine.
2) Put angle gauge 1 in contact with the accelerator pedal, and measure operating angle
( = 1 2) when the pedal is operated
from low idling position 1 to high idling
position 2.
2
L
Top surface of floor
TEW00052
2. Adjusting
1) Remove the cover at the bottom of the cab,
and open the inspection cover of the engine
hood.
U42103
2) Loosen nut (1), and adjust bolt (2) so that

installed height L of the accelerator pedal
stopper is within a range of 49.5 5 mm.
3) Loosen locknut (3) and adjust the length of
the cable so that the injection pump governor lever contacts the high idling stopper
when the accelerator pedal is depressed
(high idling).
Check that the injection pump governor
contacts the low idling stopper when the
accelerator pedal is let back to the low
idling position.
Adjust the travel of the governor lever
with joint (4).
3 Cable joint nut: 13.7 1 Nm
{1.4 0.1 kgm}
After carrying out the above adjustment,
measure each part again and check that
it is within the standard value.
TEW00054
3
4
TEW00055
20-116
q
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
MEASURING OPERATING
FORCE, TRAVEL OF SPEED
LEVER
Engine stopped
Torque converter oil temperature: 60 80C
OPERATING FORCE OF SPEED LEVER

Install push-pull scale I2 or a spring balance to
the center of the control lever knob, and measure the operating force when the lever is pulled
in the direction of operation.
Carry out the measurement for each speed
range.
U42103
TRAVEL OF SPEED LEVER
Make mark (1) at the center of the control lever

knob, and measure the travel when the lever is
operated in the direction of operation.
20-117
q
MEASURING STALL SPEED


Hydraulic oil temperature: 45 55C
Check that low idling and high idling are the

standard values.
Before measuring each stall speed, install multitachometer A to speed pickup port (1) on the
engine block.
Check that the engine speed is the standard
value. If it is not within the standard range,
check for loose linkage or play.
TEW00069
Apply
TEW00070
TORQUE CONVERTER STALL SPEED

1. Start the engine and run at low idling.
2. Release the parking brake.
3. Place the speed lever at the highest position for
FORWARD or REVERSE.
4. Use the brakes to stop the machine, then use
multitachometer A to measure the speed when
the engine is run at high idling.
Turn transmission cut-off selector switch (2)
OFF and use the left brake.
(Check that the pilot lamp goes out.)
Do not keep the stall condition for more than
20 seconds. Make sure that the torque converter oil temperature does not exceed 120C.
20-118
q
U42103
the parking brake and put blocks under

the tires.
HYDRAULIC STALL SPEED

1. Start the engine and run at high idling.
2. Operate the lever to the DUMP or LIFT position
to operate the cylinder to the end of its stroke
and actuate the relief valve in the main control
valve.
3. Use multi-tachometer A to measure the engine
Do not keep the stall condition for more than
20 seconds. Operate the control lever quickly.
FULL STALL SPEED

Measure the engine speed when the torque converter stall and hydraulic stall are both carried
out at the same time.
Before measuring the full stall, check that
the torque converter stall and hydraulic stall
speeds are normal.
If either of the stall speeds are abnormal,
correct the problem and measure again.
U42103
TEW00075
20-119
q
MEASURING TORQUE CONVERTER, TRANSMISSION,

PARKING BRAKE OIL PRESSURE
MEASURING TORQUE
CONVERTER, TRANSMISSION,
PARKING BRAKE OIL
PRESSURE

Apply

the tires.
TEW00076
Preparatory work
U42103
The following preparatory work is necessary

when measuring all oil pressures.
Remove cover (1) on the left side of the rear
frame.
Turn transmission cut-off selector switch (2)
OFF and use the left brake.
(Check that the pilot lamp is OFF.)
Remove the plug from the measurement port
of the transmission valve.
Install hydraulic tester kit B to the measurement port, extend the gauge to the operators compartment, then start the engine and
measure the pressure.
Check that no oil is leaking from any connection.
Measurement method
1. Priority pressure
1) Measurement port (P1, PT 1/8)
2) Start the engine, run at low idling, and measure the pressure at the rated speed.
2. Torque converter outlet port pressure
2) Start the engine, run at low idling, and measure the pressure at the rated speed.
Hydraulic tester kit

TEW00078
P4
P1,P5
20-120
q
P3
P2
TEW00080
MEASURING TORQUE CONVERTER, TRANSMISSION,

PARKING BRAKE OIL PRESSURE
3. Pilot pressure
2) Start the engine and measure the pressure.
4. Clutch pressure
2) Start the engine.
3) Release the parking brake.
4) Place the directional lever at neutral, and
measure the pressure when the speed lever
is operated.
U42103
5. Parking brake pressure

2) Start the engine, and measure the pressure
when the parking brake is released.
20-121
q
METHOD OF OPERATING EMERGENCY MANUAL SPOOL
METHOD OF OPERATING
EMERGENCY MANUAL SPOOL
Outline
The transmission valve is controlled electrically, but
if there should be any failure in the electrical system, or if there is any failure in the solenoid valve
or spool and the machine cannot move, it is possible to operate the emergency manual spool to move
the machine.
This operation of the spool is designed only for

use if the machine cannot be moved because of
a failure in the transmission control, and it is
necessary to move the machine from a dangerous working area to a safe place where repairs
can be carried out.
This spool must not be operated except when
there has been a failure.
carrying out this operation, keep strictly
to the order of operation and pay careful attention to safety when moving the machine.
To prevent the machine from moving, lower the

bucket to the ground, apply the parking brake,
and put blocks under the tires.
Always
TEW00076
stop the engine before operating the
spool.
1. Remove cover (1) from the left side of the rear

frame.
2. Remove lock plate (3) from emergency manual
spool (2) of the transmission valve.
The lock plate can be removed simply by
loosening the mounting bolts.
3. Operate emergency spool (2) to the operating
position according to the direction of movement
of the machine (forward or reverse).
REVERSE: Push in the spool until it enters
the detent. (Approx. 8 mm)
FORWARD: Pull the spool until it enters the
detent. (Approx. 8 mm)
TEW00082
3
RNF
88
4. Check that the area around the machine is safe,

then remove the blocks from under the tires.
5. Sit in the operators seat and depress the left
brake pedal fully.
TEW00083
20-122
q
U42103
When
METHOD OF OPERATING EMERGENCY MANUAL SPOOL
6. Start the engine, then release the parking brake

and slowly let the brake pedal out to start the
machine.
When the engine is started, the transmission is

also engaged and the machine will start, so always check carefully that the area around the
machine and in the direction of travel is safe,
and keep the brake pedal depressed fully when
starting the engine.
7. After moving the machine, stop the engine, then
apply the parking brake and put blocks under
the tires.
U42103
8. Return the manual spool to the neutral position

and install the lock plate.
20-123
q
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL
MEASURING CLEARANCE
BETWEEN TIRE AND WHEEL
a
Lock ring
Tire inflation pressure: Specified pressure
Method of measuring
b
1. Fitting of wheel lock ring

Using feeler gauge O, measure dimensions a
and b at four places around the circumference.
TEW00084
2. Clearance of wheel lock ring

Measure dimension c.
TEW00085
20-124
q
U42103
TESTING AND ADJUSTING STEERING WHEEL

STEERING WHEEL
Marks
MEASURING PLAY OF STEERING WHEEL

Engine speed: Stopped

Machine posture: Facing straight forward
Method of measurement
1. Move the steering wheel 2 or 3 times lightly to
the left and right, check that the steering mechanism is at the neutral position, then make a
mark on the outside frame of the machine monitor.
TEW00086
U42103
2. Turn the steering wheel to the right, and make a

mark at the position where the operating force
starts to become heavy (when the steering valve
lever starts to move).
3. Turn the steering wheel to the left in the opposite direction from Step 2, and make a mark at
the point where the operating force becomes
heavy (when the steering valve lever starts to
move). Then measure the distance in a straight
line between the marks made in Step 2 and
Step 3.
TDW00087
20-125
q
MEASURING OPERATING FORCE OF STEERING WHEEL

Road surface: Flat, horizontal, dry paved surface

Engine speed: Low idling (fork empty)
Measurement method
1. Install push-pull scale I2 to the steering wheel
knob.
3. Pull push-pull scale I2 in the tangential direction

and measure the value when the steering wheel
moves smoothly.
Avoid measuring when the steering wheel
starts to move.
20-126
q
U42103
2. Start the engine.

After starting the engine, raise the fork
approx. 400 mm and remove the safety bar.
MEASURING OPERATING TIME FOR STEERING

WHEEL

Engine speed: Low and high idling
Measurement method
After starting the engine, raise the fork
approx. 400 mm and remove the safety bar.
U42103
2. Operate the steering wheel to the end of its

stroke to turn the machine to the left or right.
3. Measure the time taken to operate the steering
wheel to the end of the stroke to the right (left).
Operate the steering wheel as quickly as possible without using force.
Carry out the measurements both at low
idling and high idling, and to both the left
and right.
20-127
q
TESTING AND ADJUSTING STEERING CONTROL

STEERING CONTROL
Engine speed: 1,200 rpm
Tire inflation pressure: Standard pressure
Testing
1. Start the engine and operate the steering to set
the front and rear frames straight.
2. Check the looseness of locknut (2) of stopper
bolt (1).
3
1
TKW00897
U42103
3. Start the engine and measure clearance between

the front frame and rear frame stopper when
the steering wheel is turned fully to the left and
right.
When measuring the clearance, check that
the end face of the spool of stop valve (3) is
in contact with the head of the stopper bolt.
Adjusting
1. Adjust the stopper bolt.
1) Screw in stopper bolt (1) to make it the minimum length.
2) Run the engine at low idling and operate the
steering slowly to contact the frame stopper.
3) Turn the stopper bolt until the head of stopper bolt (1) contacts the end face of the spool
of stop valve (3).
4) Set the machine facing straight, and stop
the engine.
5) Loosen stopper bolt (1) 8.5 turns, then lock
it in position with locknut (2).
6) Carry out steps 1) 5) for both the left and
right sides.
2. Start the engine and measure clearance a between the front frame and rear frame stopper
when the steering wheel is turned fully to the
left and right.
When measuring the clearance, check that
the end face of the spool of stop valve (3) is
in contact with the head of the stopper bolt.
20-128
q
a (40 5 mm)
TKW00898
MEASURING STEERING OIL PRESSURE
MEASURING STEERING OIL

PRESSURE
Hydraulic oil: 45 55C

METHOD OF MEASURING MAIN RELIEF PRESSURE
Loosen the oil filler cap to release the pressure
TEW00104
inside the hydraulic tank, then turn the steering

wheel several times to release the remaining
pressure inside the piping.
1. Apply safety bar (1) to the frame.
2. Remove measurement plug (2) for the right turn

steering circuit.
U42103
3. Install hydraulic tester kit B to the measurement

port.
4. Start the engine, run the engine at high idling,
then turn the steering wheel to the right and
measure the pressure when the relief valve is
actuated.
To measure the pressure when turning the
steering wheel to the left, remove the plug
for the left turn steering circuit.
TEW00105
TEW00106
20-129
q
MEASURING STEERING OIL PRESSURE
Adjusting
Always
stop the engine before adjusting the

pressure.
1. Stop the engine.

2. Loosen locknut (3) of steering relief valve in
steering valve then turn adjustment screw (4) to
adjust.
TEW00108
U42103
Pressure adjustment for one turn of adjustment screw: Approx. 14.8 MPa {151 kg/cm2}
Turn the adjustment screw to adjust the set
pressure as follows.
Do not carry out any adjustment if the relief
pressure cannot be measured accurately.
20-130
q
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
MEASURING OPERATING
FORCE, TRAVEL OF BRAKE
PEDAL

Operating force of pedal

1. Install push gauge 1 to the operators foot.
Align the center of the push gauge with the
center of the pedal.
2. Start the engine, run at low idling, and measure
the operating force when the pedal is depressed.
U42103
Travel of pedal
1. Install push gauge 1 to the operators foot.
Align the center of the push gauge with the
center of the pedal.
2. Start the engine, and measure pedal angle 1
when running at low idling, and pedal angel 2
when the pedal is depressed with a force of 294 N
{30 kg}.
Install angle gauge 2 to the brake pedal
when measuring.
Pedal play
2. Push the brake pedal lightly by hand, and measure pedal angle 3 when the pedal starts to become heavy.
0m
15
tin
era
Op int
po
2
1
TEW00005
20-131
q
MEASURING BRAKE PERFORMANCE
MEASURING BRAKE
PERFORMANCE

Travel speed: 20 km/h when brakes are applied
Delay in applying brakes: 0.1 sec
Measurement method
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed position and drive the machine.
4. Measure the distance from the point where the

brakes were applied to the point where the machine stopped.
Repeat this measurement three times and
take the average.
20-132
q
U42103
3. When the travel speed reaches 20 km/h, depress

the left brake pedal with the specified operating
force.
Before carrying out this operation, determine
the run-up path and the point for applying
the brakes, then apply the brakes when the
machine reaches that point.
Switch the transmission cut-off switch ON
when carrying out this operation.
TESTING BRAKE OIL PRESSURE
TESTING BRAKE OIL

PRESSURE

Brake oil pressure: 4.9MPa {50kg/cm2}
Put blocks securely under the tires.

1
Testing
1. Remove bleeder screw (1) and nipple (3), then
install tool Q2, nipple (3), and tool Q1 in order in
the mount of bleeder screw (1).
2. Start the engine and bleed the air.
This operation is carried out with two workers. One worker operates the brake pedal
while the other worker bleeds the air from
bleeder screw (2).
Turn the transmission cut-off switch ON.
TEW00114
Q2
Q1
U42103
3. Depress the left brake, set the gauge reading to

4.9 MPa {50 kg/cm2}, then leave for 5 minutes
and measure the drop in the pressure.
4. After measuring, stop the engine, loosen the
bleeder screw to lower the pressure, then remove tool Q1.
Remove tool Q2 also.
After completing the operation, bleed the air
from the brake circuit again.
TEW00115
TEW00117
20-133
q
MEASURING BRAKE DISC WEAR
MEASURING BRAKE DISC

WEAR

Brake oil pressure:
Specified (4.9 MPa {50 kg/cm2})
Park the machine on horizontal ground and put

blocks securely under the tires.
Measurement method
1. Remove plug (1).
2. Depress the brake pedal fully.
4. Install a vinyl hose to bleeder (2), then loosen

the bleeder and drain the brake oil.
After draining the brake oil, check that the
brake piston has returned to the end of its
stroke.
5. Measure depth b from the end face of the housing to the spring guide pin.
Calculating piston stroke
S=ab
S = Max. 6.2 mm
20-134
q
U42103
3. Use calipers P to measure depth a from the end

face of the housing to the spring guide.
When measuring, keep the brake pedal depressed.
BLEEDING AIR FROM BRAKE SYSTEM
BLEEDING AIR FROM BRAKE

SYSTEM
Put blocks securely under the tires.
1. Remove cap (1) of the bleeder screw, insert a
vinyl hose into the screw, and insert the other
end in a container.
U42103
3. Depress the brake pedal, then loosen the bleeder

screw and bleed the air.
This operation is carried out with two workers. One worker operates the brake pedal
while the other worker bleeds the air from
the bleeder screw.
When depressing the brake pedal, use the
left pedal.
4. When no more bubbles come out with the fluid
from the hose, depress the pedal fully and
tighten the bleeder screw while the oil is still
flowing.
Repeat the operation to bleed the air from
the other cylinders, and after completing the
operation, check the level in the oil tank and
add more oil if necessary.
To bleed the air completely, bleed the air
first from the cylinder which is farthest from
the brake pedal.
20-135
q
BLEEDING AIR FROM BRAKE COOLING OIL LINE
BLEEDING AIR FROM BRAKE

COOLING OIL LINE
1. After connecting the cooling line piping, add
cooling oil through the oil filler then move the
machine backward and forward to rotate cooling oil pump (1). Then add cooling oil through
oil filler (2) until it reaches the top level of sight
gauge (3).
5
Cooling oil: EO10-CD
Be careful not to let the cooling oil tank become empty.
U42103
2. Repeat Step 1 until there is no change in the oil

level of sight gauge (3) of cooling oil tank (4).
20-135-1
w
MEASURING PARKING BRAKE PERFORMANCE
MEASURING PARKING BRAKE

PERFORMANCE

Road surface: Flat, dry paved road surface with
slope of 1/5 grade (1120').
Machine: Operating condition
Keep parking forced release switch (1) at the
rear of the operators seat at the OFF position.
Measurement method
1. Start the engine, set the machine facing in a
straight line, then drive the machine up a 1/5
grade slope with the fork empty.
2. Depress the brake, stop the machine, set the
directional lever to the neutral position, then
stop the engine.
U42103
3. Turn the parking brake switch ON, then gradually release the brake pedal and check that the
machine is held in position.
When the engine is stopped, the parking
brake is automatically switched ON.
Carry out the measurement in two ways:
Once with the machine facing uphill, and
once more with the machine facing downhill.
1
TEW00126
20-136
q
MANUAL RELEASE METHOD FOR PARKING BRAKE
MANUAL RELEASE METHOD

FOR PARKING BRAKE
2
The parking brake is controlled by hydraulic pressure, so if there should be any failure in the
transmission and it becomes impossible to release the parking brake, it is possible to release
it manually to move the machine.
The
manual release of the parking brake is designed only to move the machine from a dangerous working area to a safe place where repairs can be carried out. This method must not
be used except when there has been a failure.

fork to the ground and put blocks under the
tires.
Always stop the engine before carrying out this

procedure.
TEW00127
3
1
U42103
1. Loosen bolt (1), then remove lock plate (2) from

bolt (3) (3 places).
2. Tighten bolts (3) at 3 places in turn as far as the
mounting position for the plate at portion a,
then install lock plate (2) at portion a.
Tighten all three bolts uniformly a little at a
time.
Bolt (3) pushes piston (4) and (5) and releases the parking brake.
TEW00128
3. Tighten bolt (1) to secure lock plate (2) in position.
20-137
q
TESTING WEAR OF PARKING BRAKE DISC
TESTING WEAR OF PARKING

BRAKE DISC
2
If the parking brake becomes weak, measure

the piston stroke as follows.

3
fork to the ground and put blocks under the

tires.
Always stop the engine before carrying out this

procedure.
3. Tighten the three manual release bolts (3) in

turn and measure dimension b when brake
pistons (4) and (5) are pushed in fully.
Piston stroke (L) = a b
L = Max. 9.9
TEW00127
5
1
3
a
4
TEW00130
3
b
TEW00131
If the piston stroke is greater than 9.9 mm,

check thickness W of brake disc (6). For
details, see DISASSEMBLY AND ASSEMBLY,
REMOVAL OF PARKING BRAKE DISC.
Dimension W: Min 2.83 mm
A A
W
AA
20-138
q
TEW00132
U42103
2. Measure dimension a with the three manual

release bolts (3) in contact lightly with brake
pistons (4) and (5).
1. Loosen bolt (1), then remove lock plate (2) from

parking brake manual release bolt (3) (3 places).
MEASURING WORK EQUIPMENT CONTROL LEVER
MEASURING WORK
EQUIPMENT CONTROL LEVER

Install the safety bar to the frame.

Measurement method
U42103
1. Operating force of work equipment control lever

Install push-pull scale I2 to the work equipment
control lever and measure the operating force.
Install the push-pull scale to the center of
the knob.
Operate the control lever at the same speed
as for normal operations, and measure the
minimum value for the force needed to operate the knob.
2. Travel of work equipment control lever
Measure travel L at each position when operating the work equipment control lever.
Mark the lever knob and use scale J to measure.
L
L
LOWER
FLOAT
RAISE
TILT
DUMP
TEW00134
20-139
q
MEASURING WORK EQUIPMENT CONTROL LEVER
Adjusting
1. Remove cover (1).
2. With solenoid (6) pulled, fix the solenoid in position so that the clearance between cam (3)
and roller (4) is dimension a.
Dimension a: 0 0.5 mm
Set the fork control lever and lift arm control
lever at the HOLD position.
If cam (3), roller (4), or spring (5) are broken,
replace them before adjusting.
1
TEW00136
3. Lift arm control lever

Operate the lift arm control lever and adjust the
length of rod (2) so that roller (4) is dimension b
at the notch at both ends of cam (3).
Dimension b: 0 1 mm
6
TEW00137
4. Fork control lever

Operate the fork control lever and adjust the
length of rod (2) so that roller (4) is dimension C
at the notch at both ends of cam (3).
Dimension C: 0 1 mm
C
4
TEW00139
20-140
q
TEW00140
U42103
5
4
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
MEASURING WORK
EQUIPMENT HYDRAULIC
PRESSURE

Apply

the tires.
1. PPC relief valve pressure

Measuring
1) Raise lift arm (1), set support (2) or stopper
R in position under the lift arm, then remove
cover (3).
Loosen the oil filler cap to release the pres-
U42103
sure inside the hydraulic tank, then operate

the fork control lever at least 40 times between TILT and HOLD to completely release
the pressure in the accumulator.
After operating the fork control lever, operate the fork control lever to the DUMP
position and check that the fork does
not dump.
Always stop the engine before operating the lever.
2) Remove plug (4) for measuring the hydraulic pressure in the fork cylinder circuit of the
main control valve.
3) Install hydraulic tester kit B to the measurement port.
Install the 90 elbow in the hydraulic
tester kit to the measurement port, then
connect the hose.
Check that there is no oil leakage from
any joint.
Use a hose which is long enough to
reach the operators compartment.
4) Start the engine, raise the lift arm approx.
400 mm, then operate the control lever to
tilt back the fork, and measure the pressure
when the relief valve is actuated.
Be careful not to apply pressure suddenly to the oil pressure gauge.
TEW00143
When
removing the oil pressure gauge, release the pressure inside the circuit in the
same way as when installing the gauge.
TEW00144
20-141
q
Adjusting
Always
stop the engine when adjusting the oil

pressure.
1) Stop the engine and remove cover (1).
2) Loosen locknut (2), then turn adjustment
screw (3) to adjust.
Pressure adjustment for one turn of adjustment screw:
Approx. 1.79 MPa {18.3 kg/cm2}
Turn the adjustment screw to adjust the
set pressure as follows.
Do not carry out any adjustment if the
relief pressure cannot be measured accurately.
TEW00145
TEW00146
2(Adjustment
amount)
TEW00147
20-142
q
U42103
2. Work equipment relief valve pressure

Measurement method
Loosen the oil filler cap to release the pressure

inside the hydraulic tank, then operate the control lever several times to release the remaining
pressure inside the piping.
When operating each lever, set the fork so that
portion a is raised 30 mm 50 mm, then lower
portion b to the ground and stop the engine.
After operating each lever, check that both bottom surfaces of the fork (portions a and b) contact the ground surface.
U42103
1) Remove oil pressure measurement plug (1)

from the fork cylinder circuit.
2) Install hydraulic tester kit B to the measurement port.
Check that there is no oil leakage from
any joint.
Use a hose which is long enough to
reach the operators compartment.
3) Start the engine, raise the lift arm approx.
400 mm, then operate the control lever to
tilt back the fork, and measure the pressure
when the relief valve is actuated.
Be careful not to apply pressure suddenly to the oil pressure gauge.
1
B
When
removing the oil pressure gauge, release the pressure inside the circuit in the
same way as when installing the gauge.
TEW00150
20-143
q
Adjusting
Always
stop the engine when adjusting the oil

pressure.
1
1) Raise lift arm (1), set support (2) or stopper

R in position under the lift arm, then remove
cover (3).
2) Remove locknut (4) of the relief valve.
3) Turn adjustment screw (5) to adjust.

Pressure adjustment for one turn of adjustment screw:
Approx. 5.18 MPa {52.9 kg/cm2}
Turn the adjustment screw to adjust the
set pressure as follows.
Do not carry out any adjustment if the
relief pressure cannot be measured accurately.
3
TEW00151
TEW00152
TEW00153
TEW00154
20-144
q
U42103
MEASURING WORK EQUIPMENT
MEASURING WORK
EQUIPMENT

Steering position: Neutral
Measurement method
1. Lift arm RAISE time
Set the fork at the lowest position from the
ground with the fork tilted back fully, then raise
it and measure the time taken for the fork to
reach the maximum lift arm height.
U42103
2. Lift arm LOWER time

Set the fork horizontal, then lower the lift arm
from the maximum height and measure the time
taken for the fork to reach the lowest position
from the ground.
3. Fork DUMP time

Raise the lift arm to the maximum height, and
measure the time taken to move the fork from
the tilt position (fork fully tilted back) to the dump
position (fork fully tipped forward).
4. Fork TILT time

1) Raise the lift arm to the maximum height,
and measure the time taken to move the
fork to the tilt position (fork fully tilted back).
2) Set the fork horizontal to the ground and
measure the time taken to move the fork
from the horizontal position to the tilt position (fork fully tilted back).
20-145
q
MEASURING WORK EQUIPMENT
MEASURING HYDRAULIC DRIFT WORK EQUIPMENT


Stop the engine, leave for 5 minutes, then measure for 15 minutes.
Lift arm: Horizontal
Fork: Horizontal
No load
Apply
the safety lock to the work equipment

control levers.
Never go under the work equipment.

Measurement method
2. Leave for 5 minutes, then start the measurement.

3. Wait for 15 minutes, then measure retraction
amount A of the fork cylinder rod and retraction
amount B of the lift arm cylinder rod.
20-146
q
U42103
1. Set the lift arm and fork in a horizontal position,

then stop the engine.
TESTING AND ADJUSTING FORK POSITIONER

FORK POSITIONER

2
1
Testing
1. Stop the engine and check that the clearance
between switch (1) and angle (2) is the standard
value.
TEW00161
2. Start the engine, run at idling and check the

actuation position.
(Check three times and take the average value.)
U42103
Adjusting
1. Lower the fork to the ground, operate the fork
to the desired angle, then return the lever to
HOLD and stop the engine.
2. Adjust nut (6) of switch (1) so that clearance a
from the tip of switch protector (3) to the switch
sensing surface is the standard value, then secure the switch in position.
Clearance a: 0.5 1.0 mm
3 Switch mounting nut: 17.7 2 Nm
{1.8 0.2 kgm}
1
TEW00162
3. Using shims, adjust clearance b between the

sensing surface of switch (1) and angle (2) to
the standard value, then secure in position.
Use shims to adjust the angle so that the
clearance between the switch sensing surface and the angle is within the standard
value for the whole stroke of the angle, then
secure in position.
Check that the center of the switch sensing
surface and the angle do not move, then
secure in position.
After adjusting, operate the fork control lever, check that the positioner is actuated at
the desired position, then secure in position.
Clearance b: 3 5 mm
3
1
TEW00163
1
b
TEW00164
20-147
q
TESTING AND ADJUSTING LIFT ARM KICK-OUT

LIFT ARM KICK-OUT
Testing
1. Stop the engine, and check that the clearance
between switch (1) and plate (2) is the standard
value.
2. Start the engine, run at high idling, and check
the actuation position.
(Check three times and take the average value.)
1
2
TEW00165
Adjusting
1. Raise the lift arm to the desired height, return
the lift arm control lever to the HOLD position,
then stop the engine.
Always apply the safety lock to the work equipment control lever.
3. Secure the switch in position so that clearance a

between the sensing surface of the switch and
plate (2) is the standard value.
Clearance a: 3 5 mm
3 Switch mounting nut: 17.7 2 Nm
{1.8 0.2 kgm}
After adjusting, operate the lift arm control
lever and check that the kick-out is actuated
at the desired position.
20-148
q
U42103
2. Adjust the position of the plate so that the center

of switch (1) is aligned with the top of plate (2),
then secure in position.
TESTING AND ADJUSTING LIFT ARM KICK-OUT
Proximity switch actuation pilot lamp (red)

The proximity switch is equipped with a pilot lamp
which shows when it is being actuated, so use this
when adjusting.
Actuation pilot lamp
TEW00166
Proximity switch
actuation
pilot lamp
U42103
Detector position
Lights up
Goes out
When detector is positioned at detection When detector has moved away from
surface of proximity switch
detection surface of proximity switch
Fork
positioner
Proximity switch
Detector
TEW00167
Proximity switch
Detector
TEW00168
Lift arm kick-out
20-149
q
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
ADJUSTING MAIN MONITOR

(SPEEDOMETER MODULE)
The speedometer on the main monitor is a common part for all machines, and the input signal
for the travel speed differs according to the machine, so it is necessary to adjust the monitor
for use with the particular model.
It is also necessary to change the switches if the
optional E.C.S.S. (Electronically Controlled Suspension System) is installed.
Rear of main monitor
DIP SW4
DIP SW1
DIP SW2
DIP SW3
Adjustment procedure
Tire size
26.5-25-24PR
Switch 1
(model
selection)
Switch 2
(speedometer correction)
Switch 3
(tachometer input
selection)
TDW00173
Rotary switch
Turn
TDW00174
DIP SW 1, 2, 3
3) When the cap is removed from dipswitch (4)
at the back of the speedometer, an ON/OFF
switch can be seen.
Adjust the setting if the E.C.S.S. (Electronically Controlled Suspension System) is installed.
Switch 4
Switch
No.
Without
With
E.C.S.S.
E.C.S.S.
1
ON
ON
2
ON
ON
3
ON
OFF
4
ON
ON
4) After completing the adjustment, fit the rubber caps securely and install the main monitor.
20-150
q
DIP SW 4
1 2 3 4
ON
OFF
OFF
Adjustment
position TDW00175
TDW00176
Reference
Amount of correction for switch (2)
Switch posi0 1 2 3 4 5 6 7
tion
Amount of
correction (%) +14 +12 +10 +8 + 6 +4 +2 +0
Switch posi8
tion
Amount of
correction (%) 0
2 4 6 8 10 12 14
U42103
Turn off the power, then remove the machine

monitor and adjust the switches at the back of
the speedometer.
1. Setting machine model
1) Remove the rubber caps from dipswitches
(1), (2), (3), and (4) at the back of the speedometer.
2) When the rubber cap is removed, a rotary
switch can be seen inside. Using a flatheaded screwdriver, turn this switch to adjust it to the settings in the table below.
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR
CHECKING FOR ABNORMALITY

IN FUEL LEVEL SENSOR
If there is a marked difference between the actual amount of fuel remaining in the fuel tank
and the display on the fuel gauge (the fuel tank
is full but the fuel gauge does not indicate FULL),
check the fuel level sensor as an individual part
and measure the resistance at the three positions for the float.
FULL
Measurement method
Connect one end of the probe of terminal (1),

contact the other probe with terminal (2), and
measure the resistance.
Resistance for fuel level sensor at each point

Unit:
FULL (top)
1/2 (horizontal) EMPTY (bottom)
32
85+100
10 +13
EMPTY
The resistance values are only given as a guideline.

2 1
E
U42103
F
B
Y
2
1
TEW00177
20-151
q
TROUBLESHOOTING
Points to remember when troubleshooting ....................................................................................... 20-202
Sequence of events in troubleshooting .............................................................................................. 20-203
Precautions when carrying out maintenance ..................................................................................... 20-204
Handling connectors ............................................................................................................................. 20-211
Checks before troubleshooting ............................................................................................................ 20-212
Method of using troubleshooting charts ............................................................................................ 20-214
Connector types and mounting locations .......................................................................................... 20-222
Connection table for connector pin numbers .................................................................................... 20-228
Troubleshooting of engine system (S mode) .................................................................................... 20-251
Troubleshooting of main monitor system (M mode) ....................................................................... 20-301
Troubleshooting of maintenance monitor system (K mode) ........................................................... 20-351
Troubleshooting of electrical system (E mode) ................................................................................. 20-401
U42103
Troubleshooting of hydraulic and mechanical system (chassis related) (T mode) ...................... 20-451
Troubleshooting of ECSS (Electronically Controlled Suspension System) (D mode) (Option) ... 20-501
20-201
q
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
2.
3.
When carrying out troubleshooting, do not hurry

to disassemble the components.
If components are disassembled immediately any
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 manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occurred apart from
the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred before?
Check before troubleshooting
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202
q
4)
5)
4.
5.
6.
Check the stroke of the control valve spool.

Other maintenance items can be checked externally, so check any item that is considered
to be necessary.
Confirming failure
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
carry out any investigation or measurement that may make the problem worse.
Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the
causes of failure, then use the troubleshooting flowchart to locate the position of the
failure exactly.
The basic procedure for troubleshooting
is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
Measures to remove root cause of failure
Even if the failure is repaired, if the root cause

of the failure is not repaired, the same failure
will occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.
U42103
1.
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING

Office, shop
Jobsite
TEW00180
TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first
ask the following points.
Name of customer
Type, serial number of machine
Details of jobsite, etc.
2) Ask questions to gain an outline of the problem.
Condition of failure
Work being carried out at the time of the
failure
Operating environment
Past history, details of maintenance, etc.
Ring
Ring
TEW00182
Breakdown
Step 2
Determining probable location of cause
TEW00183
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
Step
Repair at jobsite
Hurray !
It's repalred
U42103
TEW00184
Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary
tools.
T-adapter
Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the necessary replacement parts.
Step 7
Pinpoint locations of failure (carry out
troubleshooting)
Decide action to take
TEW00186
Step 8
Repair at workshop
1) Before starting troubleshooting, locate and

repair simple failures.
Check before starting items
Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
Machine
volume
Shop manual
Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
TEW00188
Step 4
Go to jobsite
Step 5
Ask operator questions to confirm details of
failure.
TEW00189
Was there anything strange about the machine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
failure?
TEW00190
20-203
q
TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine
over a long period, and to prevent failures or
other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it
gives sections on Handling electric equipment
and Handling hydraulic equipment
(particlularly hydraulic oil).
1. PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT
Main failures occurring in wiring harness

(1) Defective contact of connectors (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the
connectors is deformed or the position
is not correctly aligned, or because there
is corrosion or oxidization of the contact
surfaces.
20-204
q
U42103
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one component to another component,
connectors used for connecting and disconnecting one wire from another wire, and protector or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the
direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations they are frequently removed
and installed again, so they are likely to suffer deformation or damage. For this reason,
it is necessary to be extremely careful when
handling wiring harnesses.
TEW00191
Improper insertion
TEW00192
TROUBLESHOOTING
(2) Defective compression or soldering of

connectors
The pins of the male and female connectors are in contact at the compressed
terminal or soldered portion, but there
is excessive force on the wiring, and the
plating peels to cause improper correction or breakage.
U42103
(3) Disconnections in wiring

If the wiring is held and the connectors
are pulled apart, or components are lifted
with a crane with the wiring still connected, or a heavy object hits the wiring,
the compression of the connector may
be lost, or the soldering may be damaged, or the wiring may be broken.
(4) High pressure water entering connector
The connector is disigned 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 at the same
time, if the water does enter, it is difficult for it to be drained. Therefore, if
water should get into the connector, the
pins will be short-circuited by the water,
so if any water gets in, immediately dry
the connector or take other appropriate
action before passing electricity through
it.
(5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact.
If there is oil or grease or dirt stuck to
the connector, wipe it off with a dry cloth
or blow dry with air, and spray it with a
contact restorer.
When wiping the mating portion of
the connector, be careful not to use
excessive force or deform the pins.
If there is water or oil in the air, it
will increase the contamination of the
points, so clean with air from which
all the water and oil has been removed.
Improper compression
TEW00193
TEW00194
TEW00195
TEW00196
20-205
q
TROUBLESHOOTING
2) Removing, installing, and drying connectors

and wiring harnesses
Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires.
For connectors held by a screw, loosen
the screw fully, then hold the male and
female connectors in each hand and pull
apart. For connectors which have a lock
stopper, press down the stopper with
your thumb and pull the connectors
apart.
Press lightly
when removing
Lock stopper
TEW00197
Connecting connectors
(1) Check the connector visually.
a. Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
b. Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
c. Check that there is no damage or
breakage to the outside of the connector.
If there is any oil, water, or dirt stuck
to the connector, wipe it off with a
dry cloth. If any water has got inside
the connector, warm the inside of
the wiring with a dryer, but be careful not to make it too hot as this will
cause short circuits.
If there is any damage or breakage,
replace the connector.
20-206
q
U42103
(2) Action to take after removing connectors

After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the connector portion.
TEW00198
TROUBLESHOOTING
(2) Fix the connector securely.

Align the position of the connector correctly, then insert it securely.
For connectors with lock stopper
Push in the connector until the stopper
clicks into position.
Cliks into position
U42103
TEW00199
(3) Correct any protrusion of the boot and

any misalignment of the wiring harness
For connectors fitted with boots, correct
any protrusion or the boot. In addition,
if the wiring harness is misaligned, or
the clamp is out of position, adjust it to
its correct position.
When blowing with dry air, there is
danger that the oil in the air may
cause improper contact, so clean with
air from which all the water and oil
has been removed.
TEW00200
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.
(1) Disconnect the connector and wipe off
the water with a dry cloth.
If the connector is blown dry with
air, there is the risk that oil in the air
may cause defective contact, so avoid
blowing with air.
TEW00196
(2) Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
Hot air from the dryer can be used,
but be careful not to make the connector or related parts too hot, as
this will cause deformation or damage to the connector.
TEW00202
20-207
q
TROUBLESHOOTING
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits between pins caused by water.
After completely drying the connector, blow it with contact restorer and
reassemble.
T-adapter
3) Handling control box

(1) The control box contains a microcomputer and electronic control circuits.
These control all of the electronic circuits on the machine, so be extremely
careful when handling the control box.
(2) Do not open the cover of the control box
unless necessary.
(3) Do not place objects on top of the control box.
(4) Cover the control connectors with tape
or a vinyl bag.
(5) During rainy weather, do not leave the
control box in a place where it is exposed to rain.
(6) Do not place the control box on oil, water, or soil, or in any hot place, even for
a short time. (Place it on a suitable dry
stand)
(7) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the control box. Fit
an arc welding ground close to the welding point.
TEW00204
TEW00205
TEW00206
20-208
q
U42103
TEW00203
TROUBLESHOOTING
2. POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT

With the increase in pressure and precision of
hydraulic equipment, the most common cause
of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when
disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
U42103
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters,
or repairing the machine in rain or high
winds, or places where there is a lot of dust.
2) Disassembly and maintenance work in the
field
If disassembly or maintenance work is carried out on hydraulic equipment in the field,
there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to
use unit exchange. Disassembly and maintenance of hydraulic equipment should be
carried out in a specially prepared dustproof
workshop, and the performance should be
confirmed with special test equipment.
TEW00207
3) Sealing openings
After any piping or equipment is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left open
or is blocked with a rag, there is danger of
dirt entering or of the surrounding area being made dirty by leaking oil so never do
this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of
it, or take it back with you for disposal.
TEW00208
4) Do not let any dirt or dust get in during

refilling operations.
Be careful not to let any dirt or dust get in
when refilling with hydraulic oil. Always keep
the oil filler and the area around it clean,
and also use clean pumps and oil containers. If an oil cleaning device is used, it is
possible to filter out the dirt that has collected during storage, so this is an even more
effective method.
TEW00209
20-209
q
TROUBLESHOOTING
5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can also
be drained out easily from the circuit together with the oil, so it is best to change
the oil when it is still warm. When changing
the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the
oil from the hydraulic tank; also drain the oil
from the filter and from the drain plug in the
circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic
oil.
Flushing oil
TEW00210
7) Cleaning operations
After repairing the hydraulic equipment
(pump, control valve, etc.) or when running
the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the ultrafine (about 3) particles that
the filter built into the hydraulic equipment
cannot remove, so it is an extremely effective device.
TEW00211
20-210
q
U42103
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.
TROUBLESHOOTING
HANDLING CONNECTORS
HANDLING CONNECTORS
1. When removing the connectors from the clips,
pull the connector in a parallel direction to the
clip.
If the connector is twisted to the left and
right or up and down, the housing may
break.
TEW00212
U42103
Stopper
TEW00213
2. When disconnecting male and female connectors, release the lock and pull in parallel with
both hands.
Never try to pull out with one hand.
TEW00214
3. 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.
TEW00215
20-211
q
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Remedy
1. Check fuel level, type of fuel
Add fuel
2. Check for dirt or water in fuel
Clean, drain
3. Check hydraulic oil level
Add oil
4. Check filter (hydraulic, transmission, torque converter)
Replace
5. Check oil level
Add oil
6. Check engine oil
Add oil
7. Check coolant level
Add water
8. Check clogging of dust indicator
Clean or check
9. Check for loose or corroded battery terminals or wiring
Tighten or replace
10. Check for loose or corroded alternator terminals or wiring
Tighten or replace
11. Check for loose or corroded starting motor terminals or wiring
Repair or replace
12. Check operation of gauges
Repair or replace
13. Check for abnormal noise or smell
Repair
14. Check for oil leakage
Repair
15. Bleed air from system
Bleed air
16. Check effect of brakes
Adjust or repair
17. Check battery voltage (engine stopped)

18. Check battery electrolyte level
24 26V
Repair or replace
Add electrolyte or
replace
Electrical components
Other check items
Judgement
standard
19. Check for discolored, burned, or bare wiring
Replace
20. Check for missing wiring clamps, hanging wires
Repair
21. Check for water on wiring
Dry place affected by
(check carefully for water at connectors and terminals)
water
22. Check for broken or corroded fuses
Replace
23. Check alternator voltage (engine running at over half throttle)
Replace
(If the battery charge is low, it may reach approx. 25 V
28.5 29.5V Repair or check
immediately after starting)

24. Noise when battery relay is operated
(turn starting switch ON-OFF)
20-212
q
Replace
U42103
Lubricant, coolant
Hydraulic, mechanical
Electrical components
components
Checks before starting
Item
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure
mode (problem with the machine). (See Example (1))
2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further
divided into sections marked with small letters (for example, (a)), so go to the appropriate
section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item in the failure mode. (See Example (2))
3) Method of following troubleshooting chart
YES
Check or measure the item inside
, and according to the answer follow either the
NO
YES line or the NO line to go to the next
. (Note: The number written at the top right
corner of the
is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right. (See Example (3))
Below the [ ] there are the methods for inspection or measurement, and the judgement
values.
If the judgement values below the
are correct or the answer to the question inside
the
is YES, follow the YES line; if the judgement value is not correct, or the answer to
the question is NO, follow the NO line.
Below the
is given the preparatory work needed for inspection and measurement,
and the judgement values. If this preparatory work is neglected, or the method of operation
or handling is mistaken, there is danger that it may cause mistaken judgement, or the
equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item 1).
4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with . (See Example (4))
The precautions marked are not given in the
, but must always be followed when
carrying out the check inside the
.
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
20-214
q
U42103
1. Category of troubleshooting code number

Troubleshooting code No.
Component
S-
Troubleshooting of engine
M-
Troubleshooting of main monitor
K-
Troubleshooting of maintenance monitor
E-
Troubleshooting of electrical system
T-
Troubleshooting of hydraulic and mechanical system
D-
Troubleshooting of ECSS (Electronically Controlled Suspension System) (Option)
TROUBLESHOOTING
< Example >
Abnormality in buzzer
(1) M-15
(2) (a) Buzzer does not sound when starting switch is turned ON (during self-check)
Cause
(3)
Defective contact, or
disconnection in wiring
harness between CNL06
(female) (8) and CNL43
(male)
YES
1
Does buzzer
sound?
2 YES
Is voltage between
CNL42 (female)
1) Turn starting
switch ON.
NO and chassis
ground normal?
2) Contact CNL43
U42103
(female) to
chassis ground.
NO
1) 20 30 V
2) Turn starting
switch ON.
Remedy
After inspection,
repair or replace
Defective buzzer
Replace
(female) and CNFS2 (9)
After inspection,
repair or replace
YES
(4)
Defective main monitor.
Replace
Before carrying
out troubleshooting, check that all the related connectors are properly inserted.
1
Always connect any disconnected connectors before going on the next step.
Does buzzer
stop?
1) Turn starting
switch ON.
2) Disconnect
CNL06.
YES
Go to Troubleshooting for
maintenance monitor
2
Does buzzer
3 YES
NO stop?
1) Turn starting
switch ON.
2) Disconnect
CNL19.
Does buzzer
NO stop?
1) Turn starting
switch ON.
2) Disconnect
CNL43.
NO
Wiring harness between

CNL06 (female) (8) and
CNL43 (male) short
circuiting with chassis
ground
After inspection,
repair or replace
Defective buzzer
Replace
20-215
q
TROUBLESHOOTING
3. Using troubleshooting chart for engine-related failure

This troubleshooting chart is divided into three
sections: questions, check items, and troubleshooting. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton without using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items
that can be obtained from the user, depending
on the users level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
U42103
Causes
Questions
(1) (2) (3)
(a)
(b)
(c)
(d)
(e)
Check items
Troubleshooting
20-216
q
ii
iii
inje
ctio
n)
Causes
ed t
urbo
cha
Clog
rger
ged
, int
air c
erfe
lean
Wor
renc
er e
n pi
e
lem
ston
ent
ring
Clog
, cyl
ged
inde
, sei
r
zed
Imp
inje
rope
c
tion
r inj
noz
ecti
Defe
zle
on t
ctiv
imin
e in
g
ject
ion
pum
p (e
xces
sive
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with , and of these, causes that have a high probability are marked with .
Check each of the [Questions] and [Check items] in
turn, and marked the or in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with to use as reference
for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes.
2. Use the in the Cause column as reference
for [Degree of use (Operated for long period)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
Seiz
U42103
TROUBLESHOOTING
Confirm recent repair history
Degree of use
Operatred for long period
20-217
q
TROUBLESHOOTING
Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel
Causes
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Seiz
ed t
Clog urboch
arge
ged
r, in
air
W or
terfe
n pis cleaner
elem rence
t
on r
Clog
ent
in
g, c
ged
y
,
lind
se
Imp
er
rope ized inje
r inje
ctio
Defe
n
ctio
ctiv
n tim nozzle
e in
ing
Imp
rope jection
pum
r va
Cru
lve
p (e
she
clea
xces
d, c
ran
sive
logg
Lea
inje
kag
ed m ce
ctio
e of
uffle
n)
Defe
air b
r
ctiv
etw
e co
een
Deff
n
t
urbo
tact
ectiv
o
c
harg
f va
e in
lve,
er a
ject
valv
ion
nd h
e se
pum
ead
at
p (ra
ck, p
lung
er s
eize
d)

Degree of use
Operated for long period

Gradually became black
U42103
Questions
Suddenly became black

Color of exhaust gas
Blue under light load

Engine oil must be added more frequently
Power was lost
Suddenly
Gradually
Non-specified fuel has been used

Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular

When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
When compression pressure is measured, it is found to be low

Speed of some cylinders does not change when operating
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
20-218
q
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy or does

not return
TROUBLESHOOTING
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
U42103
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
20-219
q
TROUBLESHOOTING
4. Method of using matrix troubleshooting tables

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type)
to locate the causes of failures in the machine. The troubleshooting tables are divided broadly into
categories for the main components, such as the steering system and work equipment hydraulic
system. Follow the procedure given below and carry out troubleshooting to locate the problems
accurately and swiftly.
Step 1. Questioning the operator

The questions to ask the operator are given
below the failure symptom. If the answers
to the questions match the information given,
follow the arrow to reach the probable cause
of the failure.
Consider the contents of the questions and
consult the table while proceeding to Steps
2 and 3 to grasp the true cause.
1. Steering does not work Symptom [Example]
Step 2. Checks before troubleshooting

Before starting the main troubleshooting and
measuring the hydraulic pressure, first check
the Checks before Starting items, and check
for oil leakage and loose bolts. These checks
may avoid time wasted on unnecessary troubleshooting.
The items given under Checks before Starting are items which must be considered particularly for that symptom before starting
troubleshooting.
Checks before starting [Example]
Is the oil level and type of oil in the

hydraulic tank correct?
Is there any leakage of oil from the
steering control valve?
[Example 1]
Remedy
20-220
q
No.
Problems
Steering does not work to the left or right
Same as Item 1, but abnormality in actuation of work equipment
Steering can only be operated to one side.
Steering wheel is heavy and cannot be turned.
ses
[Example 2]
Cau
Step 3. Using cross-reference table

1) Operate the machine to carry out the
checks in the troubleshooting item column.
Mark the items where the results match
the symptom.
It is not necessary to follow the troubleshooting checks in order; follow
an order which is easiest to carry
out troubleshooting.
2) Find the appropriate cause from the
cause column. If the symptom appears,
the marks on that line indicate the possible causes. (For item No. 2 in the table
on the right, the possible causes are c or
e.)
If there is only one :
Carry out the other troubleshooting items
(where the same cause is marked with
), check if the symptom appears, then
repair.
If there are two s:
Go on to Step 3) to narrow down the
possible causes.
Remedy
Problems
1
2
3
4
5
U42103
Ask the operator about the following points.

Did the steering suddenly stop working? Breakage in steering equipment
Had the steering gradually been becoming heavy? Internal wear of steering
equipment, defective seal
U42103
Problems
1
2
3
4
5
Applicable troubleshooting item located in Step 3).

Applicable troubleshooting item located in Step 1).
Ignore these causes
Remedy
Common causes
Problems
1
2
3
4
5
Remedy
7) Remedy
If the causes are narrowed down to one common cause, take the aciton given in the remedy column.
The symbols given in the remedy column
indicate the following:
X: Replace, : Repair, A; Adjust, C: Clean
ses
5) Narrow down the possible causes.

There is one common cause among the
causes located in Steps 2) and 4). (One cause
marked appears on the line for both items.)
This cause is common to both the symptoms in troubleshooting Steps 1) and 3).
The causes which are not common to
both troubleshooting items (items which
are not marked for both symptoms)
are unlikely causes, so ignore them.
(In the example given on the right, the
causes for Troubleshooting Item 2 are c
or e, and the causes for Troubleshooting
Item 5 are b or e, so cause e is common
to both.)
6) Repeat the operations in Steps 3), 4) and 5)
until one cause (one common cause) remains.
If the causes cannot be narrowed down
to one cause, narrow the causes down
as far as possible.
Remedy
Cau
3) Operate the machine and check the troubleshooting items other than those in 1).
Operate the machine and check the items in
the same way as in 1), and if the symptom
appears, mark that item. (In the chart on the
right, the symptom appears again for item
5).
4) Find the appropriate cause from the cause
column. In the same way as in Step 2), if the
symptom appears, the marks on that line
indicate the possible causes. (For item No.5
in the table on the right, the possible causes
are b or e.)
Cau
ses
Cau
ses
TROUBLESHOOTING
Problems
Action to take
1
2
3
4
5
20-221
q
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS

The Address column in the table below shows the address in the connector arrangement drawing
(3-dimensional drawing).
(1/3)
Mounting location
Address
ConConNo.
nector nector
of
No.
Type pins
Mounting location
Address
CNB03 (Connector)
Front washer tank (OPT)
G9
CNLR2
SWP
type
14
Floor wiring harness
A8
CNB04 (Connector)
Rear washer tank (OPT)
G9
CNLR3
SWP
type
C7
14
Bulkhead wiring harness
I3
CNLR4
SWP
type
14
A7
CNC01 M type
Front wiper motor (OPT)
D7
CNLR5 X type
C7
CNC02 M type
Radio (OPT)
D7
CNLR6 L type
A7
CNC03 M type
Working lamp right (OPT)
E8
CNR06 X type
Radiator level sensor
I8
CNC04 M type
Working lamp left (OPT)
E8
CNR07 X type
Fuel level sensor
J4
CNC06 (Connector)
Room lamp (OPT)
F8
CNR08 M type
L.H. rear combination

lamp
K6
CNC07 M type
Rear wiper motor (OPT)
F8
CNR09 M type
R.H. rear combination

lamp
H9
CNE06 X type
Water temperature
sensor
J8
CNT01 X type
F solenoid
H2
CNT02 X type
R solenoid
H3
CNT03 X type
Hi-Lo solenoid
H2
CNT04 X type
Speed solenoid
H2
CNT05 X type
Parking brake solenoid
G2
CNT06 X type
Speed sensor
G2
CNT07 X type

temperature sensor
I3
CNBR1
SWP
type
CNER1
SWP
type
14
Engine wiring harness
K5
CNER2
SWP
type
K4
CNF01 M type
Head lamp right
B6
CNF02 M type
Combination lamp right
B5
CNF03 M type
Combination lamp left
F1
CNF04 M type
Head lamp left
E1
CNF05 X type
Fork positioner
B4
CNT08 X type
Parking brake indicator

sensor
G1
CNF06 X type
Lift arm kick-out
E1
CNT10 X type
Float switch (OPT)
E8
CNFR1 S type
10
Rear frame wiring

harness
F1
CNT11 X type
Emergency steering
switch (OPT)
E7
CNFR2 X type
Rear frame wiring

harness
G1
CNTL1
SWP
type
C7
CNGR1
Intermediate connector
K6
CNTL2
SWP
type
A7
CNGW1 M type
Working lamp
J8
CNLR1 S type
12
C8
20-222
q
U42103
ConConNo.
nector nector
of
No.
Type pins
TROUBLESHOOTING
Connector pin arrangement diagram (1/3)
U42103
20-223
q
TROUBLESHOOTING
(2/3)
Mounting location
Address
CNFS1 L type
Fuse box
R6
CNFS2 S type
12
Fuse box
R6
CNFS3 M type
Fuse box
R5
CNFS4 L type
Fuse box
R5
CNFS5 M type
Fuse box
R5
CNFS6 M type
Fuse box
R5
CNL01
SWP
type
Transmission
combination switch
M4
CNL02
SWP
type
Transmission
combination switch
M4
CNL03
SWP
type
Transmission
combination switch
M5
CNL04
SWP
type
14
Transmission
combination switch
M2
CNL05 AMP040 20
connector
Main monitor
M3
CNL06 AMP040 16
connector
Main monitor
M4
CNL07 AMP040 12
connector
Main monitor
M3
CNL08 AMP040
connector
Main monitor
M3
CNL63
Horn switch
M2
20-224
q
U42103
ConConNo.
nector nector
of
No.
Type pins
TROUBLESHOOTING
U42103
20-225
q
TROUBLESHOOTING
(3/3)
Mounting location
Address
Engine stop motor

(standard specification machine)
a9
CNE04 X type
RPM sensor
c5
CNE05 (Connector)
Water temperature
sensor
a9
CNE06 X type
Water temperature
sensor
X7
CNE09
Heater relay
Z8
CNE10 X type
Engine oil level sensor
Z1
CNE13 X type
Starting motor
b3
CNE15
Alternator
V6
CNE16
Alternator
W6
CNE17
Alternator
W7
CNE19 (Connector)
Dust indicator
c6
CNE20 (Connector)
Dust indicator
c5
CNE03
SWP
type
CNER1
SWP
type
14
a2
CNER2
SWP
type
Z1
20-226
q
U42103
ConConNo.
nector nector
of
No.
Type pins
TROUBLESHOOTING
U42103
20-227
q
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins, while the terms male housing and female housing
refer to the mating portion of the housing.
No.
of
pins
X type connector
Male (female housing)
Female (male housing)
TEW00219
TEW00220
U42103
2
TEW00221
TEW00222
2
TEW00223
TEW00224
4
TEW00225
20-228
q
TEW00226
TROUBLESHOOTING
No.
of
pins
AMP040 type connector

U42103
TEW00227
12
TEW00228
12
12
TEW00229
TEW00230
16
16
16
TEW00231
10
20
11
TEW00232
20
10
11
20
TEW00233
TEW00234
20-229
q
TROUBLESHOOTING
No.
of
pins
SWP type connector

TEW00235
TEW00236
U42103
TEW00238
TEW00237
1 4
11
14 10
11
14
7 10 14
TEW00239
20-230
q
TEW00240
TROUBLESHOOTING
No.
of
pins
M type connector
2
TEW00242
TEW00241
U42103
TEW00244
TEW00243
TEW00245
TEW00246
TEW00247
TEW00248
20-231
q
TROUBLESHOOTING
No.
of
pins
S type connector
TEW00249
TEW00250
10
10
U42103
10
TEW00251
12
TEW00252
12
12
20-232
q
TEW00253
TEW00254
TROUBLESHOOTING
No.
of
pins
L type connector
Male (male housing)
Female (female housing)
TEW00258
TEW00257
Diode type connector

Male (male housing)
U42103
No.
of
pins
2
2
2
TEW00261
TEW00262
20-233
q
TROUBLESHOOTING
No.
of
pins
Simple connector (ring connector)

Male (male housing)
TEW00264
TEW00263
TEW00265
U42103
TEW00263
20-234
q
TROUBLESHOOTING OF ENGINE SYSTEM

(S MODE)
S- 1
Starting performance is poor (Starting always takes time) .................................................. 20-252
S- 2
Engine does not start ............................................................................................................... 20-253

(1) Engine does not turn .......................................................................................................... 20-253
(2) Engine turns but to exhaust gas comes out (Fuel is not being injected) ................... 20-254
U42103
(3) Exhaust gas comes out but engine does not start (Fuel is being injected) ................ 20-255
S- 3
Engine does not pick up smoothly (Follow-up is poor) ........................................................ 20-256
S- 4
Engine stops during operations .............................................................................................. 20-257
S- 5
Engine does not rotate smoothly (hunting) ........................................................................... 20-258
S- 6
Engine lacks output(no power) ................................................................................................ 20-259
S- 7
Exhaust gas is black (incomplete combustion) ...................................................................... 20-260
S- 8
Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20-261
S- 9
Oil becomes contaminated quickly ......................................................................................... 20-262
S-10
Fuel consumption is excessive ................................................................................................ 20-263
S-11
Oil is in cooling water, or water spurts back, or water level goes down .......................... 20-264
S-12
Oil pressure lamp lights up (drop in oil pressure) ................................................................ 20-265
S-13
Oil level rises ............................................................................................................................. 20-266
S-14
Water temprautre becomes too high (overheating) .............................................................. 20-267
S-15
Abnormal noise is made .......................................................................................................... 20-268
S-16
Vibration is excessive ............................................................................................................... 20-269
20-251
q
TROUBLESHOOTING
S-1
S-1 Starting performance is poor (Starting always takes time)

General causes why starting performance is poor
Defective electrical system
Insufficient supply of fuel
Improper selection of fuel

(At ambient temperature of 10C or below, use ASTM D975
No. 1, and 10C or above, use ASTM D975 No. 2 diesel fuel.)
Battery charging rate.
Causes
100%
90%
80%
75%
70%
20C
1.28
1.26
1.24
1.23
1.22
0C
1.29
1.27
1.25
1.24
1.23
10C
1.30
1.28
1.26
1.25
1.24
Ambient
temperature
Legend
: Items to confirm the cause
Degree of use
Troubleshooting
Check items
Questions
Ease of starting

Gradually became worse
Starts when warm
Indicator lamp does not light up

Replacement of filters has not been carried out according to
operation manual
Battery charge lamp is ON
Starting motor cranks engine slowly
Engine does not pick up smoothly, and combustion is irregular
Mud is stuck to fuel tank cap
When engine is cranked with starting motor
1) Little fuel comes out even when injection pump sleeve
nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug
is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When air element is inspected directly, it is found to be
clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Heater mount does not become warm
Voltage is 26 30V betweem alternator terminal B and Yes
terminal E with engine at low idling
No
Either specific gravity of electrolyte or voltage of battery is low
When control rack is pushed, it is found to be heavy or does
not return (when blind plug at rear of pump is removed, it
can be seen that plunger control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged
Remedy
20-252
q
U42103
The specific gravity should exceed the value for the charging
rate of 70% in the above table.
In cold weather the specific gravity must exceed the value for
the charging rate of 75% in the above table.
Replace
Repair
Clean
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Adjust
Replace
Repair
Clean
Wor
n
Defe piston
r
c
Clog tive co ing, cy
li
n
g
Clog ed air tact of nder
cl
v
g
Clog ed fue eaner e alve, va
l
l
l
g
Clog ed fue filter, st ement ve seat
lf
ra
g
Defe ed feed ilter, st iner
r
c
Defe tive in pump ainer
stra
take
ctiv
iner
e re
Defe
h
gu eate
c
Defe tive alt lator r (ribbo
e
n ty
c
Defe tive or rnator
pe)
d
c
Defe tive in eterior
ject
a
ctiv
t
e
d
ion
e in
Lea
tim batter
je
ka
y
Clog ge, clo ction p ing
ump
ggin
ged
g, a
fuel
(rac
i
k
r
tank
,
i
air b n fuel s plunge
r stu
y
reat
ck)
her stem
hole
Charging rate
TROUBLESHOOTING
S-2
S-2 Engine does not start
Causes
iring
ew
Defe
Replace
ctiv
ctiv
Defe
Defe
Replace
Legend
e or
General causes why engine does not turn

Internal parts of engine seized
If internal parts of the engine are
seized, carry out troubleshooting for
Engine stops during operations.
Failure in power train
Defective electrical system
of s
tarti
ng c
dete
ircu
rior
ctiv
it
ated
e st
batt
artin
Bro
ery
gm
ken
otor
ring
gea
Defe
r
ctiv
e sa
fety
Defe
rela
ctiv
y or
e ba
safe
ttery
Defe
ty s
rela
ctiv
witc
y
e ba
h
t
t
e
Defe
ry te
ctiv
r
m
e ad
inal
just
con
Defe
men
nec
ctiv
tion
t of
e en
e
n
g
gine
ine
Defe
s
stop
top
ctiv
e st
mot
mot
artin
or
or w
g sw
ire
itch
(1) Engine does not turn
Questions

Degree of use
Condition of horn when starting

switch is turned ON
Horn does not sound

Horn sound level is low
Rotating speed is slow
Makes grating noise
When starting switch is turned to

START, pinion moves out, but
Soon disengages again
When starting switch is turned to ON, there is no clicking sound
When starting switch is turned to ON, linkage does not move
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) 5), turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are
3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of
starting motor are connected, engine starts
5) There is no 24V voltage between battey relay terminal B
and terminal E
Carry out troubleshooting for defective wiring of starting circuit
Battery terminal is loose
When ring gear is inspected directly, tooth surface is found

to be chipped
Replace
Replace
Adjust
Replace
Replace
Replace
Remedy
Replace
Does not move even when engine stop motor linkage is

disconnected
Check items
When starting switch is turned to START, pinion does not

move out
When battery is checked, battery electrolyte is found to be low
Troubleshooting
U42103
Makes rattling noise and

does not turn
20-253
q
TROUBLESHOOTING
S-2
(2) Engine turns but no exhaust gas comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust gas comes out
Supply of fuel impossible
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
22
30
4
20
14
10
Diesel fuel
32
0
50
10
68
20
86
30
104 122F
40 50C
ASTM D975 No.2
Legend
ken
inje
ctio
Defe
n pu
ctiv
mp
e in
driv
ject
e sh
Seiz
ion
aft,
ed,
p
ump
key
brok
(
e
r
ack,
n fe
Clog
ed p
plun
ged
ump
ger
fuel
seiz
pist
filte
Clog
ed)
on
r, st
ged
r
a
iner
feed
pum
Lack
p st
of fu
rain
el
er
Clog
ged
, lea
king
Clog
fuel
ged
pipi
fuel
ng
tank
Defe
air b
ctiv
e en
reat
gine
her
Imp
hole
stop
rope
mot
r fue
or
l us
ed
Ambient temprature
Type of fuel
Bro
Standards for use of fuel
Causes

Exhaust gas suddenly stops coming out (when starting again)

operation manual
U42103
Questions
Degree of use
Fuel tank is found to be empty

There is leakage from fuel piping
When starting switch is turned ON, linkage does not move
When fuel filter is drained, fuel does not come out
Check items
When engine is cranked with starting motor,

1) Injection pump coupling dose not rotate
2) No fuel comes out even when fuel filter air bleed plug is
loosened
3) No fuel spurts out even when injection pipe sleeve nut is
loosened
Rust and water are found when fuel is drained
Troubleshooting
Check injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Check feed pump directly
When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
20-254
e
Replace
Replace
Repair
Repair
Add
Clean
Clean
Replace
Replace
Remedy
Replace
Does not move even when engine stop motor linkage is

disconnected
TROUBLESHOOTING
S-2
(3) Exhaust gas comes out but engine does

not start
(Fuel is being injected)
General causes why exhaust gas comes out
but engine does not start
Lack of rotating force due to defective
electrical system
Improper selection of fuel
Legend
Defe
ctive
, bro
Defe
ken
ctiv
valv
e
e sy
inje
Wor
stem
ctio
n pi
n pu
(valv
ston
mp
e, ro
Clog
r
i
(rac
n
cker
g, c
ged
k, p
y
leve
fuel
lind
l
u
Clog
r, et
nge
er
filte
c.)
ged
r stu
r, st
feed
ck)
rain
Clog
er
pum
ged
p st
air c
rain
Defe
lean
er
ctiv
er e
e
inta
lem
Defe
k
ent
e he
ctiv
ater
e or
Lea
(ribb
dete
kag
on h
riota
e, cl
eate
ted
ogg
Clog
batt
r typ
ing,
ged
ery
e)
air i
inje
Clog
n fu
c
t
i
o
el sy
ged
n no
fuel
stem
zzle
Imp
, de
tank
rope
fect
air b
r fue
ive
reat
spra
l us
her
ed
y
hole
Causes

Degree of use
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around head
operation manual
Rust is found when fuel is drained
U42103
Indicator lamp does not light up

Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not
contact stopper
Check items
When engine is cranked with starting motor,

1) Little fuel comes out even when injection pump sleeve
nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug
is loosened
starting engine, temperature of some cylinder is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly
When control rack is pushed, it is found to be heavy, or
does not return

found to be clogged
be clogged
When air element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or pump
is heavy
Clean
Clean
Repair
Replace
Clean
Repair
Clean
Clean
Replace
Remedy
Replace
Replace
Troubleshooting
20-255
q
TROUBLESHOOTING
S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick
up smoothly
Improper fuel used
Clog
Legend
ged
air c
Clog
lean
ged
er e
fuel
lem
Clog
filte
e nt
ged
r
, str
feed
Clog
pum ainer
ged
p st
inje
Seiz
rain
ctio
er
ed i
n no
n
j
ecti
zzle
Wor
o
, de
n pu
n pi
fect
mp
ston
ive
Seiz
plun
ring
spra
ed t
g
,
y
er
c
urbo
ylin
Imp
de r
cha
rope
r
g
e
r, in
r va
Clog
lve
terfe
ged
clea
re nc
ra nc
fuel
e
Clog
e
tank
ged
a
i
,
r
leak
b
Defe
r
e
ing
athe
ctiv
fuel
r ho
e co
pipi
le
ntac
ng
t of
valv
e, v
alve
seat
Causes
Questions
Degree of use

operation manual
U42103

Engine pick-up suddenly became poor

Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
When fuel filter, strainer are inspected directry, they are
found to be clogged
Troubleshooting

be clogged
does not return
When valve clearance is checked directly, it is found to be
20-256
q
Replace
Clean
Repair
Adjust
Replace
Replace
Replace
Clean
Repair
Clean
Remedy
Clean
When feed pump is operated, operation is too light or too heavy
TROUBLESHOOTING
S-4
S-4 Engine stops during operations

General causes why engine stops during
operations
Seized parts inside engine
Overheating
If there is overheating and insufficient output, carry out troubleshooting for overheating.
Failure in power train
If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.
Bro
Legend
ken
, sei
Bro
zed
ken
pist
, sei
on c
zed
Bro
onn
ken
cran
valv
ksha ecting r
Bro
e sy
od
ken
stem ft bear
, sei
ing
(val
zed
Bro
ve,
ken
gea
rock
r tra
pum
er le
Bro
in
p au
ken
ver,
xilia
fuel
etc.
ry e
Lack
)
pum
quip
of fu
p dr
m
e
i
el
ve s
nt
Clog
haft
ged
, key
fuel
Clog
filte
ged
r
,
s
f
t
e
r
a
e
Bro
iner
d pu
ken
mp
, sei
stra
Clog
zed
ine
f
ged
, lea eed pum r
Clog
king
p pi
ged
fuel
ston
fuel
pipi
Defe
tank
ng
ctiv
a
e
i
r
inje
brea
Fail
ctio
ther
ure
n pu
in c
hole
mp
has
(rac
sis p
k, p
owe
lung
r tra
er s
in
tuck
)
Causes

Degree of use
Questions
Condition when engine

stopped
Engine overheated and stopped

Engine stopped slowly
There was hunting and
engine stopped
Fuel gauge lamp lights up

operation manual
When feed pump is operated, there is no response or it is heavy
Carry out troubleshooting in chassis volume
Does not turn at all

Try to turn by hand using
barring tool
Turns in opposite direction

Moves amount of backlash
Shaft does not turn

Metal particles are found when oil is drained
Remove oil pan and check directly
When gear train is inspected, it does not turn
Turns when pump auxiliary equipment is removed
found to be clogged
be clogged
Check feed pump directly
Clean
Replace
Repair
Clean
Replace
Add
Clean
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
When control rack is pushed, it is fond to be heavy or does

not return
Check items
Engine turns, but stops when transmission control lever is

operated
Troubleshooting
U42103
Abnormal noise was heard

and engine stopped suddenly
20-257
q
TROUBLESHOOTING
S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
Air in fuel system
Defective governor mechanism
Legend
Defe
ctiv
e op
erat
Defe
ion
ctiv
of g
e ad
ove
j
ustm
Defe
rnor
ent
ctiv
of g
e op
ove
erat
Low
rnor
ion
spe
of c
ed i
ontr
s to
Lack
o
l
o
rack
low
of fu
el
Clog
ged
feed
Clog
pum
eed
p st
rain
fuel
er
filte
Clog
r, st
eed,
rain
air in
e
r
Clog
circu
it be
eed
, air
twee
in ci
n fu
Clog
rcui
el ta
ged
t
nk a
b
e
fuel
twe
nd f
en f
tank
eed
eed
pum
air b
pum
p
reat
p an
her
d no
hole
zzle
Causes

Degree of use

Occurs at certain speed range
Condition of hunting
Ocuurs even when speed is

raised
U42103
Questions
Occurs at low idling
Ocuurs on slopes
operation manual
Rust is found when fuel is drained
Check items
When feed pump is operated,

1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too high
Engine is sometimes difficult to stop
When governor lever is moved it is found to be stiff
Troubleshooting
When injection pump is tested, governor is found to be

improperly adjusted
does not return
be clogged
20-258
q
Clean
Repair
Repair
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust

found to be clogged
TROUBLESHOOTING
S-6
S-6 Engine lacks output (no power)

General causes why engine lacks output
Improper fuel used
(if non-specified fuel is used, output
drops)
Lack of output due to overheating
If there is overheating and insufficient
output, carry out troubleshooting for
overheating.
Legend
Clog
ged
air c
Seiz
lean
ed t
er e
urbo
lem
Wor
cha
ent
n pi
rger
ston
, int
Clog
ring
erfe
ged
, cyl
renc
fuel
inde
e
Clog
filte
r
ged
r, st
f
rain
eed
Clog
er
pum
ged
p st
inje
rain
Seiz
ctio
er
ed i
n
noz
njec
zle,
Imp
tion
defe
rope
p
u
ctiv
r va
mp
e sp
Defe
lve
ray
clea plunge
ctiv
r
e co
ranc
Ben
ntac
e
t fue
t
o
f
l lev
valv
Clog
er li
e, v
ged
nka
alve
, lea
ge,
seat
Clog
defe
k
ing
ged
ctiv
fuel
fuel
e ad
pipi
tank
just
ng
men
air b
t
reat
her
hole
Causes
Questions
Degree of use
Power was lost

Suddenly
Gradually

operation manual
U42103
Black

Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
High idling speed of engine is low
When trubocharger is rotated by hand, it is found to be heavy
When feed pump strainer are inspected directly, it is found

to be clogged
dose not return
When lever is placed at FULL position, it does not contact
stopper
When feed pump is operated, operation is too light or too heavy
Clean
Adjust
Repair
Adjust
Replace
Replace
Clean
Repair
Clean
Replace
Remedy
Clean
Replace
Troubleshooting

found to be clogged
20-259
q
TROUBLESHOOTING
S-7
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
Legend
Seiz
ed t
Clog urboch
arge
ged
r, in
air c
Wor
terfe
lean
n pi
renc
er e
ston
e
lem
Clog
ring
ent
ged
, cyl
,
seiz
inde
Imp
ed i
r
rope
njec
r inj
tion
Defe
ecti
noz
ctiv
on t
zle
e in
imin
Imp
g
rope jection
p
r
u
v
m
alve
Cru
p (e
she
clea
xces
d, c
ranc
sive
logg
Lea
e
inje
kag
e
dm
ctio
e of
uffle
n)
Defe
air b
r
ctiv
etw
e
e
en t
con
Deff
urbo
tact
ecti
of v
cha
ve i
rger
alve
njec
, va
and
tion
lve
hea
pum
seat
d
p (ra
ck, p
lung
er s
eize
d)
Causes

Degree of use

Gradually became black
U42103
Questions
Suddenly became black


Power was lost
Suddenly
Gradually

Check items

Exhaust noise is abnormal
Muffler is crushed
When air cleaner is inspected directly, it is found to be clogged
Troubleshooting

When valve clearance is checked directly it is found to be
When muffler is removed, exhaust gas color returns to normal
20-260
q
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy, or does

not return
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive (or exhaust gas is blue)

Do not run the engine at idling for more
than 20 minutes continuously. (Both low
and high idling)
General causes why oil consumption is excessive
Abnormal combustion of oil
External leakage of oil
Wear of lubrication system
ken
pist
Wor
on r
n pi
ing
ston
Clog
ring
ged
, cyl
brea
inde
Lea
ther
r lin
kag
or b
e fro
er
reat
Lea
m
oil f
kag
her
ilter
e fro
hos
, oil
Lea
e
mo
kag
coo
il pi
e fro
ler
p
ing
Lea
m
oil d
kag
e fro
rain
Bro
mo
plug
ken
il pa
oil c
n, c
Wor
ylin
oole
der
n se
r
hea
al a
Wor
d, e
t tur
tc.
n se
bine
al a
e
n
Wor
t blo
d
n, b
wer
r
oke
end
Dus
nr
t su
cked ear sea
Turb
Wor
l, se
i
n fro
och
n va
al su
m in
arge
lve
rfac
take
(ste
r
e
m, g
syst
uide
em
), br
oke
n se
al
Bro
Legend
Questions

Degree of use
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust gas is blue under light load
Amount of blow-by gas
Abnormally excessive
None
Check items
Area around engine is dirty with oil

There is oil in engine cooling water
When exhaust pipe is removed, inside is found to be dirty
with oil
Inside of turbocharger intake pipe is dirty with oil
Oil level in clutch or TORQFLOW transmission damper
chamber rises
Clamps for intake system are loose
When breather element is inspected, it is found to be
clogged with dirty oil
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Check rear seal directly
When intake manifold is removed, dust is found inside
Repair
Repair
Repair
Repalce
Repalce
Repair
Replace
Repair
Repair
Clean
Repair
Remedy
Replace
When intake manifold is removed, inside is found to be dirty

with oil
Replace
Troubleshooting
U42103
Causes
20-261
q
TROUBLESHOOTING
S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
Intake of exhaust gas due to internal wear
Clogging of lubrication passage
Improper combustion
Improper oil used
Operation under excessive load
Legend
Questions

Degree of use

Amount of blow-by gas
Abnormally excessive
None
Carry out troubleshooting for "Exhaust is black"
Check items
Black
Oil filter caution lamp stays on even when oil pressure rises
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly
Troubleshooting

When breather element is inspected directly, it is found to be clogged with
dirty oil, or hose is broken
When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
20-262
q
Repalce
Repalce
Clean
Clean
Replace
Replace
Clean
Remedy
Replace
When safety valve is directly inspected, spring is found to be catching or

broken
U42103
Wor
n pi
ston
ring
Clog
, cyl
ged
inde
brea
r
ther
Clog
, bre
ged
athe
oil f
r tub
ilter
Wor
e
n va
lve,
valv
Clog
e gu
ged
ide
oil c
oole
Clog
r
ged
turb
och
Defe
rage
ctiv
r dr
e se
ain
a
l at
Defe
pipe
turb
ctiv
o
cha
e sa
rger
fety
Exh
turb
valv
aus
ine
e
t ga
end
s is
blac
k
Causes
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
Leakage of fuel
ject
ion
pum
p (e
ject
xces
Defe
ion
sive
ctiv
noz
e in
z
inje
le sp
j
e
ctio
ctio
Imp
r
a
n)
y
n pu
rope
mp
r fue
plun
l inj
Exte
ger
ecti
rnal
on t
leak
imin
age
Lea
g
from
kag
e of
fuel
fuel
pipi
Defe
insi
ng,
ctiv
de h
fuel
e oi
e
a
filte
l
d
seal
Defe
c
r
o
v
insi
e
ctiv
r
de f
e ad
eed
just
pum
men
p (p
t of
isto
fuel
n)
leve
r lin
kag
e
Replace
e in
ctiv
Defe
ctiv
e in
Defe
Legend
Adjust
Causes
Questions

More than for other machines of
same model
Condition of fuel consumption

Gradually increased
Suddenly increased
Exhaust gas color
Black
White
Check items
There is irregular combustion

When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling speed is high
Injection pump test shows that injection amount is excessive
Speed of some cylinders does not change when operating on reduced
cylinders
When control rack is pushed, it is found to be heavy, or does not return
When check is made using delivery method, injection timing is found to be
incorrect
Remove feed pump and check directly
Adjust
Repair
Repair
Adjust
Remedy
Repair
When engine speed is measured, low idling speed is found to be high

Replace
Troubleshooting
U42103
Degree of use
20-263
q
TROUBLESHOOTING
S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes
down
General causes why oil is in cooling water
Internal leakage in lubrication system
Internal leakage in cooling system
Bro
Replace
Questions

Degree of use

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Excessive air bubbles inside radiator, spurts back

Hydraulic oil, torque converter transmission oil is cloudy white
When hydraulic oil, torque converter transmission oil is drained, water is
found
Pressure-tightness test of cylinder head shows there is leakage
Remove cylinder head and check directly
Remedy
20-264
q
Replace
Troubleshooting
Check items
Engine oil level has risen, oil is cloudy white
U42103
rusi
on o
f lin
oole
er
r for
ken
pow
line
r
e
r tra
O-ri
Inte
ng,
in
rnal
hole
crac
s ca
ks in
use
cylin
d by
der
pitti
bloc
ng
k
Bro
ken
Replace
oil c
ket
gas
ent
prot
ead
ffici
Insu
Replace
ken
Bro
Replace
ken
Bro
Replace
hea
oil c
Legend
d, h
oole
r co
re, O
-ring
Causes
TROUBLESHOOTING
S-12
S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights
up
Leakage, clogging, wear of lubricating
system
Defective oil pressure control
Improper oil used (improper viscosity)
Deterioration of oil due to overheating
Standards for engine oil selection
Selection of oil SAE number according
to ambient temperature
Type of oil
22
30
4
20
14
10
32
0
50
10
68
20
86
30
104 122F
40 50C
Causes
SAE 30
Engine oil
Legend
Questions
Dregree of use
Replacement of filter has not been carried out according to

operation manual
Caution lamp lights up
Lights up at low idling
Condition when oil pressure
lamp lights up
Lights up at low, high idling

Lights up on sloes
Check items
Sometimes lights up
There is clogging, leakage from hydraulic piping (external)
Oil level sensor lamp lights up
When oil level in oil pan is checked, it is found to be low
Metal particles are stuck to oil filter element
When oil filter is inspected directly, it is found to be clogged

Oil pump rotation is heavy, there is play
There is catching of relief valve, regulator valve, spring, or
valve guide is broken
When oil level sensor is replaced, oil pressure sensor lamp
goes out
Replace
Adjust
Repair
Add
Adjust
Replace
Clean
Repair
Clean
Clean
Remedy
Clean
When oil pressure is measured, it is found to be within

standard value
Replace
Carry out troubleshooting for "Oil level

rises"
Oil is cloudy white or smells of diesel oil
Troubleshooting
U42103
SAE 15W-40
Clog
ged
oil f
Wor
ilter
n be
arin
Clog
g jo
ged
urna
stra
l
Clog
iner
ged
insi
,
d
b
e oi
roke
Bro
l pa
ken
n oi
n
l pip
Defe suction
e
i
n
ctiv
pipe
side
e
b
oil p
oil p
Insu
an
ump razing
ffci
Defe ent oil
in o
ctiv
il pa
e re
n
Defe
gula
tor v
ctiv
e
alve
relie
Lea
f va
king
lve
Defe , crush
ed h
ctiv
ydra
e oi
Defe
l lev
el se ulic pip
ctiv
e oi
ing
nso
Wat
l pre
r
er, f
ssur
uel
e se
in o
nso
il
r
SAE 10W-30
20-265
e
TROUBLESHOOTING
S-13
S-13 Oil level rises

If there is oil in the cooling water, carry
out troubleshooting for Oil is in cooling
water.
General causes why oil level rises
Water in oil (cloudy white)
Fuel in oil (diluted, and smells of diesel
fuel)
Entry of oil from other component

Degree of use
U42103
Questions
Legend
Bro
ken
oil c
oole
Defe
r co
ctiv
re, O
e no
-ring
zzle
Brok
hold
en h
ead
er s
, hea
l
eev
d ga
Clog
e
sket
ged
(inclu
wat
d
in
e
r pu
g pr
Wor
ecom
mp
n, d
brea
bus
ama
tion
ther
ged
Defe
cham
hole
rear
ctiv
ber)
, de
seal
e se
f
e
a
s
c
Lea
urfa
l of
t
i
v
e
kag
pum
ce
seal
e of
p or
fuel
aux
Defe
from
iliar
ctiv
y eq
pipi
e in
uipm
ng i
side
Defe
nsid
ent
inje
ctiv
e
c
hea
tion
e th
d co
erm
pum
Dam
v
osta
er
p (fl
age
t se
ang
d lin
at
e ty
er O
p
Crac
e
)
-ring
ks in
, ho
side
les m
cylin
ade
der
by p
bloc
ittin
k
g
Cause
There is oil in radiator cooling water

Exhaust gas is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idling, an
abnormal number of bubbles appear, or water spurts back
Check items
Water pump breather hole is clogged with mud

When water pump breather hole is clean, water comes out
Oil level goes down in clutch, TORQFLOW transmission, or
damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel is added more frequently
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage

Remove water pump and check directly
Check rear seal directly
When pump auxiliary equipment is removed, seal is found
to be broken
Remove injection pump and check directly
There is improper contact of thermostat seat valve
20-266
q
Replace
Replace
Repair
Replace
Repair
Replace
Repair
Replace
Replace
Replace
Remedy
Replace
TROUBLESHOOTING
S-14
Causes
Bro
ken
wat
er p
Clog
ump
ged
, cru
she
Clog
d ra
ged
diat
radi
or fi
ator
n
Defe
c
o
ctiv
re
e th
e
rmo
Defe
stat
ctiv
(doe
ew
a
s no
t
er te
Insu
t op
ffici
m pe
en)
ent
ratu
c
ooli
re g
Fan
ng w
aug
belt
e
ater
slip
ping
Clog
, wo
ged
r
n
, bro
fan
ken
pull
Defe
ey
oil c
ctiv
oole
e pr
r
e
s
Bro
sure
ken
valv
hea
e
d, h
Dam
ead
age
gas
d lin
ket
er O
Rise
-ring
in to
, ho
rque
les m
con
ade
vert
by p
er o
ittin
il te
mpe
g
ratu
re
S-14 Water temperature becomes too high

(overheating)
General causes why water temperature becomes too high
Lack of cooling water (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Rise in oil temperature of power train
Carry out troubleshooting for chassis.
Legend
Degree of use

Suddenly overheated
Condition of overheating
Questions
Always tends to overheat

Rises quickly
Water temperature gauge
Does not go down from red

range
Radiator water level sensor lights up

Fan belt whines under sudden load
U42103
Cloudy white oil is floating on cooling water

Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
Belt tension is found to be slack
Power train oil temperature enters red range before engine
water temperature
Carry out troubleshooting for chassis
Temperature difference between top and bottom radiator

tank is excessive
When water filler port is inspected, the core is found to be clogged

When a function test is carried out on the thermostat, it does
not open even at the cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Replace
Replace
Replace
Repair
Replace
Add
Repalce
Repair
Replace
Remedy
Repair

Replace
Troubleshooting
Temperature difference between top and bottom radiator

tank is slight
20-267
q
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made
Legend
Causes
Wor
n pi
ston
ring
Seiz
, cyl
ed t
inde
urbo
r lin
c
harg
Mis
er
sing
er, i
nter
, sei
fere
zed
Clog
nce
bus
ged
hing
, sei
zed
Defe
inje
ctiv
ctio
e in
n no
ject
Defe
zzle
ion
ctiv
pum
e in
p (ra
ject
Defo
ck, p
ion
pum
rme
lung
d fa
p (e
er s
n, in
xces
eize
Imp
terfe
d)
rope
sive
renc
r ad
inje
c
j
e of
ustm
tion
Bro
fan
)
ken
ent
belt
valv
of v
alve
e sy
Imp
stem
clea
rope
ranc
(val
r ge
e
ve,
ar tr
Lea
rock
ain
kag
e
r lev
bac
e of
klas
er, e
air b
h
Defe
tc.)
etw
ct in
een
side
t
u
rboc
muf
harg
fler
(div
er a
idin
nd h
g bo
ead
ard
out
of p
osit
ion)
Judge if the noise is an internal noise or

an external noise.
General causes why abnormal noise is made
Abnormality due to defective parts
Abnormal combustion noise
Air sucked in from intake system
Questions
Degree of use
Condition of abnormal noise

Gradually occurred
Suddenly occurred

Color or exhaust gas
U42103
Black
Metal particles are found in oil filter
Check items

Abnormal noise is loud when accelerating engine
Vibrating noise is heard from around muffler
When trubocharger is rotated by hand, it is found to be heavy
Troubleshooting
Remove gear cover and check directly

When control rack is pushed, it is found to be heavy or does not return
Fan is deformed, or belt is loose
Remove cylinder head cover and check directly
20-268
q
Replace
Repair
Repair
Adjust
Replace
Adjust
Repair
Replace
Replace
Replace
Replace
Remedy
Replace
When muffer is removed, abnormal noise disappers
TROUBLESHOOTING
S-16
S-16 Vibration is excessive

If there is abnormal noise together with
the vibration, carry out troubleshooting
for Abnormal noise is made.
General causes why vibration is excessive
Defective parts (abnormal wear, breakage)
Improper alignment
Abnormal combustion
n co
nne
ctin
Wor
g ro
n ba
d, m
lanc
ain
er, c
Wor
bea
am
ring
n su
bus
ppo
hing
r
t pil
Loo
ot
se e
ngin
em
Bro
oun
ken
ting
part
bolt
insi
Mis
s, b
de o
alig
roke
utpu
nme
n cu
t sh
nt b
shio
Imp
aft (
etw
n
rope
dam
een
r ge
per)
eng
a
ine
r tra
Valv
and
in b
e sy
pow
ackl
stem
ash
er tr
(val
Defe
ain
v
e, ro
ctiv
e in
cker
ject
leve
ion
r, et
pum
c) st
p (e
uck
xces
sive
inje
ctio
n)
Wor
Legend
Questions
Degree of use
Condition of vibration

Suddenly increased
Gradually increased

Metal particles are found in oil filter
Check items

Oil pressure is low at low idling
Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust gas is black
Remove oil pan and check directlyG
Remove side cover and check directly
Check directly for worn support pilot, play
Check directly for loose engine mounting bolts, broken cushion
Check inside of output shaft (damper) directly
When radial runout, face runout are measured, they are
found to be outside standard value
Remove front cover and check directly
Adjust
Repair
Replace
Repair
Replace
Replace
Replace
Remedy
Replace
Replace
Troubleshooting
U42103
Causes
20-269
q
TROUBLESHOOTING OF
MAIN MONITOR SYSTEM
(M MODE)
Trouble data display (option) ............................................................................................................... 20-303

M- 1
M- 2
M- 3
M- 4
U42103
M- 5
M- 6
M- 7
M- 8
M- 9
M-10
M-11
M-12
Main monitor does not work ................................................................................................... 20-304

When starting switch is turned ON and engine is started immediately,
all lamps stay lighted up .......................................................................................................... 20-305
Speedometer display does not work properly ....................................................................... 20-306
Abnormality in shift indicator
(a) Stays at N even when directional lever is at F ............................................................... 20-307
(b) Stays at N even when directional lever is at R ............................................................... 20-307
(c) Does not display N even when directional lever is at N and displays R when
directional lever is at F ....................................................................................................... 20-307
(d) Does not display N even when directional lever is at N and displays F when
directional lever is at R ...................................................................................................... 20-308
(e) Does not display 1st, 4th ................................................................................................... 20-308
(f) Does not display 3rd, 4th ................................................................................................... 20-309
(g) Does not display 2nd, 3rd .................................................................................................. 20-309
(h) Does not display 1st, 2nd .................................................................................................. 20-310
High beam does not light up ................................................................................................... 20-311
Turn signal display does not light up
(a) L.H. turn signal does not light up ..................................................................................... 20-312
(b) R.H. turn signal does not light up ..................................................................................... 20-312
Abnormality in parking display
(a) Parking lamp does not light up ......................................................................................... 20-313
(b) Parking lamp stays lighted up ........................................................................................... 20-313
Abnormality in preheating system (QGS)
(a) Does not carry out preheating .......................................................................................... 20-314
(b) Always carries out preheating for 1 minute .................................................................... 20-315
(c) Preheating stays on ............................................................................................................ 20-315
(d) Preheating time becomes shorter, or there is variation ................................................. 20-316
Night lighting does not light up .............................................................................................. 20-317
Abnormality in front working lamp (option)
(a) Neither monitor display nor front working lamp light up ............................................. 20-318
(b) Working lamp lights up but monitor display does not light up .................................... 20-318
(c) Monitor lights up but working lamp does not light up .................................................. 20-318
Abnormality in rear working lamp
(a) Neither monitor display nor rear working lamp light up ............................................... 20-319
(b) Working lamp lights up but monitor display does not light up .................................... 20-319
(c) Monitor lights up but working lamp does not light up .................................................. 20-319
Abnormality in transmission cut-off
(a) When monitor switch is pressed, cut-off function is not switched and display
is not given .......................................................................................................................... 20-321
(b) Monitor display goes out but cut-off function stays on ................................................. 20-321
(c) Monitor display lights up but cut-off function is not actuated ...................................... 20-322
20-301
q
M-14
M-15
M-16
M-17
M-18
M-19
M-20
M-21
Abnormality in parking brake dragging warning

(a) When parking brake is applied, buzzer sounds (intermittently) even when
directional lever is at N, and caution lamp flashes ........................................................ 20-323
(b) When parking brake is applied, buzzer does not sound and caution lamp
does not light up even when directional lever is at position other than N ................ 20-323
When parking brake dragging warning is given, buzzer and caution lamp
are actuated continuously, or they are not actuated
(a) Actuated continuously ........................................................................................................ 20-324
(b) Not actuated ........................................................................................................................ 20-324
Abnormality in buzzer
(a) Buzzer does not sound when starting switch is turned ON (during self-check) ......... 20-325
(b) Buzzer always sounds ........................................................................................................ 20-325
Condition of monitor switches is not stored in memory ..................................................... 20-326
Abnormality in failure display mode
(a) Does not enter failure display mode ................................................................................ 20-327
(b) Time for time elapsed since failure on failure display mode does not advance ....... 20-327
Abnormality in emergency steering normal display (option)
(a) Emergency steering normal display does not light up .................................................. 20-328
(b) Emergency steering normal display stays lighted up .................................................... 20-328
Abnormality in emergency steering actuation display (option)
(a) Emergency steering actuation display does not light up ............................................... 20-329
(b) Emergency steering actuation display stays lighted up ................................................. 20-329
Abnormality in ECSS system (option)
(a) Display does not change when switch is pressed .......................................................... 20-330
(b) Monitor display lights up but ECSS function does not work ........................................ 20-330
Failure code is not sent to main monitor (abnormality in network) (option) .................... 20-331
20-302
q
U42103
M-13
TROUBLESHOOTING
TROUBLE DATA DISPLAY
TROUBLE DATA DISPLAY (OPTION)
U42103
1. Outline
The speedometer display on the main monitor is used to display the troubleshooting
for each control system. The nature of the
troubleshooting is displayed as the failure
code, and the time elapsed since failure.
The signals between the main monitor and
controller are transmitted in serial through
the network circuit.
2. Failure code and time elapsed since failure
The failures detected by controller are
changed to a code and displayed.
For failures that have occurred and been reset, the failure code and the time elapsed
since failure are displayed to make it easy to
check failures that are not occurring at
present.
The failure codes for failures that are now
occurring flash, and the codes for failures
that are not occurring light up.
For details of the method of operating and
transferring data to the trouble data display
mode, see STRUCTURE AND FUNCTION for
the main monitor.
Note: If the engine is not stopped, it is impossible to switch to the trouble data
display mode, so the codes for failures which can only be detected
when the engine is operating light
up.
For the correspondence between the failure
codes for controller and the failed system,
see Item 5.
Example: When failure code 41 has occurred

27 hours before
SPEED
Failure code
Time elapsed
since failure
TDW00284
3. Failure code chart

ECSS control system
d0 Relief solenoid system
High pressure solenoid
d1 system
d2 Low pressure solenoid
system
d3 Speed sensor system
Abnormality in model
d4 selection
20-303
q
TROUBLESHOOTING
M-1
M-1 Main monitor does not work

Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause
YES
Remedy
Defective main monitor
Replace
(female) (1), (2) and
CNFS2 (9)
After inspection,
repair or replace
1
Is voltage
between CNL05
(1), (2) (3)
normal?
1) 20 30 V
2) Turn starting
switch ON.
YES
2
Is there continuity
between CNL05
NO (female) (3) and
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNL05.
After inspection,
repair or replace
(female) (3) and CNLR2 (11)
U42103
NO
Power source
Battery relay
Maintenance monitor Buzzer
CNL05
q
w
e
CNL06
CNFS2
o
CNLR5
Fuse
CNFS1
CNLR6
Slow blow fuse
CNE02
!6
CNL07
CNR11
!2
TDW00285
20-304
q
TROUBLESHOOTING
M-2
M-2 When starting switch is turned ON and engine is started

immediately, all lamps stay lighted up
Remedy
Cause
1 YES
Is voltage
between CNL05
(4) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch START.
Replace
After inspection,
repair or replace
(female) (4) and CNL57 (3)
NO
U42103
Neutral relay
Start signal,
neutral signal
CNL57
Starting motor
q w et y
CNL05
r
i
Starting
CNL04
Speed lever
CNLR5
Neutral
CNR10
Rear frame GND
CNL09
Starting switch
C
TDW00286
20-305
q
TROUBLESHOOTING
M-3
M-3 Speedometer display does not work properly

Check that the gap between the speed sensor and gear is normal.
Cause
2 YES
Is resistance
YES between CNL07
(female) (1) and
1
(2) normal?
Is resistance
between CNT06
(male) (1) and (2)
normal?
NO
NO
Replace
(female) (1), (2) CNTL2
(1), (2) CNT06 (1), (2)
After inspection,
repair or replace
Defective speed sensor
Replace
U42103
1) 500 1 k
2) Turn starting
switch OFF.
3) Disconnect
CNT06.
1) 500 1 k
2) Turn starting
switch OFF.
3) Disconnect
CNL07.
Remedy
Speedometer
CNL07
CNTL2
q
w
q
w
CNT06
Speed sensor
q
w
TDW00287
20-306
q
TROUBLESHOOTING
M-4
M-4 Abnormality in shift indicator

Check that the transmission shifts.
Cause
Remedy
(a) Stays at N even when directional lever is at F

1 YES
Is voltage
between CNL08
(7) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
3) Directional
lever: F
NO
Replace
After inspection,
repair or replace
(b) Stays at N even when directional lever is at R
U42103
1 YES
Is voltage
between CNL08
(8) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
3) Directional
lever: R
NO
Replace
After inspection,
repair or replace
(c) Does not display N even when directional

lever is at N and displays R when directional
lever is at F
1 YES
Is voltage
between CNL08
(8) and chassis
ground normal?
1) 0 5 V
2) Turn starting
switch ON.
3) Directional
lever: N
NO
Replace
Contact of power source

with wiring harness
After inspection,
between CNL08 (female) (8)
repair or replace
and CNL04 (4), or defective
control lever
20-307
q
TROUBLESHOOTING
(d) Does not display N even when directional

lever is at N and displays F when directional
lever is at R
1 YES
Is voltage
between CNL08
(7) and chassis
ground normal?
1) 0 5 V
2) Turn starting
switch ON.
3) Directional
lever: N
NO
M-4
Cause
Remedy
Replace

with wiring harness
between CNL08 (female)
(7) and CNL04 (2), or
defective control lever
After inspection,
repair or replace
Replace
(e) Does not display 1st, 4th
1) 20 30 V
2) Turn starting
switch ON.
3) Speed lever: 1
20-308
q
NO
After inspection,
repair or replace
U42103
1 YES
Is voltage
between CNL05
(12) and chassis
ground normal?
TROUBLESHOOTING
M-4
(f) Does not display 3rd, 4th

Cause
1 YES
Is voltage
between CNL05
(13) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
3) Speed lever: 3
Remedy
Replace
After inspection,
repair or replace
NO
(g) Does not display 2nd, 3rd

1 YES
Is voltage
between CNL05
(12) and chassis
ground normal?
NO
Replace

with wiring harness
(12) and CNL04 (5), or
defective control lever
After inspection,
repair or replace
U42103
1) 0 5 V
2) Turn starting
switch ON.
3) Speed lever: 2
Relationship between monitor

input signal and display
H : 20 30 V
L : 0V
CNL05(12)
CNL05(13)
Display
20-309
q
TROUBLESHOOTING
M-4
(h) Does not display 1st, 2nd
Cause
1) 0 5 V
2) Turn starting
switch ON.
3) Speed lever: 2
NO
Replace

with wiring harness
(13) and CNL04 (7), or
defective transmission
lever
After inspection,
repair or replace
CNL04
w
r
t
u
Transmission range
CNL05
!2
!3
CNL08
CNTL1
t
y
i
u
i
FORWARD relay
REVERSE relay
CNL66
CNL67
CNT03
Transmission lever
F
R
1ST
3RD
Hi-Lo
q
w
CNT04
U42103
1 YES
Is voltage
between CNL05
(13) and chassis
ground normal?
Remedy
SPEED
q
w
TDW00288
20-310
q
TROUBLESHOOTING
M-5
M-5 High beam does not light up

Before starting troubleshooting, check that the lamp bulb is not blown.
Cause
2 YES
Is there continuity
YES between CNL06
(female) (13) and
1
chassis ground?
Is voltage
between CNL06
(12) and chassis
ground normal?
U42103
1) 20 30 V
2) Turn starting
switch ON.
1) Turn starting
switch OFF.
2) Disconnect
CNL06.
3) Dimmer switch:
H beam
Remedy
Replace
After inspection,
repair or replace
NO
After inspection,
repair or replace
(female) (12) and CNFS2 (2)
NO
Hi beam
CNL06
CNFS2
!2
!3
w
q
CNL02
w
e
Lamp switch
Dimmer switch
CNLR1
!0
i
CNFR1
r
w
CNF01
w
e
R.H. head lamp
TDW00290
20-311
q
TROUBLESHOOTING
M-6
M-6 Turn signal display does not light up

Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the
monitor is not blown.
Cause
Remedy
(a) L.H. turn signal does not light up

1 YES
Is voltage
between CNL06
(14) and chassis
ground normal?
After inspection,
repair or replace
NO
1) Repeat 0V and
20 30 V.
2) Turn starting
switch ON.
Replace
(b) R.H. turn signal does not light up

1) Repeat 0 V and
20 30 V.
2) Turn starting
switch ON.
CNL06
!4
!5
After inspection,
repair or replace
NO
Turn signal
Replace
To turn signal lamp
CNL03
r
e
w
Turn signal switch

L
R
CNL12
L
B
E
Hazard switch
Turn signal unit
TDW00291
20-312
q
U42103
1 YES
Is voltage
between CNL06
(15) and chassis
ground normal?
TROUBLESHOOTING
M-7
M-7 Abnormality in parking display

(a) Parking lamp does not light up

Before starting troubleshooting, check that the
lamp bulb is not blown.
Cause
YES
1
Is there continuity
between CNT08
(male) (1) and
(2)?
1) Disconnect
CNT08.
2) Turn starting
switch ON.
3) Turn parking
switch ON.
2 YES
Is voltage
between CNL06
NO (11) and chassis
ground normal?
Defective parking brake

indicator switch
Replace
Replace

CNL06 (female) (11)
After inspection,
CNTL2 (3) CNT08 (female)
repair or replace
(1) short circuiting with
chassis ground
NO
1) 20 30 V
2) Turn starting
switch ON.
3) Turn parking
switch ON.
Remedy
(b) Parking lamp stays lighted up
U42103
3 YES
Is voltage
YES between CNL06
(11) and chassis
ground normal?
2
Is there continuity
YES between CNT08

1
Is there continuity
between CNT08
(male) (1) and
(2)?
1) Disconnect
CNT08.
2) Turn starting
switch ON.
3) Turn parking
switch OFF.
(female) (2) and

chassis ground?
1) Disconnect
CNT08.
1) 0 2 V
2) Turn starting
switch ON.
3) Turn parking
switch OFF.
Replace
After inspection,
repair or replace
(female) (11) CNTL2 (3)
CNT08 (female) (1)
NO
NO
NO
harness between CNT08
chassis ground
After inspection,
repair or replace

indicator switch
Replace
Parking signal
CNL06
CNTL2
!1
e
CNTL1
CNT08
Parking brake indicator
q
w
i
TDW00292
20-313
q
TROUBLESHOOTING
M-8
M-8 Abnormality in preheating system (QGS)

(a) Does not carry out preheating
Check that the water temperature is below 5C.
(1) Monitor display also does not light up
2 YES
YES
1
Is resistance
between CNE05
(male) and chassis
ground normal?
1) Disconnect
CNE05.
2) Turn starting
switch OFF.
3) Min. 4 k
Defective monitor panel
Is resistance between
CNL05 (female) (7)
and chassis ground
normal?
Remedy
Replace

CNL05 (female) (7) CNLR4
After inspection,
(2) CNER1 (8) CNE05
repair or replace
(female) short circuiting
with chassis ground
NO
1) Disconnect
CNL05.
2) Turn starting
switch OFF.
3) Min. 4 k
Cause
NO
Defective engine water

temperature sensor
Replace
Defective glow plug
Replace
Defective heater relay
Replace
harness between CNE08
and slow blow fuse
After inspection,
repair or replace
YES
2
Is voltage
YES between CNE07

and chassis
ground normal?
1
Is voltage
between CNE09
(1) and (2)
normal?
1) 20 30 V
2) Turn starting
switch ON.
1) 20 30 V
2) Turn starting
switch ON.
1) 20 30 V
2) Turn starting
switch ON.
NO
20-314
q
3 YES
Is voltage
between CNE08
NO and chassis
ground normal?
NO
(3) CNLR4 (7) CNER1
After inspection,
(4) CNE09 (female) (1), or repair or replace
between CNE09 (female)
(2) CNER2 (5) chassis
ground
U42103
(2) Only monitor display lights up
TROUBLESHOOTING
M-8
(b) Always carries out preheating for 1 minute

Check that the water temperature is below 10C.
2 YES
YES
1
Is resistance
between CNE05
(male) and chassis
ground normal?
1) Max. 8 k
2) Turn starting
switch OFF.
3) Disconnect
CNE05.
CNL05 (female) (7)
and chassis ground
normal?
1) Max. 8 k
2) Turn starting
switch OFF.
3) Disconnect
CNL05.
Cause
Remedy
Replace
After inspection,
repair or replace
(female) (7) CNLR4 (2)
CNER1 (8) CNE05 (female)
NO
NO

temperature sensor
Replace
Replace
(c) Preheating stays on

YES
U42103
1
3 YES
Does preheating
stop?
1) Turn starting
switch ON.
2) Disconnect
CNL06.
Is voltage
YES between CNL06
(4) and chassis
2
ground normal?
Does preheating
NO stop?
1) Turn starting
switch ON.
2) Remove
preheating
relay.
1) 20 30 V
2) Turn starting
switch ON.
NO
NO
Defective preheating relay Replace

CNL56 (2) short circuiting
with chassis ground
After inspection,
repair or replace

with wiring harness
between CNL56 (3)
CNLR4 (7), CNL05 (19)
After inspection,
repair or replace
20-315
q
TROUBLESHOOTING
M-8
(d) Preheating time becomes shorter, or there is variation
Cause
3 YES
Is voltage
YES between CNL05
(3) and chassis
2
ground normal?
1
Is resistance
between CNE05
(male) and chassis
ground normal?
Defective contact of wiring

After inspection,
(3) CNLR5 (3) CNR11 repair or replace
chassis ground
NO
1) Max. 0.1 V
2) Turn starting
switch ON.
Replace
Defective contact of wiring

After inspection,
repair or replace
CNER1 (8) CNE05, or
leak from chassis ground
1) Are temperature
and resistance
NO
value as shown in
table below?
2) Turn starting
switch OFF.
1) Are temperature
and resistance
value as shown NO
in table below?
2) Turn starting
switch OFF.

temperature sensor
Table
Replace
(Tolerance 0.5 k)
Temperature(C)
10
Resistance value(k)
7.7
7.1
6.5
6.0
5.5
5.1
4.7
4.3
Preheating
CNL05
!9
CNL06
U42103
YES
CNL05 (female) (7)
and chassis ground
normal?
Remedy
Starting motor SWR2 signal
CNLR4
CNER1
CNER2
CNE09
+24V
CNE08
CNE07
Preheating relay
Slow blow fuse
q
w
Glow plug
CNL56
qwety
CNL09
Starting switch
BR
TDW00293
CNLR5
Water temperature signal
- Battery +
CNR11
CNL05
e
u
CNLR4
CNER1
CNE05
Engine water
temperature sensor
TDW00294
20-316
q
TROUBLESHOOTING
M-9
M-9 Night lighting does not light up

Before starting troubleshooting, check that the lamp bulb is not blown.
Cause
1 YES
Is voltage
between CNL05
(16) and chassis
ground normal?
U42103
1) 20 30 V
2) Turn starting
switch ON.
3) Turn side lamp
switch ON.
CNL05
!6
Replace
After inspection,
repair or replace
NO
Side
Remedy
Side lamp (right)
CNFS2
t
r
CNL02
Lighting switch
t
TDW00295
20-317
q
TROUBLESHOOTING
M-10
M-10 Abnormality in front working lamp (option)

Before starting troubleshooting, check that the monitor lighting is lighted up.
Cause
Remedy
(a) Neither monitor display nor front working lamp light up

After inspection,
harness between CNL60 (1) repair or replace
CNL05 (17), CNCL1 (7)
YES
YES
Is voltage
between CNL60
(1) and chassis
ground normal?
Replace
Is voltage
YES between CNL60

2
Is voltage between
CNL60 (2), (5) and
NO chassis ground
normal?
1) 20 30 V
2) Turn starting
switch ON.
(6) and chassis

ground normal?
1) 0 3 V
2) Turn starting
switch ON.
4 YES disconnection in wiring

(1) and CNL60 (6)
Is voltage
between CNL06
NO (1) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
NO
NO
After inspection,
repair or replace
Replace
(2), (5) CNFS5 (1)
After inspection,
repair or replace
Replace
After inspection,
repair or replace
(1) CNCL1 (7) front
working lamp, or blown
working lamp bulb
After inspection,
repair or replace
U42103
1) 20 30 V
2) Turn starting
switch ON.
Defective front working

lamp relay
(b) Working lamp lights up but monitor display does not light up
1 YES
Is voltage
between CNL05
(17) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
NO
(c) Monitor lights up but working lamp does not light up
20-318
q
TROUBLESHOOTING
M-11
M-11 Abnormality in rear working lamp

Before starting troubleshooting, check that the monitor lighting is lighted up.
Cause
Remedy
(a) Neither monitor display nor rear working lamp light up

YES
YES
Is voltage
between CNL61
(1) and chassis
ground normal?
1) 0 3 V
2) Turn starting
switch ON.
After inspection,
repair or replace
Defective rear working

lamp relay
Replace
Is voltage
YES between CNL61

2
Is voltage between
CNL61 (2), (5) and
NO chassis ground
normal?
1) 20 30 V
2) Turn starting
switch ON.
U42103
(1) CNL05 (18), CNLR1
(12)
(6) and chassis

ground normal?
1) 20 30 V
2) Turn starting
switch ON.
4 YES disconnection in wiring

(2) and CNL61 (6)
Is voltage
between CNL06
NO (2) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
NO
NO
After inspection,
repair or replace
Replace
(2), (5) CNFS5 (2)
After inspection,
repair or replace
Replace
(1)
After inspection,
repair or replace
(1) CNLR1 (12) rear
working lamp, or blown
working lamp bulb
After inspection,
repair or replace
(b) Working lamp lights up but monitor display does not light up
1 YES
Is voltage
between CNL05
(18) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
NO
(c) Monitor lights up but working lamp does not light up
20-319
q
TROUBLESHOOTING
M-11
F Working lamp relay
CNL60
Working lamp F
CNL05
t y q w er
CNCL1
!7
To front working lamp
CNFS5
CNL06
q
R Working lamp relay
+24V
CNL61
CNL05
!8
CNL06
t y q w er
CNLR1
!2
To rear working lamp
CNFS5
+24V
TDW00296
20-320
q
U42103
Working lamp R
TROUBLESHOOTING
M-12
M-12 Abnormality in transmission cut-off

Cause
(a) When monitor switch is pressed, cut-off function

is not switched and display is not given
Remedy
Replace
(1) and CNFS2 (8)
After inspection,
repair or replace
(b) Monitor display goes out but cut-off function

stays on
3 YES
Is voltage
YES between CNL65
(2) and chassis
1
ground normal?
U42103
Is voltage
between CNL06
(3) and chassis
ground normal?
1) 0 3 V
2) Turn starting
switch ON.
Is voltage
YES between CNL65
(1) and chassis
2
ground normal?
NO
1) 20 30 V
2) Turn starting
switch ON.
1) 0 3 V
2) Turn starting
switch ON.
After inspection,
repair or replace
NO
NO
5 YES
Is voltage
YES between CNL65
(5) and chassis
ground normal?
4
A
Is voltage
between CNL65
(3) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
3) Turn parking
switch OFF.
1) 20 30 V
2) Turn starting
switch ON.
3) Turn parking
switch OFF.
4) Remove cut-off
relay.
5) Stop machine
cut-off function.
NO
NO
Replace
Defective transmission cutReplace

off relay
After inspection,
repair or replace
(5) and CNL12 (female) (2)
After inspection,
repair or replace
20-321
q
TROUBLESHOOTING
M-12
Cause
(c) Monitor display lights up but cut-off function is not actuated
YES
2
Remedy
Defective cut-off relay
Replace
Replace

CNL65 (2) short circuiting
with chassis ground
After inspection,
repair or replace
Contact of wiring harness

between CNL65 (3) and
(5), or defective cut-off
switch
After inspection,
repair or replace
Is voltage
YES between CNL65

1
Does cut-off
function work?
1) Turn starting
switch ON.
2) Remove cut-off
relay.
(2) and chassis

ground normal?
3 YES
Does cut-off
NO function work?
1) 20 30 V
2) Turn starting
switch ON.
1) Turn starting
switch ON.
2) Disconnect
CNL06.
NO
NO
Transmission cut-off relay
CNL65
q wet y
U42103
Transmission cut-off
CNFS2
CNL06
CNL04
+24V
Transmission lever
q
w
r
CNL08
u
i
CNL12
Transmission cut-off switch
q
w
Parking
brake
switch
CNTL1
e
r
y te w q
Neutralizer relay
CNL58
t ye r q w
FORWARD relay
CNL66
F solenoid
R solenoid
t yq w e r
REVERSE relay
CNL67
TDW00297
20-322
q
TROUBLESHOOTING
M-13
M-13 Abnormality in parking brake dragging warning

(a) When parking brake is applied, buzzer sounds

(intermittently) even when directional lever is at N,
and caution lamp flashes
Cause
1 YES
Is voltage
between CNL05
(8) and chassis
ground normal?
NO
1) 20 30 V
2) Turn starting
switch ON.
Remedy
Replace
After inspection,
repair or replace
Replace
(b) When parking brake is applied, buzzer does not

sound and caution lamp does not light up even
when directional lever is at position other than N
Check that the synchronous flash signal is normal.
U42103
YES
1
Is voltage
between CNL05
(8) and chassis
ground normal?
1) 0 5 V
2) Turn starting
switch ON.

with wiring harness
After inspection,
between CNL05 (female) (8) repair or replace
and CNL04 (female) (3)
2 YES
Is resistance
between CNL05
NO (male) (8) and (3)
normal?
1) 3 k 4 k
2) Turn starting
switch OFF.
3) Disconnect
CNL05.
Replace
NO
Neutral relay
Start signal,
neutral signal
CNL57
Starting motor
q w et y
CNL05
r
i
Starting
CNL04
Speed lever
CNLR5
Neutral
CNR10
Rear frame GND
CNL09
Starting switch
C
TDW00286
20-323
q
TROUBLESHOOTING
M-14
M-14 When parking brake dragging warning is given, buzzer and

caution lamp are actuated continuously, or they are not actuated
Cause
Remedy
2 YES
YES Does buzzer stop
and lamp go out?
1
Does buzzer stop
and lamp go out?
1) Turn starting
switch ON.
2) Connect CNL07
(6) to chassis
ground.
1) Turn starting
switch ON.
2) Connect CNL19
(female) (5) to
chassis ground.
NO
NO
Defective maintenance
monitor
Replace
(female) (5)
After inspection,
repair or replace
Replace
monitor
Replace
(b) Not actuated

2 YES
YES Do buzzer and
lamp work?
1
Do buzzer and
lamp work?
1) Turn starting
switch ON.
2) Disconnect
CNL07.
1) Turn starting
switch ON.
2) Disconnect
CNL19.

CNHL19 (female) (5) short After inspection,
repair or replace
ground
NO
NO
Synchronous flashing signal
CNL07
CNL19
t
TDW00300
20-324
q
Replace
U42103
(a) Actuated continuously
TROUBLESHOOTING
M-15
M-15 Abnormality in buzzer

Cause
Remedy
(a) Buzzer does not sound when starting switch is

turned ON (during self-check)
(male)
YES
1
Does buzzer
sound?
2 YES
Is voltage between
CNL42 (female)
1) Turn starting
switch ON.
NO and chassis
ground normal?
2) Contact CNL43
(female) to
chassis ground.
NO
1) 20 30 V
2) Turn starting
switch ON.
After inspection,
repair or replace
Defective buzzer
Replace
(female) and CNFS2 (9)
After inspection,
repair or replace
Defective main monitor.
Replace
(b) Buzzer always sounds
U42103
YES
1
Does buzzer
stop?
YES
Go to Troubleshooting for
maintenance monitor
1) Turn starting
switch ON.
2) Disconnect
CNL06.
Does buzzer
NO stop?
1) Turn starting
switch ON.
2) Disconnect
CNL19.
3 YES
Does buzzer
NO stop?
1) Turn starting
switch ON.
2) Disconnect
CNL43.
CNL19
Buzzer output
CNL06
r
Maintenance monitor
NO
CNFS2

CNL43 (male) short
ground
After inspection,
repair or replace
Defective buzzer
Replace
CNL42
+24V
Buzzer
CNL43
i
TDW00301
20-325
q
TROUBLESHOOTING
M-16
M-16 Condition of monitor switches is not stored in memory

Cause
1 YES
Is voltage
between CNL07
(10) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
Remedy
Replace
After inspection,
repair or replace
NO
Starting switch ACC
!0
CNL09
BR
Starting switch
CNLR4
To battery relay
TDW00302
20-326
q
U42103
CNL07
TROUBLESHOOTING
M-17
M-17 Abnormality in failure display mode

Cause
Remedy
(a) Does not enter failure display mode

1 YES
Is voltage
between CNL05
(5) and chassis
ground normal?
1) 0 5 V
2) Turn starting
switch ON.
Replace

with wiring harness
After inspection,
(5) CNLR4 (6) CNER1
repair or replace
(9) alternator terminal R,
or defective alternator
NO
(b) Time for time elapsed since failure on

failure display mode does not advance
1 YES
U42103
Is voltage
between CNL05
(5) and chassis
ground normal?
1) 20 30 V
2) Start engine.
NO
Replace
CNER1 (9) alternator
terminal R, or defective
alternator
After inspection,
repair or replace
Charge
Alternator
CNL05
CNLR4
CNER1
CNE16
TDW00303
20-327
q
TROUBLESHOOTING
M-18
M-18 Abnormality in emergency steering normal display (option)

Cause
Remedy
(a) Emergency steering normal display does not light up

YES
1
Is there continuity
between CNT10
(male) (1) and
(2)?
1) Disconnect
CNT10.
2) Turn starting
switch ON.
2 YES
Is voltage
between CNL05
NO (10) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
Defective emergency
steering normal sensor
Replace
Replace

CNL05 (female) (10)
After inspection,
repair or replace
chassis ground
NO
3 YES
Is voltage
YES between CNL05
(10) and chassis
2
ground normal?
Is there continuity
1) 0 2 V
YES between CNT10
2) Turn starting
(female) (2) and
switch ON.
1
chassis ground?
Is there continuity
1) Disconnect
between CNT10
CNT10.
NO
(male) (1) and
(2)?
1) Disconnect
CNT10.
2) Turn starting
switch ON.
After inspection,
repair or replace
CNT10 (female) (1)
NO
NO
chassis ground
After inspection,
repair or replace
Defective emergency
steering normal sensor
Replace
Emergency steering normal
CNL05
!0
CNTL1
w
i
CNT10
Emergency steering
normal sensor
q
w
TDW00307
20-328
q
Replace
U42103
(b) Emergency steering normal display stays lighted up
TROUBLESHOOTING
M-19
M-19 Abnormality in emergency steering actuation display (option)

Cause
Remedy
(a) Emergency steering actuation display does not light up

YES
1
Is there continuity
between CNT11
(male) (1) and
(2)?
1) Disconnect
CNT11.
2) Turn starting
switch ON.
2 YES
Is voltage
between CNL05
NO (11) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
Defective emergency
steering function sensor
Replace
Replace

CNL05 (female) (11)
After inspection,
repair or replace
chassis ground
NO
U42103
(b) Emergency steering actuation display stays lighted up

3 YES
Is voltage
YES between CNL05
(11) and chassis
2
ground normal?
Is there continuity
1) 0 2 V
YES between CNT11
2) Turn starting
(female) (2) and
switch ON.
1
chassis ground?
Is there continuity
1) Disconnect
between CNT11
CNT11.
NO
(male) (1) and
(2)?
1) Disconnect
CNT11.
2) Turn starting
switch ON.
Replace

CNL05 (female) (11)
After inspection,
repair or replace
chassis ground
NO
NO
chassis ground
After inspection,
repair or replace
Defective emergency
steering actuation sensor
Replace
Emergency steering actuation
CNL05
CNTL1
!1
q
i
CNT11
Emergency steering
actuation sensor
q
w
TDW00308
20-329
q
TROUBLESHOOTING
M-20
M-20 Abnormality in ECSS system (option)

Cause
Remedy
(a) Display does not change when switch is pressed

Replace
Defective ECSS controller
Go to
Troubleshooting
for ECSS
controller
(7) and CNDP2 (1)
After inspection,
repair or replace
Replace
2 YES
Is voltage
YES between CNDP2

1
(1) and chassis
Is voltage
between CNL06
(7) and chassis
ground normal?
1) 0 3 V
2) Turn starting
switch ON.
ground normal?
1) 0 3 V
2) Turn starting
switch ON.
NO
NO
ECSS
CNL06
CNDP2
q
TDW00310
20-330
q
U42103
(b) Monitor display lights up but ECSS function does

not work
TROUBLESHOOTING
M-23
M-21 Failure code is not sent to main monitor

(abnormality in network) (option)
Set dipswitch 3 at the rear of the main monitor to F.
Cause
2 YES
Is voltage
YES between CNDP2
(female) (2) and
(3) normal?
U42103
Is voltage
between CNL08
(female) (1) and
(2) normal?
1) Repeat 0V and
12V?
2) Turn starting
switch ON.
3) Disconnect
CNL08.
1) Repeat 0V and
12V?
2) Turn starting
3) Disconnect
CNDP2.
NO
NO
Defective controller
Remedy
Replace
After inspection,
repair or replace
(female) (1)(3), CNL08
(female) (2)(4) applicable
connector pins
Replace
20-331
q
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM
(K MODE)
K- 1
When starting switch is turned ON, all lamps on maintenance monitor do not
light up for 3 seconds, maintenance monitor does not work .............................................. 20-352
(a) All lamps on maintenance monitor do not light up for 3 seconds .............................. 20-352
(b) Some lamps do not light up ............................................................................................. 20-353
K- 2
When starting switch is turned ON, all lamps on maintenance monitor light up
but do not go out ...................................................................................................................... 20-353
K- 3
When engine is started immediately after starting switch is turned ON

(within 3 seconds), all lamps on maintenance monitor do not go out .............................. 20-354
K- 4
When starting switch is turned ON (engine stopped), CHECK items flash ....................... 20-355
(a) Engine oil level display flashes ......................................................................................... 20-355
(b) Engine water level display flashes .................................................................................... 20-356
K- 5
When starting switch is turned ON (engine started), CAUTION items flash ..................... 20-357
(a) Engine oil pressure display flashes .................................................................................. 20-357
(b) Battery charge level display flashes ................................................................................. 20-358
U42103
(c) Brake oil pressure display flashes .................................................................................... 20-359

(d) Brake oil temperature display flashes .............................................................................. 20-360
(e) Air cleaner display flashes ................................................................................................. 20-361
K- 6
CAUTION items are flashing but alarm buzzer does not sound .......................................... 20-362
K- 7
There is no abnormality in monitor display but alarm buzzer sounds .............................. 20-363
K- 8
CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp)
does not light up ....................................................................................................................... 20-364
(a) CHECK lamp ........................................................................................................................ 20-364
(b) CAUTION lamp .................................................................................................................... 20-364
K- 9
There is no abnormality in maintenance monitor display but

warning lamp (CHECK lamp, CAUTION lamp) lights up ...................................................... 20-365
(a) CHECK lamp ........................................................................................................................ 20-365
(b) CAUTION lamp .................................................................................................................... 20-365
K-10
Night lighting does not light up when lamp switch is turned ON

(only lighting of maintenance monitor does not light up) ................................................... 20-366
K-11
Night lighting lights up even when lamp switch is OFF, night lighting stays
lighted up ................................................................................................................................... 20-367
K-12
Service meter does not work ................................................................................................... 20-368
K-13
Service meter is running even when engine is stopped ...................................................... 20-368
K-14
Abnormality in gauge items .................................................................................................... 20-369

(a) Abnormality in fuel gauge ................................................................................................. 20-369
(b) Abnormality in engine water temperature gauge ........................................................... 20-370
(c) Abnormality in torque converter oil temperature gauge ............................................... 20-371
20-351
q
TROUBLESHOOTING
K-1
K-1 When starting switch is turned ON, all lamps on maintenance

monitor do not light up for 3 seconds, maintenance monitor does
not work
Cause
Remedy
YES
YES
Is voltage
between CNL18
(1), (2) (3)
normal?
1) 20 30 V
2) Turn starting
switch ON.
3
Is voltage between
YES CNFS1 (female) (2)
and chassis
ground normal?
Is there continuity
between CNL18
NO (female) (3) and
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNL18.
NO
NO
CNFS2
o
CNLR4
10A
Replace
(female) (1), (2) CNFS2
(9) fuse box CNFS1
(male) (2), or blown fuse
Repair wiring
harness,
replace, or
replace fuse
harness between CNFS1
slow blow fuse battery
relay, or blown fuse
Repair wiring
harness,
replace, or
replace fuse
(3) CNLR4 (12) chassis
ground
Repair wiring
harness or
replace
Slow blow fuse
Fuse box
CNL18
q
w
e
1) 20 30 V
2) Disconnect
CNFS1.
3) Turn starting
switch ON.
monitor module
CNFS1
CNLR6
Battery relay
80A
Battery terminal
!2
TDW00314
20-352
q
U42103
(a) All lamps on maintenance monitor do not light up

for 3 seconds
TROUBLESHOOTING
K-1, K-2
Cause
Remedy
(b) Some lamps do not light up

monitor module
Replace
K-2 When starting switch is turned ON, all lamps on maintenance

monitor light up but do not go out
U42103
Cause
monitor module
Remedy
Replace
20-353
q
TROUBLESHOOTING
K-3
K-3 When engine is started immediately after starting switch is turned

ON (within 3 seconds), all lamps on maintenance monitor do not
go out
Cause
1) 20 30 V
2) Disconnect
CNL19.
3) Start engine.
4) Measure when
starting motor is
turning.
YES
NO
monitor module
Replace
(female) (1) and neutral
relay
Repair wiring
harness or
replace
U42103
1
When starting
engine, is voltage
between CNL19
(female) (1) and
chassis ground
normal?
Remedy
CNL09
CNL19
C
Starting switch
yt e w q
CNL04
CNL57
Speed lever
Neutral relay
TDW00315
20-354
q
TROUBLESHOOTING
K-4
K-4 When starting switch is turned ON (engine stopped), CHECK items

flash
(a) Engine oil level display flashes

Before starting troubleshooting, check the engine
oil level again.
Cause
2 YES
Is there continuity
YES between CNL18
1
(female) (13) and
chassis ground?
Is there continuity
between CNE10
1) Turn starting
(male) (1) and
switch OFF.
chassis ground?
2) Disconnect
monitor module
Replace
Repair wiring
harness or
replace
CNER1 (3) CNE10
(female) (1)
NO
CNL18.
Defective engine oil level

sensor
NO
Replace
U42103
1) Turn starting
switch OFF.
2) Disconnect
CNE10.
Remedy
CNL18
!3
CNLR4
CNER1
CNE10
Engine oil lever sensor
TDW00316
20-355
q
TROUBLESHOOTING
K-4
Cause
(b) Engine water level display flashes

Before starting troubleshooting, check the engine
water level again.
3 YES
NO
monitor module
Replace
CNR06 (female) (1)
Repair wiring
harness or
replace
harness between CNR06
(female) (2) and chassis
ground
Repair wiring
harness or
replace
Defective radiator water

level sensor
Replace
U42103
Is there continuity
YES between CNL18
(female) (8) and
2
chassis ground?
Is there continuity
1) Turn starting
YES between CNR06
switch OFF.
(female) (1) and
2) Disconnect
1
chassis ground?
CNL18.
Is there continuity
1) Turn starting
between CNR06
switch OFF.
NO
(male) (2) and
2) Disconnect
(1)?
CNR06.
1) Turn starting
switch OFF.
NO
2) Disconnect
CNR06.
Remedy
CNL18
CNLR3
CNR06
Radiator water level sensor
q
w
TDW00317
20-356
q
TROUBLESHOOTING
K-5
K-5 When starting switch is turned ON (engine started), CAUTION

items flash
Cause
Remedy
(a) Engine oil pressure display flashes

YES
Defective engine oil

pressure sensor
Replace
monitor module
Replace
(female) (10) engine oil
pressure relay chassis
ground, or defective relay
Repair wiring
harness,
replace, or
replace relay
Contact of ground with

wiring harness between
ring terminal CNER1 (2)
CNLR4 (3) engine oil
pressure relay, or
defective relay
Repair wiring
harness,
replace, or
replace relay
1
3 YES
Does display go
out when ring
terminal is
removed?
Is there continuity
YES between CNL18
(female) (10) and
chassis ground?
2
1) Start engine.
Is voltage between
ring terminal and
NO chassis ground
normal?
NO
U42103
1) 20 30 V
2) Remove ring
terminal.
3) Start engine.
NO
1) Disconnect
CNL18.
2) Turn starting
switch OFF.
CNL18
CNLR4
CNER1
!0
+24V
Ring terminal
Engine oil pressure sensor
y t e wq
Engine oil pressure relay
CNL64
TDW00318
20-357
q
TROUBLESHOOTING
K-5
Cause
Remedy
(b) Battery charge level display flashes

2 YES
Is voltage between
YES CNL18 (female)
(12) and chassis
1
ground normal?
Is voltage between
alternator terminal R
and chassis ground
normal?
NO
NO
Replace
Disconnection in wiring
Repair wiring
(female) (12) CNLR4 (6) harness or
replace
terminal R
Defective alternator
Replace
U42103
1) 20 30 V
2) Start engine.
1) 20 30 V
2) Start engine.
monitor module
20-358
e
TROUBLESHOOTING
K-5
Cause
Remedy
(c) Brake oil pressure display flashes

4
Is voltage
YES between CNL18
(11) and chassis
ground normal?
3
Is there continuity
YES between CNB13
(female) (2) and
chassis ground?
2
Is there continuity
YES between CNB08
1) Start engine.
2) Disconnect
CNB13.
(male) (1) and

(2)?
monitor module
(female) (11) and CN41
NO (female) (2), or between
CN41 (female) (1) CNLR2
(8) CNBR1 (6) CNB13
(female) (1), or defective
diode
Replace
Repair wiring
harness,
replace, or
replace diode
harness between CNB13
Repair wiring
(female) (2) and CNB08
harness or
(female) (1), or between
replace
CNB08 (female) (2)
CNBR1 (4) chassis ground
NO
1) Start engine.
2) Disconnect
CNB08.
Is there continuity
between CNB13
(male) (1) and
(2)?
U42103
1) Start engine.
2) 0 3 V
YES Defective maintenance
NO
1) Start engine.
2) Disconnect
CNB13.
NO
Defective brake
accumulator charge oil
pressure switch (CNB08
end)
Replace
Defective brake
accumulator charge oil
pressure switch (CNB13
end)
Replace
CN41
CNL18
!1
wq
CNLR2
CNBR1
y
r
CNB13
q
w
CNB08
Brake accumulator oil

pressure switch
q
w
TDW00320
20-359
q
TROUBLESHOOTING
K-5
Cause
Remedy
(d) Brake oil temperature display flashes

YES
1
Is there continuity
between brake oil
temperature relay (2)
and chassis ground?
NO
2 YES
Is there continuity
between maintenance
monitor (16) and
CNL18 (16)?
Replace
monitor module
Replace
harness between
maintenance monitor
(16) and CNL18 (16) , or
defective relay
Repair wiring
harness,
replace, or
replace relay
U42103
NO
Defective brake oil

temperature
20-360
q
TROUBLESHOOTING
K-5
Cause
Remedy
(e) Air cleaner display flashes

YES
YES
3
Is there continuity
YES between CNL18
(female) (15) and
chassis ground?
Does display go
out?
1) Start engine.
2) Disconnect
CNE19.
2
Is voltage between
CNE19 (female) (1)
NO and chassis
ground normal?
NO
NO
Replace
monitor module
Replace
CNL80 (female) (6) CNLR5
(2) chassis ground, or
defective dust indicator
relay
Repair wiring
harness,
replace, or
replace relay
Short circuit, or contact of

CNE19 (female) (1) CNER1
(5) CNLR4 (5) CNL80
(female) (2) with chassis
ground, or defective dust
indicator relay
Repair wiring
harness,
replace, or
replace relay
U42103
1) Turn starting
switch ON.
2) Disconnect
CNE19.
3) 20 30 V
1) Turn starting
switch OFF.
2) Disconnect
CNL18.
Defective dust indicator

sensor
+24
CNL18
!5
yt e w q
CNLR5
CNLR4
CNER1
CNE19
Dust indicator
CNER2
CNE20
Dust indicator relay
CNL80
TDW00321
20-361
q
TROUBLESHOOTING
K-6
K-6 CAUTION items are flashing but alarm buzzer does not sound
The buzzer does not sound for CHARGE or ENGINE OIL LEVEL.
Cause
YES
2
Does buzzer sound
YES when CNL19 (female)

3 YES
pin (4) is connected

to chassis ground?
1
1) Turn starting
switch ON.
Is voltage between
CNL42 (female) (1)
and chassis
ground normal?
1) Turn starting
switch ON.
NO
NO
monitor module
Replace
(male) (1)
Replace
Defective buzzer
Replace
(female) (1) CNFS2 (9)
+24V
Repair wiring
harness or
replace
U42103
1) 20 30 V
2) Disconnect
CNL42.
3) Turn starting
switch ON.
NO
Does buzzer sound

when CNL43 (female)
pin (1) is connected
to chassis ground?
Remedy
+24V
CNFS2
CNL42
Alarm buzzer
Maintenance monitor
CNL19
CNL43
Main monitor
CNL06
i
TDW00322
20-362
q
TROUBLESHOOTING
K-7
K-7 There is no abnormality in monitor display but alarm buzzer

sounds
Before carrying out troubleshooting, check that there is no abnormality display on the main
monitor.
Cause
YES
Contact of chassis ground

Repair wiring
with wiring harness
harness or
replace
(4) and CNL43 (male) (1)
2 YES
Is there continuity
between CNL19
NO (female) (4) and
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNL19.
monitor module
NO
Replace
U42103
1) Turn starting
switch OFF.
2) Disconnect
CNL43.
Replace
Defective buzzer
1
Is there continuity
between CNL43
(female) (1) and
chassis ground?
Remedy
+24V
CNFS2
CNL42
Alarm buzzer
Maintenance monitor
CNL19
CNL43
Main monitor
CNL06
i
TDW00322
20-363
q
TROUBLESHOOTING
K-8
K-8 CAUTION items are flashing but warning lamp (CHECK lamp,
CAUTION lamp) does not light up
Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause
Remedy
YES
Does check lamp

light up when
CNL19 (female) pin
(2) is connected to
chassis ground?
1) Disconnect
CNL19.
2) Turn starting
switch ON.
2 YES
NO
Does check lamp

light up when
CNL06 (male) pin
(10) is connected to
chassis ground?
NO
1) Disconnect
CNL06.
2) Turn starting
switch ON.
monitor module
Replace
(female) (10)
Repair wiring
harness or
replace
Replace
monitor module
Replace
(female) (10)
Repair wiring
harness or
replace
Replace
(b) CAUTION lamp

1
YES
Does caution lamp

light up when
CNL19 (female) pin
(3) is connected to
chassis ground?
1) Disconnect
CNL19.
2) Turn starting
switch ON.
2 YES
NO
Does caution lamp

light up when
CNL06 (male) pin (9)
is connected to
chassis ground?
1) Disconnect
CNL06.
2) Turn starting
switch ON.
NO
Maintenance monitor end
Main monitor end
CNL19
CNL06
!0
o
TDW00324
20-364
q
U42103
(a) CHECK lamp
TROUBLESHOOTING
K-9
K-9 There is no abnormality in maintenance monitor display but

warning lamp (CHECK lamp, CAUTION lamp) lights up
Before carrying out troubleshooting, check that there is no abnormality display on the main
monitor.
Cause
Remedy
(a) CHECK lamp

Repair wiring
with wiring harness
harness or
replace
(2) and CNL06 (female)
(10)
1 YES
Is there continuity
between CNL19
(female) (2) and
chassis ground?
monitor module
NO
1) Turn starting
switch OFF.
2) Disconnect
CNL19.
Replace
(b) CAUTION lamp

Repair wiring
with wiring harness
harness or
replace
U42103
1 YES
Is there continuity
between CNL19
(female) (3) and
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNL19.
monitor module
NO
Maintenance monitor end
Main monitor end
CNL19
CNL06
!0
Replace
TDW00324
20-365
q
TROUBLESHOOTING
K-10
K-10 Night lighting does not light up when lamp switch is turned ON
(only lighting of maintenance monitor does not light up)
Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause
1 YES
harness of lamp holder
Is voltage
between CNL21
(female) (1) and
(2) normal?
Replace
Repair wiring
harness or
replace
NO
U42103
1) 20 30 V
2) Disconnect
CNL21.
3) Turn starting
switch ON.
4) Turn lamp
switch ON.
Remedy
Fuse box
Lighting
CNL21
CNFS2
q
w
t
w
CNLR5
10A
+24V
CNL02
Lamp switch
q
t
TDW00326
20-366
q
TROUBLESHOOTING
K-11
K-11 Night lighting lights up even when lamp switch is OFF, night
lighting stays lighted up
Cause
2 YES
Is voltage between
YES CNFS2 (female) (4)

and chassis
ground normal?
1) 0V
2) Disconnect
CNFS2.
3) Turn lamp
switch OFF.
4) Turn starting
switch ON.
U42103
Is lamp switch
normal?
1) Turn starting
switch OFF.
2) Disconnect
CNL02.
3) Check that
continuity
between CNL02
(male) (1) and
(5) is as shown
in table below
when lamp
switch is turned
ONOFF.
NO
NO
Switch
Continuity
ON
OFF
Continuity
NO continuity
Remedy
Contact of +24V with

CNFS2 (male) (4) fuse
box CNFS2 (5) CNL21
(female) (1)
Repair wiring
harness or
replace
Contact of +24V with

CNFS2 (female) (4)
Repair wiring
harness or
replace
Defective lamp switch
Replace
Fuse box
Lighting
CNL21
CNFS2
q
w
t
w
CNLR5
10A
+24V
CNL02
Lamp switch
q
t
TDW00326
20-367
q
TROUBLESHOOTING
K-12, K-13
K-12 Service meter does not work

Cause
1
YES
Is voltage
between CNL22
(female) (2) and
(1) normal?
1) 20 30 V
2) Start engine.
3) Disconnect
CNL22.
3
Is there continuity
YES between CNL22

(female) (1) and
chassis ground?
2
Is voltage between
alternator terminal
NO R and chassis
ground normal?
1) 20 30 V
2) Start engine.
1) Turn starting
switch OFF.
2) Disconnect
CNL22.
NO
NO
Defective service meter
Replace
terminal R
Repair wiring
harness or
replace
chassis ground
Repair wiring
harness or
replace
Defective alternator
Replace
U42103
YES
Remedy
K-13 Service meter is running even when engine is stopped

Cause
1 YES
Is voltage
between CNL22
(female) (2) and
(1) normal?
1) 0 4 V
2) Turn starting
switch ON.
3) Disconnect
CNL22.
NO
CNL22
CNLR4
CNER1
CNE13
CNLR5
Service meter
Remedy
Defective service meter
Replace
Defective alternator, or
contact of wiring harness
(2) CNLR4 (6) CNER1
(9) alternator terminal R
with +24V
Replace
alternator, or
repair, replace
wiring harness
Starting motor
Alternator
TDW00328
20-368
q
TROUBLESHOOTING
K-14
K-14 Abnormality in gauge items

(a) Abnormality in fuel gauge
Before carrying out troubleshooting, check the
fuel level again.
(1) Little or nothing is displayed in the display area
YES
Cause
Remedy
Defective fuel sensor
Replace
monitor module
Replace
1
3 YES
Does fuel gauge
show FULL?
Is there continuity
YES between CNL18
(female) (6) and
2
chassis ground?
1) Disconnect
Is there continuity
CNR07.
1)
Turn starting
between CNR07
2) Connect short
switch OFF.
(female)
(2)
and
connector to
NO
2) Connect short
chassis ground?
CNR07 (female).
connector to
3) Turn starting
1) Turn starting
CNR07 (female).
switch ON.
switch OFF.
3) Disconnect
2) Disconnect
CNL18.
CNR07.
Repair wiring
harness or
(female) (1) CNLR4 (10) replace
CNL18 (female) (6)
NO
U42103
NO
ground
Repair wiring
harness or
replace
Defective fuel sensor
Replace
(2) Display always shows FULL and does not move

YES
1
Do all display
areas on fuel
gauge go out?
1) Disconnect
CNR07.
2) Turn starting
switch ON.

with wiring harness
Repair wiring
between CNR07 (female) harness or
(1) CNLR4 (10) CNL18 replace
(female) (6)
2 YES
Is there continuity
between CNR07
NO (female) (1) and
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNR07.
monitor module
NO
Replace
Fuel sensor
CNL18
CNLR4
!0
CNR07
q
w
TDW00329
20-369
q
TROUBLESHOOTING
K-14
(b) Abnormality in engine water temperature gauge
Cause
Remedy
(1) Nothing is displayed in the display area

YES

temperature sensor
1
Does engine water
temperature gauge
display minimum
level?
1) Disconnect
CNE06.
2) Turn starting
switch ON.

Repair wiring
with wiring harness
harness or
between CNE06 (female)
replace
(1) CNER1 (6) CNLR4
(1) CNL18 (female) (4)
2 YES
Is there continuity
between CNE06
NO (female) (1) and
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect
CNE06.
Replace
NO
monitor module
Replace

temperature sensor
Replace
monitor module
Replace
(female) (1) CNER1 (6)
CNLR4 (1) CNL18
(female) (4)
Repair wiring
harness or
replace
chassis ground
Repair wiring
harness or
replace
(2) Display shows lowest level and does not move

YES
3 YES
Is there continuity
YES between CNL18
(female) (4) and
2
chassis ground?
1) Disconnect
Is there continuity
CNE06.
1) Turn starting
between CNE06
2) Connect short
switch OFF.
NO (female) (2) and
connector to
2) Connect short
chassis
ground?
CNE06 (female).
connector to
3) Turn starting
1) Turn starting
CNE06 (female).
switch ON.
switch OFF.
3) Disconnect
2) Disconnect
CNL18.
CNE06.
NO
20-370
e
NO
U42103
1
Do all display
areas on engine
water temperature
gauge go out?
TROUBLESHOOTING
K-14
(c) Abnormality in torque converter oil temperature gauge
Cause
Remedy
(1) Nothing is displayed in the display area

YES
Defective torque converter

Replace
oil temperature sensor
1
Does torque
converter oil
temperature gauge
display minimum
level?

with wiring harness
Repair wiring
between CNT07 (female)
harness or
(1) CNTL2 (4) CNL18
replace
(female) (5)
2 YES
Is there continuity
between CNT07
NO (female) (1) and
chassis ground?
1) Disconnect
CNT07.
2) Turn starting
switch ON.
1) Turn starting
switch OFF.
2) Disconnect
CNT07.
monitor module
NO
Replace
(2) Display shows lowest level and does not move

YES
Defective torque converter

Replace
oil temperature sensor
U42103
1
Do all display areas
on torque converter
oil temperature
gauge go out?
3 YES
Is there continuity
YES between CNL18
(female) (5) and
2
chassis ground?
1) Disconnect
Is there continuity
CNT07.
1) Turn starting
between CNT07
2) Connect short
switch OFF.
NO (female) (2) and
connector to
2) Connect short
chassis ground?
CNT07 (female).
connector to
3) Turn starting
1) Turn starting
CNT07 (female).
switch ON.
switch OFF.
3) Disconnect
2) Disconnect
CNL18.
CNT07.
NO
NO
CNL18
CNTL02
t
!2
monitor module
Replace
CNL18 (female) (5)
Repair wiring
harness or
replace
CNLR4 (12) chassis
ground
Repair wiring
harness or
replace
CNT07

temperature sensor
CNLR4
TDW00331
20-371
q
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E MODE)
E- 1
Engine does not start ............................................................................................................... 20-402

(a) Starting motor does not turn ............................................................................................ 20-402
(b) Starting motor turns ........................................................................................................... 20-406
E- 2
Engine does not stop ................................................................................................................ 20-408
E- 3
Engine stops when machine is traveling ................................................................................ 20-408
E- 4
Parking brake does not work ................................................................................................... 20-409

(a) Parking brake has no effect when parking brake switch is turned ON (parking) ....... 20-409
(b) Parking brake has no effect when brake pressure drops ............................................... 20-409
E- 5
Parking brake is applied when machine is traveling ............................................................ 20-410
E- 6
Parking brake is released when starting switch is turned ON ............................................. 20-412
E- 7
Transmission does not change to neutral when parking brake is applied ........................ 20-412
E- 8
Transmission does not work normally ................................................................................... 20-414

(a) Problem in common circuit for transmission (always stays in 2nd) ........................... 20-416
(b) Problem in H-L circuit ........................................................................................................ 20-416
U42103
(c) Problem in speed circuit .................................................................................................... 20-417

(d) Problem in 4th circuit (does not enter 4th) ...................................................................... 20-417
(e) Contact in H-L circuit .......................................................................................................... 20-418
(f) Contact in speed circuit ..................................................................................................... 20-420
(g) Contact in 4th circuit (always stays in 4th) ...................................................................... 20-422
(h) Problem in FORWARD circuit (REVERSE is normal) ....................................................... 20-424
(i) Problem in REVERSE circuit (FORWARD is normal) ....................................................... 20-426
(j) Problem in common circuit for FORWARD and REVERSE
(does not travel forward, parking brake is normal) ........................................................ 20-428
(k) Contact in FORWARD circuit ............................................................................................. 20-430
(l) Contact in REVERSE circuit ................................................................................................ 20-432
(m) Problem in common circuit for FORWARD and REVERSE ............................................. 20-434
E- 9
Kick-down switch does not work ............................................................................................. 20-436
E-10
Kick-down works only when kick-down switch is ON ........................................................... 20-438
E-11
Kick-down operation cannot be canceled ............................................................................... 20-438

(a) Not canceled even when directional lever is moved from F to N or R ....................... 20-438
(b) Not canceled even when speed lever is moved from 2nd to other position
(becomes 4th) ............................................................................................................................ 20-440
E-12
Kick-down switch is actuated by mistake when traveling in 2nd ........................................ 20-442
20-401
q
TROUBLESHOOTING
E-1
E-1 Engine does not start

When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry
out checks, always turn the starting switch OFF before starting.
When connecting the T-adapter (or socket adapter), connect to the connector specified as CN( ).
After checking, connect the disconnected connectors and disconnect the T-adapter immediately to
return to the original condition before going on to the next check.
YES
(a) Starting motor does not turn

YES
3
Is voltage between
Is voltage between
YES starting motor
YES both battery relay
terminal (E) and

chassis 20 30 V?
terminals and
chassis 20 30 V?
4
Is actuating
sound heard from
NO battery relay?
1) Starting switch
ON
OFF.
2
Is there continuity
1) Turn starting
switch ON.
NO
2) Check voltage
between chassis
and both
terminals
connected by
thick cable.
YES between starting

motor terminal
(E) and chassis?
NO
1) Turn starting
switch ON.
20-402
q
Is voltage 20 30V
between both
connection terminals
of CNR12 and CNR13
of battery relay?
1) Turn starting
switch ON.
NO
Is voltage
between CNE13
(female) (1) and
chassis 20 30 V?
1) Disconnect
CNE13.
2) Directional
lever: Neutral
3) Turn starting
switch to
START.
YES
NO
NO
Go to A on next page
U42103
1) Turn starting
switch ON.
TROUBLESHOOTING
E-1
Cause
Defective starting motor

assembly
Remedy
Replace
After inspection,
disconnection in cable
between battery relay and repair or replace
starting motor
If answer is NO for both
terminals: Defective
contact or disconnection
in wiring harness
between battery and
battery relay
If answer is NO for one
terminal: Defective
battery relay
U42103
Defective battery relay
YES
7
Is voltage between
starting switch
terminal BR and
chassis 20 30 V?
1) Turn starting
switch ON.
NO
After inspection,
repair or replace
Replace
Replace
harness between starting
switch terminal BR CNL09
(2) CNLR4 (9) CNR03
After inspection,
(diode) CNR12 (female),
repair or replace
or defective contact, or
and chassis ground
Defective starting switch
Replace
disconnection in starting
motor ground cable
After inspection,
repair or replace
20-403
q
TROUBLESHOOTING
E-1
YES
YES
3
Is voltage
YES between CNL57
(female) (5) and
chassis 20 30 V?
1
Does starting
motor turn when
relay is replaced?
1) Disconnect
CNL57.
2) Turn starting
switch to
START.
1) Replace neutral
relay (CNL57)
with stop lamp
relay (CNL53).
2) Directional lever:
Neutral
3) Turn starting
switch to START.
terminal C and
chassis 20 30 V?
Is voltage between
starting switch
NO terminal B and
chassis 20 30 V?
NO
1) Turn starting
switch to
START.
1) Turn starting
switch OFF.
NO
2
Is voltage
between CNL57
NO (female) (1) and
(2) 20 30 V?
8 YES
Is voltage
YES between CNL04
(3) and chassis 20
30 V?
1) Disconnect
CNL57.
Neutral
3) Turn starting
switch to START.
7
Is voltage
YES between CNL04

(female) (1) and
chassis 20 30 V?
6
Is there continuity
between CNL57
NO (female) (2) and
chassis?
1) Disconnect
CNL04.
2) Turn starting
switch ON.
NO
9 YES
Is actuating
sound heard from
NO battery relay?
1) Starting switch
ON
OFF.
1) Turn starting
switch OFF.
2) Disconnect
CNL57.
20-404
NO
1) Connect Tadapter to
CNL04.
Neutral
3) Turn starting
switch ON.
Go to B on
previous
NO page
U42103
5 YES
YES Is voltage between
starting switch
4
TROUBLESHOOTING
E-1
Cause
Defective neutral relay
Remedy
Replace
After inspection,
repair or replace
CNR01, 02 (diode) CNER1
(10) CNE13 (female) (1)
harness between starting After inspection,
switch terminal C CNL09 repair or replace
Defective starting switch
Replace
U42103
switch terminal B CNL09 After inspection,
repair or replace
(1) CNFS3 (4) fuse
CNFS3 (6) CNLR5 (1)
CNR17 slow blow fuse
30A battery relay
(female) (1)
After inspection,
repair or replace
Defective directional lever

Replace
switch
YES
10
Is voltage between
both battery relay
terminals and
chassis 20 30 V?
1) Turn starting
switch ON.
NO
2) Check voltage
between chassis
and both
terminals
connected by
thick cable.
harness between battery
After inspection,
relay slow blow fuse 80A
repair or replace
CNR15 CNLR6 (1)
CNFS1 (2) fuse CNFS2
If answer is NO for both
terminals: Defective
contact or disconnection
in wiring harness between After inspection,
battery and battery relay repair or replace
If answer is NO for one
terminal: Defective battery
relay
ground
After inspection,
repair or replace
20-405
q
TROUBLESHOOTING
E-1
(b) Starting motor turns
YES
YES
YES
3
1
Is voltage
YES between CNE03
(7) and chassis 20
30 V?
1) Connect Tadapter to
CNE03.
2) Turn starting
switch ON.
1) Turn starting
switch ON
OFF and check
visually.
1) Replace engine
stop relay
(CNL62) with
stop lamp relay
5
(CNL53).
2) Turn starting
Is voltage
switch ON
between CNL62
OFF and check NO (female) (1) and
visually.
chassis 20 30V?
Is voltage
between CNE03
NO (female) (4) and
chassis 20 30 V?
1) Turn starting
switch OFF.
2) Disconnect
CNE03.
1) Disconnect
CNL62.
2) Turn starting
switch ON.
NO
YES
Does engine stop

motor work when
NO relay is replaced?
Is there continuity
YES between CNL62
(female) (2) and
chassis?
20-406
1) Turn starting
switch OFF.
2) Disconnect
CNL62.
NO
U42103
Does engine stop

motor work?
NO
TROUBLESHOOTING
E-1
Cause
Defective adjustment of
wire between engine stop
motor and lever
Remedy
Adjust
Defective engine stop

motor, or defective contact,
or disconnection in wiring After inspection,
repair or replace
chassis ground
YES
7
U42103
Is there continuity
between CNE03
(female) (5) and
(7)?
1) Disconnect
CNE03.
2) Turn starting
switch ON.
NO

relay
Replace

motor
Replace
CNLR3 (5) CNL62 (female) After inspection,
repair or replace
(5), or between CNE03
(female) (7) CNER2 (4) CNLR3 (6) CNL62 (female)
(3)
ground
After inspection,
repair or replace
(female) (2)
After inspection,
repair or replace
Blown fuse, or defective

contact, or disconnection
in wiring harness between After inspection,
CNF2 (female) (11) CNLR repair or replace
(3) CNER2 (1) CNE03
(female) (4)
20-407
q
TROUBLESHOOTING
E-2, E3
E-2 Engine does not stop

Cause
YES
Remedy
Defective adjustment
between engine stop
motor and stop lever
Adjust

motor
Replace
CNLR3 (4) CNL62
(female), or between
CNL62 (female) (3)
CNLR3 (6) CNER2 (4)
CNE03 (female)
(7), or defective relay
(CNL62)
After inspection,
repair or replace
YES
Does engine stop
motor work?
1) Turn starting
Is voltage
switch ON
between CNE03
OFF and check
visually.
NO (7) and (8) 20 30
V?
YES
1) Connect
3
T-adapter to
Is voltage
CNE03 (engine
between CNE03
stop motor
(3) and (8) 20 30
connector) (8 NO
V?
pin).
2) Turn starting
1) Connect
switch OFF.
T-adapter to
CNE03.
NO
2) Turn starting
switch OFF.
4 YES Defective engine stop

Is voltage
between CNE03
(4) and (8) 20 30
V?
1) Connect
T-adapter to
CNE03.
motor
NO CNLR3 (3) CNFS2
(female) (11), or blown
fuse
Replace
After inspection,
repair or replace
E-3 Engine stops when machine is traveling

Check if the starting motor turns. If it does not turn, check
E-1(a) (Engine does not start).
YES
1
Does engine stop
motor work?
YES
2
Defective adjustment
between engine stop
motor and stop lever
Adjust

motor
Replace

relay
Replace
switch terminal BR
CNL09 (2) CNL62
(female) (1)
After inspection,
repair or replace
Does voltage between
1) Turn starting
CNE03 (7) and (8)
switch ON
NO switch between 0V
OFF and check
and 20 30 V?
visually.
1) Connect
T-adapter to
CNE03.
2) Turn starting
switch ON
OFF.
20-408
q
3 YES
Is voltage between
CNL62 (female) (2)
NO and (female) (1) 20
30 V?
1) Disconnect
CNL62 (engine
stop relay).
2) Turn starting
switch ON.
NO
U42103
TROUBLESHOOTING
E-4
E-4 Parking brake does not work

When carrying out troubleshooting of the brake system, stop the machine on flat ground.
(a) Parking brake has no effect when parking brake switch is

turned ON (parking)
YES
1
Is problem
removed when
CNL01 is
disconnected?
2
Is there continuity
between CNL01
NO (female) (2) and
(3)?
1) Disconnect
CNL01.
2) Turn starting
switch OFF.
3) Disconnect
CNL58.
4) Disconnect
CNL59.
U42103
1) Disconnect
CNL01.
2) Start engine.
(Charge brake
oil pressure)
YES
3 YES
Is voltage between
CNT05 (female) (1)
NO and chassis
approx. 0V?
NO
1) Connect
T-adapter to
CNT05.
2) Start engine.
(Charge brake oil
pressure)
3) Turn parking
brake switch ON.
Cause
Remedy

switch
Replace

at CNL01 (female) (2) end
and (3) end
After inspection,
repair or replace

solenoid
Replace

at CNL01 (female) (2) end
and (1) end
After inspection,
repair or replace
Defective emergency
brake switch CNB09
Replace
Defective emergency
brake switch CNB10
Replace

solenoid
Replace
(b) Parking brake has no effect when brake pressure drops

(Does not work as emergency brake)
YES
1
Is problem
removed when
CNB09 is
disconnected?
2 YES
Is problem
removed when
1) Turn starting
switch ON.
NO CNB10 is
disconnected?
2) Turn parking
brake switch ON
1) Turn starting
OFF.
switch ON.
NO
2) Turn parking
brake switch ON
OFF.
20-409
q
TROUBLESHOOTING
E-5
E-5 Parking brake is applied when machine is traveling

When carrying out troubleshooting of the brake system, stop the machine on flat ground.
2 YES
Is there continuity
YES between CNT05
(female) (2) and
chassis?
NO
1) Disconnect
CNT05.
2) Turn starting
switch OFF.
YES
YES
4
1
YES Is problem
Is voltage
between CNT05
(female) (1) and
chassis 20 30V?
1) Replace parking
brake safety
relay (CNL59)
with stop lamp
relay (CNL53).
2) Start engine.
(Charge brake oil
pressure)
1) Connect
T-adapter to
CNT05.
2) Start engine.
(Charge brake
oil pressure)
U42103
removed when
relay is replaced?
Is problem
removed when
NO short connector is
connected?
1) Connect short
connector to
CNB09 (female)
and CNB10
(female).
2) Start engine.
(Charge brake
oil pressure)
3
Is continuity of
CNL01 (male)
NO (1)(2)(3) as shown
in Table 1?
1) Disconnect
CNL01.
2) Turn starting
switch OFF.
3) Operate parking
brake switch
ON/OFF.
YES
7
Is there continuity
YES between CNL59
(female) (1) and
(3)?
6
Is voltage
between CNL59
NO (female) (5) and
chassis 20 30V?
1) Disconnect
CNL59.
2) Turn starting
switch ON.
Table 1
NO
Operation
ON (parking)
OFF (travel)
20-410
q
Between terminal (2) (3) Between terminal (1) (3)

No continuity
Continuity
Continuity
No continuity
1) Disconnect
CNL59.
2) Turn starting
switch OFF.
NO
NO
TROUBLESHOOTING
E-5
Cause

solenoid
Replace
After inspection,
repair or replace

safety relay
Replace
Defective emergency
brake switch
Replace
YES
11 harness between CNB10
Is voltage
YES between CNB10
U42103
10
Is voltage
YES between CNB09
(female) (1) and
chassis 20 30 V?
Is there continuity
YES between CNL59
(female) (2) and
8
chassis?
Is voltage
between CNL59
(female) (1) and
chassis 20 30 V?
1) Disconnect
CNL59.
2) Turn starting
switch ON.
3) Turn parking
brake switch
ON.
1) Disconnect
CNL59.
2) Turn starting
switch OFF.
NO
(female) (1) and

chassis 20 30 V?
1) Disconnect
NO
CNB10.
2) Turn starting
switch ON.
3) Turn parking
brake switch ON
OFF.
1) Disconnect
CNB09.
2) Turn starting
NO
switch ON.
3) Turn parking
brake switch ON
OFF.
NO
Remedy
(female) (2) and CNT05

(female) (1)
After inspection,
repair or replace
(female) (2) and CNB10
(female) (1)
After inspection,
repair or replace
(female) (2)
After inspection,
repair or replace
After inspection,
repair or replace
FS2 (female) (7) and L01
(female) (1)
After inspection,
repair or replace
(1) and CNL59 (3)
After inspection,
repair or replace
fuse
After inspection,
repair or replace

switch
Replace
20-411
q
TROUBLESHOOTING
E-6, E-7
E-6 Parking brake is released when starting switch is turned ON

Cause
1
Is problem
removed when
relay is replaced?
YES
2
Is problem
1) Replace parking
removed when
safety relay
NO CNL01 is
(CNL59) with
disconnected?
stop lamp relay
1)
Disconnect
(CNL53).
CNL01.
2) Start engine.
2) Start engine.
(Charge brake
(Charge brake
oil pressure)
oil pressure)
3) Turn starting
3) Turn starting
switch ON.
switch ON.
3 YES
Is there continuity
between CNL59
NO (female) (3) and
(5)?
1) Disconnect
CNL59.
2) Turn starting
switch OFF.
3) Turn parking
brake switch
OFF.
NO
E-7 Transmission does not change to neutral

when parking brake is applied
(but parking brake works normally)
YES
1
Is voltage between
neutralizer relay
CNL58 (female) (5)
chassis 20 30 V?
1) Disconnect
neutralizer
NO
CNL58.
2) Turn starting
switch ON.
3) Shift directional
lever between F,
N, and R, and
check each
voltage.
20-412
q

relay
Replace

switch
Replace

between CNL59 (5) and
(3)(1) (female)
After inspection,
repair or replace

After inspection,
between CNL01 (1) and (2)
repair or replace
(female)
U42103
YES
Remedy
Abnormal contact of
CNL58 (female) (5)
CNL12 (female) (1), CNL65
After inspection,
CNL12 (female) (2)
repair or replace
(female) (1), CNL67
(female) (1)
with +24V wiring harness
Defective neutralizer relay Replace
TROUBLESHOOTING
E-8
E-8 Transmission does not work normally

When carrying out troubleshooting of the transmission system, stop the machine on flat ground.
If condition is as shown in
Table 2 1 (transmission is
always in 2nd)
Table 1 or Table 2 2
2
Travels in both Check voltage
FORWARD and between CNT03 (1)
REVERSE.
(female) and chassis,
and between CNT04
(1) (female) and
chassis.
1
Does machine
travel forward
and in reverse?
1) Start engine.
2) Turn parking
switch ON
OFF.
3) Operate
directional lever
FORWARD
REVERSE.
Table 2 7
1) Disconnect
CNT03 and
CNT04.
2) Turn starting
switch ON.
3) Turn parking
switch ON
OFF.
4) Operate speed
lever with
directional lever
at FORWARD,
NEUTRAL, and
REVERSE to
Travels in only
check condition.
FORWARD or
REVERSE, or
3
does not travel Check voltage
in either
between CNT01 (1)
direction.
(female) and chassis,
and between CNT02
(1) (female) and
chassis.
Table 2 4 or Table 2 5 or
Table 2 6 (does not enter 4th)
Table 2 8
Table 2 9 (transmission is
always in 4th)
(REVERSE is normal)
(FORWARD is normal)
Table 4 3 (does not travel
in either direction)
Table 4 4 (REVERSE is
normal)
Table 4 5 (FORWARD is
normal)
1) Disconnect
CNT01 and
CNT02.
2) Turn starting
Table 4 6 (does not travel
switch ON.
in either direction)
3) Turn parking
switch ON
OFF.
4) Operate directional lever with speed lever in
all positions (1st to 4th) to check condition.
Go to applicable item.
20-414
q
Remedy
Problem in common
circuit for transmission
Go to E-8(a)
Problem in H-L circuit
Go to E-8(b)
Problem in speed circuit
Go to E-8(c)
Problem in 4th circuit
Go to E-8(d)
Contact in H L circuit
Go to E-8(e)
Contact in speed circuit
Go to E-8(f)
Contact in 4th circuit
Go to E-8(g)
Problem in FORWARD
circuit
Go to E-8(h)
Problem in REVERSE
circuit
Go to E-8(i)
Problem in common
circuit for FORWARD and
REVERSE
Go to E-8(j)
Contact in FORWARD
circuit
Go to E-8(k)
Contact in REVERSE
circuit
Go to E-8(l)
Problem in common
circuit for FORWARD and
REVERSE
Go to E-8(m)
U42103
Cause
TROUBLESHOOTING
E-8
:
:
Transmission
range
1
2
3
4
(H L)
(Speed)
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
Table 1 (normal)
Transmission
range
1
2
3
4
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
Table 2-1 (abnormal)
Transmission
range
1
2
3
4
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
U42103
Transmission
range
1
2
3
4
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
Directional
lever
FORWARD
REVERSE
(F)
(R)
Between
CNT01
(female) (1)
chassis
ground
Between
CNT02
(female) (1)
chassis
ground
Table 3 (normal)
Directional
lever
FORWARD
REVERSE
Between
CNT01
(female) (1)
chassis
ground
Between
CNT02
(female) (1)
chassis
ground
Transmission
range
1
2
3
4
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
Transmission
range
1
2
3
4
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
Transmission
range
1
2
3
4
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
Directional
lever
FORWARD
REVERSE
Between
CNT01
(female) (1)
chassis
ground
Between
CNT02
(female) (1)
chassis
ground
Transmission
range
1
2
3
4
0 0.5 V
20 30 V
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
Transmission
range
1
2
3
4
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
Transmission
range
1
2
3
4
Between
CNT03
(female) (1)
chassis
ground
Between
CNT04
(female) (1)
chassis
ground
Directional
lever
FORWARD
REVERSE
Between
CNT01
(female) (1)
chassis
ground
Between
CNT02
(female) (1)
chassis
ground
Between
CNT01
(female) (1)
chassis
ground
Between
CNT02
(female) (1)
chassis
ground
Between
CNT01
(female) (1)
chassis
ground
Between
CNT02
(female) (1)
chassis
ground
Between
CNT01
(female) (1)
chassis
ground
Between
CNT02
(female) (1)
chassis
ground
Directional
lever
FORWARD
REVERSE
Directional
lever
FORWARD
REVERSE
Directional
lever
FORWARD
REVERSE
20-415
q
TROUBLESHOOTING
E-8
(a) Problem in common circuit for transmission (always stays in 2nd)
1 YES
Is voltage between
CNL04 (5)(6)(7)(8)
and chassis as
shown in table?
Cause
Remedy
Problem in H-L circuit and

speed circuit
Go to E-8 (b), E-8 (c)
Defective speed lever

switch
NO
1) Connect
T-adapter to
CNL04.
2) Turn starting switch ON.
3) Shift speed lever and check.
:
:
Replace
20 30 V
0 0.5 V
Between
Between
Between
Between
CN04(5) chassis CN04(6) chassis CN04(7) chassis CN04(8) chassis
1
2
3
4
U42103
Transmission
range
(b) Problem in H-L circuit

Cause
YES
2
Is voltage
YES between CNT03
(female) (1) and
chassis 20 30V?
1
Is there continuity
between CNT03
(female) (2) and
chassis?
1) Disconnect
CNT03.
2) Turn starting
switch OFF.
20-416
q
1) Disconnect
CNT03.
2) Turn starting
switch ON.
3) Speed lever: 3rd
NO
3 YES
Is voltage
between CNL04
NO (7) and chassis 20
30V?
NO
1) Connect
T-adapter to
CNL04.
2) Turn starting
switch ON.
3) Speed lever: 3rd
Remedy
Defective H L solenoid
Replace
CNT03 (female) (1)
After inspection,
repair or replace

switch
Replace
ground
After inspection,
repair
TROUBLESHOOTING
E-8
(c) Problem in speed circuit
Cause
YES
2
Is voltage
YES between CNT04

1
Is there continuity
between CNT04
(female) (2) and
chassis?
1) Disconnect
CNT04.
2) Turn starting
switch OFF.
(female) (1) and

chassis 20 30 V?
1) Disconnect
CNT04.
2) Turn starting
switch ON.
3) Speed lever: 1st
3 YES
Is voltage
between CNL04
30 V?
NO
1) Connect
T-adapter to CNL04.
3) Speed lever: 1st
Defective speed solenoid
Replace
CNT04 (female) (1)
After inspection,
repair or replace

switch
Replace
ground
After inspection,
repair or replace
U42103
NO
Remedy
(d) Problem in 4th circuit (does not enter 4th)

1 YES
Is voltage
between CNL04
(8) and chassis
ground 20 30V?
1) Connect
NO
T-adapter to
CNL04.
2) Turn starting
switch ON.
3) Speed lever: 4th
After inspection,
(female) (8) CN37
repair or replace
CNTL1 (male) (6) or CNL04
(female) (8) CN38
CNTL1 (male) (5)
switch
Replace
20-417
q
TROUBLESHOOTING
E-8
(e) Contact in H-L circuit
YES
1
Is voltage
between CNT03
(female) (1) and
chassis 20 30 V?
2
Is there continuity
between CNTL1
NO (female) (5) and
(3)(4)(6)?
1) Turn starting
switch OFF.
2) Disconnect
CNT03.
3) Disconnect
CNTL1.
YES
3
Is voltage
between CNTL1
NO (male) (5) and
chassis 20 30 V?
1) Disconnect
CNTL1.
2) Disconnect
CNL04.
3) Turn starting
switch ON.
YES
4
Is there continuity
between CNTL1
NO (male) (5) and
(3)(4)(6)?
1) Turn starting
switch OFF.
2) Disconnect
CNTL1.
3) Disconnect
CNL04.
YES
5
Is there continuity
between CNL04
NO (female) (7) and
(1)(2)(3)(4)(6)?
1) Turn starting
switch OFF.
2) Disconnect
CNTL1.
3) Disconnect
CNL04.
4) Disconnect
CNL66.
20-418
q
U42103
1) Disconnect
CNT03.
2) Disconnect
CNTL1.
3) Turn starting
switch ON.
YES
NO
TROUBLESHOOTING
E-8
Cause
Abnormal contact of
CNT03 (female) (1) and
CNTL1 (female) (5) with
+24V wiring harness
Remedy
After inspection,
repair or replace
Abnormal contact of wiring

harness between CNTL1
(female) (1) with wiring
After inspection,
(female) (3) CNT01 (female) repair or replace
(1), CNTL1 (female) (4)
CNT02 (female) (1),
CNTL1 (female) (6) CNT04
(female) (1)
U42103

After inspection,
(male) (5) and CNL04 (male) repair or replace
(7) with +24V wiring harness
(male) (5) and CNL04
(male) (3) CNL66 (female)
(2), CNTL1 (male) (4)
CNL67 (female) (2), CNTL1
(5)
After inspection,
repair or replace

(female) (7) and CNTL1
(male) (5) with wiring
(male) (1) CNFS2 (female)
After inspection,
(8) or CNL04 (female) (2)
repair or replace
CNL66 (female) (5) or
CNL04 (female) (3) CNL57
(female) (1) or CNL04
(female) (4) CNL67 (female)
CNL66 (3)
Defective transmission
control switch
Replace
20-419
q
TROUBLESHOOTING
E-8
(f) Contact in speed circuit
YES
1
Is voltage
between CNT04
(female) (1) and
chassis 20 30 V?
2
Is there continuity
between CNTL1
NO (female) (6) and
(3)(4)(5)?
1) Turn starting
switch OFF.
2) Disconnect
CNT04.
3) Disconnect
CNTL1.
YES
3
Is voltage
between CNTL1
NO (male) (6) and
chassis 20 30 V?
1) Disconnect
CNTL1.
2) Disconnect
CNL68.
3) Disconnect
CNL04.
4) Turn starting
switch ON.
YES
4
Is there continuity
between CNTL1
NO (male) (6) and
(3)(4)(5)?
1) Turn starting
switch OFF.
2) Disconnect
CNTL1.
3) Disconnect
CNL68.
4) Disconnect
CNL04.
YES
5
Is there continuity
between CNL04
NO (female) (5) and
(1)(2)(3)(4)(6)?
1) Turn starting
switch OFF.
2) Disconnect
CNTL1.
3) Disconnect
CNL68.
4) Disconnect
CNL04.
5) Disconnect
CNL66.
20-420
q
U42103
1) Disconnect
CNT04.
2) Disconnect
CNTL1.
3) Turn starting
switch ON.
YES
NO
TROUBLESHOOTING
E-8
Cause
Abnormal contact of
+24V wiring harness
Remedy
After inspection,
repair or replace

After inspection,
CNT02 (female) (1),
(female) (1)
U42103
Abnormal contact of
After inspection,
CNTL1 (male) (6) and
CNL04 (female) (5), CNL68 repair or replace
(female) (4) with +24V
wiring harness
After inspection,
(male) (3) CNL66 (female) repair or replace
(2), CNTL1 (male) (4)
(7)
(male) (6) with wiring
(female) (1) CNFS2 (female)
After inspection,
repair or replace
CNL66 (female) (5) or
(female) (4) CNL67 (female)
CNL66 (female) (3)
control switch, or
abnormal contact of
CNL68 (3)(4) (male)
After inspection,
repair or replace
20-421
q
TROUBLESHOOTING
E-8
(g) Contact in 4th circuit (always stays in 4th)

Cause
1 YES
Is voltage
between CNL04
(female) (8) and
chassis 20 30V?
NO
Abnormal contact of
CNL04 (female) (8) CN37
After inspection,
(female) (2), CN38 (female)
repair or replace
(2) with +24V wiring
harness
switch
Replace
U42103
1) Disconnect
CNL04.
2) Turn starting
switch ON.
Remedy
20-422
q
TROUBLESHOOTING
E-8
(h) Problem in FORWARD circuit (REVERSE is normal)
2 YES
Is there continuity
YES between CNT01
(female) (2) and
chassis?
NO
1) Disconnect
CNT01.
2) Turn starting
switch OFF.
YES
Is voltage
between CNT01
(female) (1) and
chassis 20 30V?
20-424
q
7 YES
Is voltage
YES between CNL66
(female) (5) and
chassis 20 30V?
6
3
Is problem
removed when
Is there continuity
YES between CNL66

5
(female) (6) and

chassis?
1) Replace
1) Disconnect
Is there continuity
FORWARD
CNL66.
YES between CNL66
solenoid relay
2) Turn starting
(female)
(2)
and
(CNL66) with
switch OFF.
chassis?
REVERSE
4
solenoid relay
1) Disconnect
(CNL67).
Is voltage
CNL66.
2) Start engine.
between CNL66
2) Turn starting
NO
3) Turn parking NO (female) (1) and
switch OFF.
switch ON
chassis 20 30V?
OFF.
1) Disconnect
4) Directional
CNL66.
lever:
2) Turn starting
FORWARD
switch ON.
NO
3) Turn parking
switch ON
OFF.
NO
1) Disconnect
CNL66.
2) Turn starting
switch ON.
3) Directional
lever: FORWARD
NO
U42103
1) Disconnect
CNT01.
2) Turn starting
switch ON.
3) Turn parking
switch ON
OFF.
4) Directional
lever:
FORWARD
TROUBLESHOOTING
E-8
Cause
Remedy
After inspection,
repair or replace
Defective FORWARD
solenoid
Replace
Defective FORWARD relay Replace

(female) (5)
After inspection,
repair or replace
U42103

Replace
switch
After inspection,
repair or replace
CNT01 (female) (1)
After inspection,
repair or replace
(female) (1)
After inspection,
repair or replace
20-425
q
TROUBLESHOOTING
E-8
(i) Problem in REVERSE circuit (FORWARD is normal)
2 YES
Is there continuity
YES between CNT02
(female) (2) and
chassis?
NO
YES
Is voltage
between CNT02
(female) (1) and
chassis 20 30 V?
1) Disconnect
CNT02.
2) Turn starting
3
switch ON.
3) Turn parking
Is problem
switch ON
removed when
OFF.
4) Directional
lever: REVERSE
1) Replace
REVERSE
solenoid relay
(CNL67) with
FORWARD
solenoid relay
(CNL66).
2) Start engine.
3) Turn parking
switch ON NO
OFF.
4) Directional
lever: REVERSE
20-426
q
7 YES
Is voltage
YES between CNL67
(female) (5) and
chassis 20 30 V?
Is there continuity
YES between CNL67
(female) (6) and
chassis?
Is there continuity
YES between CNL67
(female) (2) and
chassis?
4
Is voltage
between CNL67
(female) (1) and
chassis 20 30 V?
1) Disconnect
CNL67.
2) Turn starting
switch ON.
3) Turn parking
switch ON
OFF.
NO
1) Disconnect
CNL67.
2) Turn starting
switch OFF.
1) Disconnect
CNL67.
2) Turn starting
switch OFF.
NO
1) Disconnect
CNL67.
2) Turn starting
switch ON.
3) Directional
lever: REVERSE
NO
NO
U42103
1) Disconnect
CNT02.
2) Turn starting
switch OFF.
TROUBLESHOOTING
E-8
Cause
Remedy
After inspection,
repair or replace
Defective REVERSE
solenoid
Replace
Defective REVERSE relay
Replace
(female) (5)
After inspection,
repair or replace
U42103

Replace
switch
After inspection,
repair or replace
CNT02 (female) (1)
After inspection,
repair or replace
(female) (1)
After inspection,
repair or replace
20-427
q
TROUBLESHOOTING
E-8
(j) Problem in common circuit for FORWARD and REVERSE

(does not travel forward, parking brake is normal)
YES
2
Is voltage
YES between CNL04
1
Is voltage
between CNL66
(female) (1) and
chassis 20 30 V?
3 YES
Is voltage
between CNL04
NO (female) (1) and
chassis 20 30 V?
1) Connect
T-adapter to
CNL04.
2) Turn starting
switch ON.
3) Directional
lever: F N R
YES
1) Disconnect
CNL66.
2) Turn starting
switch ON.
3) Turn parking
brake switch ON
OFF.
Is problem removed
when transmission
NO cut-off switch is
turned OFF?
1) Disconnect
CNL04.
2) Turn starting
switch ON.
NO
YES
Is problem removed
when short connector
is connected instead
of transmission cut-off
switch?
1) Connect short
NO
connector to
CNL12 (female).
2) Start engine.
YES
3) Turn
transmission
cut-off selector
switch ON.
U42103
(2), (4) chassis as

shown in table?
1) Start engine.
YES
9
6
Is voltage
Is problem
removed when
YES between CNL58

8
1) Replace
neutralizer relay
(CNL58) with
stop lamp relay
(CNL53).
2) Start engine.
Is there continuity
YES between CNL58

7
Is voltage
between CNL58
NO (female) (1) and
chassis 20 30 V?
(female) (2) and

chassis?
1) Disconnect
CNL58.
2) Turn starting
switch OFF.
1) Disconnect
CNL58.
2) Turn starting
NO
switch ON.
3) Turn parking
brake switch ON
OFF.
:
:
Between
Between
CN04(2) chassis CN04(4) chassis
Divectional
lever
F
N
R
20-428
q
20 30 V
0 0.5 V
(female) (3) and

chassis 20 30 V?
1) Disconnect
CNL58.
2) Turn starting
switch ON.
NO
NO
TROUBLESHOOTING
E-8
Cause
Go to E-8 (h) and (i)
Remedy
U42103

Replace
switch
harness between CNFS2
(female) (1)
After inspection,
repair or replace
cut-off switch
Replace
CNL65 (female) (5)
After inspection,
repair or replace
Defective neutralizer relay Replace

After inspection,
repair or replace
CNL12 (female) (2)
(female) (1)
fuse CNFS1 (male) (2)
After inspection,
repair or replace
After inspection,
repair or replace
(female) (2)
After inspection,
repair or replace
20-429
q
TROUBLESHOOTING
E-8
(k) Contact in FORWARD circuit
YES
YES
Is problem
removed when
relay is replaced?
1) Replace
2
FORWARD relay
Is voltage
(CNL66) with F
between CNT01
working lamp
relay (CNL60). NO (female) (1) and
chassis 20 30 V?
2) Start engine.
3) Turn parking
1) Disconnect
brake switch ON
CNT01.
OFF.
2) Disconnect
4) Directional
CNTL1.
lever:
3) Turn starting
FORWARD
switch ON.
YES
Is there continuity
between CNTL1
NO (female) (3) and
(4)(5)(6)?
U42103
1) Turn starting
switch OFF.
2) Disconnect
CNT01.
3) Disconnect
CNTL1.
YES
4
Is voltage
between CNTL1
NO (male) (3) and
chassis 20 30 V?
1) Disconnect
CNTL1.
2) Disconnect
CNL66.
3) Turn starting
switch ON.
YES
5
Is there continuity
between CNTL1
NO (male) (3) and
(4)(5)(6)?
1) Turn starting
switch OFF.
2) Disconnect
CNTL1.
3) Disconnect
CNL66.
YES
6
Is there continuity
between CNL04
NO (female) (2) and
(1)(3)(4)(5)(6)(7)(8)?
1) Turn starting
switch OFF.
2) Disconnect
CNL66.
3) Disconnect
CNL04.
20-430
q
NO
TROUBLESHOOTING
E-8
Cause
Remedy
Defective FORWARD relay Replace

After inspection,
repair or replace
wiring harness
U42103

After inspection,
CNT03 (female) (1),
(female) (1)
After inspection,
repair or replace
wiring harness
After inspection,
(2), CNTL1 (male) (5)
(5)
(female) (1) CNFS2 (female)
(8), CNL04 (female) (3)
After inspection,
CNL57 (female) (1),
repair or replace
(female) (5), CNL04 (female)
(5) CNTL1 (male) (6),
(7) CNTL1 (male) (5),
(2) or CN38 (2)
control switch
Replace
20-431
q
TROUBLESHOOTING
E-8
(l) Contact in REVERSE circuit
YES
YES
Is problem
removed when
relay is replaced?
1) Replace
2
REVERSE relay
Is voltage
(CNL67) with F
between CNT02
working lamp
relay (CNL60). NO (female) (1) and
chassis 20 30 V?
2) Start engine.
3) Turn parking
1) Disconnect
brake switch ON
CNT02.
OFF.
2) Disconnect
4) Directional
CNTL1.
lever: REVERSE
3) Turn starting
switch ON.
YES
Is there continuity
between CNTL1
NO (female) (4) and
(3)(5)(6)?
U42103
1) Turn starting
switch OFF.
2) Disconnect
CNT02.
3) Disconnect
CNTL1.
YES
4
Is voltage
between CNTL1
NO (male) (4) and
chassis 20 30 V?
1) Disconnect
CNTL1.
2) Disconnect
CNL67.
3) Turn starting
switch ON.
YES
5
Is there continuity
between CNTL1
NO (male) (4) and
(3)(5)(6)?
1) Turn starting
switch OFF.
2) Disconnect
CNTL1.
3) Disconnect
CNL67.
YES
6
Is there continuity
between CNL04
NO (female) (4) and
(1)(2)(3)(5)(6)(7)(8)?
1) Turn starting
switch OFF.
2) Disconnect
CNL67.
3) Disconnect
CNL04.
20-432
q
NO
TROUBLESHOOTING
E-8
Cause
Remedy
Defective REVERSE relay
Replace
Abnormal contact of
+24V wiring harness
After inspection,
repair or replace
U42103

After inspection,
CNT03 (female) (1),
(female) (1)
Abnormal contact of
CNTL1 (female) (4) and
CNL67 (female) (2) with
+24V wiring harness
After inspection,
repair or replace

After inspection,
(2), CNTL1 (male) (5)
(5)
(female) (1) CNFS2
After inspection,
(3) CNL57 (female) (1),
CNL04 (female) (2) CNL66 repair or replace
(5) CNTL1 (male) (6),
(7) CNTL1 (male) (5),
(2) or CN38 (2)
control switch
Replace
20-433
q
TROUBLESHOOTING
E-8
(m) Problem in common circuit for FORWARD and REVERSE
Cause

between CNT01 (female) (1)
and CNL66 (female) (2) with After inspection,
repair or replace
CNL67 (female) (2)
YES
1
Is there continuity
between CNT01
(female) (1) and
CNT02 (female) (1)?
2 YES
Is there continuity
between CNL04
NO (female) (2) and
CNL04 (female) (4)?
1) Turn starting
switch OFF.
2) Disconnect
CNL04.
NO

between CNL04 (female) (2)
and CNL66 (female) (5) with After inspection,
repair or replace
CNL67 (female) (5)
control switch
Replace
U42103
1) Turn starting
switch OFF.
2) Disconnect
CNT01 and
CNT02.
Remedy
20-434
q
TROUBLESHOOTING
E-9
E-9 Kick-down switch does not work

(the regular F1 to F4 shifts normally)
When connecting the T-adapter (or socket adapter), connect to the connector specified as CN(
).
YES
YES
2
Is problem
removed when
relay is replaced?
1) Replace kickdown relay
(CNL68) with
REVERSE
solenoid relay
(CNL67).
2) Start engine.
YES
3
Is problem
removed when
6
Is there continuity
YES between CNL15
(female) (1) and
CNL66 (female) (4)?
1) Replace
FORWARD
solenoid relay
(CNL66) with
REVERSE
solenoid relay
(CNL67).
2) Start engine.
1
Is there continuity
between CNL15
(male) (1) and
(male) (2)?
1) Disconnect
CNL15.
2) Press kick-down
switch.
3) Turn starting
switch OFF.
5
Is there continuity
YES between CNL68
(female) (5) and
CNL15 (female) (2)?
4
Is there continuity
between CNL68
NO (female) (6) and
chassis ground?
1) Disconnect
CNL68.
2) Turn starting
switch OFF.
NO
20-436
q
U42103
YES
1) Disconnect
CNL68 and
CNL15.
2) Turn starting
switch OFF.
NO
1) Disconnect
CNL15 and
CNL66.
2) Turn starting
switch OFF.
NO
NO
TROUBLESHOOTING
E-9
Cause
YES
Is voltage
YES between CNL68

(female) (3) and
chassis 20 30V?
U42103
Is voltage
between CNL66
(female) (3) and
chassis 20 30V?
1) Disconnect
CNL66.
2) Speed lever:
2nd
3) Turn starting
switch ON.
1) Disconnect
NO
CNL68.
2) Speed lever: 2nd
3) Turn starting
switch ON.
9 YES
Is voltage
between CNL04
30V?
NO
1) Connect
T-adapter to CNL04.
2) Speed lever: 2nd
Remedy
Defective kick-down relay
Replace
Defective FORWARD
solenoid relay
Replace
(female) (5)
After inspection,
repair or replace
(female) (6)
After inspection,
repair or replace
(female) (6)
After inspection,
repair or replace

switch
Replace
(female) (4)
After inspection,
repair or replace
(female) (2)
After inspection,
repair or replace
ground
After inspection,
repair or replace
Defective kick-down
switch
Replace
20-437
q
TROUBLESHOOTING
E-10, E-11
E-10 Kick-down works only when kick-down switch is ON (Kick-down

switch relay does not hold in position (self-holding function) )
).
Cause
1 YES
Is problem
removed when
relay is replaced?
NO
Replace
(female) (4) CNL68
(female) (2) CNL68
(female) (5)
After inspection,
repair or replace
U42103
1) Replace kickdown relay

(CNL68) with
REVERSE
solenoid relay
(CNL67).
2) Start engine.
Remedy
E-11 Kick-down operation cannot be canceled

(a) Not canceled even when directional lever is moved from F to N or R
Cause
1 YES
Is problem
removed when
relay is replaced?
1) Replace
FORWARD
solenoid relay
(CNL66) with
REVERSE
solenoid relay
(CNL67).
2) Start engine.
20-438
q
NO
Remedy
Defective FORWARD
solenoid relay
Replace

(3) and (4)
After inspection,
repair or replace
TROUBLESHOOTING
E-11
(b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th)
YES
1
Is there continuity
between CNL04
(female) (1) and
CNL04 (female) (6)?
2
Is there continuity
between CNL04
NO (female) (2) and
CNL04 (female) (6)?
1) Turn starting
switch OFF.
2) Disconnect
CNL04.
3) Disconnect
CNL66.
YES
3
Is voltage
between CNL66
NO (female) (3) and
chassis 20 30 V?
1) Disconnect
CNL66.
2) Disconnect
CNL04.
3) Turn starting
switch ON.
YES
4
Is voltage
between CNL66
NO (female) (4) and
chassis 20 30 V?
1) Disconnect
CNL66.
2) Disconnect
CNL68.
3) Disconnect
CNL15.
4) Turn starting
switch ON.
20-440
q
YES
5
Is voltage
between CNL68
NO (female) (2) and
chassis 20 30 V?
1) Disconnect
CNL68.
2) Disconnect
CNL15.
3) Turn starting
switch ON.
YES
6
Is there continuity
between CNL04
NO (female) (1) and
CNL04 (female) (5)?
1) Turn starting
switch OFF.
2) Disconnect
CNL04.
3) Disconnect
CNFT1.
NO
U42103
1) Turn starting
switch OFF.
2) Disconnect
CNL04.
3) Disconnect
CNL66.
YES
TROUBLESHOOTING
E-11
Cause
Remedy
Abnormal contact of
CNL04 (female) (1) (6)
After inspection,
repair or replace
Abnormal contact of
CNL04 (female) (2) (6), or
defective speed lever
switch
After inspection,
repair or replace
Abnormal contact of
CNL04 (6) and CNL66 (3)
After inspection,
repair or replace
Abnormal contact of
CNL66 (female) (4)
After inspection,
wiring harness
U42103
Abnormal contact of
CNL68 (female) (2)
After inspection,
wiring harness
Abnormal contact of
CNL04 (female) (1) (5)
YES
7
Is voltage
between CNL68
(female) (4) and
chassis 20 30V?
1) Disconnect
CNL68.
2) Disconnect
CNTL1.
3) Disconnect
CNL04.
4) Starting switch
ON.
NO
After inspection,
repair or replace
Abnormal contact of
CNL04 (female) (5)
CNL68 (female) (4), CN37 After inspection,
(female) (1), CNTL1 (male) repair or replace
(6) with +24V wiring
harness, or defective
speed lever switch
Abnormal contact of
CNTL1 (6) and CNT04 (1)
After inspection,
repair or replace
20-441
q
TROUBLESHOOTING
E-12
E-12Kick-down switch is actuated by mistake when traveling in 2nd

).
Cause
YES
1
1) Disconnect
CNL15.
2) Turn starting
switch OFF.
3) Do not press
kick-down
switch.
20-442
q
YES
Defective kick-down
switch
Replace
Replace

(1) (2)
After inspection,
repair or replace
Is there continuity
between CNL68
NO (male) (1) (2)
and (3) (4)?
1) Disconnect kickdown relay
NO
(CNL68).
2) Turn starting
switch OFF.
YES
3
Is there continuity
between CNL15
(female) (1) and
CNL15 (female) (2)?
1) Disconnect
CNL15.
2) Turn starting
switch OFF.
3) Directional
lever: N
4 YES Contact of wiring harness

Is there continuity
between CNL68
NO (female) (1) and
CNL68 (female) (2)?
1) Disconnect
CNL68.
2) Turn starting
switch OFF.
3) Directional
lever: N

(1) (2)

NO (3) (4)
After inspection,
repair or replace
After inspection,
repair or replace
U42103
Is there continuity
between CNL15
(male) (1) and
CNL15 (male) (2)?
Remedy
TROUBLESHOOTING OF HYDRAULIC AND

MECHANICAL SYSTEM (CHASSIS RELATED)
(T MODE)
POWER TRAIN
T- 1
Machine does not start ............................................................................................................. 20-452
T- 2
Travel speed is slow, thrusting power is weak, lacks power on slopes ............................ 20-454
T- 3
Excessive shock when starting machine or shifting gear ..................................................... 20-456
T- 4
Excessive time lag when starting machine or shifting gear ................................................ 20-457
T- 5
Torque converter oil temperature is high .............................................................................. 20-458
U42103
STEERING SYSTEM
T- 6
Steering does not turn .............................................................................................................. 20-459
T- 7
Steering wheel is heavy ........................................................................................................... 20-460
T- 8
Steering wheel wobbles or there is excessive shock............................................................ 20-461
T- 9
Machine steers to one side when traveling ........................................................................... 20-461
T-10
Turning radius to left and right is different ........................................................................... 20-461
BRAKE SYSTEM
T-11
Brakes do not work or braking effect is poor ........................................................................ 20-462
T-12
Brakes are not released or brakes drag .................................................................................. 20-463
T-13
Parking brake is not released or brake drags ........................................................................ 20-464
WORK
T-14
T-15
T-16
T-17
T-18
T-19
T-20
T-21
T-22
T-23
T-24
T-25
T-26
T-27
T-28
EQUIPMENT
Lift arm does not rise ............................................................................................................... 20-465
Lift arm movement is slow or lift arm lacks lifting power ................................................... 20-466
When lift arm is raised, it moves slowly at a certain height ............................................... 20-467
Fork cannot be pushed with lift arm cylinder (fork floats) ................................................... 20-467
Excessive hydraulic drift of lift arm ........................................................................................ 20-467
Lift arm shakes during operation ............................................................................................ 20-467
Lift arm drops momentarily when control lever is operated from HOLD to RAISE ......... 20-468
Fork does not tilt back .............................................................................................................. 20-469
Fork movement is slow or tilt back lacks power ................................................................... 20-470
Fork movement becomes slow during tilt-back operation ................................................... 20-471
Fork cannot be pushed with fork cylinder .............................................................................. 20-471
Excessive hydraulic drift of fork .............................................................................................. 20-471
Fork shakes during loading operation .................................................................................... 20-472
Fork dumps momentarily when control lever is operated from HOLD to TILT ................ 20-472
Lift arm, fork control levers are heavy or do not move smoothly ...................................... 20-473
Explanation of symbols in Table

The following symbols are used on the Cause column to show the action to be taken to remove the
cause.
: Correct, A: Adjust, C: Clean
X: Replace,
20-451
q
TROUBLESHOOTING
T-1
POWER TRAIN
T-1 Machine does not start
Charging
pump
Remedy
No. Problems
1
Does not start in any transmission range
Does not start in certain transmission ranges
Does not start when oil temperature rises
Torque converter stall speed does not go down to specified speed

in any transmission range
Torque converter stall speed does not go down to specified speed

in certain transmission ranges
Torque converter charging pressure does not rise
Transmission clutch pressure does not rise in any speed range
Transmission clutch pressure does not rise in certain speed

ranges
Metal particles (aluminium, copper, iron, etc.) stuck to filter or

strainer
20-452
q
Torque
converter
U42103
Air
suck
ed i
Cau
n at
ses
Defe
cha
ctiv
rgin
e ch
g pu
argi
No
mp
ng p
driv
suct
ump
e fo
ion
r ch
end
Brea
a
rgin
kag
g pu
e in
mp
side
Defe
(def
torq
ctiv
ecti
ue c
e op
ve P
onv
erat
TO)
Brea
erte
ion
r (be
kag
of to
e in
arin
rque
side
g, tu
Defe
con
tran
rbin
ctiv
vert
smi
e, p
e op
e
s
r
ump
s
relie
erat
ion
Defe
, sta
con
ion
f
v
ctiv
a
trol
tor,
of c
l
v
e op
e
lutc
valv
seal
erat
h pr
Defe
, etc
e
i
o
e
.)
n of
ssur
ctiv
e op
con
e re
trol
erat
gula
Clog
i
v
t
o
a
o
n
l
r
ve (
ged
of s
valv
dirt
olen
orifi
e of
cau
ce o
oid
con
ght,
valv
f co
trol
scuf
ntro
e
valv
fing
l va
e
, etc
lve
.)
Ask the operator the following questions.

Did the problem suddenly start?
Yes = Internal part seized or broken
Was there any abnormal noise when this
happened?
Yes = Component broken.
Checks before troubleshooting
Does the machine monitor function properly?
Is the transmission oil level correct?
Is the type of oil correct?
Is the transmission filter or strainer
clogged?
Does the electrical circuit of the transmission control work properly?
Is the transmission oil deteriorated?
Does the oil smell of burning?
Is there any damage or leakage of oil
that can be seen externally?
Is the drive shaft broken?
Is the wheel brake or parking brake
locked?
U42103
Exce
ssiv
e lea
kage
Defe
of o
ctiv
il fro
e op
m tr
erat
Brea
ansm
ion
kag
i
nsid
issio
e in
e tra
side
n clu
Exc
nsm
tch
tran
essi
shaf
issio
smi
ve l
t sea
ssio
n cl
eaka
utch
n (b
l po
ge o
eari
rtion
(
Brea
f oil
s
e
n
i
z
g
(wo
e
kag
from
, ge
d
,
rn, b
w
e in
ar, h
or n,
park
roke
side
o
o
u
i
n
i
s
n)
l
g br
accu
ing)
l
e
a
kag
ake
mul
e
seal
, br o
ator
(wo
ken
valv
r n, b
)
e (a
roke
bno
rma
n)
l we
ar o
f sp
ool
por t
ion)
TROUBLESHOOTING
Transmission
k
l
m
n
T-1
Accumulator
valve
20-453
TROUBLESHOOTING
T-2
T-2 Travel speed is slow, thrusting power is weak, lacks power on

slopes

clogged?
Is there any oil leaking from the joints of
the piping or valves?
Is there any dragging of the wheel brake
or parking brake?
Is the tire inflation pressure and tread
pattern normal?
Is the method of operation correct?
Charging
pump
Remedy
No. Problems
1
Abnormality in all transmission ranges
Abnormality in certain transmission ranges
When oil temperature is low, abnormal noise comes from

charging pump
Torque converter oil overheats
Abnormality in high idling and low idling speeds
Abnormality in each stall engine speed
Torque converter relief pressure is low

Low in every transmission range
8
9
Transmission
clutch pressure
Low in certain transmission ranges

Indicator is unstable and fluctuates violently
10
11
Transmission oil level changes
12
Metal particles stuck to transmission strainer or torque converter

filter
13
Cut-off valve does not cut-off even when hydraulic pressure in

work equipment circuit is high.
20-454
q
Torque
converter
Transmission
control valve
U42103
Air
suck
ed i
Cau
n at
ses
Defe
cha
ctiv
rgin
e ch
g pu
a
r
Defe
mp
ging
suct
ctiv
pum
e to
ion
p
rque
end
Oil l
con
eaka
vert
ge i
e
n
r
s
relie
Brea
ide
torq
f va
kag
lve
ue c
e in
onv
side
Defe
erte
torq
ct in
r (se
ue c
side
al ri
onv
ng,
tran
Defe
erte
bus
smi
r (be
ctiv
hing
ssio
e op
a
, sna
r
ing,
n co
erat
p rin
ntro
turb
ion
g, b
l va
ine,
of c
eari
lve
p
lutc
u
ng,
m
(we
h pr
p, s
etc.)
ar, s
essu
t
a
tor,
crat
re re
e
c
tc.)
hes
gula
on s
tor v
poo
alve
l,etc
of c
.)
ontr
ol v
alve
Checking for abnormalities

Measure digging operations and speed
when traveling on level ground and on
slopes, and check if there is actually an
abnormality or whether it is just the feeling of the operator.
U42103
C
Control
valve
i
j
rom
oil f
rom
seal
lve
ring
l va
ntro
k
l
side
e in
kag
tran
of tr
ans
mis
smi
sion
Clog
ssio
tran
clut
n cl
ged
s
u
ch p
mis
tran
tch
s
ack
ion
pist
smi
Clog
sha
on s
ssio
ged
ft
eal
n br
torq
e
a
u
t
Exc
her
e co
essi
nve
ve l
rter
eaka
coo
ge o
ler c
f oil
ircu
Brea
it
from
kag
park
e in
side
ing
brak
accu
Leak
e se
mul
al (w
age
ator
of o
orn,
valv
i
l fro
e (a
brok
Defe
m
bno
en)
ct in
seal
rma
of s
eng
l we
haft
ine
ar o
rela
in w
f sp
Defe
ted
ork
ool
part
equ
ctiv
port
ipm
e cu
ion)
ent
t-off
and
valv
stee
e
ring
circu
it pu
mp
Brea
e of
kag
Lea
oil f
f co
ce o
orifi
e of
kag
Lea
ged
Clog
TROUBLESHOOTING
T-2
Torque converter,
transmission circuit
m
Accumulator
valve
n
o
Others
p
q
Cut-off
valve
20-455
TROUBLESHOOTING
T-3
T-3 Excessive shock when starting machine or shifting gear

Is the engine idling speed too high?
Is there play in any of the drive shafts?
Control valve
a
Remedy
No. Problems
1
Shock is excessive in every transmission range
Shock is excessive in certain transmission ranges
Clutch pressure is too high
20-456
q
Transmission
Accumulator
valve
U42103
Defe
ctiv
Cau
e op
erat
ses
Stuc
ion
k ac
of tr
cum
a
n
u
s
lato
Defe
mis
sion
r pis
ctiv
ton
e op
clut
ch p
erat
Defe
ion
ress
ctiv
of m
ure
e op
regu
o
d
e
ulat
ratio
Defe
lato
ion
n of
ctive
r va
valv
lve
quic
ope
e
ratio
k re
Clog
turn
n of
ged
valv
chec
oil d
e
k va
rain
lve i
hole
n dr
Defe
a
r
a
o
in ci
ctiv
und
e op
rcui
circ
t of
erat
um f
dire
ion
e
renc
ctio
of a
e of
nal
ccum
sele
c
lutc
ulat
ctor
h pa
or v
spo
ck c
alve
ol
ylin
der

It is difficult to measure if the shock is excessive or normal, so judge that the shock
is excessive in the following cases.
When it is clear that the shock has become greater than before.
When the machine is compared with
another machine of the same class and
the shock is found to be greater.
TROUBLESHOOTING
T-4
T-4 Excessive time lag when starting machine or shifting gear
Defe
ctiv
Cau
e op
Clog
erat
ses
ged
ion
o
o
rific
f ac
Defe
cum
e
ctiv
ulat
e op
Lea
or
erat
kag
ion
e of
o
f
Lea
o
q
i
u
l
i
d
kag
ck r
ue t
e of
etur
ow
Lea
n va
oil f
ear
kag
rom
lve
of p
e of
isto
tran
Lea
oil f
n, s
s
m
kag
r
poo
om
issio
e of
l, or
tran
n cl
oil f
smi
utch
bore
rom
s
sion
pac
j
o
k
int o
Brea
clut
ch p , piston
f tra
kag
e in
nsm
a
seal
side
issio ck, sha
ft se
accu
n ho
al ri
mul
u
sing
ng
ator
and
valv
valv
e (b
e
roke
n sp
ring
, wo
rn s
poo
l)

Was there excessive time lag? Was there
any abnormality in the travel speed or
thrusting force? Was there any lack of
power when traveling up slopes?
Yes = Go to T-2 Travel speed is slow,
thrusting power is weak, lacks
power on slopes
U42103

Is there any oil leaking from the joints of
the piping or valves?
Transmission
Accumulator
control valve Transmission valve
Remedy
No. Problems
1
Time lag is excessive in every transmission range
Time lag is excessive in certain transmission ranges
Clutch pressure is low in every transmission range
Clutch oil pressure is low in transmission ranges where time lag is

excessive
20-457
q
TROUBLESHOOTING
T-5
T-5 Torque converter oil temperature is high

suck
ed i
Cau
Defe
n at
ses
ctiv
cha
e ch
rgin
Defe
argi
g pu
ctiv
ng p
mp
e to
ump
suct
Lea
rque
ion
kag
con
end
e of
vert
Brea
oil i
er re
nsid
kag
l
i
e
e
e
f
torq
insi
valv
Defe
de t
e
ctiv
orqu ue con
e tra
vert
e
Brea
c
n
er (s
o
smi
nve
kag
s
eal
rter
sion
e in
ring
(bea
side
clut
, bu
Clog
r
c
i
t
h
n
r
s
a
g, p
pres
nsm
ged
ump hing, sn
sure
issio
tran
, tur
ap r
regu
smi
n
ing,
bine
ssio
lato
bea
, sta
n br
r va
Defe
ring
tor,
e
l
v
a
e
ther
, etc
ctiv
etc.
e bl
)
.)
eed
ing
Leak
of a
age
ir fr
of o
om
Defe
il fro
torq
ct in
ms
ue c
eal o
eng
onv
ine
f
erte
shaf
rela
r co
t in
ted
oler
wor
part
k eq
or c
uipm
logg
ed c
ent
circu
ircu
it
it an
d st
eeri
ng c
ircu
it pu
mp

Does oil temperature rise during torque
converter stall and go down when there
is no load?
Yes = Selection of transmission range
Does oil temperature rise only when carrying out scooping work?
Yes = Improvement in method of operation
Are the radiator water level and fan belt
tension correct?
clogged?
Charging Torque
pump
converter
Remedy
No. Problems
1
When oil temperature is low, abnormal noise comes from

charging pump
Abnormality in high idling and low idling speeds
Abnormality in each stall engine speed
Abnormality in travel speed, thrusting force, and gradeability in all

transmission ranges
Abnormality in travel speed, thrusting force, and gradeability in

certain transmission ranges
Torque converter relief pressure is low
7
8
Low in every transmission range

Transmission
clutch pressure
Low in certain transmission ranges

Indicator is unstable and fluctuates violently
10
Transmission oil level changes
11
Metal particles stuck to transmission strainer or torque converter

filter
20-458
q
Trans- Torque converter,

mission transmission circuit Others
U42103
Air

Measure the torque converter oil temperature. Is it actually high?
Yes = Defective oil transmission gauge
TROUBLESHOOTING
T-6
STEERING SYSTEM
T-6 Steering does not turn
Cau
Oil d
ivid
ses
ed a
Stee
t
s
teer
ring
ing
, sw
Stee
valv
itch
ring
e
, PP
C pu
relie
Saft
mp
f va
ey v
brok
l
v
e
a
lve
en
Dem
and
s
p
P
o
i
o
l
ot p
l
Defe
ress
ct in
ure
side
load
stee
port
ring
Inte
ion
cylin
rnal
der
defe
Inte
(lea
ct
rnal
kag
e of
defe
oil f
ct
ro
mp
isto
n
seal
)

Did the problem suddenly happen?
Part broken in steering related equipment
Had the steering been heavy before, or had
there been any other symptom?
Internal wear or defective seal in steering
related equipment
Is the oil level and type of oil in the hydraulic tank correct?
Has the safety bar been removed from the
frame?
Hydraulic
pump
PTO or
pump
broken
U42103
Hydraulic
pump
b c
Defect inside
steering valve
Others
Valves
d
Orbit- Stop
rol
valve
g h
Remedy
No. Problems
1
Steering does not turn to in either direction
Same as Item 1, but there is abnormality in movement of

worke quipment
Steering does not turn in one direction (left or right)
Steering wheel is heavy and does not turn
There is no rise at all in steering circuit pressure
Steering wheel turns, but steering does not turn in either direction
Steering wheel turns, but steering turns only in one directiion

(left or right)
There is a close relationship between the steering circuit and work equipment circuit, so if any
abnormality is felt in the steering, check also the operating condition of the work equipment.
20-459
q
TROUBLESHOOTING
T-7
T-7 Steering wheel is heavy

Did the problem suddenly happen?
Part broken in steering related equipment
Had the steering been heavy before, or had
there been any other symptom?
Internal wear or defective seal in steering
related equipment
Hydraulic
pump
defective
Defect inside
steering valve
Tank
pump
Remedy
Stop
valve
Others
Valves
b c
A
g h
j
C
k
C
No. Problems
1
Steering wheel is heavy when turned in either direction

(left and right)
Steering is heavy when turned in one direction (left and right)
Steering is particularly heavy when engine is running at low speed
Boom RAISE lacks speed with engine at full throttle
Steering wheel is heavy and there is jerking
Hydraulic oil overheats
Pressure in steering circuit is low
Pressure rises in steering cylinder return piping
There is a close relationship between the steering circuit and work equipment circuit, so if any
abnormality is felt in the steering, check also the operating condition of the work equipment.
20-460
q
U42103
Checking for abnormalities.

Measure the operating force of the
steering wheel and the time taken
for the steering to turn, and compare with the Standard Values Table to judge if there is any abnormality.
Oil d
aus
ivid
es
ed a
Stee
t ste
ring
erin
,
swit
g va
Stee
ch,
lve
ring
PPC
relie
pum
Saft
f
valv
p br
ey v
e
oke
alve
Dem
n
and
spo
Pilo
ol
t pre
ssur
Inte
e lo
rnal
defe ad por
I
n
tion
ct
tern
Defe
al d
ct in
efec
s
i
t
de s
Filte
teer
r clo
ing
gge
cylin
d on
Oil c
der
oole
hyd
(lea
raul
r clo
kag
ic o
gge
e of
il re
d
oil f
turn
rom
side
pist
, by
on s
pas
eal)
s va
lve
defe
ctiv
e

Is there any abnormality in the column?
Is there any oil leakage from the hydraulic
hoses, valves, or cylinders?
Is there any oil leakage from the hydraulic
hoses, valves, or cylinders?
Is there any scuffing or the center hinge pin
bearing and steering cyinder pin or bushing?
Tire inflation pressure
TROUBLESHOOTING
T-8, T-9, T-10
T-8 Steering wheel wobbles or

there is excessive shock
U42103
ring
Valves
a
Remedy
rnal
Stee
Steering
valve
defective
Inte
Safe
ty v
alve
Cau
s
es

Drive the wheel loader in a safe place, and check
how the steering wheel wobbles and under what
conditiions.
If there is wobble of the steering wheel, and
in addition the steering wheel is heavy or
there are other problems, go to 2. Steering
wheel is heavy.
valv
e se
lect
or s
defe
poo
ct in
l ou
orbi
t of
Defe
trol
pos
ct in
(reli
ition
side
ef v
alve
stee
)
ring
cylin
der
(ins
ide
surf
ace
of c
ylin
de r,
pist
on s
eal,
nut,
bolt
)

Is there any abnormality in the column?
Is there any play in the center hinge pin
bearing and steering cylinder pin bushing?
Is there any variation in the inflation pressure of the tires?
Is there any play in the steering?
Cylinder
No. Problems
1
Steering wheel wobbles when traveling on rough road surfaces
Steering wheel wobbles or suddenly turns when operating or

traveling
Steering wheel wobbles when traveling at speed
Body wobbles when engine is started
T-9 Machine steers to one side

when traveling
Cause: Defective steering valve
Spool out of position
Leakage of oil inside steering cylinder
Variation in tire inflation pressure
T-10 Turning radius to left and

right is different
Cause: Dividing of steering to left and right, lock
position of stopper (At end of steering,
relief noise can be heard from valve)
20-461
q
TROUBLESHOOTING
T-11
BRAKE SYSTEM
ctiv
e br
Cau
Defe
ake
ses
ctiv
pist
e
o
n se
ope
Defe
ratio
al in
ctiv
side
n of
e br
Wea
brak
axle
ake
r or
e pi
port
o
ston
i
t
o
h
n in
Con
er a
insi
side
tact
bno
de a
rma
with
axle
xle
Air
lity
met
in b
of b
al p
rake
rake
o
r
Defe
t
circ
ion
linin
uit
ct i
due
g in
to c
side
Defe nside b
omp
rake
axle
ctiv
l
ete
e ac
v
alve
wea
Defe
cum
r
ctiv
u
of b
lato
e op
rake
r pis
Defe
erat
linin
ton
ctiv
i
o
seal
g in
n of
e pi
side
, ins
lot p
c
uffic
axle
ump harge
valv
ient
(for
e
gas
cha
pres
rge)
sure
, scu
ffing

Yes = Brake equipment broken
Did the problem gradually appear?
Yes = Deterioration of seal, wear of
lining, disc
Is the hydraulic oil level correct?
Is the brake pedal play correct?
Is there any leakage of oil from the brake
tube or connector?
Is there any deformation of the tube?
Is the tire inflation pressure and tread
pattern normal?
Defe

Measure the braking force and compare
with the Standard Value Table to check
if the braking effect is poor.
Remedy
No. Problems
1
Resistance is low when brake pedal is depressed
Brake pedal is heavy when it is depressed
Abnormal operating force is needed to obtain specified braking force
Abnormal noise is heard from axle brake when brake is applied
Machine cannot travel (lacks rimpull)
Jack up 4 wheels and set axles on stand. In F1, when brakes are
applied, only certain wheels rotate quickly
Air can be seen flowing out when air is bled from brake circuit.
Returns to normal after air is bled.
Abnormal oil leakage is found when checking leakage of oil inside axle.
Many metal particles are found in axle oil
10
No abnormality in operating force or travel of brake pedal, but

braking effect is poor
11
Number of times of braking effect is small when engine is stopped
12
Accumulator is not charged, buzzer sounds
13
There is a time lag in effect of brake
20-462
q
g h
U42103
T-11 Brakes do not work or braking effect is poor
TROUBLESHOOTING
T-12
T-12 Brakes are not released or brakes drag

Does the brake pedal come back fully?
Is the parking brake fully released?
U42103
Defe
ct in
Cau
side
ses
brak
Abn
orm
e va
ality
lve
(pis
in b
Defe
ton
rake
ctiv
stuc
linin
e op
k)
g in
erat
side
ion
of b
axle
rake
pist
on i
nsid
e ax
le

Is there any abnormal heat from the
brakes?
Does the machine travel smoothly under inertia on level ground?
Remedy
No. Problems
1
Brake remains applied even when brake pedal is released
When brake pedal is released and oil is bled from air bleeder,
circuit pressure goes down and brake is released
Jack up 4 wheels and set axles on stand. When engine is stopped

and parking brake is released, certain wheels are heavy when they
are rotated by hand
20-463
q
TROUBLESHOOTING
T-13
T-13 Parking brake is not released or brake drags
Remedy
No. Problems
1
When parking brake switch is turned OFF, parking brake is not

released
When parking brake switch is OFF and engine is stopped, parking

brake is not applied
When parking brake switch is ON, parking brake effect is weak
When emergency parking brake switch is turned ON, parking brake is not released
In such a case, the probable cause is following.
a. Defective operaction of emergency parking brake cancel valve
b. Breakage in wiring harness in line for emergency parking brake cancel switch
c. Insufficient gas pressure in brake accumulator, damaged piston seal
20-464
q
U42103
Defe
ct in
Cau
side
ses
park
Insu
ing
ffici
brak
ent
oil p
e so
Catc
ress
leno
hing
ure
id v
due
due
alve
to p
Bro
t
o
defe
ken
eeli
ng o
ctiv
wiri
e tra
ng h
f pa
Defe
n sm
rkin
arne
ctiv
g br
issio
ss in
e op
a
n va
k
e di
p
erat
arki
Defe
lve
s
c lin
ion
ng b
ctiv
o
ing
rake
e op
f pa
rkin
erat
s
w
itch
g br
ion
line
ake
of e
pist
mer
on
gen
cy p
arki
ng b
rake
can
cel v
alve

Is the emergency parking brake cancel
switch OFF?
(it is always canceled when this switch
is ON)
Is the parking brake always applied automatically when the engine is stopped?
TROUBLESHOOTING
T-14
WORK EQUIPMENT
T-14 Lift arm does not rise
Clog
ged
Cau
suct
No
ion
ses
PTO
port
d
r
ive
Defe
for p of pum
ctiv
p or
ump
e hy
Defe
exce
dra
ctiv
ssiv
e PP ulic pu
e ai
mp
C pu
r in
and
oil
Defe
mp
swit
ctiv
ch p
e op
ump
erat
ion
Defe
of d
ctiv
ema
e op
Defe
nd s
e
ratio
ctiv
poo
n
e
l
o
ope
f
Defe
r
e
ratio
lief
ctiv
v
n of
alve
e
o
Brea
pera
spo
o
tion
kag
e in
of m l
side
ain
Dam
valv
relie
e bo
age
f va
d lif
dy (
lve
t arm
lift a
rm c
cylin
ontr
der
ol s
pist
poo
on s
l)
eal

Yes = Equipment seized, damaged
Was there any abnormal noise
when this happened? (from
where?)
Was there previously any symptom, such
as the speed becoming slow?
Yes = Wear of internal parts, deterioration in spring
U42103

Is the hydraulic oil level correct?
Is the travel of the lift arm control lever
and spool properly adjusted?
Tank pump
a
Steering
Main control
PPC valve valve
Cylinder
valve
g h
Remedy C
No. Problems
1
Fork cannot be operated and lift arm cannot be raised
Chassis can be raised with lift arm but lift arm cannot be raised, or
fork can be operated but lift arm cannot be raised
Lift arm can be raised when there is no load but cannot be raised
when there is a load
Abnormal noise comes from hydraulic pump
Excessive hydraulic drift of lift arm cylinder
When engine is running at full throttle, steering operation is too

light and fast
When engine is running at full throttle, steering operation is heavy

and slow
20-465
q
TROUBLESHOOTING
T-15
T-15 Lift arm movement is slow or lift arm lacks lifting power

There is a strong connection between
lifting power and speed, so this problem
first appears as a lack of lifting speed.
Measure the lift arm lifting speed when
the fork is loaded and use the Standard Value Table to judge if there is any
abnormality.
Tank
pump
Remedy C
No. Problems
1
Fork tilting power and speed are abnormal and lift arm lifting
speed is slow
Fork tilting power and speed are normal but lift arm lifting speed
is slow
As in Item 1, but lifting speed is particularly slow when oil

temperature rises

light and fast

and slow
Excessive hydraulic drift of cylinder
Relief pressure of relief valve in main control valve is low
Relief pressure of relief valve in main control valve is too high
20-466
q
Steering
PPC valve Main control Cylinder
valve
valve
Cut-off
valve
U42103
Clog
ged
Cau
suct
Defe
ion
ses
ctiv
por
e hy
drau t of pu
m
l
Defe
ic p
ump p or ex
ctiv
cess
e op
and
ive
e
swit
r
a
tion
Defe
c
h pu air in o
of d
ctiv
il
mp
e
e
m
o
p
Defe
and
erat
spo
ctiv
i
o
n
e op
ol
of re
Defe
erat
lief
ctiv
ion
valv
e op
of s
e
Brea
erat
poo
kag
ion
l
e or
of m
wea
ain
Dam
r ins
relie
age
ide
f va
d lif
valv
lve
t arm
or d
e bo
efec
dy (
cylin
tive
lift a
Defe
der
adju
rm c
pist
ctiv
stm
ontr
on s
e op
ent
ol s
eal
erat
poo
ion
l)
of c
ut-o
ff va
lve
or d
efec
tive
adju
stm
ent

Is the travel of the lift arm control lever
and main control valve spool properly
adjusted?
Is there any seizure of the work equipment linkage? (Is there any abnormal
noise?)
TROUBLESHOOTING
T-16, T-17, T-18, T-19
T-16 When lift arm is raised, it moves slowly at a certain height

Can any deformation be seen in the lift arm cylinder?
Cause
Swelling or internal damage to lift arm cylinder tube
For other abnormalities when the lift arm is raised, go to "T-15 Lift arm movement is slow or
lift arm lacks lifting power."
T-17 Fork cannot be pushed with lift arm cylinder (fork floats)
See "T-15 Lift arm movement is slow or lift arm lacks lifting power."
Is the stroke of the lift arm control spool in the main control valve properly adjusted?
Cause
Defective seating of suction valve at lift arm cylinder rod end of main control valve
Oil leakage from lift arm cylinder piston seal
U42103
T-18 Excessive hydraulic drift of lift arm

Yes = Dirt caught in valve, broken part
Yes = Worn parts
Is the lift arm control spool at the neutral position?
Yes = Seized link bushing, defect in spool detent
Troubleshooting and Cause
When measuring the hydraulic drift, is there any sound of oil leakage from inside the lift arm
cylinder?
Yes = Defective cylinder packing
T-19 Lift arm shakes during operation

When digging or leveling operations are carried out with the lift arm control lever at HOLD, the
fork and lift arm move up and down to follow the shape of the ground.
Troubleshooting and Cause
Measure the hydraulic drift of the lift arm and check if it is possible to lift the chassis with the lift
arm cylinder.
1. If the hydraulic drift of the lift arm cylinder is outside the standard value, go to "T-18 Excessive
hydraulic drift of lift arm."
2. If the chassis cannot be raised with the lift arm cylinder, go to "T-17 Fork cannot be pushed
with lift arm cylinder."
3. If the hydraulic drift of the lift arm is normal, operate the lift arm several times, and operate the
lift arm cylinder to the end of its stroke. Is it now possible to raise the chassis with the lift arm
cylinder?
Yes = Vacuum had formed inside cylinder
However, if this problem appears frequently, the suction valve at the lift arm cylinder rod end
is defective.
20-467
q
TROUBLESHOOTING
T-20
T-20 Lift arm drops momentarily when control lever is operated from
HOLD to RAISE
U42103
Checking problem
When the engine is run at low idling and the lift arm control lever is operated slowly from
HOLD to RAISE, the lift arm goes down under its own weight. When the lever is operated fully
to the RAISE position, the condition returns to normal.
Cause
Defective seating of check valve for lift arm control spool in main control valve
20-468
q
TROUBLESHOOTING
T-21
T-21 Fork does not tilt back
Clog
ged
Cau
suct
No
ion
ses
PTO
port
d
r
of p
ive
Defe
for p
ump
ctiv
ump
e hy
or e
Defe
xces
drau
ctiv
sive
lic p
e PP
u
air i
m
C pu
p an
n oi
mp
Defe
d sw
l
ctiv
i
t
ch p
e op
ump
erat
Defe
ion
of d
ctiv
ema
e re
Defe
lief
nd s
valv
ctiv
poo
e
e
l
s
poo
Defe
l
ctiv
e
o
Brea
pera
tion
kag
e in
of m
side
ain
valv
Dam
relie
e bo
f va
age
dy (
lve
d fo
fork
rk c
ylin
con
der
trol
pist
spo
on s
ol)
eal

Yes = Equipment seized, damaged
Was there any abnormal noise
when this happened? (from
where?)
Was there previously any symptom, such
as the speed becoming slow?
Yes = Wear of internal parts, deterioration in spring
U42103

Is the travel of the fork control lever and
spool properly adjusted?
Tank pump
a
Remedy C
Steering
Main control
Cylinder
PPC valve valve
valve
g h
No. Problems
1
Lift arm cannot be operated and fork cannot be tilted back
Chassis can be raised with fork but fork cannot be tilted back, or
lift arm can be operated but fork cannot be tilted back
Fork can be tilted back when there is no load but cannot be tilted
back during digging or scooping operations
Excessive hydraulic drift of fork cylinder

light and fast

and slow
20-469
q
TROUBLESHOOTING
T-22
T-22 Fork movement is slow or tilt-back lacks power

Check if there is lack of tilt-back power
during actual operations.
Measure the operating speed of the fork
and use the Standard Value Table to
check if there is any abnormality
Tank
pump
Remedy C
No. Problems
1
Lift arm lifting power and speed are abnormal and fork tilt-back
power or speed are abnormal
Lift arm lifting power and speed are normal but fork tilt- back
power or speed are abnormal
As in Item 1, but problem is particularly bad when oil temperature

rises

light and fast

and slow
Excessive hydraulic drift of fork cylinder
Relief pressure of relief valve in main control valve is low
Relief pressure of relief valve in main control valve is too high
20-470
q
Steering
PPC valve
valve
Main control
valve
Cylinder
Cut-off
valve
U42103
Clog
ged
Cau
suct
Defe
ion
ses
ctiv
port
e hy
of p
drau
ump
Defe
lic p
or e
ump
ctiv
xces
e op
and
sive
erat
swit
air
i
Defe
on o
ch p
ctiv
f
ump in oil
d
e
e op
man
Defe
erat
d sp
ctiv
ion
ool
e op
of re
erat
l
i
e
f
ion
Defe
v
a
l
ve
of s
ctiv
poo
e op
l
erat
ion
Defe
of m
ctiv
ain
Brea e opera
relie
tion
kag
f va
e or
of s
lve
afet
or d
wea
y va
efec
Dam
r ins
lve (
tive
ide
age
with
adju
valv
d fo
suct
rk c
e bo
stm
i
ylin
ent
o
d
n
y (fo
v
d
a
e
l
r pis
ve)
Defe
rk c
at fo
ontr
ton
ctiv
rk cy
ol s
seal
e op
poo
lind
erat
l)
er b
ion
otto
of c
me
ut-o
nd
ff va
lve
or d
efec
tive
adju
stm
ent

Is the travel of the fork control lever and
main control valve spool properly adjusted?
Is there any seizure of the work equipment linkage? (Is there any abnormal
noise?)
TROUBLESHOOTING
T-23, T-24, T-25
T-23 Fork movement becomes slow during tilt-back operation

Can any deformation be seen in the fork cylinder?
Cause
Swelling or internal damage to fork cylinder tube
For other abnormalities when the fork is operated, go to "T- 22 Fork movement is slow or tilt
back lacks power."
T-24 Fork cannot be pushed with fork cylinder

See "T-22 Fork movement is slow or tilt back lacks power."
Is the stroke of the fork control spool in the main control valve properly adjusted?
Cause
Defective seating of safety valve (with suction valve) at fork cylinder rod end of main control
valve
Oil leakage from fork cylinder piston seal
U42103
T-25 Excessive hydraulic drift of fork

Yes = Dirt caught in valve, broken part
Yes = Worn parts
Is the fork control spool at the neutral position?
Yes = Seized link bushing, defect in spool detent
Use the Standard Value Table to check if the hydraulic drift of the fork is actually excessive.
Cause
Oil leakage inside fork cylinder
Defective seating of safety valve (with suction valve) at bottom end
Defective oil tightness of fork spool
20-471
q
TROUBLESHOOTING
T-26, T-27
T-26 Fork shakes during loading operation

(Main control valve at HOLD)
Is there play in the work equipment linkage pin, bushing? (Is there any abnormal noise?)
Cause
Defective fork cylinder piston seal
Defective operation of safety valve (with suction valve) at fork cylinder rod end. If any other
problem occurs at the same time, carry out troubleshooting according to the nature of the
problem.
T-27 Fork dumps momentarily when control lever is operated from

HOLD to TILT
Checking problem
When the engine is run at low idling and the fork control lever is operated slowly from HOLD
to TILT, the fork dumps momentarily under its own weight. When the lever is operated fully to
the TILT position, the condition returns to normal.
U42103
Cause
Defective seating of check valve for fork control spool in main control valve
20-472
q
TROUBLESHOOTING
T-28
ure,
Seiz
U42103
Lever
a
Remedy
No.
Ben
stiff
nes
s of
Cau
ses

Check the values in the Standard Value
Table to check if the operating force of
the lever is actually excessive.
rota
t PP
ting
Defe C valve
port
ctiv
spo
ion
e
o
of c
l
clea
Defe
ontr
ranc
ctiv
ol le
e be
e
ver,
o
Dirt
ut-o
twe
link
en P
f-ro
cau
und
ght
P
C
Defo
nes
valv
in P
s of
PC v
e bo
rma
PPC
alve
tion
dy a
Ben
valv
nd s
of v
spo
t ma
e bo
ol
alve
poo
in c
dy a
l
b
Catc
o
o
ntro
dy d
nd s
hing
l
u
v
poo
e
a
of m
to u
lve
l
Defe
spo
nev
ain
ctiv
ol
en t
con
e cle
ight
trol
Defe
a
enin
valv
ranc
ctiv
e sp
g of
e be
e ou
Dirt
ool
valv
twe
t-ofdete
cau
e
em
n
r
o
ght
mai
und
n
oun
t
n co
in m
nes
ting
s of
ntro
ain
bolt
mai
con
l va
s
trol
lve
n co
bod
valv
ntro
y an
e sp
l va
d sp
lve
ool
bod
ool
y an
d sp
ool
T-28 Lift arm, fork control levers are heavy or do not move smoothly
PPC valve
b
Main control valve

f
g h
Problems
Levers are heavy when there is a load and oil pressure is high
Levers become heavy as oil temperature changes
Levers become heavy at places during operation regardless of oil

pressure or temperature
Levers are always heavy during operation regardless of oil

pressure or temperature
Levers are still heavy after control lever link is disconnected at

valve connection
20-473
q
TROUBLESHOOTING OF ECSS (ELECTRONICALLY

CONTROLLED SUSPENSION SYSTEM)
(D MODE)
Judgement Table for controller electrical system .............................................................................. 20-502

D- 1
ECSS does not work ................................................................................................................. 20-503

(a) Error code [d0] is displayed .............................................................................................. 20-504
(b) Error code [d1] is displayed .............................................................................................. 20-504
(c) Error code [d2] is displayed .............................................................................................. 20-505
(d) Error code [d3] is displayed .............................................................................................. 20-505
(e) Error code [d4] is displayed .............................................................................................. 20-506
(f) No abnormality display is given ....................................................................................... 20-506
D- 2
ECSS cannot be canceled ......................................................................................................... 20-510
D- 3
Output is turned ON
U42103
(travel speed does not become 5 km/h) (deviates around 5 km/h) ..................................... 20-511
D- 4
Output is turned ON when transmission is in 1st ................................................................. 20-511
D- 5
Output is turned ON when transmission is in 4th ................................................................ 20-512
D- 6
Controller LED code is not displayed ...................................................................................... 20-513
D- 7
ECSS is abnormal but main monitor does not give abnormality display ......................... 20-513
20-501
q
TROUBLESHOOTING
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM

Self-diagnosis table (abnormality display)
Solenoid
(relief)
system
Failure mode
ECSS does not
work or does not
work properly
Travel speed
Solenoid
Solenoid
(high pressure) (low pressure) sensor
system
system
system
Model
selection
abnormality
d0
d1
d2
d3
d4
D-1 (a)
D-1 (b)
D-1 (c)
D-1 (d)
D-1 (e)
Troubleshooting
code when no
abnormality
display is given
D-1 (f)
ECSS cannot be
canceled
D-2
Output is turned
ON but travel
speed does not
become 5 km/h
(deviates)
D-3
Output is turned
ON when
transmission is in
1st
D-4
Output is turned
ON when
transmission is in
4th
D-5
LED code display

is not given
D-6
ECSS is abnormal
but main monitor
does not give
abnormality
display
D-7
20-502
q
U42103
Error code
TROUBLESHOOTING
D-1
D-1 ECSS does not work
Carry out troubleshooting with the starting switch ON.
Check that the ECSS switch on the main monitor is ON.
Cause
Remedy
3
Displaying [d0].
Go to Item (a)
Go to Item (b)
Go to Item (c)
Go to Item (d)
Go to Item (e)
Go to Item (f)
4
Displaying [d1].
2
YES Which code is
monitor
displaying?
5
Displaying [d2].
U42103
6
1
Displaying [d3].
Is there an
abnormality
display?
7
Displaying [d4].
NO
20-503
q
TROUBLESHOOTING
D-1
(a) Error code [d0] is displayed
Cause
YES
Remedy
Replace
Defective solenoid
Replace
harness between CNAL1
(female) (21) CNSAS (4)
CNAF4 (female) (1)
After inspection,
repair or replace
harness between CNAF4
CNCL1 (12) chassis
ground
After inspection,
repair or replace
Replace
Defective solenoid
Replace
CNAF5 (female) (1)
After inspection,
repair or replace
CNCL1 (12) chassis
ground
After inspection,
repair or replace
1
CNAL1 (female) (21)
and chassis ground
normal?
YES
2
Is there continuity
1) Disconnect
between CNAL1
CNAL1.
YES
(female) (21) and
NO
3
2) DC resistance:
chassis ground?
20 40
Is there continuity
1) Disconnect
between CNAF4
CNAL1.
NO (female) (2) and
2) Disconnect
chassis ground?
CNAF4.
1) Disconnect
NO
3) Connect short
CNAF4.
connector to
CNAF4 (female).
(b) Error code [d1] is displayed

YES
CNAL1 (female) (20)
and chassis ground
normal?
YES
2
Is there continuity
1) Disconnect
between CNAL1
CNAL1.
YES
(female) (20) and
3
2) DC resistance: NO
chassis ground?
20 40
Is there continuity
1) Disconnect
between CNAF5
CNAL1.
NO (female) (2) and
2) Disconnect
chassis ground?
CNAF5.
1) Disconnect
NO
3) Connect short
CNAF5.
connector to
CNAF5 (female).
20-504
q
U42103
TROUBLESHOOTING
D-1
(c) Error code [d2] is displayed

Cause
YES
Remedy
Replace
Defective solenoid
Replace
CNAF6 (female) (1)
After inspection,
repair or replace
1
CNAL1 (female) (11)
and chassis ground
normal?
YES
2
Is there continuity
1) Disconnect
between CNAL1
CNAL1.
YES
(female) (11) and
NO
3
2) DC resistance:
chassis ground?
Is there continuity
20 40
1) Disconnect
between CNAF6
CNAL1.
NO (female) (2) and
2) Disconnect
chassis ground?
CNAF6.
1) Disconnect
NO
3) Connect short
CNAF6.
connector to
CNAF6 (female).
CNCL1 (12) chassis
ground
After inspection,
repair or replace
U42103
(d) Error code [d3] is displayed

YES
1
Does error
display go off?
2 YES
Is there continuity
between CNAL3
1) Connect short
connector to
NO (female) (4) and
(12)?
CNT06 (female).
2) Turn starting
1) Disconnect
switch OFF
CNAL3.
ON.
2) Connect short
connector to
CNT06 (female).
NO
Defective speed sensor
Replace
Replace
(4) CNSAS (9) or CNAL3
(12) CNSAS (10)
After inspection,
repair or replace
(If any other
controller is
abnormal, check
all the wiring
harnesses for the
speed sensor
system)
20-505
q
TROUBLESHOOTING
D-1
(e) Error code [d4] is displayed
Cause
2 YES
Is continuity of
YES wiring harnesses
normal?
NO
1) Disconnect
CNAL2.
2) Is continuity between CNAL2
(female) (1) (4) and chassis
ground as shown in table?
Is connection of
wiring harnesses
normal?
1) Disconnect
CNAL4.
2) Is continuity
NO
between CNAL4 (female)
(1),(2),(3),(5) chassis ground as
shown in table?
Remedy
Replace
(female) and CNAL4
(male), or contact with
chassis ground
After inspection,
repair or replace
(female) and chassis
ground, or contact with
chassis ground
After inspection,
repair or replace
Replace
Go to
troubleshooting
of main monitor
Table
CNAL4(female)
CNAL2(female)
(5)
(2)
(3)
(1)
(1)
(2)
(3)
(4)
WA320
No
No
No
Yes
No
No
No
Yes
WA380
No
No
Yes
No
No
No
Yes
No
WA420
No
Yes
No
No
No
Yes
No
No
WA450
No
Yes Yes Yes
No
Yes Yes Yes
WA470
No
Yes Yes Yes
No
Yes Yes Yes
Model
U42103
Connector
(f) No abnormality display is given

(1) Does not work at all
YES
1
Is voltage
between CNAL2
(15) and chassis
ground normal?
2 YES
Is voltage between
CNL06 (female) (7)

1) 0 3 V
2) Turn starting NO and chassis
ground normal?
switch ON.
3) Turn main
1) 20 30 V
monitor ECSS
2) Disconnect
switch ON.
CNL06.
20-506
q
NO
After inspection,
(female) (15) CNDP2 (1) repair or replace
CNL06 (female) (7)
TROUBLESHOOTING
D-1
(2) Works when bucket is loaded but not when empty
Defective pressure switch

or defective chassis
hydraulic system
YES
2
Is there continuity
YES between CNAF7

1
Does controller
LED display 55?
1) Turn starting
switch ON.
2) Empty bucket.
3 YES
(male) (1) and

(2)?
Cause
Is there continuity
between CNAL2
1) Turn starting
NO (female) (8) and
switch ON.
chassis ground?
2) Disconnect
CNAF7.
1) Turn starting
3) Empty bucket.
switch OFF.
NO
NO
Remedy
Replace

with wiring harness
After inspection,
repair or replace
(8) CNSAS (7) CNAF7
(female) (1)
Replace
Defective chassis
hydraulic system
Defective chassis
hydraulic system
(3) Works when bucket is empty but not when loaded

YES
U42103
1
3 YES
Does controller
LED display 55?
1) Turn starting
switch ON.
2) Load bucket.
Is voltage
YES between CNAL2
(8) and chassis
ground normal?
2
Is there continuity
between CNAF7
NO (male) (1) and
(2)?
1) Turn starting
switch ON.
2) Disconnect
CNAF7.
3) Load bucket.
1) 0 3 V
2) Turn starting
switch ON.
3) Load bucket.
NO
NO
Replace
(female) (8) CNSAS (7) After inspection,
repair or replace
CNAF7 (female) (1), or
between CNAF7 (female)
(2) CNSAS (8) CNAL4
(4) chassis ground
Defective pressure switch
or defective chassis
hydraulic system
Replace
20-507
q
TROUBLESHOOTING
D-1
D-1 (a), (b), (c) Related electric circuit diagram

Solenoid system
CNAL1
CNSAS
!1
@0
@1
q
q
CNAF6
CNAF5
CNAF4
Solenoid 2
(high
pressure)
Solenoid 1
(relief)
!2
CNTL1
CNCL1
Solenoid 3
(low
pressure)
U42103
TDW00349
D-1 (d) Related electric circuit diagram

Speed sensor system
CNSAS
CNAL3
r
!2
Speed (+)
Speed ()
CNTL2
CNT06
!0
Speed sensor
TDW00350
CNAL2
CNAL4
For connections, see

diagrams on right
D-1 (e) Related electric circuit diagram

Model selection system
WA320
a
WA380
a
WA420
a
WA450
WA470
a
TDW01366
20-508
q
TROUBLESHOOTING
D-1
D-1 (f-(1)) Related electric circuit diagram

ECSS operation switch and network
CNAL1
Network (+)
CNDP2
CNL08
!2
e
e
CNAL2
o
!5
r
Network ()
CNL06
ECSS operation switch
u
TDW00352
D-1 (f-(2)), (f-(3)) Related electric circuit diagram

Pressure switch system
CNAL2
CNSAS
CNAF7
Pressure switch
U42103
CNAL4
r
TDW00353
20-509
q
TROUBLESHOOTING
D-2
D-2 ECSS cannot be canceled

Check that the ECSS switch on the main monitor is OFF.
Cause
YES
1
Is voltage
between CNAL2
(15) and chassis
ground normal?
1) 20 30 V
2) Turn starting
switch ON.
3) Turn main
monitor ECSS
switch OFF.
2 YES
NO
CNAL1
Network (+)
CNDP2
CNL08
!2
e
!5
Go to
troubleshooting
of main monitor
CNAL2
o
Replace

with wiring harness
After inspection,
repair or replace
(15) CNDP2 (1) CNL06
(female) (7)
Is there continuity
between CNAL2
NO (female) (15) and
chassis ground?
1) Disconnect
CNAL2.
2) Disconnect
CNL06.
Remedy
U42103
w
r
Network ()
ECSS operation switch
CNL06
u
TDW00352
20-510
q
TROUBLESHOOTING
D-3, D-4
D-3 Output is turned ON (travel speed does not become 5 km/h)

(deviates around 5 km/h)
Cause
2 YES
YES Is monitor speed
display incorrect?
1
Is machine model
code normal?
1) Start engine.
NO
U42103
Defective speed sensor,

or defective mount of
speed sensor
Replace or
adjust
Replace
Go to Troubleshooting
D-1 (e)
1) Check LED
NO
display code.
2) See
STRUCTURE
AND FUNCTION
for details of the
codes.
D-4 Output is turned ON when transmission

is in 1st
1 YES
Is resistance
between CNAL2
(female) (14) and
chassis ground
normal?
1) Disconnect
CNAL2.
2) 50 70
Remedy
NO
CNAL2
!3
!4
CNSAS
Hi/Lo
Speed
CNTL1
Cause
Remedy
Replace
speed solenoid
After inspection,
repair or replace
CNL04
Directional,
speed switch
To solenoid
TDW00355
20-511
q
TROUBLESHOOTING
D-5
D-5 Output is turned ON when transmission is in 4th

Cause
1 YES
Is resistance
between CNAL2
(female) (13) and
chassis ground
normal?
1) Disconnect
CNAL2.
2) 50 70
NO
CNAL2
!3
!4
CNSAS
Hi/Lo
Speed
CNTL1
Remedy
Replace
Hi/Lo solenoid
After inspection,
repair or replace
CNL04
Directional,
speed switch
To solenoid
TDW00355
20-512
q
U42103
TROUBLESHOOTING
D-6, D-7
D-6 Controller LED code is not displayed
Cause
YES
1
3 YES
Is power source
voltage normal?
1) 20 30 V
2) Measure voltage
between CNAL1NO
(8), (18) (9),
(19).
Is voltage between
YES CNDP1 (male) (1)
and chassis
2
ground normal?
Is there continuity
between CNAL1
(female) (9), (19)
chassis ground?
U42103
1) Disconnect
CNAL1.
1) 20 30 V
2) Disconnect
CNDP1.
Replace
(female) (8), (18) CNDP1
(female) (1)
After inspection,
repair or replace
Abnormality in fuse box
Repair
After inspection,
(female) (9), (19) CNSAS repair or replace
(1) CNTL1 (8) CNCL1
(12) chassis ground
NO
CNAL1
i
NO
Remedy
CNDP1
+24V
Fuse box
!7
!8
CNSAS
o
!9
GND
CNTL1
CNCL1
!2
TDW00359
D-7 ECSS is abnormal but main monitor does not give abnormality
display
Cause
Remedy
Check that the ECSS controller is displaying an error code.

Go to troubleshooting of
main monitor
20-513
q
U42103
30
METHOD OF USING MANUAL ................... 30- 3

PRECAUTIONS WHEN CARRYING OUT
OPERATION ............................................ 30- 4
SPECIAL TOOL LIST ..................................... 30- 6
STARTING MOTOR
Removal .................................................. 30- 9
Installation .............................................. 30- 9
ALTERNATOR
Removal .................................................. 30-10
Installation .............................................. 30-10
ENGINE OIL COOLER
Removal .................................................. 30-11
Installation .............................................. 30-11
FUEL INJECTION PUMP
Removal .................................................. 30-12
Installation .............................................. 30-13
WATER PUMP
Removal .................................................. 30-14
Installation .............................................. 30-14
TURBOCHARGER
Removal .................................................. 30-15
Installation .............................................. 30-15
NOZZLE HOLDER
Removal .................................................. 30-16
Installation .............................................. 30-16
THERMOSTAT
Removal .................................................. 30-17
Installation .............................................. 30-17
CYLINDER HEAD
Removal .................................................. 30-18
Installation .............................................. 30-22
RADIATOR
Removal .................................................. 30-24
Installation .............................................. 30-26
ENGINE
Removal .................................................. 30-27
Installation .............................................. 30-32
TORQUE CONVERTER, TRANSMISSION
Removal .................................................. 30-34
Installation .............................................. 30-41
TORQUE CONVERTER
Disassembly ........................................... 30-43
Assembly ................................................ 30-45
TRANSMISSION
Disassembly ........................................... 30-48
Assembly ................................................ 30-53
TRANSMISSION CLUTCH PACK
Disassembly ........................................... 30-59
Assembly ................................................ 30-68
PARKING BRAKE
Disassembly ......................................... 30- 80
Assembly .............................................. 30- 82
Removal ................................................ 30- 85
Installation ............................................ 30- 87
Disassembly ......................................... 30- 88
Assembly .............................................. 30- 93
TRANSMISSION ACCUMULATOR VALVE
Disassembly ......................................... 30- 99
Assembly .............................................. 30-100
DRIVE SHAFT
Disassembly ......................................... 30-101
Assembly .............................................. 30-103
FRONT AXLE
Removal ................................................ 30-105
Installation ............................................ 30-107
REAR AXLE
Removal ................................................ 30-108
Installation ............................................ 30-111
FRONT DIFFERENTIAL
Removal ................................................ 30-114
Installation ............................................ 30-117
REAR DIFFERENTIAL
Removal ................................................ 30-119
Installation ............................................ 30-122
DIFFERENTIAL
Disassembly ......................................... 30-124
Assembly .............................................. 30-127
FINAL DRIVE
Disassembly ......................................... 30-135
Assembly .............................................. 30-138
CENTER HINGE PIN
Removal ................................................ 30-142
Installation ............................................ 30-151
30-1
w
30-2
w
WORK EQUIPMENT, PPC, BRAKE COOLING

PUMP
Removal ................................................ 30-219
Installation ............................................ 30-222
PPC VALVE
Removal ................................................ 30-223
Installation ............................................ 30-224
Disassembly ......................................... 30-225
Assembly .............................................. 30-226
MAIN CONTROL VALVE
Removal ................................................ 30-227
Installation ............................................ 30-229
Disassembly ......................................... 30-230
Assembly .............................................. 30-232
FORK CYLINDER
Removal ................................................ 30-234
Installation ............................................ 30-235
LIFT ARM CYLINDER
Removal ................................................ 30-236
Installation ............................................ 30-237
GRAPPLE ARM CYLINDER
Removal ................................................ 30-238
Installation ............................................ 30-239
HYDRAULIC CYLINDER
Disassembly ......................................... 30-240
Assembly .............................................. 30-243
WORK EQUIPMENT
Removal ................................................ 30-246
Installation ............................................ 30-250
COUNTERWEIGHT
Removal ................................................ 30-252
Installation ............................................ 30-252
FUEL TANK
Removal ................................................ 30-253
Installation ............................................ 30-254
CAB (OPTION)
Removal ................................................ 30-255
Installation ............................................ 30-256
MAIN MONITOR
Removal ................................................ 30-257
Installation ............................................ 30-258
MAINTENANCE MONITOR
Removal ................................................ 30-259
Installation ............................................ 30-259
U42103
STEERING VALVE (ORBIT-ROLL)

Removal ............................................... 30-157
Installation ............................................ 30-158
STEERING VALVE
Disassembly ......................................... 30-159
Assembly .............................................. 30-162
Removal ................................................ 30-167
Installation ............................................ 30-168
STEERING DEMAND VALVE
Disassembly ......................................... 30-169
Assembly .............................................. 30-173
STEERING, SWITCH PUMP
Removal ................................................ 30-177
Installation ............................................ 30-180
STEERING CYLINDER
Removal ................................................ 30-181
Installation ............................................ 30-182
BRAKE VALVE
Removal ................................................ 30-183
Installation ............................................ 30-184
RIGHT BRAKE VALVE (TANDEM)
Disassembly ......................................... 30-185
Assembly .............................................. 30-186
LEFT BRAKE VALVE (SINGLE)
Disassembly ......................................... 30-187
Assembly .............................................. 30-188
SLACK ADJUSTER
Removal ................................................ 30-189
Installation ............................................ 30-190
Disassembly ......................................... 30-191
Assembly .............................................. 30-192
BRAKE
Disassembly ......................................... 30-193
Assembly .............................................. 30-199
PARKING BRAKE DISC
Removal ................................................ 30-208
Installation ............................................ 30-210
HYDRAULIC TANK
Removal ................................................ 30-211
Installation ............................................ 30-213
BRAKE COOLING OIL TANK
Removal ................................................ 30-214
Installation ............................................ 30-215
BRAKE OIL COOLER
Removal ................................................ 30-216
Installation ............................................ 30-218
METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked 1, and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the
installation procedure it applies to.
(Example)
REMOVAL OF ASSEMBLY ............ Title of operation
................................................................. Precautions related to safety when carrying out
the operation
1. XXXX (1) ............................................. Step in operation
.......................................................... Technique or important point to remember when
removing XXXX (1).
2. (2): .............................................. 1 Indicates that a technique is listed for use during
installation
3. assembly (3)
U42103
.................................................... See Lubricant and Coolant Table
INSTALLATION OF ASSEMBLY .... Title of operation

Carry out installation in the reverse
order to removal.
1 ................................................ Technique used during installation
................................................ Technique or important point to remember when

installing (2).
Adding water, oil ............................. Step in operation
................................................ Point to remember when adding water or oil

5
................................................ Quantity of filling oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
w
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.

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

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
Hoses and tubes using sleeve nuts
Nominal
number
Plug (nut end)
02
03
04
05
06
10
12
07376-50210
07376-50315
07376-50422
07376-50522
07376-50628
07376-51034
07376-51234
2)
U42103
1)
Sleeve nut (elbow end)

Use the two items below as a set
07221-20210
07221-20315
07221-20422
07221-20522
07221-20628
07221-21034
07221-21234
(Nut),
(Nut),
(Nut),
(Nut),
(Nut),
(Nut),
(Nut),
07222-00210
07222-00312
07222-00414
07222-00515
07222-00616
07222-01018
07222-01219
(Plug)
(Plug)
(Plug)
(Plug)
(Plug)
(Plug)
(Plug)
Split flange type hoses and tubes
Nominal Flange (hose end)

number
04
05
07379-00400
07379-00500
Sleeve head
(tube end)
Split flange
07378-10400
07378-10500
07371-30400
07371-30500
Part number
06
08
10
12
14
16
18
20
22
24
27
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
07049-02734
30-4
w
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14 11.5
18
16 13.5
20
18
15
22
20
17
25
22 18.5
28
24
20
30
27 22.5
34
Taper 1/8
Nominal
number
3) If the part is not under hydraulic pressure, the following corks can be used.
L
DEW00401
2. Precautions for installation operations
U42103
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with antifriction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times,
stopping 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operations
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level.
Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
related parts.
30-5
w
SPECIAL TOOL LIST
SPECIAL TOOL LIST

Symbol
1
Disassembly, assembly of
differential assembly
final drive assembly
793-615-1330
Pin
793-615-1220
Holder
793-615-1210
Holder
793-520-2410
Bracket
793-520-2510
Bracket
790-520-2620
Plate
790-425-1620
Fixture
790-425-1630
Fixture
793-520-2320
Fixture
790-101-1002
Pump
790-101-2102
Puller
30-6
w
790-101-2300
Push-puller
793-520-2370
Push tool
793-520-2350
Push tool
793-520-2540
Guide
793-520-2360
Bar
793-463-1110
Stopper
01011-51845
Bolt
01643-31845
Washer
Lifting tool (B)
Removal of
parking brake disc
Lifting tool (A)
Qty
793-615-1320
Installation of center
hinge pin
Removal of
slack adjuster assembly
793-615-1310
Part Name
2
transmission assembly,
transmission clutch pack A
assembly
Removal of front
differential assembly
Part No.
01580-11815
Nut
793-415-1150
Plate
01010-51085
Bolt
01580-11008
Nut
Remarks
For
FORWARD/
1st clutch
Installation,
For
removal of
REVERSE/ clutch pack
2nd, 3rd/
4th clutch
For
FORWARD, Jig for
REVERSE settling
piston
piston seal
ring
For 1st
4th piston
U42103
Nature of work
Nature of work
Symbol
Part No.
Cylinder repair stand
790-502-1003
or
790-502-2000
790-101-1102
Pump
Qty
Remarks
Removal,
installation
of round
head
Removal,
installation
of nylon
nut
790-330-1100
Wrench assy
799-302-1280
Socket
(width across flats: 55)
Steering
cylinder
790-101-5021
Grip
Press fitting of
coil bushing
01010-50816
Bolt
Kit Part No.:

790-201-1702
790-201-1930
Push tool
Lift arm
cylinder
790-201-1850
Push tool
Fork
cylinder
790-201-1761
Push tool
Steering
cylinder
790-720-1000
Expander
Installation of
piston ring
796-720-1690
Ring
07281-01919
Clamp
796-720-1690
Ring
07281-02169
Clamp
796-720-1660
Ring
07281-01159
Clamp
Steering
cylinder
790-101-5021
Grip
Insertion of
dust seal
01010-50816
Bolt
Kit Part No.:

790-201-1500
790-201-1660
Plate
Fork
cylinder
790-201-1570
Plate
Steering
cylinder
790-201-1990
Plate
Lift arm
cylinder
792-520-2110
Installer
790-425-1640
Eye bolt
792-530-1600
Push plate
790-425-1620
Fixture
790-425-1630
Fixture
791-542-1520
Installer
U42103
hydraulic cylinder
R
2
Part Name
Steering
cylinder
brake assembly
SPECIAL TOOL LIST
Lift arm
cylinder
Fork
cylinder
30-7
w
STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
1
Disconnect
the cable from the negative () terminal of the battery.
1. Open engine hood left side cover.

2. Disconnect starting motor wiring connector (1).
3. Disconnect wiring (2).
4. Remove starting motor assembly (3).
DEW00402
INSTALLATION OF STARTING
MOTOR ASSEMBLY
U42103
Carry out installation in the reverse order to

removal.
1
When installing the starting motor assembly, install ground connection (4) securely.
DEW00403
30-9
w
ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
Disconnect
1. Open engine hood left side cover and lock in

position.
2. Disconnect 3 set of wiring (1).

Mark the wiring with tags to prevent mistakes when assembling.
4
6
2
DEW00404
3. Loosen mounting bolt and nut (2), and adjustment plate mounting bolt (3).
4. Loosen locknut (4) and adjustment nut (5), and
move alternator assembly (6) towards engine,
then remove fan belt (7) from alternator assembly (6).
1
U42103
5. Remove mount bolt and nut (2), and adjustment

plate mounting bolt (3), then remove alternator
assembly (5).
INSTALLATION OF
ALTERNATOR ASSEMBLY

removal.
1
Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting fan belt tension.
30-10
w
ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
1
1. Lift off engine hood assembly.
2. Drain engine coolant.

3. Remove turbocharger lubrication return tube (1).
4. Disconnect wiring harness clamp (2).
5. Remove oil cooler assembly (3).
DEW00405
6. Remove nut (4), then remove core (6) from cover

(5).
1
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY
U42103

removal.
1
3 Core mounting nut:
43.2 15.7 Nm {4.4 1.6 kgm}
DEW00406
Refilling with water

Add water through the water filler to the specified level. Run the engine to circulate the water
through the system. Then check the water level
again.
30-11
w
FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
7 6
5
1. Remove coupling cover (1) of fuel injection
pump.
2. Disconnect accelerator cable (2) and stop motor
cable (3).
1
3
3. Disconnect fuel hoses (4), (5), (6), and (7).

After disconnecting fuel supply hose (4),
bend it and tie it with wire to prevent the
fuel from leaking.
DEW00407
4. Disconnect fuel injection pipes (8) and (9).1

5. Remove lubrication tubes (10) and (11).
10
11
DEW00408
6. Remove 2 lock bolts (12) of cross coupling and

laminate coupling.
2
Before removing the bolts, mark the mounting position of the laminate coupling and
cross coupling.
7. Remove fuel injection pump assembly (13).
3
12
30-12
w
13
DEW00409
U42103
FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY

removal.
1
3 Injection tube sleeve nut:
23.5 1 Nm {2.4 0.1 kgm}
2
3 Laminate coupling mounting bolt:
61.8 3 Nm {6.3 0.3 kgm}
3
Install the injection pump. For details, see
TESTING AND ADJUSTING, Testing and adjusting fuel injection timing.
U42103
3 Injection pump mounting bolt:

29.4 5 Nm {3.0 0.5 kgm}
30-13
w
WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
Disconnect
1. Lift off engine hood.

3. Disconnect alternator wiring (1) and water temperature sensor wiring harness (2), loosen
mounting bolt and adjustment bolt of alternator
assembly, then remove fan belt.
1
DEW00416
4. Remove water pump tubes (3), (4), and (5).

4
5. Remove mounting bolts (6), then remove water

pump assembly (7).
2
DEW00417
INSTALLATION OF WATER
PUMP ASSEMBLY
7

removal.
1
Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting fan belt tension.
DEW00418
2
3 Mounting bolt:
66.7 7.9 Nm {6.8 0.8 kgm}

again.
30-14
w
U42103
TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1
1. Lift off engine hood.

2. Remove intake connector (1), and loosen belt
clamp (2) of intake connector joint hose.
3. Remove 4 mounting bolts of flange (3) between
muffler assembly and turbocharger.
4. Remove turbocharger lubrication inlet tube (4)
and return tube (5).
5. Remove mounting bolts of turbocharger assembly (6), then pull out turbocharger assembly from
air intake connector, and remove.
U42103
INSTALLATION OF
TURBOCHARGER ASSEMBLY

removal.
DEW00419
DEW00420
30-15
w
NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
1
1. Disconnect fuel injection pipe (1) and spill tube
(2).
1
2. Remove 2 mounting bolts (3) of nozzle holder.
2
2
3. Screw bolt 1 (10 mm) in to mount of spill

tube, then lever with bar 2 and remove nozzle
holder assembly (4).
Be careful not to let dirt or dust get inside.
3
DEW00421
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
removal.
1
3 Spill pipe mounting joint bolt:
24.5 5 Nm {2.5 0.5 kgm}
3 Injection pipe mounting sleeve nut:
23.5 1 Nm {2.4 0.1 kgm}
2
Tighten the nozzle holder mounting bolts in
turn uniformly.
3 Nozzle holder assembly mounting bolt:
21.6 3 Nm {2.2 0.3 kgm}
30-16
w
DEW00422
U42103
THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Open engine hood left side cover and lock in
position.
3. Disconnect block (1).

Do not disconnect the hose.
4. Remove thermostat (2).
DEW00423
U42103
INSTALLATION OF
THERMOSTAT ASSEMBLY

removal.

again.
DEW00424
30-17
w
CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
1
Disconnect

Drain engine coolant.
1. Remove engine hood assembly.
2. Remove exhaust muffler assembly (1) and oil

filter assembly (2).
Remove oil filter assembly (2) together with
the filter head and 2 tubes.
When removing the muffler assembly, be
careful not to bend the drain tube.
DEW00425
3. Disconnect radiator upper hose (3) and aeration

tube (4).
DEW00426
4. Disconnect dust indicator wiring (5) and heater

relay wiring (6).
Disconnect wiring clamps (6-1) and (6-2).
8
7
5. Remove intake connector (7), then remove air

cleaner assembly (8).
1
5
6
6-2
6-1
6. Disconnect heater relay wiring (9), remove intake connector (10), then remove turbocharger
lubrication inlet tube (11).
11
10
DEW00427
13
14
7. Remove 6 fuel injection pipes (12), 5 fuel spill

pipes (13), and return hose (14).
2
9
DEW00428
30-18
w
12
DEW00429
U42103
CYLINDER HEAD
8. Remove water temperature sensor connector

(15) from holder, then disconnect.
16
15
9. Remove turbocharger lubrication return tube

(16).
DEW00430
17
U42103
10. Lift off turbocharger and exhaust manifold assembly (17).

3
Remove together with the air cleaner assembly mounting bracket.
DEW00431
11. Disconnect fuel filter hoses (18) and (19).

18
19
DEW00432
12. Disconnect corrosion resistor hoses (20) and (21)

at filter end.
22
13. Lift off intake manifold assembly (22).

Remove with the corrosion resistor and fuel
filter assembly still installed to the intake
manifold.
21
20
DEW00433
DEW00434
30-19
w
CYLINDER HEAD
14. Disconnect connector (23) from water manifold.

23
DEW00435
15. Remove water manifolds (24).
DEW00436
16. Remove head cover (25).
25
DEW00437
17. Remove nozzle holder assembly (26).
5
26
DEW00438
30-20
w
U42103
24
CYLINDER HEAD
18. Remove rocker arm assembly (27).

6
Loosen the locknut, then loosen the adjustment screw 2 3 turns.
27
DEW00439
19. Remove bracket (28), rocker arm housing (29),

push rods (30), and crossheads (31).
7
Remove bracket (28) from the No. 1 cylinder
only.
29
31
30
U42103
28
DEW00440
20. Remove cylinder head assembly (32).
32
DEW00441
30-21
w
CYLINDER HEAD
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
removal.
1
3 Air cleaner intake connector clamp:
8.3 0.5 Nm {0.85 0.05 kgm}
2
3 Fuel injection pipe sleeve nut:
29.4 5 Nm {3.0 0.5 kgm}
3 Spill pipe mounting bolt:
24.5 5 Nm {2.5 0.5 kgm}
3
Screw in the exhaust manifold mounting
bolts 2 3 threads by hand, tighten mounting bolts 1 3, then tighten the other
mounting bolts.
3 Exhaust manifold mounting bolt:
66.7 7.9 Nm {6.8 0.8 kgm}
4
3 Head cover mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
5
Tighten the nozzle holder mounting bolts in
turn uniformly.
3 Nozzle holder mounting bolt:
21.6 3 Nm {2.2 0.3 kgm}
6
Check that the ball of the adjustment screw
is fitted securely in the socket of the push
rod.
Adjust the valve clearance. For details, see
TESTING AND ADJUSTING, Adjusting valve
clearance.
3 Rocker arm assembly mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
3 Locknut:
66.2 7.4 Nm {6.75 0.75 kgm}
7
3 Rocker arm housing mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
Adjust the crosshead as follows.
i) Loosen the locknut and turn the adjustment screw back.
ii) Press the top of the crosshead lightly
and screw in the adjustment screw.
iii) When the adjustment screw contacts the
valve stem, screw it in a further 20.
iv) Tighten the locknut to hold it in position.
3 Locknut:
66.2 7.4 Nm {6.75 0.75 kgm}
30-22
w
DEW00442
U42103
CYLINDER HEAD
U42103
8
If any rust of more than 5 mm square is
found on the shaft or the thread of the bolt,
replace the head bolt with a new bolt.
Be careful to check that there is no dirt or
dust on the mounting surface of the cylinder
head or inside the cylinder.
When installing the gasket, check that the
grommets have not come out.
Coat the thread and seat of the bolt and the
seat of the cylinder head holes completely
with molybdenum disulphide (LM-P).
Tighten the cylinder head mounting bolts 2
3 turns by hand, then tighten in the order
given in the diagram.
2 Mounting bolt:
Anti-friction compound (LM-P)
3 Cylinder head mounting bolt:
1st pass: Tighten to 68.6 9.8 Nm
{7.0 1.0 kgm}
2nd pass: Tighten to 107.9 5 Nm
{11.0 0.5 kgm}
3rd pass: 1. When using tool A.
Using an angle tightening

wrench, tighten bolt 90+300.
2. When not using tool A.
1) Using the angle of the bolt
head as the base, make start
marks on the cylinder head
and socket.
2) Make an end mark at a point
90+300 from the start mark.
3) Tighten so that the start
mark on the socket is aligned
with the end mark on the
cylinder head at the 90+300
position.
DEW00443
DEW00444
Cylinder head start mark

Socket
start mark
90
Socket
90
End mark
Position of
cylinder head
end mark
Socket
start mark
DEW00445
After tightening, make one punch mark on

the bolt head to indicate the number of times
it has been tightened.
If any bolt already has five punch marks, do
not reuse it. Replace it with a new bolt.
Add water through the water filler to the
specified level. Run the engine to circulate
the water through the system. Then check
the water level again.
Make mark with punch
DEW00446
30-23
w
RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
Stop
the machine on level ground and install

the safety bar on the frame. Lower the fork to
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels
to prevent the machine from moving.
Release the remaining pressure in the piping.
DEW00448
1. Drain
Loosen drain valve (3) and drain coolant.
If the coolant contains antifreeze, dispose of
it correctly.
6 Coolant: 43 (including sub-tank)
3
DEW00449
2. Radiator guard
1) Remove 4 mounting bolts of radiator guard,
and disconnect wiring connector (4) of working lamp and radiator water level sensor (41) at radiator end.
2) Lift off radiator guard (5).
30-24
w
U42103
When operating the levers, raise portion a of

the fork 30 50 mm and lower portion b to the
ground, then stop the engine.
After operating the levers, check that the whole
bottom surface of the fork (both portion a and
portion b) are in contact with the ground.
Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate
the control levers several times to release the
remaining pressure in the hydraulic piping.
Remove plugs (1) and (2) at the top of the hydraulic tank filter, and prevent the oil inside the
tank from flowing.
RADIATOR
3. Hood
1) Disconnect connector (6) of electric wiring
at inside of rear left of hood.
2) Remove left and right radiator baffles (7).
7
9
6
DEW00452
DEW00451
3) Sling hood (8), then remove front and rear,

left and right mounting bolts (9) and 3 top
front mounting bolts (10), and lift off hood.
10
U42103
4 Hood assembly:
230 kg (without rear fender)
305 kg (with rear fender)
10
DEW00453
4. Hoses
1) Remove 4 bolts (22) of brake oil cooler (11).
2) Move brake oil cooler (11) to side and disconnect lower hose (12) at radiator end.
3) Disconnect oil cooler hoses (13) at radiator

end.
After removing the hoses, fit plugs to
prevent the entry of dirt or dust.
13
DEW00455
30-25
w
RADIATOR
4) Disconnect upper hoses (14) and (15), and

radiator spill pipe (16) at radiator end.
18
14
15
16
5. Fan guard, stay

Remove radiator fan guard (17) and radiator stay
(18).
20
19
6. Fan
Remove mounting bolts (19) of engine fan, then
remove fan.
21
7. Radiator
Sling radiator assembly (20), then remove
mounting bolts (21), and lift off radiator.
DEW00456
17
4 Radiator assembly: 168 kg

removal.
Tighten drain plug and add water through the

radiator water filler to the specified level.
5
U42103
INSTALLATION OF RADIATOR
ASSEMBLY
Coolant: 68 (radiator)
(sub-tank)
Run the engine to circulate the water through

the system. Then check the water level again.
Refilling with oil

Tighten plugs (1) and (2) at the top of the hydraulic tank filter, and add hydraulic oil through
the oil filler to the specified level.
3 Plug at top of filter:
11.8 1 Nm {1.2 0.1 kgm}
Bleeding air
Bleed air from hydraulic line.
For details of the procedure for bleeding the air,
see PRECAUTIONS WHEN CARRYING OUT OPERATION.
30-26
w
DEW00448
ENGINE
REMOVAL OF ENGINE
ASSEMBLY
Stop


For details, see REMOVAL OF RADIATOR ASSEMBLY.
Operate
the fork control lever at least 40 times

TILT HOLD to release the pressure inside the
accumulator.
Depress
the brake pedal at least 17 times to

release the pressure inside the brake accumulator.
Disconnect
U42103
Remove plugs (1) and (2) at the top of the

hydraulic tank filter, and prevent the oil inside the tank from flowing.
Loosen oil filler cap (2-1) slowly to release

pressure inside cooling oil tank.
Loosen mounting bolts (2-3) of tube (2-2)

and set so that the oil inside the cooling oil
tank does not flow out.
DEW00448
1. Radiator
Remove radiator.
For details, see REMOVAL OF RADIATOR.
30-27
w
ENGINE
2. Electric wiring
1) Disconnect CNER1 connector (4) and CNER2
connector (5) of engine wiring harness (3).
2) Disconnect slow blow fuse 120A connector
(6) and 80A connector (7).
3) Disconnect cable (8) between starting motor
and battery relay.
4) Disconnect starting motor ground cable.
8
6
DEW00459
DEW00458
3. Fuel hose
1) Disconnect hose (9) between fuel tank and
feed pump at feed pump end.
2) Disconnect fuel return hose (10) at injection
pump end.
3) Disconnect spill hose (11) at fuel tank end.
After disconnecting the hoses, fit plugs
to prevent the entry of dirt or dust.
11
DEW00460
4. Heater hoses (Option)

1) Disconnect heater hoses (14) and (15) from
engine.
14
15
DEW00462
30-28
w
U42103
10
5. Brake piping, accelerator cable

1) Disconnect hoses (16) and (17) between right
brake valve and accumulator at pedal end.
Remove the clamps (2 places) of the
brake hoses under the floorboard.
2) Disconnect hose (18) between left brake valve
and accumulator at pedal end.
1
3) Disconnect accelerator cable (19) at bottom
of pedal.
Remove the cable clamp under the floor
board.
ENGINE
18
16
17
19
DEW00463
Remove clamp
16
17
U42103
4) Disconnect hose (20) between PPC accumulator and PPC valve inside bulkhead at accumulator end.
DNW03845
DEW00465
5) Disconnect hose (22) of radiator sub-tank

(21).
Remove the hoses from the hose clamp.
6) Brake cooling piping
Disconnect hoses (22-1) and (22-2) at brake
cooling oil tank end.
Loosen the mounting bolts of tube (223) to bleed air inside the cooling oil tank
and set so that the oil inside the cooling
oil tank does not flow out.
6. Bulkhead
1) Remove cover (28) at bottom front of bulkhead (27).
28
27
DEW00468
30-29
w
4 Bulkhead: 135 kg
(including accumulator charge valve)
3) Raise bulkhead (27) straight up for approx.
400 mm.
The bulkhead comes near the cab when
it is lifted, so be careful not to hit anything. (with cab)
To prevent the bulkhead from falling after it is raised, place blocks to the left
and right on opposite sides.
7. Fuel control cable
1) Disconnect fuel control cable (30) from ball
joint (31).
2
2) Remove fuel control cable from bracket (32).
Eyebolt
Remove clamp
27
29
400 mm
2) Install eyebolts at top 4 corners of bulkhead

(27), then sling and remove bottom mounting bolts (29).
ENGINE
(Opposite end) (This end)

DEW01212
DEW00469
32
30
DEW00471
8. Transmission support stand

Remove rear drive shaft (33), and set support
stand under transmission (34).
3
Use a stand with adjustable height, and fit it
securely in position so that it does not come
out.
33
34
Stand
DEW00472
30-30
w
DEW00473
U42103
31
9. Engine assembly
1) Remove engine oil drain valve (35) and radiator coolant drain valve (36) from fuel tank.
ENGINE
36
35
DEW00475
DEW00474
2) Sling engine assembly (37), and remove

mounting bolts (38) of engine flywheel portion and torque converter housing
Depending on the lifting tool, remove
the muffler and then sling.
4 Engine assembly: 1,120 kg
38
U42103
37
DEW00476
3) Remove engine mount bolt (39), and lift off

engine assembly (37).
4
Be careful of the direction of installation
of the cushions and spacers.
The engine flywheel ring gear and torque
converter ring gear and shaft are mated,
so set in a horizontal position before raising the engine assembly, and keep horizontal while carrying out the operation.
When lifting off the engine assembly,
check first that all the wiring and piping
have been removed before continuing
with the operation.
5
39
39
DEW00477
DEW00478
30-31
w
ENGINE
INSTALLATION OF ENGINE
ASSEMBLY

removal.
12
3 Accelerator cable mounting bolt:
53.9 5 Nm {5.5 0.5 kgm}
3
Clean the connection and mating surface of
the drive shaft before installing.
3 Drive shaft mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
4
Be careful of the direction of installation of
the cushions and spacers at the engine
mount when assembling.
3 Mount bolt:
926.7 103 Nm {94.5 10.5 kgm}
Refilling with oil

1) Tighten plugs (1) and (2) at the top of the
hydraulic tank filter, and add hydraulic oil
through the oil filler to the specified level.
11.8 1 Nm {1.2 0.1 kgm}
2) Tighten bolt (2-3), and secure tube (2-2) to
cooling oil tank.
3) Add brake cooling oil through oil filler (2-1)
to the specified level.
30-32
w
U42103
5
When connecting the engine to the torque
converter, adjust the height so that the
torque converter shaft and ring gear go in
smoothly.
Never try to use force when connecting.
Use new parts for the torque converter and
flywheel housing O-rings.
2 O-ring at mating surface of torque converter and engine flywheel:
Soapy water
DEW00448
Bleeding air
1) Bleed air from brake line, and brake cooling
line.
For details of the procedure for bleeding the
air, see TESTING AND ADJUSTING.
2) Bleed air from hydraulic line.
air, see PRECAUTIONS WHEN CARRYING
OUT OPERATION.
U42103
ENGINE
30-33
w
REMOVAL OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
Stop


For details, see REMOVAL OF RADIATOR ASSEMBLY
Operate

TILTHOLD to release the pressure inside the
accumulator.
Depress

hydraulic tank filter, and prevent the oil inside the tank from flowing.
Loosen oil filler cap (2-1) slowly to release

Loosen mounting bolts (2-3) of tube (2-2)

and set so that the oil inside the cooling oil
tank does not flow out.
U42103

1. Cover
Remove covers (3) at bottom of floor.
2
DEW00494
2. Ladders
Remove left and right ladders (3-1).
4 Ladder rail (right): 64.5 kg
4 Ladder rail (left): 59.5 kg
30-34
w
3. Electric wiring
Disconnect the following electric wiring.
1) Disconnect transmission wiring TL1 (4) and
TL2 (5).
2) Disconnect floor wiring harnesses LR5 (6),
LR6 (7), LR3 (8), LR4 (9), LR1 (10), and LR2
(11).
After disconnecting the connectors, mark
with a tag to distinguish when installing.
11
10
8
6
4
5
U42103
10
4. PPC piping
1) Disconnect hose (12) of PPC valve port P2,
hose (13) of port P4, hose (14) of port
P3, and hose (15) of port P1 at valve
end.
2) Disconnect hose (16) between PPC accumulator and PPC valve at valve end.
3) Disconnect hose (17) of PPC valve drain port
at valve end.
After disconnecting the hoses, mark with
a tag to distinguish when installing.
DEW00497
11
DEW00500
17
17
14
16
13
12
12
14
13
DEW00498
15
DEW00499
30-35
w
5. Brake piping
Remove 2 brake hose clamps under floor
board.
3) Disconnect right brake valve drain hose (21)
and left brake valve drain hose (22) at rear
frame portion.
4) Disconnect hose (23) between front brake
and right brake valve at center hinge pin.
20
18
19
23
28
DEW00501
DNW03781
Remove clamp
18 19
21
DEW00503
7. Steering valve piping

Disconnect the following pipings from the steering valve.
1) Hose (20) between steering valve (L port)
and stop valve (L.H.)
2) Hose (20-1) between steering valve (R port)
and stop valve (R.H.)
3) Hose (20-2) between steering valve (P port)
and accumulator charge valve
4) Hose (20-3) between steering valve (T port)
and drain line
8. Floor board
1) Remove mounting cover (31) of floor board
(30), then remove 4 viscous damper mounting nuts (32) holding floor board.
2) Fit lifting tool to floor board (30) and lift off
floor board.
2
Raise the floor board slowly and check
that all parts have been removed before
lifting off.
DEW00504
20-3
20
20-2 20-1
DNW03782
32
31
30
4 Floor assembly: 213 kg
30-36
w
DEW00507
DEW00508
U42103
6. Accelerator cable
1
Disconnect accelerator cable (28) under pedal.
Remove the cable clamp at the floor board
22
9. Bulkhead
1) Disconnect piping inside bulkhead.
i) Disconnect hose (34) between PPC accumulator and PPC valve inside bulkhead.
34
DEW00510
U42103
ii) Disconnect hose (36) of radiator sub-tank

(35).
iii) Disconnect tube (37), hose (38), tube (381), and hose (39) of brake cooling line.
Remove the hose from the hose
clamp.
After disconnecting the hoses, fit
plugs to prevent the entry of dirt or
dust.
Loosen the mounting bolts of tube
(37) to bleed air inside the cooling
oil tank and set so that the oil inside
the cooling oil tank does not flow
out.
2) Bulkhead
i) Remove cover (40) at bottom front of
bulkhead (39-1).
ii) Remove mounting bolts (42) at top of
hood (41) and bulkhead (39-1).
Be careful not to lose the washers
and rubber of the mounting portion.
iii) Install eyebolts at the top 4 corners of
bulkhead (39-1), then sling and remove
the bottom mounting bolts.
41
42
40
39-1
39-1
4 Bulkhead: 135 kg
(including accumulator and
charge pump)
DEW00513
DEW00512
30-37
w
U42103
10. Hydraulic piping

3
1) Disconnect loader pump suction tube (43)
and steering pump suction tube (44) at pump
end.
Remove hydraulic tank hose (45), remove
tube mounting bolts (43-1), then remove tube
(43).
2) Disconnect tube (46) between loader pump
and main control valve at pump end and
center hinge pin end, then remove tube.
3) Disconnect PPC pump hose (47) at pump
end.
4) Disconnect tube (48) between steering pump
and steering valve at pump end and center
hinge pin end, then remove tube.
5) Disconnect brake cooling hose (48-1) at pump
end.
6) Disconnect brake cooling hose (48-2) at oil
filter end.
7) Disconnect tube (49) between switch pump
and steering valve at pump end and center
hinge pin end, then remove tube.
8) Disconnect tube (50) between steering valve
and cooler at center hinge pin.
11. Brake cooling oil filter
Remove brake cooling oil filter (48-3).
43-1
43
45
30-38
w
DEW00515
54
DEW00516
12. Transmission, cooler piping

4
1) Disconnect hose (51) between transmission
control valve and cooler and hose (52) between cooler and transmission at valve and
transmission ends.
oil filter and control valve at valve end.
53
51, 52
U42103
Transmission
control valve
3) Disconnect transmission pump outlet hose

(54) at pump end.
4) Disconnect hoses (55), (56), and (57) between
parking brake emergency release valve and
parking brake at parking brake control valve
hose end.
Remove the clamps mounted at the
transmission and rear frame.
5) Remove mounting bolts of transmission filler
tube (58), and rotate to transmission side,
then lock with mounting bolts.
13. Drive shafts
1) Disconnect center drive shaft (59) at transmission end.
5
Move the disconnected drive shaft to the
side.
DEW00518
55
56
58
57
Transmission
control valve
DEW00519
59
4 Center drive shaft: 36 kg
DEW00520
2) Remove rear drive shaft (60).
6
60
4 Rear drive shaft: 19 kg

Make match marks on both the center
and rear couplings.
DEW00521
30-39
w
14. Torque converter, transmission assembly

1) Install block 1 between bottom of engine
flywheel and rear axle to prevent engine from
falling when transmission and torque converter are removed.
7
DEW00522
2) Install eyebolts to top of transmission oil

filter and top of pump mounting gear case
of torque converter and transmission assembly (61).
Eyebolts
Eyebolt
4 Torque converter, transmission assembly: 1,070 kg

(including pump, filter, etc.)
DEW00523
3) Remove mounting bolts (62) of torque converter and transmission case, and engine flywheel housing.
8
DEW00524
62
DEW00525
4) Remove mount bolts (63) and (64) of torque

converter and transmission assembly, and
raise approx. 200 mm, then remove mount
bracket (65).
Do this on both the left and right. 9
5) Lift off torque converter and transmission
assembly (61).
Check that it does not hit against any
other parts, and lift off slowly.
Check that all parts have been removed
before lifting off.
63
64
65
DEW00526
30-40
w
U42103
61
INSTALLATION OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY

removal.
U42103
1
3 Cable locknut:
53.9 5 Nm {5.5 0.5 kgm}
2
Align securely with the notch hole of the
viscous damper washer, then tighten.
34
Replace the O-rings with new parts.
Install the clamps before connecting the
hoses and tubes.
56
3 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
Check that the match mark is aligned.
7
Remove block 1 at the bottom of the flywheel housing.
8
Replace the O-rings with new parts.
3 Mounting bolt:
68.6 5 Nm {7.0 0.5 kgm}
9
Align the pin hole securely.
3 Mounting bolt of bracket (65):
279.5 29.4 Nm {28.5 3.0 kgm}
3 Mount bolt (63):
926.7 103 Nm {94.5 10.5 kgm}
Adjust so that the clearance at center bolt
(64) is clearance a.
Clearance a: 1.0 1.5 mm
3 Set bolt (64):
122.6 24.5 Nm {12.5 2.5 kgm}
2 Set bolt: Thread tightener (LT-2)
65
63
64
DEW00528
DEW00527
Refilling with oil

11.8 1 Nm {1.2 0.1 kgm}
DEW00448
30-41
w

cooling oil tank.

Bleeding air
1) Bleed air from brake line, and brake cooling
line.
OUT OPERATION.
U42103
30-42
w
TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Turbine, case assembly
1) Remove stator shaft and pump assembly (2)
from turbine and case assembly (3).
2
3
DEW00529
U42103
2) Disassemble turbine and case assembly as

follows.
i) Remove pilot (4).
ii) Remove snap ring (5), then remove plate
(1).
DEW00531
DEW00530
iii) Push boss portion of turbine (6) and remove from case (7).
6
DEW00532
iv) Remove mounting bolts and disconnect

turbine (6) and boss (18).
v) Remove bearing (8) from case.
18
DEW00533
DEW00534
30-43
w
TORQUE CONVERTER
2. Stator
1) Remove snap ring (9).
2) Remove stator (10).
10
DEW00535
3. Stator shaft
Using forcing screws 1, push from stator shaft
(11) end and disconnect from pump assembly
(12).
11
DEW00536
4. Gear
Remove gear (13) from pump (14).
13
14
DEW00537
5. Bearing
Remove bearing (15) from gear (13).
13
15
DEW00538
30-44
w
U42103
12
TORQUE CONVERTER
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
13
1. Bearing
Install bearing (15) to gear (13).
15
DEW00539
U42103
2. Gear
Install gear (13) to pump (14).
3 Mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
13
14
DEW00537
3. Stator shaft
1) Install seal ring (16) to stator shaft (11).
2 Seal ring: Grease (G2-LI)
Make the protrusion of the seal ring uniform.
11
16
DEW00540
2) Push inner race of bearing and install pump

assembly (12) to shaft (11).
12
11
DEW00541
30-45
w
4. Stator
1) Install stator (10).
2) Install snap ring (9).
TORQUE CONVERTER
10
DEW00535
5. Turbine, case assembly

1) Assemble turbine and case assembly as follows.
i) Install bearing (8) to case.
Press fit the bearing until it contacts
the case.
DEW00543
ii) Install boss (18) to turbine (6).

2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
18
DEW00533
iii) Push inner race of bearing and install

turbine (6) to case (7).
6
DEW00545
30-46
w
U42103
iv) Fit plate (1) and install snap ring (5).

v) Install pilot (4).
2 Mounting bolt:
3 Mounting bolt:
30.9 3.4 Nm {3.15 0.35 kgm}
TORQUE CONVERTER
DEW00531
2) Install turbine and case assembly (3) to stator

shaft and pump assembly (2).
2 Mounting bolt:
3 Mounting bolt:
30.9 3.4 Nm {3.15 0.35 kgm}
DEW00530
U42103
DEW00529
30-47
w
TRANSMISSION
DISASSEMBLY OF
TRANSMISSION ASSEMBLY
11
2. Accumulator valve
Remove mounting bolts (5) of accumulator valve
(4), then remove accumulator valve and gasket.
After removing, cover with tape to prevent
the entry of dirt or dust.
1) Remove control valve inlet elbow (6) and
elbow (7) which goes to cooler.
2) Remove mounting bolts (9) (marked with )
of control valve (8), install eyebolts
(M:12mm), then sling.
4 Transmission control valve: 55 kg
3) Remove mounting bolts (9) and remaining
bolts (marked with ), then lift off control
valve assembly.
After removing, cover with tape to prevent the entry of dirt or dust.
13
12
10
9
14
15
16
DEW00549
21
17
19
20
18
2
3
DEW00550
4. Flow valve
Remove mounting bolts (11) of flow valve (10),
then remove flow valve and O-ring.
Remove the hose from the pump and the
hose from the oil filter.
After removing, cover with tape to prevent
the entry of dirt or dust.
8
5. Transmission oil filter
1) Remove inlet and outlet hoses of oil filter
(12).
2) Remove mounting bolt of bracket (13), then
remove together with oil filter.
6. Filler tube
Remove mounting bolts (15) of filler tube (14),
then remove filler tube.
30-48
w
DEW00551
U42103
1. Coupling
1) Pull out lower rear coupling (1).
2) Remove lower front coupling (2) and mounting bolt (3), then remove coupling.
3) Remove sensors.
7. Transmission, torque converter charging pump

1) Remove delivery hose (20) and hose (19),
and tubes (18) and (17) at suction end of
charging pump (16).
After removing, cover with tape to prevent the entry of dirt or dust.
2) Remove mounting bolts (21) of charging
pump (16), then remove pump and O-ring.
TRANSMISSION
21
16
17
19
20
18
2
3
DEW00550
8. Transmission assembly
Install transmission assembly to stand.
112
160
(939)
380
(949)
4 Transmission assembly: 950 kg

Support the transmission at the position
shown in the diagram on the right.
M12, P=1.75 70
Depth 21
10
Flywheel
mating
surface
120
U42103
250
500
9. Torque converter case

Remove mounting bolts of torque converter case
(22), then remove from transmission case.
When removing the case, slowly remove it
perpendicularly to the mounting surface.
130
728
M16, P=2.0
Depth 31
DEW00553
22
Transmission
case
4 Torque converter case: 160 kg
DEW00554
[TORQUE CONVERTER]
1. Torque converter
i) Remove 6 bolts installing torque converter
case (22) and torque converter.
ii) Fit lifting tool to gear portion of drive case
(24) of torque converter assembly (23) and
lift off from torque converter case (22).
24
Lifting tool
23
22
4 Torque converter assembly: 56 kg
DEW00555
30-49
w
TRANSMISSION
2. PTO gear
1) PTO idler assembly
i) Remove lock bolts (26) of idler shaft (25),
then remove idler shaft, O-ring (27), and
gear assembly (28).
PTO gear
PTO idler
PTO gear
DEW00556
27
26
ii) Remove nut (29) from gear assembly

(31), then remove idler hub (30).
iii) Remove snap ring (32) and spacer (33)
from gear (31), then remove bearing (34).
32
31
30
29
DDW00557
33
34
DDW00558
2) PTO gear
i) Remove snap ring (35), then lower ring
(35), and remove split spacer (37).
ii) Pull out shaft (38) and remove gear (39).
iii) Remove snap rings (40) and (42), then
remove bearings (41) and (43).
Remove the PTO gear on the opposite side in the same way.
37
42 38
43 35
41 40
30-50
w
36
39
DDW00559
U42103
25
28
TRANSMISSION
[TRANSMISSION]
1. Remove input shaft assembly.
2. 1st, FORWARD clutch
1) Remove seal rings (1) from clutch shaft.
2) Set lifting tools A1, A2, and A3 to 1st, FORWARD clutch shaft, and lift off clutch.
Input shaft
2nd, REVERSE clutch

3rd, 4th clutch
4 1st, FORWARD clutch: 76.5 kg
1st, FORWARD clutch
3. 2nd, REVERSE clutch, 3rd, 4th clutch

Set lifting tools A1, A2, and A3 to 2nd, REVERSE
clutch shaft and 3rd, 4th clutch shaft, then raise
clutches at same time and remove.
Counter gear
DEW00560
A1, A2, A3
A1, A2, A3
4 2nd, REVERSE clutch: 91 kg
U42103
4 3rd, 4th clutch: 96 kg
3rd, 4th
clutch
4. Driven gear
1) Install puller to countershaft (2) and bearing
(3) and remove bearing, then remove gear
(4) from shaft.
2) Remove snap ring (5), then remove gear (6).
3) Remove shaft (2), then remove bearing (7)
with puller.
When setting the puller in position, use
a block at the end face of the clutch shaft
when carrying out the operation.
There is oil on the shaft and gears, so be
careful not to let them slip.
1st, FORWARD cluth
2nd, REVERSE clutch
DEW00561
DEW00562
Puller
3
4
2
6
3
5. Parking brake
Disassemble parking brake.
For details, see DISASSEMBLY OF PARKING
BRAKE ASSEMBLY.
6. Output shaft
1) Remove mounting bolts (9) of gear cover
(8), then remove cover.
4
DEW00564
DEW00563
10
8
Transmission
case
DEW00565
30-51
w
TRANSMISSION
2) Install eyebolt to output shaft (10) and lift off

output shaft.
13
4 Output shaft (including gear): 33 kg

9
3) Remove snap ring (12) of output gear (11),

then remove inner bearing (13) using puller,
and remove output gear from shaft.
4) Using puller, remove inner bearing (14) on
opposite side of output shaft.
When setting the puller in position, use
a block at the end face of the clutch shaft
when carrying out the operation.
14
11
15
12
16
10
17
DDW00566
Puller
There is oil on the shaft and gears, so be

5) Remove bearing outer race (15) from transmission case.
10
6) Remove oil seal (16) and dust seal (17) of

rear coupling.
13
11
1) Remove O-rings (17-1) and (18) from transmission case.
2) Remove bearing (19) and snap ring (20) of
driven gear from case.
19
DEW00567
W
20
17-1
18
19
W-W
DEW00568
18
17-1
DEW00569
30-52
w
U42103
careful not to let them slip.
TRANSMISSION
ASSEMBLY OF
TRANSMISSION ASSEMBLY
1) Press fit bearing (19) of driven gear to transmission case, and install snap ring (20).
2) Install O-rings (17-1) and (18) to transmission case.
19
W
20
17-1
19
W-W
18
DEW00568
U42103
18
17-1
DEW00569
2. Output shaft
1) Press fit bearing outer race (15) to transmission case.
2) Press fit bearing inner (14) at output shaft
rear coupling end.
Press fit securely so that there is no clearance at the end face of the bearing.
3) Install snap ring (12) to output shaft (10),
then install output gear (11), and press fit
inner bearing (13).
4) Install eyebolt to output shaft (10), then install shaft to transmission case.
5) Install gear cover (8) to case with mounting
bolt (9).
2 Mounting bolt:
4 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
13
9
14
11
15
12
16
10
17
DDW00566
10
8
Transmission
case
DEW00565
30-53
w
4. Rear coupling oil seal

Install oil seal (16) and dust seal (17) to transmission case so that they are at position given
below.
a: 50 0.2 mm
b: 35 0.2 mm
2 Oil seal, lip of dust seal: Grease (G2-LI)
a
b
16
Grease
portion Q
17
DEW00574
5. Counter gear
1) Install snap ring (5) and gear (6) to shaft (2),
and press fit bearing (7).
2) Install snap ring and gear (4) to opposite
end of shaft (2), and press fit bearing (3).
3
4
2
5
7
6
U42103
3. Parking brake
Assemble parking brake.
For details, see ASSEMBLY OF PARKING BRAKE
ASSEMBLY.
TRANSMISSION
DEW00563
6. 2nd, REVERSE clutch, 3rd, 4th clutch

Install lifting tools A2 and A3 to 2nd, REVERSE
clutch shaft and 3rd, 4th clutch shaft, raise
clutches at same time, and install to transmission case.
Raise 2nd, REVERSE and 3rd, 4th clutches at
the same time with the lifting tool, and turn
the 3rd, 4th clutch at an angle to assemble.
A1, A3
A2, A3
3rd, 4th
clutch
7. 1st, FORWARD clutch

Install lifting tools A1 and A3 to 1st, FORWARD
clutch shaft, and assemble clutch in transmission case.
2nd, REVERSE clutch
8. Seal rings
Install seal rings (1) to shafts of 1st, FORWARD
clutch, 2nd, REVERSE clutch, and 3rd, 4th clutch.
Input shaft
DEW00576
1st, FORWARD
DEW00577
clutch
2nd, REVERSE clutch

3rd, 4th clutch
1st, FORWARD clutch
30-54
w
Counter gear
DEW00560
9. Assemble input shaft assembly and gear to transmission case.

The installed dimension of the input shaft
bushing is as follows.
c = 2.0 0.5 mm
TRANSMISSION
P
C
Bushing
Input shaft
U42103
Portion P
10. Torque converter

1) PTO gear
i) Install bearings (41) and (43) to case, and
secure with snap rings (40) and (42).
Press fit securely so that there is no
clearance at the end face of the bearing.
ii) Set gear (39) inside case, and insert shaft
(38) from outside of case.
Be careful of the gear mounting position.
iii) Set split spacer (37) in position, then install ring (36) and secure with snap ring
(35).
2) PTO idler assembly
i) Press fit bearing (34) to gear (31), then
install spacer (33) and secure with snap
ring (32).
Be careful not to forget to assemble
spacer (33).
Press fit securely so that there is no
clearance at the end face of the bearing.
ii) Install idler hub (30) to gear assembly
and tighten with nut (29).
2 Nut: Thread tightener (LT-2)
3 Nut:
417 24.5 Nm {42.5 2.5 kgm}
iii) Set gear assembly (28) inside case, insert O-ring in case, install idler shaft (25),
and tighten with lock bolts (26).
37
42 38
DEW00579
43 35
41 40
32
31
29
30
36
39
DDW00559
33
34
DDW00558
25
28
3 Idler shaft mounting bolt:

112.8 4.9 Nm {11.5 0.5 kgm}
26
27
DDW00557
30-55
w
r
TRANSMISSION
3) Torque converter
i) Fit lifting tool to gear portion of drive
case (24) of torque converter assembly
(23), and set to torque converter case
(22).
ii) Tighten bolts (22-1) installing torque converter case (22) and torque converter.
3 Torque converter mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
22-1
DDW00583
11. Torque converter case

Coat transmission case with gasket sealant, then
set torque converter case (22) in position and
tighten with mounting bolts.
2 Transmission case flange surface:
Gasket sealant (Three Bond 1207B)
Lifting tool
24
23
22
1
1
2
Inside
DEW00555
B
H
B= 25 mm
H= 25 mm
Gasket sealant
DEW00585
3 Torque converter case mounting bolt:

112.8 9.8 Nm {11.5 1.0 kgm}
DEW00586
Tool mark (spot)
22
Transmission
case
Portion Q
DEW00554
30-56
w
DEW00587
U42103
Outside
TRANSMISSION
12. Transmission, torque converter charging pump

1) Install O-ring to charging pump (16), then
set to transmission case and tighten with
mounting bolts (21).
Before installing the pump, insert the
pump drive shaft inside the torque converter input shaft assembly.
3 Pump mounting bolt:
279.4 29.4 Nm {28.5 3.0 kgm}
2) Fit O-rings to tubes (17) and (18) at suction
side of charging pump (16), then connect
hose (19) and tighten. Install O-ring to hose
(20) at discharge side also, then tighten.
3 Tube (17), (18) mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
3 Clamp of hose (19):
4.4 0.5 Nm {0.45 0.05 kgm}
21
16
17
19
20
18
2
3
U42103
DEW00550
13. Filler tube

Fit filler tube (14) with mounting bolt (15) temporarily, and move towards inside of transmission.
After mounting the transmission on the machine, install the filler tube at the specified
position.
14. Transmission oil filter
1) Install bracket (13) and oil filter to transmission.
3 Oil filter mounting bolt:
68.6 4.9 Nm {7.0 0.5 kgm}
3 Filter bracket mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
2) Install inlet and outlet hoses of oil filter (12).
3 Hose connection:
176.5 29.4 Nm {18.0 3.0 kgm}
11
4
5
13
12
10
9
14
15
DEW00549
30-57
w
TRANSMISSION

1) Install gasket to transmission end, then install eyebolt to portion of control valve (8)
marked , and set to transmission.
2) Install to portions marked and with
mounting bolts (9), then tighten.
2 Mounting bolt:
3 Mounting bolt:
34.3 4.9 Nm {3.5 0.5 kgm}
3) Install elbow (7) which goes to cooler and
inlet elbow (6) to control valve.
DEW00551
11
4
5
13
12

Install O-ring to accumulator valve (4) and tighten
with mounting bolts (5).
10
9
18. Couplings
1) Front coupling
Install front coupling (2) to output shaft, and
tighten O-ring and washer with coupling
mounting bolt (3).
3 Mounting bolt:
926.7 98.1 Nm {94.5 10.0 kgm}
2) Rear coupling
Install rear coupling (1) to rear end of output
shaft.
30-58
w
14
15
DEW00549
U42103
16. Flow valve

Install O-ring to flow valve (10), then install to
transmission case with mounting bolts (11).
2 Flow valve mounting bolt:
3 Flow valve mounting bolt:
34.3 4.9 Nm {3.5 0.5 kgm}
DISASSEMBLY OF
ASSEMBLY
A1, A2
140
FORWARD,
1st
2C
2C
50+0.5
0
110
4 FORWARD, 1st clutch assembly:

76.5 kg
90
1. Assembly of FORWARD clutch pack assembly

Lift the clutch pack assembly with lifting tools
A1 and A2, and install to lifting stand 1.
6 9t
FORWARD, 1ST CLUTCH ASSEMBLY
115.3 +0.2
0
100
200
DEW00594
1) Seal rings
Remove 3 seal rings (1) installed to shaft.
2) Bearing, thrust washer
i) Install puller to end face of shaft, and
remove bearing (2).
When setting the puller in position,
install a block to the end face of the
clutch shaft before carrying out the
operation.
ii) Remove thrust washer (3) and spacer (4)
from shaft.
Puller
2
4
2
3
DEW00596
DEW00595
6
5
7
7-1
DDW00598
DEW00597
4) End plate
Push end plate (8) with tool 2 in diagram
below, remove snap ring (9), then remove
end plate (8) from clutch case (10).
9 12
290
11
101.6
85
8
170
U42103
DEW00593
3) Needle bearing, FORWARD gear

i) Remove needle bearing (5) and FORWARD gear (6) from shaft.
ii) Remove thrust washer (7) and spacer (71).
9 12
10
12
13
10
DEW00600
DDW00601
Tool
DEW00599
30-59
w
5) Clutch plates
Remove separator plates (12), disc plates
(11), and wave springs (13) from inside clutch
(10).
Be careful not to let the separator plates
or disc plates catch in the clutch case
ring groove.
12
11
13
DEW00602
15
14
14
16
DEW00604
DEW00603
2. Disassembly of 1st clutch pack

Turn over the FORWARD clutch case and set
to stand 3.
1st clutch pack
78
5c
55
8
There is oil on the clutch pack, so be careful
6 9t
17
200
Puller
17
18
19
DEW00607
30-60
100
DEW00606
DEW00605

i) Remove roller bearing and outer race,
then install puller to end face of shaft,
and remove bearing inner (17).
operation.
ii) Remove thrust washer (18) and spacer
(19) from shaft.
67
105
not to let it slip when turning it over.
19
18
DEW00608
U42103
6) FORWARD piston
Remove FORWARD piston (14) from inside
clutch case, then remove piston seals (15)
and (16) from piston.
2) Needle bearing, 1st gear

i) Remove needle bearing (20) and 1st gear
(21) from shaft.
(22-1).
20
21
21
20
22
22-1
DEW00609
3) End plate
Push end plate (8) at 1st clutch end with tool
2, remove snap ring (9), then remove end
plate from clutch case (10).
DDW00610
8
9
11
U42103
10
12
13
DDW00612
DEW00611
4) Clutch plates
case (10).
ring groove.
11
12
13
DEW00613
5) 1st piston
Remove 1st piston (23) from inside clutch
case, then remove piston seals (24) and (25)
from piston.
The shape of the 1st piston is different
from the shape of the FORWARD piston
on the opposite side.
23
23
25
DEW00614
24
DEW00615
30-61
w
REVERSE, 2ND CLUTCH ASSEMBLY

1. Disassembly of REVERSE clutch pack
A1 and A2, and install to stand 1.
A1, A2
REVERSE, 2nd clutch

assembly
4 REVERSE, 2nd clutch assembly: 90 kg
DEW00616
1) Seal rings
remove bearing (2).
operation.
from shaft.
Puller
2
4
3
DEW00596
DEW00595
3) Needle bearing, REVERSE gear

i) Remove needle bearing (5) and REVERSE
gear (6) from shaft.
7
7-1
DEW00619
4) End plate
Push end plate (8) with tool 2, remove snap
ring (9), then remove end plate from clutch
case (10).
10
DEW00600
30-62
w
DDW00620
11
12
13
8
9
10
DDW00621
U42103
5) Clutch plates
case.
ring groove.
11
12
13
DEW00623
6) REVERSE piston
Remove REVERSE piston (14) from inside
clutch case, then remove piston seals (15)
and (16) from piston.
14
15
14
U42103
16
DEW00624
DEW00604
2. Disassembly of 2nd clutch pack

Turn over the REVERSE clutch case and set
to stand 3.
2nd clutch pack

DEW00626

operation.
(19) from shaft.
Puller
17
17
18
18
19
DEW00627
19
DEW00628
30-63
w
2) Needle bearing, 2nd gear

i) Remove needle bearing (20) and 2nd
gear (21) from shaft.
(22-1).
20
21
20
21
22
22-1
DDW00630
DEW00629
8
9
11
10
12
13
10
DEW00631
4) Clutch plates
case (10).
ring groove.
DDW00632
11
12
13
5) 2nd piston
Remove 2nd piston (23) from inside clutch
from piston.
The shape of the 2nd piston is different
from the shape of the REVERSE piston
on the opposite side.
DEW00633
23
23
25
DEW00634
30-64
w
24
DEW00615
U42103
3) End plate
Push end plate (8) at 2nd clutch end with
tool 2, remove snap ring (9), then remove
end plate from clutch case (10).
3RD, 4TH CLUTCH ASSEMBLY

1. Disassembly of 4th clutch pack
A1 and A2, and install to stand 1.
A1, A2
3rd, 4th clutch

assembly
4 3rd, 4th clutch assembly: 96 kg
DEW00636
U42103
1) Seal rings
Puller

remove bearing (2).
operation.
from shaft.
3) Needle bearing, 4th gear

i) Remove needle bearing (5) and 4th gear
(6) from shaft.
2
4
3
2
DEW00637
DEW00596
7
7-1
DEW00639
4) End plate
Push end plate (8) with tool 2, remove snap
ring (9), then remove end plate from clutch
case (10).
DDW00640
10
DEW00641
11
12
13
8
9
10
DDW00642
30-65
w
5) Clutch plates
case (10).
ring groove.
11
12
13
DEW00643
14
15
14
16
DEW00604
DEW00644
2. Disassembly of 3rd clutch pack

Turn over the 4th clutch case and set to
stand 3.
3rd clutch pack

DEW00646

operation.
(19) from shaft.
17
Puller
17
18
19
18
DEW00647
30-66
w
19
DEW00648
U42103
6) 4th piston
Remove 4th piston (14) from inside clutch
from piston.
2) Needle bearing, 3rd gear

i) Remove needle bearing (20) and 3rd gear
(21) from shaft.
20
21
20
4 3rd gear: 29 kg
(22-1).
21
22
22-1
DEW00649
3) End plate
Push end plate (8) at 3rd clutch end with
tool 2, remove snap ring (9), then remove
end plate from clutch case (10).
DDW00650
10
8
9
11
12
U42103
13
10
DDW00652
DEW00651
4) Clutch plates
case (10).
ring groove.
11
12
13
DEW00653
5) 3rd piston
Remove 3rd piston (23) from inside clutch
from piston.
The shape of the 3rd piston is different
from the shape of the 4th piston on the
opposite side.
23
23
25
DEW00654
24
DEW00615
30-67
w
ASSEMBLY OF
ASSEMBLY
FORWARD/1st clutch
FORWARD, 1ST CLUTCH ASSEMBLY

When assembling the FORWARD, 1st clutch, always check dimension A of the FORWARD
clutch case.
A: 90.5 mm
DDW00656
14
15
14
16
DEW00603
After assembling the seal rings to piston, set to tools A4 and A5 and settle for
at least 5 seconds.
Carry out the settling operation for each
piston.
2 Outer circumference of seal ring, contact surface: Oil (EO10-CD)
DEW00604
Piston
Piston
A4
A5
DEW00659
2) Clutch plates
Install separator plates (12), disc plates (11),
and wave springs (13) inside clutch case (10).
Before assembling the clutch disc plates,
put them in a soaking bath for at least 2
minutes.
Oil: EO10-CD
(API 10W-CD Class or above)
12
DEW00660
11
13
DEW00602
30-68
w
U42103
1. Assembly of FORWARD clutch pack

1) FORWARD piston
Install piston seals (15) and (16) to FORWARD
piston (14), then install inside clutch case.
Replace the piston seal rings with new
parts.
3) End plate
Assemble end plate (8) to clutch case (10),
then push with tool 2, and secure with snap
ring (9).
4) Needle bearing, FORWARD gear

i) Assemble spacer (7-1) and thrust washer
(7) inside clutch case in order.
Before assembling the spacer, warm
it up at 80C 120C for 80 minutes.
8
11
10
10
2 Thrust washer (7): Oil (EO10-CD)
ii) Install FORWARD gear (6) to shaft, and

assemble needle bearing (5).
12
13
DEW00600
DDW00601
6
6
U42103
7
7-1
DEW00597

i) Assemble thrust washer (3) and spacer
(4) to shaft in order.
Before assembling bearing (2) and
spacer (4), warm them up at 80C
120C for 80 minutes.
When press fitting the bearing, check
that there is no clearance.
ii) Press fit bearing (2) to shaft.
After press fitting the bearing, check
the dimension of clearance B between spacer (4) and thrust washer
(3).
B: 0.27 1.23 mm
(FORWARD clutch end)
DDW00598
2
4
B
3
DDW00666
30-69
w
6) Seal rings
Install 3 seal rings (1) to shaft.
1
2
DEW00595
23
23
25
DEW00614
at least 5 seconds.
piston.
24
DEW00615
Piston
Piston

A4
A5
DEW00659
2) Clutch plates
Before assembling clutch disc plates (1),
minutes.
Oil: EO10-CD (API 10W-CD Class or
above)
DEW00660
11
12
13
DEW00613
30-70
w
U42103
2. Assembly of 1st clutch pack

1) 1st piston
Install piston seals (24) and (25) to 1st piston
(23), then install inside clutch case.
parts.
3) End plate
ring (9).
8
9
11
10
12
13
DEW00611
4) Needle bearing, 1st gear

i) Assemble spacer (22-1) and thrust
washer (22) inside clutch case in order.
ii) Install 1st gear (21) to shaft, and assemble needle bearing (20).
20
DDW00612
21
20
21
U42103
22
22-1
DEW00609

the dimension of clearance C between spacer (19) and thrust washer
(18).
C: 0.14 1.36 mm (1st clutch end)
DDW00610
17
C
19
18
DDW00677
30-71
w
REVERSE, 2ND CLUTCH ASSEMBLY

When assembling the REVERSE, 2nd clutch, always check dimension D of the REVERSE
clutch case.
D: 90.5 mm
FORWARD/1st clutch
DDW02348
14
15
14
16
DEW00624
at least 5 seconds.
piston.
DEW00604
Piston
Piston
A4
A5
DEW00659
2) Clutch plates
minutes.
Oil: EO10-CD (API 10W-CD Class or
above)
DEW00660
11
12
13
DEW00623
30-72
w
U42103
1. Assembly of REVERSE clutch pack

1) REVERSE piston
Install piston seals (15) and (16) to REVERSE
piston (14), then install inside clutch case.
parts.
3) End plate
then push with tool 2, AND secure with
snap ring (9).
2 Thrust washer: Oil (EO10-CD)
10
8
9
11
12
13
10
DEW00641
U42103
4) Needle bearing, REVERSE gear

ii) Install REVERSE gear (6) to shaft, and
assemble needle bearing (5).
DEW00639

the dimension of clearance E between spacer (4) and thrust washer
(3).
E: 0.27 1.23 mm
(REVERSE clutch end)
DDW00642
7
7-1
DDW00640
2
E
4
3
DDW00688
30-73
w
6) Seal rings
2
DEW00595
2. Assembly of 2nd clutch pack

1) Install piston seals (24) and (25) to 2nd piston (23), then install to clutch case.
parts.
23
25
DEW00634
at least 5 seconds.
piston.
24
DEW00615
Piston
Piston
A4
A5
DEW00659
2) Clutch plates
minutes.
Oil: EO10-CD
DEW00660
11
12
13
30-74
w
DEW00633
U42103
23
3) End plate
ring (9).
8
9
11
10
12
13
10
DEW00631
4) Needle bearing, 2nd gear

ii) Install 2nd gear (21) to shaft, and assemble needle bearing (20).
21
20
DDW00632
20
21
U42103
22
22-1
DEW00629

the dimension of clearance F between spacer (19) and thrust washer
(18).
F: 0.34 1.56 mm
(2nd clutch end)
DDW00630
17
F
19
18
DDW00699
30-75
w
3RD, 4TH CLUTCH ASSEMBLY

1. Assembly of 4th clutch pack
1) 4th piston
Install piston seals (15) and (16) to 4th piston (14), then install inside clutch case.
parts.
14
15
14
16
DEW00604
DEW00644
Piston
Piston
A4
A5
DEW00659
2) Clutch plates
minutes.
Oil: EO10-CD
DEW00660
11
12
13
DEW00643
3) End plate
ring (9).
10
DEW00641
30-76
w
11
12
13
8
9
10
DDW00642
U42103
at least 5 seconds.
piston.
4) Needle bearing, 4th gear

ii) Install 4th gear (6) to shaft, and assemble needle bearing (5).
DEW00639
U42103

7
7-1
DDW00640
2
4
G
3

the dimension of clearance G between spacer (4) and thrust washer
(3).
G: 0.37 1.33 mm
(4th clutch end)
6) Seal rings
DDW00709
1
2
DEW00637
30-77
w
2. Assembly of 3rd clutch pack

Install piston seals (24) and (25) to 3rd piston
(23), then install to clutch case.
Replace the piston seal rings with new parts.
23
23
25
DEW00615
DEW00654
After assembling the seal rings to piston,

set to tools A4 and A5 and settle for at least
5 seconds.
Carry out the settling operation for each piston.
24
Piston
Piston
A4
A5
DEW00659
2) Clutch plates
minutes.
Oil: EO10-CD (API 10W-CD Class or above)
DEW00660
11
12
13
DEW00653
3) End plate
ring (9).
10
11
12
13
DEW00651
30-78
w
8
9
10
DDW00652
U42103
4) Needle bearing, 3rd gear

Before assembling the spacer, warm it
up at 80C 120C for 80 minutes.
20
21
20

ii) Install 3rd gear (21) to shaft, and assemble needle bearing (20).
21
22
22-1
DEW00649
U42103

DDW00650
17
18
19

DEW00647

the dimension of clearance H between spacer (19) and thrust washer
(18).
H: 0.34 0.56 mm
(3rd clutch end)
17
H
19
18
DDW00721
30-79
w
PARKING BRAKE
DISASSEMBLY OF PARKING
BRAKE ASSEMBLY
Stop

Release the parking brake.

1. Loosen drain plug and drain transmission oil.
6 Transmission: 40
3. Suction tube
1) Remove mounting bolt (3) and washer (4) of
coupling (2) at front end of transmission,
then remove coupling.
2) Remove suction tube (5) at transmission end.
4
DEW00722
4. Parking brake
1) Remove lock plates (7) of manual release
bolts (6) and parking brake, then remove 3
release bolts (6).
2) Remove parking bake case (8).
6
7
DEW00723
3) Remove mounting bolts (10) of housing (9),

then remove housing.
30-80
w
10
DEW00724
U42103
2. Drive shaft
Remove guard of drive shaft, and disconnect
lower front drive shaft (1) at transmission end.
Move the disconnected drive shaft to the
right end.
4) Remove spline hub (12) and piston (13) from

output shaft (11), then remove springs (14)
and (15).
PARKING BRAKE
11
12
13
14
15
DDW00725
5) Remove mounting bolts (17) of retainer (16),

then remove retainer and shim (18).
Check the number and thickness of the
shims, and keep in a safe place.
Sling the output shaft to prevent it from
falling.
17
18
Raise
11
U42103
Bearing
6) Remove bearing race from retainer (16), then

remove bearing inner race from output shaft
(11).
16
DEW00726
30-81
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PARKING BRAKE
ASSEMBLY OF PARKING
BRAKE ASSEMBLY
18
17
1. Parking brake
1) Press fit bearing outer race to retainer (16),
and bearing inner race to output shaft (11).
Raise
11
Bearing
2) Install output shaft to transmission case, then

insert shim (18) in retainer (16), and tighten
with mounting bolts (17).
Keep the output shaft horizontal when
raising it.
16
DEW00726
3) Adjusting shim
i) Assemble shim of standard value, then
tighten retainer (16) with 3 bolts.
Standard shim thickness: 1.2 mm
3 places
(bolts)
16
Assemble retainer (16) so that the 4

casting holes are at the bottom.
ii) Adjust shim so that rotating torque of
output shaft is 9.8 98.1 Ncm (1 10
kgcm).
When doing this, check that there is
no end play.
4) Install springs (14) and (15) to retainer, then
install piston (13) and spline hub (12) to output shaft (11).
2 Tip of spline hub: Grease (LM-G)
DEW00728
11
12
13
14
15
DDW00725
30-82
w
U42103
3 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
PARKING BRAKE
5) Set brake housing assembly (9) to transmission front case, and install brake piston pushing tool 4.
6) Push in piston (13) with bolt of pushing tool,
and tighten with 3 housing mounting bolts
(10).
Mesh the spline hub and disc before
starting.
13
12
3 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
10
DDW00730
10
30
45
30
110
15t
3-M12
300
26
0
160
M10,
65
27
M12, 100
All screws
U42103
M12 mm
Eyebolt
mount
A-A
DEW00731
7) Install parking brake case (8).

8) Install parking brake manual release bolts
(6), and secure with lock plates (7).
10
DEW00724
6
7
2. Suction tube
1) Install suction tube (5).
Use a new part for the O-ring.
8
DEW00723
30-83
w
3. Coupling
Tighten transmission front coupling (2), O-ring
and washer (4) with mounting bolt (3).
PARKING BRAKE
2 End face of coupling:

Anti-friction compound (LM-G)
3 Mounting bolt:
921.8 98.1 Nm {94.0 10.0 kgm}
4. Drive shaft
1) Connect front drive shaft (1).
Clean the connection and mating surface of the drive shaft before installing.
4
DEW00722
3 Drive shaft:
112.8 9.8 Nm {11.5 1.0 kgm}
2) Install drive shaft guard.
5. Refilling with oil
1) Tighten drain plug and add transmission oil.
Transmission: 60
Run the engine to circulate the oil

through the system. Then check the oil
level again.
30-84
w
r
U42103
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
Stop

Disconnect
1. Ladder
Remove left ladder (1).
4 Ladder (left): 59.5 kg
U42103
2. Covers
1) Remove left side cover (2) of rear frame.
2) Remove bottom cover (3) of floor.
3) Remove front cover (3-1) of bulkhead.
10
11
3-1
3. Electric wiring
Disconnect following electric wiring.
1) Disconnect wiring TL1 (4) and TL2 (5) for
transmission.
LR6 (7), LR3 (8), LR4 (9), LR1 (10), and LR2
(11).
4
DEW00736
10
11
DEW00500
8
6
4
5
4. Modulating valve
Remove mounting bolts of modulating valve
(12-1), then remove valve.
DEW00497
12-1
12
DNW03846
30-85
w
5. Hydraulic piping
1) Disconnect hose (13) between transmission,
torque converter charging pump and flow
valve at flow valve end.
1
2) Disconnect hose (14) between flow valve and
transmission oil filter at flow valve end.
2
oil filter and transmission control valve at
control valve end.
3
control valve and cooler at control valve end.
4
13
14
15
17
16
19
DDW00740
18
19
16
DEW00741
2) Remove mounting bolts (18) of transmission

control valve (19), and remaining bolts
(marked with ) and lift off control valve
assembly.
7
Remove the gasket from the control
valve.
Eyebolt position
19
DDW00742
30-86
w
U42103
6. Remove flow valve (17) from transmission case.

5
1) Remove mounting bolts (18) of control valve,
and install eyebolts (M:12mm), then sling.
6
4 Transmission control valve: 55 kg
INSTALLATION OF
TRANSMISSION CONTROL
VALVE ASSEMBLY

removal.
13
3 Hose connection:
176.5 29.4 Nm {18.0 3.0 kgm}
24
5
2 Mounting bolt: Thread tightener (LT-2)
U42103
3 Mounting bolt:
34.3 4.9 Nm {3.5 0.5 kgm}
6
When installing the control valve, be careful
not to hit the solenoid valve or other parts.
7
Use a new part for the gasket.
2 Mounting bolt (marked with ):
3 Mounting bolt:
34.3 4.9 Nm {3.5 0.5 kgm}
30-87
w
DISASSEMBLY OF
VALVE ASSEMBLY
1. Disassembly of modulation, accumulator, upper, lower valve
1) Remove mounting bolts (1)(marked with )
of modulation and accumulator valve, then
remove gasket (2). (WA450-3S only)
2) Remove mounting bolts (3)(marked with )
of upper valve assembly, then remove gasket (4).
After removing, cover with tape to prevent dirt or dust from entering the valve.
Modulation,
accumulator valve
Upper valve assembly

Lower valve assembly
2. Disassembly of modulation, accumulator valve

1) Remove mounting bolts (6) of accumulator
cover (5), then remove O-ring (7), accumulator valve (8), outer spring (9), inner spring
(10), stopper (11), and spring (12) from valve
body.
12 11
DDW00743
10
5
DDW00744
2) Remove mounting bolts (14) of modulation

valve cover (13), then remove O-ring (15),
fill valve (16), sleeve (17), O-ring (18), fill
spring (19), and plug (20) from valve body.
15
14
13
20
19
18
17
3. Disassembly of upper valve assembly

1) Manual valve
i) Loosen mounting bolt (2) of lock plate
(1), remove lock plate, pull out manual
valve spool (3), then remove O-ring (4).
ii) Remove plug (5) from valve body.
16
DDW00745
4
1
DEW00746
30-88
w
2
DDW00747
U42103
2) Upper L cover
i) Remove mounting bolts (7) of connector
bracket (6), then remove bracket.
ii) Remove remaining mounting bolts (7)
of upper L cover (8), then remove cover
and gasket (9).
After removing, cover with tape to
prevent dirt or dust from entering
the valve.
7
6
8
9
DDW00757
3) Pilot valve
Remove pilot valve (11) and pilot spring (12)
from valve body (10).
11
10
U42103
12
DDW00758
4) Main relief valve

i) Remove valves (14) and (15), and spring
(16) from main relief valve (13), then remove main relief valve from valve body.
ii) Remove main relief spring (17).
the valve.
13 14
16
15
17
DDW00759
5) Torque converter outlet valve

Remove dummy spool (18), torque converter
outlet spring (19) and torque converter outlet valve (20) from valve body.
18
19
20
DDW00760
30-89
w
6) Quick return valve

i) Remove mounting bolts (22) of upper R cover
(21), then remove cover and gasket (23).
ii) Remove quick return spring (24) from valve
body, then remove quick return valve (25).
iii) Remove valve plug (26) of quick return valve,
then remove orifice plug (27), spring (28),
ball (29), and valve (30).
27
26
25 24
23
P 21 22
28
29
30
P
DDW00761
4. Disassembly of lower valve assembly

1) Solenoid valve, pilot filter
i) Remove directional selector solenoid
valve (1) and O-ring from lower valve.
ii) Remove H-L selector solenoid valve (2),
range selector solenoid valve (3), and Oring from lower valve.
iii) Remove parking brake solenoid valve (4)
and O-ring from lower valve.
iv) Remove pilot filter from lower valve.
Solenoid valve
Solenoid valve
Lower valve
Pilot filter
DEW00762
1
1
2
Lower valve
DDW00763
30-90
w
U42103
Solenoid valve
2) Lower L cover
Remove mounting bolts (6) of lower L cover
(5), then remove cover and gasket (7).
6
5
7
DDW00764
3) Directional selector valve

Remove F return spring (9) and sleeve (10)
of directional valve from valve body (8), then
remove valve spool (11).
9
10
11
U42103
DDW00765
4) H-L selector valve

i) Remove spool (12) of H-L valve from
valve body.
ii) Remove plug (13) from spool (12), then
remove spring (14) and ball (15).
the valve.
12
12
15
14
13
DDW00766
5) Range selector valve

i) Remove spool (16) of range selector
valve from valve body.
ii) Remove plug (17) from spool (16), then
remove spring (18) and ball (19).
the valve.
16
16
19
18
17
DDW00767
30-91
w
6) Priority valve
Remove spool (20) and stopper (21) of priority valve from valve body.
20
21
DDW00768
7) Parking brake valve

Remove spool (22) and return spring (23) of
parking brake valve from valve body.
22
DDW00769
8) Lower R cover
i) Remove mounting bolts (25) of lower R
cover (24), then remove cover and gasket (26).
ii) Remove R return spring (27) and sleeve
(28) of directional valve, return springs
(29) and (30) of H-L selector valve and
range selector valve, and spring (31) of
priority valve from valve body.
the valve.
30-92
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25
24
29
30
31
26
27
28
DDW00770
U42103
23
ASSEMBLY OF
VALVE ASSEMBLY
25
1. Assembly of lower valve assembly
1) Lower R cover
i) Install R return spring (27) and sleeve
(28) of directional valve, return springs
(29) and (30) of H-L selector valve and
range selector valve, and spring (31) of
priority valve to valve body.
Free height of spring:
42 mm (27)
48 mm (29), (30)
150 mm (31)
ii) Install gasket (26), and tighten lower R
cover (24) with mounting bolts (25).
29
24
30
31
26
27
28
DDW00770
U42103
3 Lower R cover mounting bolt:

31.4 2.9 Nm {3.2 0.3 kgm}
2) Parking brake valve

Install spool (22) and return spring (23) of
parking brake valve to valve body.
Free height of spring: 46 mm (23)
22
2 Outside circumference of parking

brake valve spool: Oil (EO10-CD)
23
DDW00769
3) Priority valve
Install spool (20) and stopper (21) of priority
valve in valve body.
20
2 Outside circumference of priority

valve spool: Oil (EO10-CD)
21
DDW00768
30-93
w
4) Range selector valve

i) Install spring (18), ball (19), and plug (17)
to spool (16).
Free height of spring: 23.5 mm
16
16
3 Range selector spool plug (17):

9.8 12.8 Nm {1.0 1.3 kgm}
2 Range selector spool plug (17):
19
18
17
ii) Install spool (16) of range selector valve

to valve body.
2 Outside circumference of range
selector spool: Oil (EO10-CD)
DDW00767
H-L selector valve
12
5) H-L selector valve
i) Install spring (14), ball (15), and plug (13)
to spool (12).
Free height of spring: 23.5 mm
15
14
13
DDW00766
2 Outside circumference of H-L selector spool: Oil (EO10-CD)
6) Directional selector valve

Install F return spring (9) and sleeve (10) of
directional valve to valve body (8), then install valve spool (11).
Free height of spring: 42 mm
2 Outside circumference of directional selector valve spool:
Oil (EO10-CD)
9
10
11
8
DDW00765
30-94
w
U42103
3 H-L selector spool plug (13):

9.8 12.8 Nm {1.0 1.3 kgm}
2 H-L selector spool plug (13):
ii) Install spool (12) of H-L valve to valve
body.
12
7) Lower L cover
Install gasket (7) to valve body, and set lower
L cover (5) in position, then tighten with
mounting bolts (6).
6
5
7
3 Lower L cover mounting bolt:

31.4 2.9 Nm {3.2 0.3 kgm}
DDW00764
8) Solenoid valve, pilot filter

i) Install pilot filter to lower valve.
U42103
1
3 Filter mounting bolt:
68.6 4.9 Nm {7.0 0.5 kgm}
ii) Install O-ring to lower valve, then install
parking brake solenoid valve (4).
iii) Install O-ring to lower valve, then install
H-L selector solenoid valve (2) and range
selector solenoid valve (3).
Lower valve
DDW00763
iv) Install O-ring to lower valve, then install

directional selector solenoid valve (1).
Check that the O-ring is fitted securely.
Assemble the part of parking brake
solenoid valve (4) with the OUT
stamp.
3 Solenoid valve (1) (4):
1.7 1 Nm {0.17 0.1 kgm}
Solenoid valve
Solenoid valve
Solenoid valve
Lower valve
Pilot filter
DEW00762
30-95
w
2. Assembly of upper valve assembly

1) Quick return valve
i) Assemble orifice plug (27), spring (28),
ball (29), and valve (30) to quick return
valve, then install valve plug (26).
Free height of spring (28): 40 mm
3 Quick return valve plug (26):
34.3 4.9 Nm {3.5 0.5 kgm}
ii) Install quick return valve (25) to valve
body, then install quick return spring (24).
Free height of spring (24): 31.5 mm
27
26
25 24
P 21 22
23
28
29
30
P
DDW00761
2 Outside circumference of quick

return valve spool:
Oil (EO10-CD)
iii) Install gasket (23), and set upper cover
(21) in position, then tighten with mounting bolts (22).
U42103
3 Upper R cover mounting bolt:

31.4 2.9 Nm {3.2 0.3 kgm}
2) Torque converter outlet valve

Install torque converter outlet valve (20),
torque converter outlet spring (19), and
dummy spool (18) to valve body.
18
19
2 Outside circumference of valve spool,

dummy spool: Oil (EO10-CD)
20
DDW00760
3) Main relief valve

i) Install main valve spring (17).
ii) Install valves (14) and (15), and spring
(16) to main relief valve (13), then install
main relief valve (13) to valve body.
13 14
16
15
17
DDW00759
30-96
w

2 Outside circumference of valves (14),
(15): Oil (EO10-CD)
2 Outside circumference of main relief
4) Pilot valve
Install pilot valve (11) and pilot spring (12)
to valve body (10).
Free height of spring (12): 74.2 mm
12
11
10
U42103
2 Outside circumference of pilot valve

spool: Oil (EO10-CD)
DDW00758
5) Upper L cover
Install gasket (9), and set upper L cover (8)
in position, then tighten with mounting bolts
(7) together with connector bracket (6).
3 Upper L cover mounting bolt:
31.4 2.9 Nm {3.2 0.3 kgm}
7
6
8
9
DDW00757
6) Manual valve
i) Install plug (5) to valve body.
ii) Assemble manual valve spool (3), and
install O-ring (4), then secure lock plate
(1) with mounting bolt (2).
2 Outside circumference of manual
3 Plug (4):
39.2 4.9 Nm {4.0 0.5 kgm}
3 Lock plate mounting bolt:
53.9 19.6 Nm {5.5 2.0 kgm}
4
1
DEW00746
2
DDW00747
30-97
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3. Assembly of modulation, accumulator valve

(WA450-3S only)
1) Install plug (20), fill spring (19), O-ring (18),
sleeve (17), fill valve (16), and O-ring (15) to
valve body, and tighten modulation valve
cover (13) with mounting bolts (14).
Free length of spring (19): 29 mm
15
14
13
20
19
2) Install spring (12), stopper (11), inner spring

(10), outer spring (9), accumulator valve (8),
and O-ring (7) to valve body, and tighten
accumulator cover (5) with mounting bolts
(6).
Free length of spring: 100 mm (9)
66 mm (10)
22 mm (12)
3 Cover mounting bolt at accumulator end:
31.4 2.9 Nm {3.2 0.3 kgm}
18
17
12 11
16
DDW00745
10
9
5
DDW00744
4. Assembly of modulation, accumulator, upper,

lower valve
1) Install gasket (4), then install upper valve
assembly with mounting bolts (3) (marked
with ).
2) Install gasket (2), and tighten modulation,
accumulator valve with mounting bolts (1)
(marked with ). (WA450-3S)
3 Mounting bolt:
49.0 4.9 Nm {5.0 0.5 kgm}
3 Modulation, accumulator valve
mounting bolt:
49.9 4.9 Nm {5.0 0.5 kgm}
30-98
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Modulation,
accumulator valve
Upper valve assembly

Lower valve assembly
DDW00743
U42103
2 Outside circumference of fill valve

spools (16), (17): Oil (EO10-CD)
3 Fill valve cover mounting bolt:
31.4 2.9 Nm {3.2 0.3 kgm}
DISASSEMBLY OF
TRANSMISSION
ACCUMULATOR VALVE
ASSEMBLY
2nd
1st
FORWARD
1. Remove mounting bolts (2) of cover (1) from

accumulator valve assembly, then remove cover
and O-ring (3).
1) Remove accumulator valves (5) from FORWARD, 1st, and 2nd ports in accumulator
body (4).
2) Remove accumulator spring (6) and stopper
(7) from FORWARD port.
3) Remove accumulator spring (8), stopper (9),
and spacer (10) from 1st port.
4) Remove accumulator spring (11), stopper
(12), and spacer (13) from 2nd port.
Accumulator valve
DEW00801
assembly
2
5
7
FORWARD 1st
DEW00802
2nd
1
3
12
9
U42103
8
10
11
13
DEW00803
30-99
30-99
ASSEMBLY OF
TRANSMISSION
ACCUMULATOR VALVE
ASSEMBLY
1. Install bottom cover (1) and O-ring (3) to accumulator body (4), and tighten with mounting
bolts (2).
3 Mounting bolt:
34.3 4.9 Nm {3.5 0.5 kgm}
1) Install accumulator spring (11), stopper (12),
and spacer (13) to 2nd port.
FORWARD 1st
2nd
5
2) Install accumulator spring (8), stopper (9),
and spacer (10) to 1st port.
12
9
4
8
10
11
13
1
1st
DEW00803
2nd
FORWARD
4) Install accumulator valves (5) to each port.

2 Outside circumference of accumulator valve: Oil (EO10-CD)
Accumulator valve
DEW00801
assembly
3. Install top cover (1) and O-ring (3) to accumulator body (4), and tighten with mounting bolts
(2).
3 Cover mounting bolt:
34.3 4.9 Nm {3.5 0.5 kgm}
30-100
w
DEW00802
U42103
3) Install accumulator spring (6) and stopper

(7) to FORWARD port.
Free height of accumulator spring:
158 mm (2nd)
145 mm (1st)
185 mm (FORWARD)
Length of accumulator stopper:
125 mm (2nd)
105 mm (1st)
136 mm (FORWARD)
Thickness of accumulator spacer:
10 mm (2nd)
30 mm (1st)
DRIVE SHAFT
DISASSEMBLY OF DRIVE
SHAFT ASSEMBLY
a
1) Remove coupling and tube (1).
Make match marks a to prevent the coupling from being installed in the opposite direction.
DEW00809
Cover (11) is caulked at 4 places with a

punch, so do not remove it unless necessary.
When removing cover (11), be careful
not to damage cover (11) or tube (1).
When removing the caulking, use a
screwdriver to raise the caulked portion.
U42103
Caulking
11
DEW00810
Caulking
Washer
11
Seal
DEW00811
2) Loosen bolt (2), and remove coupling (3) and

retainer.
Make match marks to prevent the coupling from being installed in the opposite direction.
3) Using press, pull out flange bearing (4).
3
2
DDW00812
30-101
w
DRIVE SHAFT
2. Center drive shaft, rear drive shaft

Carry out the same operation as in Step 1)
for the front drive shaft.
When removing the rear drive shaft, push it
in towards the transmission.
DEW00813
2) Remove strap (8) of spider (7), and pull out

bearing cap (10).
Use the same procedure for the front,
center, and rear drive shafts.
10
DEW00814
30-102
w
U42103
3. Spider, bearing
1) Remove bolts (6) of spider and bearing assembly (5), and tap with plastic hammer to
remove.
DRIVE SHAFT
ASSEMBLY OF DRIVE SHAFT

1. Spider, bearing
1) Insert bearing cap (10) in mount of spider
(7).
If the spider and bearing cap is worn,
replace the spider and bearing as a set.
When welding strap (8) of the cap, be
careful not to damage the bearing with
the heat.
Assemble so that the grease nipples are
facing in the same direction.
Use the same procedure for the front,
center, and rear drive shafts.
10
DEW00814
2) Set spider and bearing assembly (5) to drive

shaft mount, and lock with bolt (6).
3 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
2 Bearing cap: Grease (G2-LI)
U42103
DEW00813

1) Press fit flange bearing (4).
Do not knock the flange bearing in directly with a hammer.
DEW00817
2) Align match marks, and tighten coupling (3)

and retainer (9) with mounting bolt (2).
Tighten the bolt to the specified tightening torque after installing to the machine.
2 Spline portion: Grease (G2-LI)
3 Mounting bolt: 926.7 98.1 Nm
{94.5 10.0 kgm}
9
3
DEW00818
30-103
w
DRIVE SHAFT
3) Align match marks, and install coupling and

tube (1).
Check that the couplings are facing in
the same direction.
If the spline is worn, replace the whole
drive shaft assembly.
2 Spline portion: Grease (G2-LI)
DEW00819
Caulking
11
DEW00810
Caulking
Washer
11
Seal
DEW00811
3. Center, rear drive shaft

Carry out the same operation as in Step 3)
for the front drive shaft.
30-104
w
U42103
If cover (11) has been removed, carry

out the operation in the following order.
i) Insert seal and washer in cover (11) and
tube (1), assemble cover (11), then caulk
with a punch at points on diametrically
opposite sides.
FRONT AXLE
REMOVAL OF FRONT AXLE

ASSEMBLY
Stop

Release the remaining pressure inside piping.

DEW00822
DEW00823
Jack up the axle, and set block 1 under the

front frame.
U42103
1. Tire, wheel
Sling left and right tires and wheels (1) of front
axle, then remove mounting nuts and lift off.
1
4 Tire, wheel: 683 kg (26.5-25 tire)
2. Draining oil
1) Loosen oil filler cap (2-1) slowly to release
2) Loosen mounting bolts (2-3) of tube (2-2) to
bleed air inside the cooling oil tank and set
so that oil inside cooling oil tank does not
flow out.
3) Remove drain plug (2-4) and drain oil from
case.
6 Brake chamber: 18 (both sides)
3. Drive shaft
Disconnect front drive shaft (2) from front axle.
2
4 Front drive shaft: 40 kg
Make match marks on the drive shaft and
the coupling.
2
DEW00824
30-105
w
FRONT AXLE
4. Brake piping
1) Remove cover of plate at front of front frame,
disconnect front brake piping and tube (3)
between brake valve and slack adjuster at
slack adjuster end.
2) Remove tubes (4) and (5) between slack adjuster and left and right wheel cylinders.
After disconnecting the piping, fit plugs
4
DEW00825
U42103
5. Front brake cooling piping

1) Disconnect brake cooling tubes (5-1) and (52) at axle end.
2) Remove tubes (5-3), (5-4).
6. Front axle
1) Sling one end of front axle housing and fit a
jack under other end.
2) Fit jack under differential case.
3) Remove mounting bolts (7), then use hoist
and jack to maintain balance and lift off.
3
Be careful not to let slack adjuster on
top of axle housing hit frame.
4 Front axle: 1455 kg

DEW00826
4) Pull out front axle from chassis.
30-106
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FRONT AXLE
INSTALLATION OF FRONT
AXLE ASSEMBLY

removal.
1
3 Tire mounting nut:
470.7 49.0 Nm {48.0 5.0 kgm}
Remove the block from under the front
frame.
2
Clean the connections and mating surface
of the drive shaft.
112.8 9.8 Nm {11.5 1.0 kgm}
U42103
3
3 Front axle mounting bolt:
1618.1 166.7 Nm {165.0 17.0 kgm}

1) Tighten drain plug (2-4).
2) Tighten bolt (2-3) and secure tube (2-2) to
cooling oil tank.
4) Add hydraulic oil through the oil filler of the
hydraulic tank to the specified level.
2. Testing, adjusting brake
1) Bleed air from brake line and adjust brake.
For details, see TESTING AND ADJUSTING.
2) After completing all of the operations, check
for any leakage of brake oil.
3. Bleeding air from brake cooling oil line
Bleed air from brake cooling oil line.
Bleeding air from brake cooling oil line.
30-107
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REAR AXLE
REMOVAL OF REAR AXLE

ASSEMBLY
Stop

Release the remaining pressure inside piping.

Garage jack
DEW00827
DEW00828
Jack up the axle, and set block 1 under the rear

frame.
1. Tire, wheel
Sling left and right tires and wheels (1) of rear
axle, then remove mounting nuts and lift off.
1
DEW00829
2. Draining oil
flow out.

case.
30-108
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U42103
REAR AXLE
3. Drive shaft
Disconnect rear drive shaft (2) from rear axle.
2
DEW00830
U42103
4. Brake piping
1) Disconnect rear brake piping and hoses (3)
slack adjuster end.
Always remove the brake tubes before
removing the axle. There is danger that
they may be crushed when the axle is
lifted off.
5. Rear brake cooling piping
1) Disconnect rear brake hose (5-1) at axle end.
2) Remove tubes (5-2) and (5-3).
6. Grease tubes
Disconnect grease tubes (6) and (7) from rear
axle support.
7
DEW00849
30-109
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REAR AXLE
7. Rear axle, support

1) Secure axle support and rear axle with chain.
2) Sling rear axle housing with nylon lifting
tool, and remove both left and right mounting bolts (8).
3
Chain
4 Rear axle, support: 1600 kg
(Front
support)
Rear axle
DEW00851
13 (Rear
support)
8. Rear support
1) Sling rear support of rear axle and support
assembly, and remove thrust cap (9). 5
9
11
2) Remove thrust washer (10), thrust plate (11),

and thrust washer (12) from rear axle. 6
3) Lift off rear support.
4 Rear support: 148 kg

4) Remove packing (14) and bushing (15) from
rear support.
8
9. Front support
1) Remove retainer (18) of front support, then
remove O-ring and packing.
9
2) Remove packing (16) and bushing (17) from
front support.
:
30-110
w
18
17 16
14 15 12
10
DEW00831
U42103
3) Pull out rear axle and support together from

chassis, then lower.
4
Maintain the balance of the axle when
lowering it.
Remove the axle after removing the fuel
tank.
For details, see REMOVAL OF FUEL
TANK.
REAR AXLE
INSTALLATION OF REAR AXLE

ASSEMBLY

removal.
1
470.7 49 Nm {48.0 5.0 kgm}
Remove the block from under the rear frame.
2
of the drive shaft.
112.8 9.8 Nm {11.5 1.0 kgm}
U42103
3
3 Axle support mounting bolt:
1029.7 98.7 Nm {105.0 10.0 kgm}
After installing the rear axle, install the fuel
tank.
For details, see INSTALLATION OF FUEL
TANK.
4
Secure the rear axle and the axle support
(rear support) with a chain.
Be careful not to damage the packing with
the rear axle coupling.
2 Rear axle front mount: Grease (G2-LI)
5
3 Thrust cap mounting bolt:
279.5 29.4 Nm {28.5 3.0 kgm}
3 Thrust cap mounting bolt:
6
2 Thrust washer: Grease (G2-LI)
3 Thrust plate mounting bolt:
279.5 29.4 Nm {28.5 3.0 kgm}
2 Thrust plate mounting bolt:
30-111
w
8:
Set so that the chamfered side of the bushing is on the axle housing side, and assemble so that the clearance is clearance b.
Clearance b: Min. 0.5 mm
Pay attention to the direction of the packing,
fit it securely in the groove, and assemble
so that the lip is not turned over.
Install the bushing and packing to the front
support in the same way as for the rear
support.
Clearance c: Min. 0.5 mm
Packing
Clearance b
Chamfered side
Bushing
DEW00832
Clearance c
Bushing
Packing
14
DEW00833
9
Use new parts for the O-rings and packing.
2 Retainer mounting bolt:
Bleed the air from the brake system and carry

out an actuation check.
Bleeding air.
Add hydraulic oil through the oil filler of the
30-112
w
18
O-ring
Packing
DEW00834
U42103
7
Check that the slit in the bushing is facing
the side.
2 Rear axle mount: Grease (G2-LI)
REAR AXLE
Refilling with oil

cooling oil tank.
U42103
REAR AXLE

Testing, adjusting brake

Bleeding air from brake cooling oil line

30-113
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FRONT DIFFERENTIAL
REMOVAL OF FRONT
DIFFERENTIAL ASSEMBLY
Stop



front frame.
Loosen oil filler cap (1-1) slowly to release pressure inside cooling oil tank.
Loosen mounting bolts (1-3) of tube (1-2) and
set so that the oil inside the cooling oil tank
does not flow out.
1. Tires, wheels
Sling left and right tires and wheels (1) of front
axle, then remove mounting nuts, and lift off.
1
DEW00823
DEW00822
2. Drive shaft
1) Disconnect front drive shaft (2) from front
axle.
2
2-1
4 Front drive shaft: 40 kg

Make match marks on the drive shaft
and coupling.
2) Remove flange bearing (2-1), and move front
drive shaft towards right side.
2
DEW00837
DEW00838
3. Draining oil
1) Set plugs (2-2), (3-1) immediately at bottom,
then remove them and drain oil.
6 Axle oil: 57
3-1
30-114
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3
DEW00839
U42103
FRONT DIFFERENTIAL
g
il
case.

4. Cover
Remove cover (3), then remove O-ring (4).3
DEW00840
5. Axle shaft
Using forcing screws (Thread dia.=12mm,
Pitch=1.75mm), pull out axle shaft (5) approx.
200 mm together with sun gear (6).
U42103
6
DEW00841
6. Slack adjuster
1) Remove following hydraulic piping clamps.
Clamps for tube (7) between slack adjuster and axle.
Remove both the left and right
clamps.
Clamp for tube (8) between slack adjuster
and brake chamber.
2) Remove mounting bolts of slack adjuster
bracket (9), and insert block between slack
adjuster and axle.
When removing the differential, set the
bracket at a height where there is no
interference.
7. Front brake cooling piping
Remove front brake tube (9-1).
After disconnecting the piping, fit plugs to
DEW00843
30-115
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FRONT DIFFERENTIAL
8. Differential
1) Remove 2 mounting bolts of differential (10),
and install guide bolts (Thread Dia.=14mm,
Pitch=2mm, Length=50mm).
Screw in the thread of the guide bolts
fully.
First, screw in the guide bolts, then remove the remaining mounting bolts.
2) Fit lifting tool 2 to differential case (11).
10
11
DEW00844
4 Differential: 235 kg
11
B
12
C
10
DEW00845
DEW00846
6) Operate jack, and pull differential out from

chassis, then remove O-ring (13).
5
13
DEW00847
30-116
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U42103
3) Install forcing screws, and pull differential

(10) along guide bolt to pull it out approx.
20 mm from axle housing.
4
Be careful not to damage the O-ring of
the differential.
4) Install tools B and C to jack, and insert between differential and axle housing, then install differential (10) to tool B.
5) Adjust height of lifting tool and jack, and
remove differential (10) slowly.
FRONT DIFFERENTIAL
INSTALLATION OF FRONT

removal.
2-1
1
470.7 49 Nm {48.0 5.0 kgm}
2
U42103
2
Fit flange bearing (2-1) temporarily.
Connect front drive shaft (2) to the differential and the center drive shaft ends.
Tighten flange bearing (2-1) fully.
When connecting the drive shaft, clean
the mating surface of the spider and the
coupling, then install.
3 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
3 Flange bearing mounting bolt:
549.2 58.8 Nm {56.0 6.0 kgm}
DEW00838
DEW00837
3
4
Adjust the lifting tool and the height of the

jack for the differential, and assemble the
differential along the guide bolt.
Fit the O-ring securely in the groove, and
be careful that it does not get caught
when installing.
When the clearance between axle housing
(12) and differential (10) is approx. 20 mm,
remove installation tool B and tighten the
mounting bolts uniformly.
2 Differential mounting bolt:
176.5 19.6 Nm {18.0 2.0 kgm}
11
B
12
C
10
DEW00845
DEW00846
5
30-117
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FRONT DIFFERENTIAL
Refilling with oil

1) Tighten the drain plugs (2-2) and (3-1) and
add oil through the level plug to the specified level.
Set the machine with the drain plug immediately at the bottom, then add oil
through the level plug.
5
Axle oil: 57
3-1
3
DEW00839

cooling oil tank.
U42103




30-118
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REAR DIFFERENTIAL
REMOVAL OF REAR
Stop


U42103
Garage jack
Jack up the axle, and set block 1 under the rear

frame.
Loosen mounting bolts (1-3) of tube (1-2) to bleed

air inside the cooling oil tank and set so that oil
inside cooling oil tank does not flow out.
Remove drain plug (1-4) and drain oil from case.
DEW00827
DEW00828
1. Tires, wheels
Sling left and right tires and wheels (1) of rear
axle, then remove mounting nuts, and lift off.
1
DEW00829
2. Drive shaft
Disconnect rear drive shaft (2) from rear axle.
2
DEW02361
30-119
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REAR DIFFERENTIAL
3. Brake piping
1) Disconnect rear brake piping and hose (3)
slack adjuster end.
Always remove the brake tubes before
removing the axle. There is danger that
they may be crushed when the axle is
lifted off.
4. Rear brake cooling piping

1) Disconnect rear brake hoses (5-1) at axle end.
U42103
2) Remove tubes (5-2) and (5-3).

5. Grease tubes
Disconnect grease tubes (6) and (7) from rear
axle support.
7
DEW00849
6. Rear axle support

1) Secure axle support and rear axle with chain.
2) Sling rear axle housing with nylon lifting
tool, and remove both left and right mounting bolts (8).
3
4 Rear axle, support: 1600kg
3) Pull out rear axle and support together from
chassis, then lower.
4
Maintain the balance of the axle when
lowering it.
Remove the axle after removing the fuel
tank.
For details, see REMOVAL OF FUEL
TANK.
30-120
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Chain
DEW00851
REAR DIFFERENTIAL
7. Draining oil
Set plugs (9-1) and (9-2) immediately at bottom,
then remove them and drain oil.
6 Axle oil: 57
9-1
9
DEW00859
8. Cover
Remove cover (9), then remove O-ring (10).
5
U42103
10
DEW00860
9. Axle shaft
Pitch=1.75mm), pull out axle shaft (11) and sun
gear (12) approx. 200 mm.
6
13
14
11
12
10. Slack adjuster

Remove cover (13) from axle, then remove slack
adjuster (14) together with bracket.
DEW00861
DEW00862
11. Rear differential

Using forcing screws, lift off rear differential (15),
then remove O-ring from rear differential. 7
15
4 Rear differential: 244 kg
DEW00863
30-121
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REAR DIFFERENTIAL
INSTALLATION OF REAR

removal.
1
470.7 49 Nm {48.0 5.0 kgm}
Remove the block from under the rear frame.
2
of the drive shaft.
112.8 9.8 Nm {11.5 1.0 kgm}
After installing the rear axle, install the fuel

tank.
For details of the installation of the fuel tank,
see INSTALLATION OF FUEL TANK.
4
When installing the rear axle to the chassis,
be extremely careful not to damage the bushing and packing of the front support with
the differential coupling.
Secure the rear axle and the support (rear
end) with a chain, then install to the chassis.
2 Rear axle front support portion:
Grease (G2-LI)
5
6
When inserting axle shaft (11), rotate the
differential coupling lightly by hand to install.
Do not push it in by force.
30-122
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U42103
3
3 Axle support mounting bolt:
1029.7 98.1 Nm {105.0 10 kgm}
REAR DIFFERENTIAL
7
Fit the O-ring securely in the groove, and be
careful that it does not get caught when installing.
176.5 19.6 Nm {18.0 2.0 kgm}
Refilling with oil

1) Tighten the drain plugs (9-1) and (9-2) and
add oil through the level plug to the specified level.
5
9-1
9
DEW00859
Axle oil: 57
U42103

cooling oil tank.



30-123
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DIFFERENTIAL
DISASSEMBLY OF
1. Differential gear
1) Remove ring gear adjustment bolt.
2) Loosen adjustment ring lock bolt, and remove lock plate (2).
Rotate the adjustment ring, and separate the differential gear from the pinion
gear.
3) Remove bearing cap (2).
Check the match marks on the left and
right bearing caps. Make new match
marks if the old match marks cannot be
seen.
4) Remove adjustment ring (3) and bearing cup
(4).
DEW00864
DEW00865
5) Remove differential gear (5) from differential case.

The pilot bearing will hit the carrier, so
tip it over slightly to the right when lifting it off.
5
4 Differential gear assembly: 75 kg
DEW00866
2. Plain half
1) Remove bearing (6).
2) Remove plain half (7).
Check the match marks. Make new match
marks if the old match marks cannot be
seen.
DEW00867
30-124
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U42103
3) Remove side gear (8), cross shaft (9), thrust

washer (10), and pinion gear (11).
DIFFERENTIAL
11
10
DEW00868
U42103
9
11
3. Ring gear, flange half

2) Remove mounting bolts, then remove ring
gear (13) and flange half (14).
10
DEW00869
12
4. Turning over
Turn over differential gear.
14
13
DEW00870
5. Pinion gear
1) Loosen mounting bolts of coupling (15).
Leave the coupling temporarily fitted.
15
DEW00871
30-125
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2) Remove pinion gear (17) from differential

case (16).
Check the shim thickness and use as a
guide when assembling.
DIFFERENTIAL
17
16
DEW00872
6. Pinion shaft
1) Using press, pull out pinion shaft (18).
18
DEW00873
2) Remove bearing cups (20) and (21) from cage

(19).
21
20
19
DEW00874
3) Remove pilot bearing (22) and bearing (23)

from pinion shaft (18).
Do not remove pilot bearing (22) and
bearing (23) unless necessary.
Use the same procedure to disassemble
the front differential.
18
22
30-126
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23
DEW00875
U42103
19
DIFFERENTIAL
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
Block
When replacing the pinion or ring gear, always

replace them as a set, and be careful not to mix
them with other sets.
Replace the flange half and plain half also as a
set.
22
23
18
18
1. Pinion shaft
1) Press fit pilot bearing (22) to pinion shaft
(18).
DEW00877
DEW00876
2) Press fit bearing (23) to pinion shaft (18).

Press-fitting force for bearing (23), pilot
bearing (22): 49 kN {5 ton}
25
U42103
3) Press fit bearing cups (20) and (21) to cage

(19).
Press-fitting force for bearing cup: 49 kN
(5 ton)
2 Inside diameter of cage, outside diameter of cup: Axle oil
4) Assemble cage (19) to pinion shaft (18), then
assemble spacer (25).
19
20
21
There should be
no clearance.
DEW00878
19
18
DEW00879
2. Adjusting preload
1) Press fit bearing (24) to pinion shaft (18).
2) Push bearing with press, and measure rotating force of cage with a spring balance.
2 Bearing portion: Axle oil
Coat the bearing portion fully with oil,
and settle it before measuring.
Press force: 202 kN {20.6 ton}
Reading of spring balance:
Max. 14.7 N {1.5 kg}
24
18
DEW00880
DEW00881
30-127
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DIFFERENTIAL
3) If the measured value is not within the standard value, replace bearings (23) and (24) and
spacer (25) with new parts, then adjust again.
4) If the measured value is within the standard
value, check that the end play of cage is also
within the standard value.
End play: Max. 0.212 mm
24
25
23
DDW00882
Make
surfaces flush
27A
Make surfaces flush
10 0.5
27A
10 0.5
27
26
26
27
Front
Rear
DEW00883
2) Install O-rings (26A) and (15A), then install

cage (26) and coupling (15).
3 Coupling mounting bolt:
926.7 103 Nm {94.5 10.5 kgm}
15
15A
26
27A
26A
27
DDW00884
3) Assemble pinion gear assembly (17) to differential case (16) without installing shims.
3 Cage mounting bolt:
176.5 19.6 Nm {18.0 2.0 kgm}
17
16
DDW00885
30-128
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U42103
3. Pinion gear
1) Press fit oil seal (27) and dust seal (27A) to
cage (26).
Use new parts for the oil seal and dust
seal, and be careful to install facing in
the correct direction.
2 Lip of oil seal, lip of dust seal:
Grease (G2-LI)
2 Press-fitting portion of oil seal,
dust seal: Thread tightener (LT-2)
DIFFERENTIAL
4) Install tool D to differential case (16).

5) Measure distance L from tool D to pinion
gear, and calculate shim thickness.
When replacing the bearing, pinion gear,
and ring gear, use the above procedure
to adjust the shim.
Shim thickness:
Standard value (L thickness of tool)
Standard value: (243 + a) (115 + b)
Depth micrometer
D Thickness of tool
Dimensions a and
b stamped here
DEW00887
17
16
U42103
DEW00886
6) Assemble pinion gear (17) and shim to differential case (16), and tighten mounting
bolts.
2 Mounting bolt:
3 Mounting bolt:
176.5 19.6 Nm {18.0 2 kgm}
4. Ring gear
1) Knock pin (27) into flange half (14) so that it
protrudes distance a from case.
a = 3.5 mm
2) Press fit bearing (12) to flange half (14).
3) Install flange half (14) to ring gear (13).
2 Mounting bolt:
3 Mounting bolt:
279.5 29.4 Nm {28.5 3.0 kgm}
DEW00872
27
14
12
14
DEW00889
14
DEW00890
13
DEW00891
30-129
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DIFFERENTIAL
5. Side gear
Install washer (28), and assemble side gear (8).
Insert the washer securely to the pin inside
the case.
2 Washer: Grease (G2-LI) (both faces)
28
8
DEW00892
27
10
11
DEW00893
2) Install washer (28), and assemble side gear

(8).
Insert the washer securely to the pin inside the case.
2 Washer: Grease (G2-LI) (both faces)
28
DEW00895
DEW00896
3) Press fit bearing (6) to plain half (7).

4) Install plain half (7).
Insert cross shaft (9) securely in the
groove of the case and plain half.
Check match marks, then set in position
and install.
2 Mounting bolt:
3 Mounting bolt:
176.5 19.6 Nm {18.0 2 kgm}
7
6
7
DEW00897
30-130
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DEW00898
U42103
6. Pinion gear
Assemble pinion gear (11) and thrust washer
(10) to cross shaft (9).
Align the stopper position of the thrust
washer when assembling.
2 Thrust washer (gear contact surface):
Axle oil
7. Plain half
1) Knock pin (27) into plain half (7) so that it
protrudes distance a from plain half.
a = 3.5 mm
DIFFERENTIAL
8. Differential gear
1) Raise gear (5), and assemble bearing cup (4)
to bearing, then install to case.
5
4
DEW00899
2) Align with thread of differential case (16),

and install adjustment ring (3).
U42103
3) Align match mark and install bearing cap

(2).
Be careful not to damage the thread of
the cap.
3
16
DEW00900
9. Adjusting preload of bearing

1) Turn adjustment ring with a bar until ring
gear contacts pinion gear, and adjust until
there is no more backlash.
Rotate the bearing sufficiently to give
complete contact between the bearing
and other contact parts, then tap the ring
gear with a copper hammer.
Coat the bearing well with oil.
If the adjustment ring on one side is loosened one turn, tighten the adjustment
ring on the other side by one turn.
DEW00901
2) Install spring balance to ring gear, and measure free rotation torque.
Free rotation torque:
19.6 24.5 N {2.0 2.5 kg}
Target value: 24.5 N {2.5 kg}
DEW00902
30-131
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DIFFERENTIAL
10. Adjusting tooth contact, backlash

Adjust the backlash as follows.
1) Adjust the ring gear with the adjustment ring.
When doing this, turn the adjustment
rings on both sides by the same amount
in the same direction.
DEW00903
Adjust the tooth contact as follows.

1) Mix red lead (minium)with oil, then coat the
tooth face of 7 or 8 teeth of the ring gear.
2) Rotate the pinion gear forward and in reverse and check the tooth contact.
Use the following procedure to judge the
tooth contact and carry out adjustment.
30-132
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U42103
2) Put a dial gauge in contact with tooth face

of outside edge of ring gear, then turn adjustment ring to adjust.
Keep the pinion gear fixed in position
and measure at 3 or 4 places.
Backlash: 0.30 0.41 mm
DIFFERENTIAL
11. Adjusting tooth contact

Coat face of 7 or 8 teeth of bevel gear lightly with red lead (minimum). Hold the bevel gear by hand
to act as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the
teeth.
Tooth contact
DEW00910
Cause
Procedure for adjustment
The tooth contact pattern

should start from about
5 mm from the toe of
the bevel gear and cover
about 50% of the length
of the tooth. It should
be in the center of
the tooth height.
Adjust the pinion gear by adjusting the shims at

the cage. Adjust the bevel gear in the same way as
when adjusting backlash.
Bevel pinion gear is too

far from bevel gear.
1. Reduce shims at pinion

gear to bring closer
to bevel gear.
2. Move bevel gear further
away from pinion
gear and adjust
backlash correctly.
1
DEW00908
U42103
DEW00904
Bevel pinion gear is too

close to bevel gear.
1. Increase shims at pinion

gear to move away
from bevel gear.
2. Move bevel gear closer
to pinion gear and adjust
backlash correctly.
1
DEW00909
DEW00905
Bevel gear is too close to

pinion gear.
1. Reduce shims at pinion gear

to bring closer to bevel gear.
2. Move bevel gear further
away from pinion
gear and adjust
backlash correctly.
1
DEW00908
DEW00906
Bevel gear is too far from 1. Increase shims at pinion

pinion gear.
gear to move away
from bevel gear.
2. Move bevel gear closer
to pinion gear and
adjust backlash correctly.
1
DEW00907
DEW00909
When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between
the left and right. Always keep the same total thickness of shims.
30-133
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12. Lock plate

After completing the adjustment of the tooth
contact, wipe off the red lead and install lock
plate (1).
3 Mounting bolt:
176.5 19.6 Nm {18.0 2 kgm}
DIFFERENTIAL
DEW00864
13. Adjusting bolt

After carrying out all adjustments, screw in bolt
(29) until it contacts rear face of the ring gear,
then turn back 1/2 turns and tighten locknut (30).
2 Adjustment bolt: Gasket sealant (LG-5)
29
30
DDW00913
30-134
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U42103
3 Locknut: 225.6 19.6 Nm {23.0 2.0 kgm}
FINAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
Stop



front frame.
U42103
Garage jack
1. Tire, wheel
Jack up axle, and insert support stand under
axle, then lift off tire and wheel (1).
After removing the tire and wheel, set the
support stand under the axle housing portion.
4
DEW00827
DEW00828
Tire, wheel: 683 kg (26.5-25 tire)
2. Draining oil
Set plug (2) immediately at bottom, then remove it and drain oil.
DEW00823
6 Axle oil: 57
DEW00917
3. Cover
3
DEW00918
DEW00919
30-135
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FINAL DRIVE
4. Axle shaft
Pitch=1.75mm), pull out axle shaft (5) approx.
200 mm.
5. Planetary carrier
Remove 3 mounting bolts, and lift off planetary
carrier (6).
Make match marks to use as a guide when
assembling.
Be careful of the center of gravity, and remove slowly.
DEW00920
DEW00921
4 Planetary carrier: 86 kg
DEW00922
2) Remove mounting bolts of retainer (10), then

remove ring gear (11).
shims between the retainer and axle
housing, and keep in a safe place.
10
4 Ring gear: 35 kg
11
DEW00923
7. Disassembly of planetary carrier

1) Using press, pull out shaft (12), and remove pinion gear (13).
Lock ball (14) is inserted in the shaft,
so be careful not to lose the ball.
Write the number on the case and distinguish the parts to prevent the removed parts from being mixed with
other parts.
12
13
14
DEW00924
30-136
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U42103
6. Ring gear
1) Using tools E and F, secure wheel hub (8)
and brake (9) in position.
Install tools E and F at three equally
spaced places, then use a washer to adjust the clearance.
2) Remove bearing (17) from pinion gear (13).

The bearings are settled in sets, so distinguish them to prevent them from being mixed with other sets.
FINAL DRIVE
17
13
DEW00925
8. Disassembly of ring gear

1) Remove lock plate (21) from ring gear hub
(20), then remove ring gear (22).
20
21
U42103
22
DEW00926
2) Using forcing screws (Thread dia.=12mm,

Pitch=1.75mm, Length=70mm), remove bearing (23) from ring gear hub (20).
20
23
DEW00927
30-137
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FINAL DRIVE
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
1. Assembly of ring gear
1) Press fit bearing (23) to ring gear hub (20).
After press fitting, check that there is no
clearance from the rib.
20
23
DEW00928
2) Set ring gear hub (20) to ring gear (22), and

install lock plate (21).
Assemble the lock plates with the wide
lock plates on the inside.
Remove all oil and grease from the tap
holes for the bolts.
2 Mounting bolt:
3 Mounting bolt:
31.4 3 Nm {3.2 0.3 kgm}
21
22
DEW00929
2. Assembly of planetary carrier

1) Assemble bearing (17) to pinion gear (13),
and insert from bottom of carrier, then use
lifting bar 1 to set to carrier mount.
There are 3 pinion gears. Assemble them
all to the carrier.
13
17
17
DEW00930
DEW00931
2) Align carrier and gear hole, then press fit

cooled shaft (12).
Do not touch the cooled shaft directly by
12
hand.
Press fit so that the lock ball hole is on
the outside. Stop just before the hole
and align the hole.
Cool the shaft at 30C for 20 minutes.
14
DEW00932
30-138
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DEW00933
U42103
20
3) Assemble lock ball (14) to shaft, and press

fit shaft again.
After press fitting the shaft, check that
the gear rotates smoothly.
FINAL DRIVE
7
14
17
13
12
DEW00934
3. Ring gear
1) Raise ring gear (11), and insert in axle housing.
Align the spline groove and insert slowly.
U42103
11
DEW00935
2) Tighten retainer (10) temporarily with 3

mounting bolts, and remove tools E and F.
Remove all oil and grease from the retainer mounting bolt holes.
Tighten the retainer temporarily without
fitting any shim.
Rotate wheel hub (8) to settle the bearing, and tighten so that the torque is
constant.
72.6 1 Nm {7.5 0.1 kgm}
E
9
DEW00922
3) Use depth micrometer from measurement

hole of retainer (10) to measure clearance a
between end face of retainer and end face
of housing.
Measure at two places and take the average.
Shim thickness = Clearance a + 0.3 mm.
Select the shim thicknesses to give

the minimum number of shims.
Shim thickness: 1.0 mm, 0.5 mm, 0.2

mm, 0.05 mm
11
10
a
DEW00937
10
DEW00938
30-139
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G
DEW00939
Assemble O-ring to wheel hub (8), then raise
planetary carrier (6), and install.
Align the mounting holes and install slowly
so that the O-ring does not come out of
position.
DEW00940
5. Axle shaft
Install axle shaft (5).
If the sun gear is not aligned, rotate the
wheel hub to align the position.
DEW00920
6. Cover
Insert O-ring (4) in groove of cover, and install
cover (3).
3 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
4
DEW00942
30-140
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U42103
4) Install tool G to brake and wheel hub (8),

then remove retainer, install selected shim,
and install retainer again.
When assembling the shim, always install tool G first.
Rotate wheel hub (8) and tighten uniformly until the torque is the specified
torque.
2 Mounting bolt:
3 Mounting bolt:
176.5 19.6 Nm {18.0 2.0 kgm}
FINAL DRIVE
FINAL DRIVE
7. Tire, wheel
Install tire and wheel (1), then remove support.
3 Mounting nut:
470.7 49 Nm {48.0 5.0 kgm}
(Width across flats: 30 mm)

Tighten drain plug and add oil through level
plug (24) to specified level.
Set the machine with the drain plug immediately at the bottom, then add oil through
the level plug.
U42103
24
Axle oil: 57 (both front and rear)
DEW00944
30-141
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CENTER HINGE PIN
REMOVAL OF CENTER HINGE

PIN
Stop


Loosen mounting bolts (1-3) of tube (1-2) and

does not flow out.
tank from flowing.
U42103
Operate

accumulator.
Depress

2
DEW00494
1. Covers
2. Ladders
Ladder rail (left): 59.5 kg
30-142
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CENTER HINGE PIN
3. Electric wiring
Disconnect the following electric wiring.
1) Disconnect front frame wiring FR1 (4) and
FR2 (5).
2) Disconnect transmission wiring TL1 (6) and
TL2 (7).
LR6 (9), LR3 (10), LR4 (11), LR1 (12), and LR2
(13).
DEW00949
12
10
13
12
13
11
11
10
9
8
DEW02353
U42103
4. PPC piping
1) Disconnect hoses (14), (15), (16), (17), and
(18) between PPC valve and main control at
connection inside front frame.
DEW00950
14
15
16
17
18
DEW00951

hose (21) of port P4, hose (22) of port
P3, and hose (23) of port P1 at valve
end.
Disconnect hose (24) between PPC accumulator and PPC valve at valve end.
Disconnect hose (25) of PPC valve drain
port at valve end.
After disconnecting the hoses, mark
After disconnecting the hoses, fit
plugs to prevent the entry of dirt or
dust.
25
22
25
21
24
20
22
20
21
DEW00952
23
DEW00953
30-143
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CENTER HINGE PIN
5. Brake piping
Remove 2 brake hose clamps under floor
board.
28
27
26
37
DEW00954
Remove clamp
26 27
30
31
DEW00956
DEW00957
4) Disconnect hose (32) between front brake

and right brake valve at center hinge pin.
6. Brake cooling piping
Disconnect brake cooling hoses (32-1) from front
frame end.
After disconnecting the piping, fit plugs to
7. Accelerator cable
1
Disconnect accelerator cable (37) under pedal.
board.
8. Steering valve piping
Disconnect following pipings from steering valve.
1) Hose (37-1) between steering valve (L port)
and stop valve (L.H.)
2) Hose (37-2) between steering valve (R port)
and stop valve (R.H.)
3) Hose (37-3) between steering valve (P port)
and accumulator charge valve
4) Hose (37-4) between steering valve (T port)
and drain line
30-144
w
37-4
37-1
37-3 37-2
DNW03847
U42103
3) Disconnect right brake valve drain hose (30)

and left brake valve drain hose (31) at rear
frame.
DNW03853
CENTER HINGE PIN
9. Floor board
1) Remove mounting cover (39) of floor board
(38), then remove 4 viscous damper mounting nuts (40) holding floor board.
40
39
38
DEW00963
DEW00962
2) Fit lifting tool to floor board (41) and lift off

floor board.
2
Raise the cab slowly and check that all
parts have been removed before lifting
off.
U42103
4 Floor assembly: 213 kg
10. Steering cylinder pins

1) Remove left and right steering cylinder pins
(42) at rod end.
42
DEW00965
11. Stop valve

3
1) Disconnect hose (43) between steering valve
and stop valve (R.H.), and hose (43-1) between stop valve (R.H.) and steering valve at
stop valve side.
2) Disconnect hose (43-2) between steering
valve and stop valve (L.H.), and hose (43-3)
between stop valve (L.H.) and steering valve
at stop valve side.
3) Remove stop valve (left and right side) (434) and stop bolt (left and right side) (43-5).
4) Remove fitting bracket (43-6) for hose between steering valve and stop valve at frame
side.
43-2
43-3
43-1
43
43-6
43-4
43-5
DNW03848
30-145
w
12. PPC hoses

Remove PPC hoses, bracket (44), and clamps
(45) and (46) at center pin, and move towards
rear frame.
CENTER HINGE PIN
44
45
46
DEW00967
U42103
13. Hydraulic hoses

4
and cooler.
2) Disconnect hose (48) between hydraulic
pump and main control valve.
3) Disconnect main control valve drain hose
(49).
4) Disconnect hose (50) between switch pump
and steering valve and hose (51) between
steering pump and steering valve.
5) Remove hose mount bracket.
53
54
14. Drive shaft
5
Remove drive shaft guard (53), disconnect center
drive shaft (54) at flange bearing end, then move
drive shaft to side.
4 Center drive shaft: 36 kg
DEW00969
15. Supporting frame

1) Jack up rear frame to adjust height, then
insert blocks.
Insert blocks under the rear frame on
the left and right sides.
Rear frame
Blocks
30-146
w
DEW00970
CENTER HINGE PIN
2) Jack up front frame to adjust height , then

insert blocks. Put rollers between block and
frame so that front frame can be pulled out.
Insert blocks under the front frame on
the left and right sides.
Front frame
Roller
Blocks
DEW00971
16. Lower hinge pin

6
Remove lock bolt, then remove lower hinge pin
(55).
U42103
55
DEW00972
17. Upper hinge pin

7
1) Remove mounting bolts, then remove retainer (56).
shims between the retainer and frame,
and keep in a safe place.
2) Remove lock bolt (57-1), then adjust height
and remove upper hinge pin (57).
Adjust the height carefully and make it
possible to remove the pin by hand.
57
56
DEW00973
57-1
DEW00974
3) Remove spacer (58).
58
DEW00975
30-147
w
18. Disconnection of frame

8
Pull out front frame towards front slowly, and
disconnect frame.
Be careful that the spacer at the bottom of
the upper hinge does not catch in the rear
frame.
Be careful of the balance when disconnecting.
Be careful not to forget to disconnect any
part.
Remove the safety bar.
CENTER HINGE PIN
Front frame
Rear frame
DEW00976
59
DEW00977
2) Remove retainer (60).

60
DEW00978
3) Remove dust seal (61) from retainer.

Remove the dust seal at the frame end
also.
61
DEW00979
30-148
w
U42103
19. Lower hinge

9
1) Pull out bushing (59) from rear frame.
Remove the lower hinge bushings at
both the top and bottom.
CENTER HINGE PIN
62
DEW00980
20. Upper hinge pin

0
1) Remove mounting bolts, then remove retainer (63).
U42103
63
DEW00981
2) Remove dust seal (64) from retainer.

64
DEW00982
30-149
w
CENTER HINGE PIN
3) Remove spacer (65) and dust seal (66) from

front frame.
65
66
65
DDW00984

67
DDW00985
30-150
w
U42103
DEW00983
CENTER HINGE PIN
INSTALLATION OF CENTER
HINGE PIN

removal.
1
3 Cable locknut:
53.9 4.9 Nm {5.5 0.5 kgm}
2
Align securely with the notch hole of the
viscous damper washer, then tighten.
3
Install stop bolt (left and right) at the position
shown in the right figure.
For bolt adjustment procedure, see the related portion of TESTING AND ADJUSTING section.
100
37
100
100
5
Align the match marks exactly.
112.8 9.8 Nm {11.5 1.0 kgm}
37
U42103
4
100
DMW03786
6
2 Outside circumference of lower hinge
pin: Grease (G2- LI)
7
Upper hinge
1) Insert upper hinge pin (57), and assemble
spacer (58).
2 Outside circumference of hinge pin:
Grease (G2-LI)
58
58
57
DDW00987
DEW00988
30-151
w
CENTER HINGE PIN
2) Install retainer (56) to upper hinge pin,

tighten with 3 bolts, then select shims so
that clearance a between hinge and retainer
is below 0.2 mm, and assemble.
When adjusting the shims, tighten retainer mounting bolts temporarily to prevent from turning.
Tighten the retainer mounting bolts to
the specified torque, then tighten the pin
mounting bolts.
3 Pin mounting bolt:
205.9 19.6 Nm {21.0 2.0 kgm}
(when adjusting shims)
3 Pin mounting bolt:
205.9 19.6 Nm {21.0 2.0 kgm}
107.9 9.8 Nm {11.0 1.0 kgm}
8
Connection of frame
56
DEW00989
56
57
Always
Align the pin holes exactly.

DDW00990
9
Lower hinge
1) Using tools H, I, K1, K2, and K3, press fit
bearing (62) and spacer (69) to front frame.
When press fitting, use tool K3 as a
guide.
Be careful not to fit the bearing at an
angle.
Fill the inside of the bearing with grease.
When assembling the bearing, be careful not to forget to assemble the spacer.
The bearing clearance is adjusted, so do
not change the combination with the
spacer.
When replacing, always replace as a set.
2) Press fit dust seal (61) to retainer(60).
Press fit so that the dust seal lip surface
is facing the outside.
2 Lip of oil seal: Grease (G2-LI)
K2
62
69
K3
K1
K4
I
Block
DEW00991
60
61
DEW00992
30-152
w
U42103
use a bar when aligning the pin

holes. Never insert your fingers.
CENTER HINGE PIN
Feeler gauge
DEW00993
3) Tighten retainer (60) with 3 mounting bolts,

select shims so that maximum clearance a
between retainer and hinge is less than 0.1
mm, then assemble.
3 Mounting bolt:
19.6 2 Nm {2.0 0.2 kgm}
3 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
Clearance
U42103
60
4) Press fit dust seal (70) to frame.

5) Bushing
Press fit bushing (59) to lower hinge of rear
frame with press.
DDW00994
Rear frame
70
59
Hydraulic
cylinder
DEW00995
DEW00996
30-153
w
0
Upper hinge
1) Assemble tools H, I, J, K2, K3, and K4 to top
of front frame upper hinge. Set bearing (67)
in tool K1, then set to press-fitting portion
from above and press fit.
When press fitting, use tool K3 as a
guide.
Be careful not to fit the bearing at an
angle.
Fill the inside of the bearing with grease.
When assembling the bearing, be careful not to forget to assemble spacer (68).
The bearing clearance is adjusted, so do
not change the combination with spacer
(68).
When replacing, always replace as a set.
CENTER HINGE PIN
K4
K1
K3
K2
DEW00997
64
I
K4
K3
67
67
K2
From
H
68
63
Front
frame
Block
DEW00998
DEW01000
67
DEW00999
2) Press fit dust seal (64) to retainer (63).

Press fit so that the dust seal lip surface is facing the outside.
63
64
DEW01001
30-154
w
U42103
K1
CENTER HINGE PIN
3) Tighten retainer (63) with 3 mounting bolts,

select shims so that maximum clearance a
between retainer and hinge is less than 0.1
mm, then assemble.
3 Mounting bolt:
19.6 2 Nm {2.0 0.2 kgm}
3 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
63
Feeler gauge
DEW01002
63
Clearance
U42103
DDW01003
4) Assemble dust seal (66) and spacer (65) from

under front frame.
Assemble from below so that the large
chamfered side of spacer (65) is on the
bearing side.
66
65
DEW01004
Refilling with oil

11.8 1 Nm {1.2 0.1 kgm}
2
DEW00494
30-155
w
CENTER HINGE PIN

cooling oil tank.
U42103



Bleed air from hydraulic line

30-156
w
STEERING VALVE
REMOVAL OF STEERING
VALVE ASSEMBLY (ORBIT
ROLL)
Park
the wheel loader on level ground, install

safety bar on frame. Lower the fork on the
ground, stop the engine, apply the parking brake
and put blocks under the tires.
After the engine is stopped, operate the steering wheel two to three times leftward and
rigthtward, and make the steering valve neutral.
1. Cover
Remove cover (1) on the lower portion of floor.
U42103
2. Steering valve
1) Remove cover (2) on the steering column.
2) Loosen the bolts and remove column joint
(3) from the steering shaft.
1
Mark the match mark on the joint and
the steering valve.
3. Piping
Disconnect following pipings from the steering
valve.
(L port) and stop valve (L.H.) at the steering
valve side, and remove nipple (5).
(R port) and stop valve (R.H.) at the steering
valve side, and remove nipple (5).
(P port) and accumulator charge valve at the
steering valve side, and remove nipple (5).
(T port) and drain line, and remove nipple
(9).
DMW03788
9
8
4
4. Steering valve
Remove mount bolts of bracket (10) and remove
it with steering valve (11).
2
5 5
DNW03789
4 Steering valve: 8 kg
10
11
DNW03790
30-157
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STEERING VALVE
INSTALLATION OF STEERING
VALVE ASSEMBLY (ORBIT
ROLL)

removal.
1
3 Column connecting bolt:
55.9 7.9 Nm {5.7 0.8 kgm}
2
3 Steering valve mounting bolt:
52.0 6.9 Nm {5.3 0.7 kgm}
3 Bracket mounting bolt:
88.3 34.3 Nm {9.0 3.5 kgm}
Align the spline of steering column side with
the spline of steering valve side.
Adding oil (hydraulic tank)
Add oil to the specified oil level through oil filler,
start the engine and circulate oil through the
piping. Check oil level again.
U42103
30-158
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STEERING VALVE
DISASSEMBLY OF STEERING
VALVE
Use a wire brush to remove all the dirt and dust
stuck to the joint around the outside circumference of the unit.
Carry out the operation in a clean place to prevent dirt or dust from sticking to the valve.
As far as possible, hold the valve in a vice when
disassembling.
DISASSEMBLY OF ROTOR
1. Set rotor side facing up, and hold mounting
flange lightly in vice 1.
Put a copper plate in contact with the vice and
be careful not to tighten the vice too hard.
U42103
DLW01700
2. Remove screw (1), then remove end cap (2).

3. Remove O-ring (3) from end cap (2).
1
2
3
DLW01701
4. Pull out rotor set (4), then remove O-ring (5).

Be careful not to drop the star inside the
rotor set.
5. Remove spacer (6).
4
6
DLW01702
30-159
w
STEERING VALVE
6. Remove drive shaft (7).
10
7. Remove spacer plate (8).
8. Remove O-ring (9) from housing (10).
8
7
9
DLW01703
DISASSEMBLY OF CONTROL SIDE

9. Remove housing (10) from vice, and place on a
clean cloth. Be careful not to damage the finished surface.
11
10. Raise tip of snap ring (11) with screwdriver, and

remove from housing.
DLW01704
11. Turn spool and sleeve to place pin in a horizontal position, then push in spool and sleeve with
your thumb, and remove bushing (12) from housing.
12
DLW01705
12. Remove X-ring seal (13) from bushing (12).

13. Remove dust seal (14) from bushing (12) with
screwdriver.
Be careful not to damage the bushing.
13
12
14
DLW01706
30-160
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U42103
10
STEERING VALVE
14. Remove 2 bearing races (15) and thrust needle

(16) from spool and sleeve.
15
16
15
DLW01707
15. Pull out spool and sleeve assembly (17) from

housing (10) in the direction of the arrow.
To prevent the spool and sleeve assembly
from catching in the housing, rotate the spool
and sleeve assembly slowly to the left and
right when pulling out from the housing.
10
17
16. Pull out pin (18) from spool and sleeve assembly (17).
U42103
18
DLW01708
17. Push spool (20) inside sleeve (19) slightly to

front, and remove 6 centering springs (21) from
spool (20) carefully by hand.
18. Turn spool (20) slowly and pull out from rear of
sleeve (19) (in the direction of the arrow).
19
21
20
19
20
DLW01709
19. Remove O-ring (22) from housing.

20. Remove set screw (23) from housing.
22
21. Screw a threaded bar into check sheet (24), and

pull out check sheet (24).
22. Remove O-rings (25) and (26) from check sheet
(24).
25
23
23. Tap housing, and remove ball (27) and retainer

(28).
24
28
26
27
DLW01710
30-161
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STEERING VALVE
ASSEMBLY OF STEERING
VALVE
Check all parts for damage or burrs.
Wash all metal parts in clean solvent and blow
dry with air.
Do not use a file or polish any part with rough
sandpaper.
Coat the O-rings with clean grease. (No need to
put grease on new X-ring seals)
Coat the O-ring for the rotor set with a small
amount of grease.
ASSEMBLY OF CONTROL SIDE

1. Insert retainer (28) in housing with tweezers.
Check that the retainer is not inserted at an
angle.
23
25
24
2. Insert ball (27).
26
28
DLW01711
4. Install set screw (23).

Check that the set screw is set in slightly
from the end face of the housing.
9 Set screw : 11.8 Nm {1.2 kgm}
8 Set screw : adhesive (LT-2)
5. Assemble spool (20) and sleeve (19) so that

spring groove is on same side.
Rotate the spool and slide it in.
Grip the splined portion of the spool lightly
and check that the spool rotates smoothly
inside the sleeve.
If there are match marks, check that the
match marks are aligned.
Spring slot
19
Spring slot
Identification mark
20
DLW01712
30-162
w
U42103
27
3. Fit O-rings (26) and (25) in check sheet (24), and

push check sheet (24) into housing.
Be careful to set the top and bottom of the
check sheet facing in the correct direction.
STEERING VALVE
6. Align spring groove positions of spool (20) and

sleeve (19), and set on flat plate, then insert
spring (21) in spring groove.
Set so that the notches at both ends are at
the bottom.
20
21
19
DLW01713
7. Insert pin (18) in spool and sleeve assembly

(17).
17
U42103
18
DLW01714
8. Insert spool and sleeve assembly (17) in housing (10) in the direction of the arrow.
1) Keep pin horizontal and rotate to left and
right a little at a time to insert.
Be extremely careful not to get it caught.
2) Make the spool and sleeve assembly flush
with the rear end face of the housing.
If it is inserted beyond the end face, the pin
will fall out.
3) Check that spool and sleeve rotate smoothly
inside housing.
17
10
DLW01715
9. Install O-ring (22) to housing (10).

10. Fit 2 bearing races (15) and thrust needle (16) in
case (10).
16
15
15
22
10
DLW01716
30-163
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STEERING VALVE
11. Insert dust seal (14) in bushing (12).

11
12. Insert X-ring seal (13) in bushing (12).

13. Insert bushing (12) in spool, and rotate to install.
Tap with a plastic hammer to assemble to
the specified position.
It must be in contact horizontally with the
bearing race.
14
12
10
DLW01717
14. Fit snap ring (11) in housing.

Screwdriver
14
11
12
13
DLW01718
ASSEMBLY OF ROTOR
15. Hold flange of housing lightly in vice.
Be careful not to tighten the vice too hard.
Check that the spool and sleeve are set in
slightly from the housing surface with fourteen holes.
DLW01719
16. Insert O-ring (9) in housing.

17. Put on spacer plate (8), and align positions of
bolt hole and tap hole of housing.
DLW01720
30-164
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U42103
22
STEERING VALVE
18. Turn spool and sleeve assembly to make pin

(18) and port surface of housing parallel, then
mesh pin and yoke of drive shaft (7).
To position accurately, draw a line on the
end face of the drive shaft spline.
Port surface
7
Make pin and
port surface parallel
18
DLW01721
19. Insert O-ring (5) in rotor set (4).
U42103
5
DLW01722
20. Make O-ring (5) end of rotor set to spacer plate

end, then align insert portion of star of rotor (4)
with drive.
1) Check that lines A,B,C, and D are all parallel.
2) Without removing joint of drive (7), position
bolt holes of rotor set.
This procedure is very important for determining the valve timing of unit.
Inset portion of star of rotor set A

B
7 (Make line)
Pin
Port surface
21. Insert spacer (6) inside rotor set.
DLW01723
1
2
22. Set end cap (2) on rotor set, and align bolt hole.
DLW01724
30-165
w
23. Coat thread of screw with grease, and tighten

end cap.
Install the handle to the spool, and check
that the spool rotates.
9 End cap mounting screw
First step : 14.7 Nm {1.5 kgm}
Second step :
27.0 1.5 Nm {2.75 0.15 kgm}
STEERING VALVE
6
1
7
5
U42103
DLW01725
30-166
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STEERING VALVE
REMOVAL OF STEERING
VALVE ASSEMBLY
Stop


tank from flowing out.
U42103
1. Covers
Remove covers (3) under floor.
2. Hydraulic piping
1
Disconnect following tubes and hoses at steering valve end.
1) Disconnect hose (4) between stop valve (R.H.)
and steering valve at steering valve side.
2) Disconnect hose (4-1) between stop valve
(L.H.) and steering valve at steering valve
side.
and steering valve port (P1).
and steering valve port (P2).
5) Disconnect hose (7) from steering valve port
(PB) to cut-off valve.
6) Disconnect tube (8) at steering valve port
(A) and tube (9) at port (B).
7) Disconnect steering valve drain port tube
(10).
After disconnecting the tubes and hoses,
fit plugs to prevent the entry of dirt or
dust.
DEW00494
7 6
5
4
4-1
10 12
11
DNW03791
3. Steering valve
Sling steering valve (11), then remove mounting bolt (12), and lift off steering valve.
4 Steering valve: 24 kg
Carry out the removal operation with two
people.
The steering valve has oil on it so be careful

not to let it slip.
30-167
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STEERING VALVE
VALVE ASSEMBLY

removal.
1
When installing the tube, remove the clamp
to prevent any force from being brought to
bear on the tube.
Refilling with oil
U42103
Tighten the plug at the top of the hydraulic tank

filter, and add hydraulic oil through the oil filler
11.8 1 Nm {1.2 0.1 kgm}
30-168
w
DISASSEMBLY OF STEERING
DEMAND VALVE
1
1. Remove safety valve assembly (1).

The set pressure of the safety valve is fixed,
so do not disassemble it.
DKW03808
2. Remove main relief valve assembly (2).

The set pressure of the main relief valve is
fixed, so do not disassemble it.
U42103
DKW03809
3. Removal of demand spool

1) Remove plug (3).
3
DKW03810
2) Remove spring (4).

4
DKW03811
30-169
w
3) Remove demand spool (5).

Remove slowly, taking care not to damage the spool.
If shims are fitted, check the number and
thickness of the shims, and keep in a
safe place.
5
DKW03812
6
DKW03813
4. Removal of steering spool

1) Remove 2 bolts (7).
Remove on the opposite side in the same
way.
7
DKW03814
2) Remove case (8) and spring (9).

way.
9
8
DKW03815
30-170
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U42103
4) Remove plug (6).
3) Remove spring seat (10).

Remove slowly, taking care not to damage the spool.
way.
10
DKW03816
13
U42103
4) Remove steering spool assembly (13).

Remove slowly, and be careful not to
bend or damage the spool assembly.
To prevent it from falling into the valve
body, remove the poppets at both ends.
DKW03817
5. Disassembly of steering spool assembly

1) Remove cap screw (14).
The cap screw is coated with adhesive
(Loctite #271), so use an industrial dryer,
and heat (200 250C) before removing.
2) Remove spring (15) and poppet (16).
way.
14
15
16
DKW03818
DKW03819
DKW03820
30-171
w
6. Disassembly of check valve

1) Remove plug (17).
20
17
DKW03821
2) Remove spring (18) and poppet (19).

18
DKW03822
7. Remove plug (20).
20
DKW03823
30-172
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U42103
19
ASSEMBLY OF STEERING
DEMAND VALVE
1. Fit O-ring to plug (20) and install to valve body.
3 Plug: 93.2 4.9 Nm {9.5 0.5 kgm}
20
DKW03823
2. Assembly of check valve

1) Install poppet (19) and spring (18).
18
U42103
19
DKW03822
2) Fit O-ring (17) and install to valve body.

3 Plug: 63.7 4.9 Nm {6.5 0.5 kgm}
20
17
DKW03821
3. Assembly of steering spool

1) Install poppet (16) and spring (15) to spool.
2) Fit O-ring to cap screw (14) and install to
spool.
2 Spool thread: Adhesive (Loctite #271)
3 Cap screw:
8.8 1.0 Nm {0.9 0.1 kgm}
14
15
16
DKW03819
DKW03818
30-173
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4. Installation of demand spool

1) Fit O-ring to plug (6) and install to valve
body.
3 Plug: 137.3 2.0 Nm {14.0 0.2 kgm}
6
DKW03824
5
DKW03825
3) Install spring (4).
4
DKW03826
4) Fit O-ring and backup ring to plug (3), and

install to valve body.
3 Plug: 137.3 2.0 Nm {14.0 0.2 kgm}
3
DKW03827
30-174
w
U42103
2) Install demand spool (5) to valve body.

If shims were fitted, assemble shims.
Install slowly, taking care not to damage
the spool.
5. Installation of steering spool assembly

1) Install steering spool assembly (13) to valve
body.
Be careful to install portion A of the spool
facing in to the correct direction.
13
A
DKW03828
2) Install spring seat (10).

3) Install spring (9).
Install on the opposite side in the same
way.
U42103
10
DKW03829
4) Fit O-ring to case (8) and install to valve

body.
5) Tighten bolt (7).
3 Bolt: 41.2 2.0 Nm {4.2 0.2 kgm}
Install on the opposite side in the same
way.
DKW03830
2
DKW03831
6. Install main relief valve assembly (2) to valve

body.
3 Main relief valve assembly:
73.5 4.9 Nm {7.5 0.5 kgm}
DKW03809
30-175
w
7. Install safety valve assembly (1) to valve body.

3 Safety valve assembly:
73.5 4.9 Nm {7.5 0.5 kgm}
U42103
DKW03808
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REMOVAL OF STEERING,
SWITCH PUMP ASSEMBLY
Stop


For details, see REMOVAL OF RADIATOR ASSEMBLY
Operate

accumulator.
U42103
Depress

2
DEW00494
1. Covers
2. Ladders
Ladder rail (left): 59.5 kg
30-177
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Remove brake hose clamps at two points
under floor board.
3) Disconnect accelerator cable (7) under pedal.
1
board.
7
DEW01071
DNW03792
Remove clamp
U42103
5) Disconnect hose (10) of radiator sub-tank (9).

Remove the hoses from the hose clamps.
DEW01073

Disconnect hoses (11) and (12) at brake cooling
oil tank end.
Loosen the mounting bolts of tube (13) to
so that the oil inside the cooling oil tank
does not flow out.
5. Bulkhead
1) Remove cover (16) at bottom front face of
bulkhead (15).
2) Remove top mounting bolts (18) holding
bulkhead (15) and hood (17).
Be careful not to lose the rubber and
washers of the mounting portion.
17
18
16
15
15
DEW01076
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DEW01077

4 Bulkhead: 135 kg
(including accumulator, charge valve)
Remove clamp
17
19
U42103
7. Pump
3
Remove mounting bolts (24) of steering and
switch pump assembly (23), then remove pump
assembly.
400 mm

400 mm.
To prevent the bulkhead from falling after it is raised, place blocks on the left
and right at opposite ends.
6. Pump piping
2
1) Disconnect suction tube (20) between hydraulic tank and steering pump at pump end.
and steering valve at pump end.
and steering valve at pump end.
After disconnecting the tubes, fit plugs
Eyebolt

DEW00470
DEW01078
23
24
20
22
21
DEW01080
4 Steering, switch pump assembly: 20 kg
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INSTALLATION OF STEERING,
SWITCH PUMP ASSEMBLY

removal.
Refilling with oil

Tighten drain plugs (1) and (2) at the top of the
11.8 1 Nm {1.2 0.1 kgm}
Add hydraulic oil through the oil filler of the

brake cooling oil tank to the specified level.
Bleeding air
1) Bleed air from brake line and brake cooling
line.
OUT OPERATION.
30-180
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U42103
1
3 Accelerator cable mounting nut:
53.9 4.9 Nm {5.5 0.5 kgm}
23
STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER ASSEMBLY
Stop


1. Hydraulic piping
Disconnect steering cylinder rod and bottom
hoses (1) and (2) at cylinder end.
After removing the hoses, fit plugs to prevent the entry of dirt or dust.
U42103
DEW01081
1
1) Remove rod bolt, then remove pin (3).
DEW01082
2) Disconnect bottom grease tube (4).

3) Remove bottom bolt, then remove pin (5).
Check the shim thickness and use as a
guide when assembling.
4) Remove steering cylinder (6).
Carry out the removal operation with two
people.
Be careful not to scratch the cylinder rod.
6
5
4 Steering cylinder: 38 kg
DEW01083
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STEERING CYLINDER
CYLINDER ASSEMBLY

removal.
Always
use a bar when aligning the pin holes.

Never insert your fingers.
DEW01084
U42103
Adjust the shims so that clearance a is the standard value.

Clearance a = Max. 0.5 mm
Remove all grease and oil from the cylinder pin,
and wipe off the grease that is pushed out.
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BRAKE VALVE
REMOVAL OF BRAKE VALVE

ASSEMBLY
Stop

Loosen
the oil filler cap slowly to release the

the steering wheel and control levers several
times to release the remaining pressure in the
hydraulic piping.
Release the pressure inside the accumulator by

depressing the brake pedal slowly and repeatedly (at least 17 times) until there is no more
reaction when the brake pedal is depressed.
4
9
6
U42103
1. Covers
Remove covers (1) under floor.
2. Piping (right brake valve)
1) Disconnect hoses (2) and (3) between accumulator and brake valve, and adapters (4) and (5) at valve end.
1
2) Disconnect brake valve drain hose and
tube (6) at valve end.
3) Disconnect hose (7) going to left brake
valve at valve end.
4) Disconnect tube (8) which goes to front
brake and tube (9) going to rear brake at
valve end.
2
3. Piping (left brake valve)
1) Disconnect tube (10) and hose from accumulator to left brake valve at brake valve
end.
3
2) Disconnect left and right brake valve hoses
and elbow (11) at brake valve end.
4
3) Remove brake valve drain tube (12) and hose
at valve end.
After disconnecting the piping, make
marks and fit plugs to prevent the entry
of dirt or dust.
4. Wiring
Disconnect connector of brake valve switch sensor (13).
13
19
19
12
DNW03793
13
11
10
DNW03794
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5. Pedals
Pull out cotter pin (26) from pin (15) of brake
pedal (14), then pull out pin, and remove pedal.
Carry out the same operation for both the
left and right brake pedals.
6. Brake valve
Remove brake valve mounting bolts (17), and
disconnect mount flange (18) and body (19), then
pull out cap (20).
BRAKE VALVE
18
19
14
15
16
20
DEW01088
17
DEW01089
INSTALLATION OF BRAKE
VALVE ASSEMBLY
removal.
1234
After completing the assembly, bleed the air
from the brake line.
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U42103
RIGHT BRAKE VALVE
DISASSEMBLY OF RIGHT
BRAKE VALVE ASSEMBLY
(TANDEM)
104
52
U42103
2. Valve
1) Install valve to jig 1 with bolts (5), and secure jig in vice.
Make match marks before disassembling
the valve.
2) Remove valve mounting bolts (10), then remove S cylinder assembly (7).
3) Remove plug (13) of S cylinder assembly,
then remove spring (14) and O-ring.
4) Remove spring (11) and O-ring (12), then
remove P cylinder assembly (8).
Remove spring (15) inside the plunger
of the P cylinder assembly.
5) Remove holder (16), springs (17), (18), and
(19) and O-ring (20) from T flange assembly
(9).
The cylinders, plungers, and spools inside the T flange assembly and the S
and P cylinders form sets, so be careful
not to mix the parts for any set.
Fit seals to prevent dirt or dust from entering, and be careful not to damage the
cylinders or flange assembly.
51.5
3
5
104
52
25.75
51
25.75
51.5
6
Jig
DEW01090
10
1. Bracket assembly
1) Remove seat (1), pedal stopper (2), and boot
(3) from brake valve.
2) Remove mounting bolts (5) of bracket assembly (4), then remove bracket assembly.
3) Remove oil seal (6) from upper portion of
brake valve.
4-11
DEW01091
Match marks
Jig
9
Vice
DEW01092
14
13
7
13
10
11
12
10
7
8
15
DEW01094
DEW01093
16
17
18
20
17
19
20
DEW01095
DEW01096
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RIGHT BRAKE VALVE
ASSEMBLY OF RIGHT BRAKE

VALVE ASSEMBLY (TANDEM)
2. Bracket assembly
Remove valve from jig 1.
1) Set T flange assembly facing up, and install
oil seal (6).
Use a new part for the oil seal.
2 Lip of oil seal: Lithium grease
2) Install bracket assembly (4), and tighten with
mounting bolts (5).
3Mounting bolt:
58.8 73.6 Nm {6.0 7.5 kgm}
3) Install seat (1), pedal stopper (2), and boot
(3) to valve.
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20
17
16
17
18
19
20
DEW01096
DEW01095
14
13
7
13
10
11
12
10
7
8
15
8
DEW01093
DEW01094
U42103
1. Valve
Install T flange assembly (9) to jig 1 with bolts
(5), and hold jig 1 in vice.
1) Install springs (19), (18), and (17) to T flange
assembly (9) in order, then install holder (16)
on top of spring.
2) Install O-ring (20) to T flange assembly (9).
2 O-ring: Lithium grease
3) Set P cylinder assembly (8) to T flange assembly (9).
When setting in position, align the match
marks.
4) Install spring (11) and spring (15) inside
plunger of P cylinder assembly to P cylinder
assembly (8).
5) Install O-ring (12) to P cylinder assembly (8).
6) Set S cylinder assembly (7) to P cylinder
assembly (8), and tighten with mounting
bolts (10).
When setting the S cylinder assembly in
position, align the match marks.
3 Mounting bolt:
58.8 73.6 Nm {6.0 7.5 kgm}
7) Install spring (14) and O-ring to S cylinder
assembly (7), and tighten with plug (13).
2 Thread of plug: Thread tightener
(Thread lock 1303B)
3 Plug:
152.0 24.5 Nm {15.5 2.5 kgm}
LEFT BRAKE VALVE
DISASSEMBLY OF LEFT BRAKE

VALVE ASSEMBLY (SINGLE)
1
104
4-11
52
1. Bracket assembly
1) Remove seat (1), pedal stopper (2), and boot
(3) from brake valve.
2) Remove mounting bolts (5) of bracket assembly (4), then remove bracket assembly.
51.5
3
5
104
52
25.75
51
25.75
Jig
DEW01090
2. Valve
1) Install valve to jig 1 with bolts (5), and secure jig in vice.
Make match marks before disassembling
the valve.
10
51.5
3) Remove oil seal (6) from upper portion of

brake valve.
DEW01091
7
Match marks
8
Jig
U42103
Vice
DEW01103
2) Remove valve mounting bolts (10), then

remove S cylinder assembly (7).
10
12
11
3) Remove plug (10) of S cylinder assembly,

then remove spring (11) and O-ring (12).
10
7
9
DEW01104
4) Remove holder (13), springs (14) and (15),

and O-ring (16) from S flange assembly (8).
The cylinders, plungers, and spools inside the S flange and the S cylinder form
sets, so be careful not to mix the parts
for any set.
Fit seals to prevent dirt or dust from entering, and be careful not to damage the
cylinders or flange assembly.
DDW01105
13
14
16
14
16
15
DEW01106
DDW01107
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LEFT BRAKE VALVE
ASSEMBLY OF LEFT BRAKE

VALVE ASSEMBLY (TANDEM)
1
1. Valve
Install S flange assembly (8) to jig 1 with bolts
(5), and hold jig 1 in vice.
1) Install springs (14) and (15) to S flange assembly (8), then install holder (13) on top of
spring.
2) Install O-ring (16) to S flange assembly (8).
2
3
5
6
DEW01090
2. Bracket assembly
Remove valve from jig 1.
1) Set S flange assembly facing up, and install
oil seal (6).
Use a new part for the oil seal.
2 Lip of oil seal: Lithium grease
2) Install bracket assembly (4), and tighten with
mounting bolts (5).
3 Mounting bolt:
58.8 73.6 Nm {6.0 7.5 kgm}
3) Install seat (1), pedal stopper (2), and boot
(3) to valve.
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13
14
16
8
16
14
15
DDW01107
DEW01106
12
7
10
11
9
10
7
9
DEW01104
DDW01105
U42103
3) Set S cylinder assembly (7) to S flange assembly (8), and tighten with mounting bolts
(9).
When setting the S cylinder assembly in
position, align the match marks.
3 Mounting bolt:
58.8 73.6 Nm {6.0 7.5 kgm}
4) Install spring (11) and O-ring (12) to S cylinder assembly (7), and tighten with plug (10).
2 Thread of plug: Thread tightener
(Thread lock 1303B)
3 Plug:
152.0 24.5 Nm {15.5 2.5 kgm}
SLACK ADJUSTER
REMOVAL OF SLACK
ADJUSTER ASSEMBLY
Stop

the safety bar on the frame. Lower the bucket to
Loosen
the oil filler cap slowly to release the

the steering wheel and control levers several
times to release the remaining pressure in the
hydraulic piping.
DEW01113
Release the pressure inside the accumulator by

depressing the brake pedal slowly and repeatedly (at least 17 times) until there is no more
reaction when the brake pedal is depressed.
U42103
1. Raise lift arm and set tool L to lift arm cylinder

rod.
When not using tool L, set a stand under the
lift arm.
2. Remove cover (1) at front of front frame.

DEW01114
3. Brake piping
1) Disconnect tube (2) between slack adjuster
and brake valve at adjuster end.
For the rear, remove slack adjuster cover
(4) and disconnect tube (3).
2) Disconnect tubes (5) between slack adjuster
and left and right brake pistons at slack adjuster end.
4. Slack adjuster
Remove mounting bolts, then remove slack adjuster (6).
1
5
DEW01115
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SLACK ADJUSTER
INSTALLATION OF SLACK
ADJUSTER ASSEMBLY

removal.
1
Installation of the slack adjuster
Tighten the mounting bolts temporarily, and
tighten them fully after connecting the piping.
Refilling with oil
Add oil through the oil filler of the hydraulic
tank to the specified level.
Bleeding air from brake system

Bleed the air from the brake line and check that
there is no oil leakage from the connections.
Bleeding air from brake system.
When bleeding the air from the brake line,
bleed the air at the slack adjuster end.
U42103
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SLACK ADJUSTER
DISASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
1
1. Bleeder
Remove bleeder (2) from body (1).
DEW01117
2. Cylinder
Remove mounting bolts, and disconnect body
(1) and cylinder (4) together with bracket (3).
The
U42103
internal parts are under the tension of

the spring, so hold the mating surface down
by hand and remove carefully.
DEW01118
3. Piston
1) Remove spring (5) and O-ring (6).
2) Push out piston (7), and remove O-ring.
When removing the piston, push out
slowly with a 10 mm diameter rod.
Be careful not to damage the thread with
the rod.
6
5
DEW01119
4. Poppet
1) Remove cover (8) from cylinder (4), then remove plug (9), spring (10), and poppet (11).
When removing the poppet, blow in air
from the oil hole in the cylinder.
Hold the cylinder oil port by hand and
be careful not to blow the air in strongly.
2) Remove O-ring (12) from poppet.
DEW01120
12
10
11
DEW01121
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SLACK ADJUSTER
ASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
4
1. Poppet
1) Assemble O-ring (12) to poppet (11).
12
11
2) Assemble poppet (11), spring (10), plug (9),
and cover (8), then assemble to cylinder (4).
8 9
DEW01122
11
DEW01123
4
7
13
DEW01124
DEW01125
3. Cylinder
1) Install O-ring (6) and spring (5) to cylinder.
Installed load of spring: 4.4 kg
2) Install body (1) and cylinder (4) together with
bracket (3).
5
6
4. Bleeder
Install bleeder (2).
DEW01126
2
DEW01128
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3
DEW01127
U42103
2. Piston
1) Install O-ring (13) to piston (7).
2) Insert piston (7) in cylinder (4).
Check that the piston moves smoothly.
10
BRAKE
DISASSEMBLY OF BRAKE
ASSEMBLY
Stop



front frame.
1
U42103
1. Tire, wheel
Jack up axle, and insert stand under axle, then
lift off tire and wheel (1).
After removing the tire and wheel, set a stand
under the axle housing.
DEW00823
DEW01130
2. Draining oil
flow out.
3) Set drain plug (2) immediately at bottom,
then remove plug and drain oil from case.
6 Axle oil: 57

case.
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BRAKE
3. Cover
3
DEW01131
Remove 3 mounting bolts, and lift off planetary
carrier (6).
Make match marks and use as a guide when
assembling.
Be careful of the center of gravity and remove slowly.
4 Planetary carrier: 86 kg
DEW01134
DEW00920
6. Ring gear
1) Using tools T4 and T5, secure wheel hub (8)
and brake (9).
Install tools T4 and T5 at three equally
spaced places, then use a washer to adjust the clearance.
2) Remove mounting bolts of retainer (10), then

remove ring gear (11).
shims between the retainer and the axle
10
4 Ring gear: 35 kg
11
DEW00923
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U42103
4. Axle shaft
Pitch=1.75mm), pull out axle shaft (5).
DEW00840
BRAKE
7. Brake, wheel hub

1) Remove brake tube (12).
2) Remove brake cooling tube (12-1).
3) Sling brake and wheel hub (13), then remove mounting bolts and lift off.
U42103
4 Brake, wheel hub: 195 kg
8. Axle housing
1) Remove bearing (14), retainer (14-1), O-ring
(15), trunnion (16), and O-ring of trunnion
mount portion from axle housing.
4 Trunnion: 54 kg
2) Remove seal ring (14-2) and O-rings (14-3)

and (14-4) from retainer (14-1).
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9. Piston, cylinder
1) Set wheel hub (17) at bottom, and remove
tool T4.
2) Using eyebolts, lift off cylinder assembly (18).
BRAKE
18
4 Cylinder assembly: 63 kg
17
DEW01140
19
4) Using tool T3, pull out pin (20) from cylinder

assembly, and remove rod (21) and piston
return spring (22).
The pin is small, so be careful not to
lose it.
T3
DEW01141
22
21
20
DEW01142
5) Blow in air from brake oil filler (23) to push

out piston (24).
Hold one end of the piston by hand, blow
in air slowly, and be careful not to let
the piston fly out.
Be careful not to damage the piston.
DEW01143
23
DEW01144
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U42103
3) Remove O-ring (19) from cylinder assembly.
BRAKE
6) Remove seals (25) and (26) from piston (24).

24
25
26
DEW01145
U42103
10. Outer gear

1) Remove O-ring (28) from outer gear (27).
2) Remove plates (29) and discs (30) from outer

gear in order, then remove spacer (31).
When removing the discs, make match
marks on the inner gear and disc, outer
gear and plate, and on the spacer.
The plates are made of a soft material,
so remove them extremely carefully and
be careful not to damage them.
3) Using tool T2, lift off outer gear (27) from

wheel hub (35), and remove seal ring (32)
and O-ring (33).
4) Remove oil seal (34) from outer gear (27).
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BRAKE
11. Wheel hub

1) Remove retainer (36) from wheel hub (35).
2) Remove seal ring (37) and O-rings (38) and
(39) from retainer (36).
3) Remove seal ring (40) and O-ring (41) from
wheel hub (35).
U42103
4) Remove bearing cups (42) and (43) from

wheel hub (35).
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BRAKE
ASSEMBLY OF BRAKE
ASSEMBLY
1. Wheel hub
1) Press fit bearing cups (42) and (43) to wheel
hub (35).
2) Install O-ring (41) to seal ring (40), and using
tool T6, install to wheel hub (35).
U42103
3) Assemble O-ring (38) and seal ring (37), then

using tool T1, assemble to retainer (36).
When assembling the O-rings and seal
rings, push with face b of the tool, then
push with face a.
4) After assembling, measure stepped difference t of seal ring at 4 places and check that
difference between measurements is less
than 1 mm.
If the difference in measurements is more
than 1mm, assemble again.
Use alcohol to completely remove the
white powder from the surface of the Oring.
Remove all oil and grease from the Oring contact surface of the seal ring and
retainer.
Be careful not to twist the O-ring when
installing it.
5) Assemble O-ring (39) to retainer (36).
2 O-ring: Grease (G2-LI)
6) Knock pin (44) 1 3 mm into wheel hub (35).
7) Align pin hole of retainer (36) and press fit

to wheel hub (35).
2 Mating surface of wheel hub O-ring
(39): Grease (G2-LI)
Be careful not to damage seal ring (37).
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BRAKE
2. Outer gear
1) Press fit oil seal (34) to outer gear (27).
2 Press-fitting portion of oil seal:
Loctite #648
U42103
2) Install O-ring (33) to seal ring (32), and using

tool T1, install to outer gear (27).
outer gear.
Tighten tool T2 uniformly so that there
is no twisting of the O-ring for the seal
ring. After press fitting, measure height
t at 4 places around the circumference
and check that the difference in the measurements is within 1 mm.
32
33
DEW01159
T1
27
DEW01160
30-200
r
BRAKE
U42103
3) Using tool T2, assemble outer gear (27) to

wheel hub (35).
When assembling, check that there are
no scratches on the seal ring mating surface.
Check that the seal ring is not installed
at an angle.
2 Mating surface of seal ring: Axle oil
4) Align match marks on outer gear (27) and

spacer (31), plates (29), and on discs (30)
and inner gear, then assemble plates and
discs in turn.
Set with the chamfered side of the spacer
facing down.
Check that the final plate is meshed securely with the outer gear spline.
Soak the discs in brake oil for at least 30
minutes before assembling.
Align the match marks on the discs and
inner gear when assembling.
5) Install O-ring (28) to outer gear (27).
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BRAKE
3. Piston, cylinder
1) Install seals (25) and (26) to piston (24).
Fit the seal in the groove securely.
2 Seal: Brake oil
24
25
26
DEW01145
2) Press fit piston (24) to cylinder (41).

When press fitting the piston, tap with a
plastic hammer. Do not use a steel or
copper hammer.
Coat the press-fitting portion of the piston and the outside circumference of the
piston with brake oil.
2 Sliding surface of piston: Brake oil
41
3) Using tool T3, insert piston return spring

(22) and rod (21) in cylinder assembly, and
lock with pin (20).
DEW01166
T3
22
21
20
DEW01142
DEW01143
4) Install O-ring (19) to cylinder assembly.
19
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DEW01141
U42103
24
BRAKE
5) Using eyebolts, install cylinder assembly (18).

3 Mounting bolt:
176.5 19.6 Nm {18.0 2.0 kgm}
18
17
DEW01140
U42103
6) Set wheel hub (8) at bottom, and using tools

T4 and T5, tighten uniformly so that it does
not come out.
4. Axle housing
1) Assemble O-ring (14-3) and seal ring (14-2),
then using tool T6, assemble to retainer (141).
When assembling the O-rings and seal
rings, push with face b of the tool, then
push with face a.
2) After assembling, measure stepped difference t of seal ring at 4 places and check that
difference between measurements is less
than 1 mm.
retainer.
Be careful not to twist the O-ring when
installing it.
3) Assemble O-ring (14-4) to retainer (14-1).
2 O-ring: Grease (G2-LI)
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BRAKE
U42103
4) Press fit retainer (14-1) to trunnion (16).

2 Mating surface of trunnion O-ring
(14-4): Grease (G2-LI)
5) Press fit bearing cup and assemble bearing
(14).
6) Install O-ring (15-2) to trunnion and axle

housing, and tighten with bolts (15-1).
3 Mounting bolt:
34.3 4.9 Nm {3.5 0.5 kgm}
7) Install O-ring (15) to trunnion (16), and fit
bearing (14).
5. Brake, wheel hub

1) Raise brake and wheel hub (13), and set to
axle housing mount, then tighten with
mounting bolts (13-1).
Be careful of the center of gravity and
raise the brake horizontally.
If it is forced in, the O-ring will be twisted
and damaged, so align the center and
install slowly.
2 Mounting bolt:
3 Mounting bolt:
926 103 Nm {94.5 10.5 kgm}
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BRAKE
2) Install brake tube (12).
U42103
3) Assemble brake cooling tubes (12-1).
6. Ring gear
1) Raise ring gear (11) and set in mounting
position, then install to axle housing.
Align the spline groove and install slowly.
2) Tighten retainer (10) with 3 bolts temporarily, and remove tools T4 and T5.
Temporarily tighten the retainer without
inserting shims.
Rotate the wheel hub to settle the bearing and tighten uniformly until the torque
is the specified torque.
73.6 1 Nm {7.5 0.1 kgm}
3) Measure clearance b between end face of
housing and end face of retainer from measurement hole of retainer (10) with depth micrometer.
Measure at two places and take the average.
Shim thickness = Clearance b + 0.3 mm.
Select the shim thickness to give the
minimum number of shims.
Shim thickness: 1.0 mm, 0.5 mm, 0.2
mm, 0.05 mm
10
11
11
DEW01176
DEW01175
11
b
10
DEW01177
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BRAKE
4) Install tools T4 and T5 to brake and wheel

hub, remove retainer, install selected shims,
then install retainer.
When assembling the shim, always install tools T4 and T5 first.
Rotate the wheel hub and tighten uniformly until the torque is the specified
torque.
2 Mounting bolt:
3 Mounting bolt:
176.5 19.6 Nm {18.0 2.0 kgm}
8. Axle shaft
Install axle shaft (5).
Rotate the wheel hub to align the position
when installing the sun gear.
DEW01179
9. Cover
Fit O-ring into groove of cover, and install cover
(3).
3 Mounting bolt:
112.8 9.8 Nm {11.5 1.0 kgm}
4
DEW01181
DEW01180
10. Tire, wheel

Install tire and wheel (1) and remove stand.
3 Mounting nut:
476.7 49.0 Nm {48.0 5.0 kgm}
DEW00823
30-206
w
U42103
Assemble O-ring to wheel hub (8), then raise
planetary carrier (6), set in mounting position,
and install.
Align the mounting holes and install slowly
so that the O-ring does not come out of
position.
BRAKE

1) Tighten drain plug of axle, and add oil
through oil filler (42) to specified level.
5
Axle oil: 57 (both front and rear)
2) Connect hose between hydraulic tank and

brake chamber, and add hydraulic oil through
oil filler of hydraulic tank to specified level.
U42103
42
DEW01182

cooling oil tank.
13. Testing, adjusting brake

14. Bleeding air from brake cooling oil line
30-207
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PARKING BRAKE DISC
REMOVAL OF PARKING BRAKE

DISC
1
Stop

the ground and stop the engine. Then put blocks
under the wheels to prevent the machine from
moving.
Do not apply the parking brake.
1. Loosen drain plug and drain transmission oil.
4
DEW00722
6 Transmission: 60
2. Drive shaft
Remove guard of drive shaft, and disconnect
lower front drive shaft (1) at transmission end.
1
After disconnecting the drive shaft, move it
to the right.
3. Suction tube
1) Remove mounting bolt (3) and washer (4) of
coupling (2) at front of transmission, then
remove coupling.
2
2) Remove suction tube (5) at transmission end.
DEW00723
4. Parking brake
1) Remove lock plates (7) of parking brake
manual release bolts (6), then remove 3 release bolts.
2) Remove parking brake case (8).
3) Screw in 3 manual release bolts (6), and
release parking brake.
Distance to screw in bolt = 28 mm
Screw in all three bolts uniformly.
6
DEW01185
30-208
r
DDW01186
U42103
PARKING BRAKE DISC
4) Set length of bolt of tools M1, M2, and M3

to 1, then tighten with coupling mounting
bolt (3).
Length of bolt of tool 1: 65 mm
M1, M2, M3
3
DEW01187
DDW01188
U42103
5) Remove snap ring (9) from case, then remove tools M1, M2, and M3.
DEW01189
6) Remove end plate (10), plate, disc, and wave

spring from case.
3
Disc
10
DEW01190
Wave spring
DEW01191
30-209
w
PARKING BRAKE DISC
INSTALLATION OF PARKING
BRAKE DISC
Wave spring

removal.
Plate
10
Disc
1
3 Drive shaft:
112.8 9.8 Nm {11.5 1.0 kgm}
3
Insert the plates and discs in the case in order,
and assemble the wave springs between the
plates.
When assembling end plate (10), pay attention to the tool mark (one groove) on the
face.
Tighten the drain plug of the transmission, and
add oil.
5
Transmission: 60
Run the engine to circulate the oil through

the system. Then check the oil level again.
30-210
r
Tool mark
(1 groove)
DDW01192
Coupling
Coat with anti-friction compound
DDW01193
U42103
2
3 Coupling mounting bolt:
921.8 98.1 Nm {94.0 10.0 kgm}
2 End face of coupling:
Anti-friction compound (LM-G)
HYDRAULIC TANK
REMOVAL HYDRAULIC TANK

ASSEMBLY
Stop the machine on level ground and install
U42103
1. Draining oil
1) Remove cover (1) on top of ladder, then remove plugs (1) and (2) at the top of the
hydraulic tank filter, and prevent the oil inside the tank from flowing out.
1
DEW01194
3
DEW01195
2) Remove plug (4) under hydraulic tank, then

loosen valve (5) and drain hydraulic oil.
6 Hydraulic tank: 206
DEW01196
2. Ladder floor
1) Sling right ladder floor (6), then remove
mounting bolts and lift off.
Be careful of the center of gravity of the
ladder floor when lifting off.
4 Ladder floor: 63 kg
DEW01197
30-211
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HYDRAULIC TANK
3. Hydraulic piping
1) Loosen clamp of hose (7) between hydraulic
tank and hydraulic pump and disconnect at
tank end.
2) Disconnect return tube (8) between main
control valve and hydraulic tank at tank end.
2
3) Disconnect tube (9) between steering valve,
hydraulic cooler, and hydraulic tank at tank
end.
3
8
9
DEW01198
4. Hydraulic tank
Sling hydraulic tank (14), then remove mounting bolts and lift off.
Raise the hydraulic tank slightly and lift it off
to the outside of the machine.
13
12
11
10
DEW01199
14
4 Hydraulic tank: 199 kg
DEW01200
30-212
w
U42103
4) Disconnect hose (10) between hydraulic tank

and brake valve at tank end.
and PPC valve at tank end.
and steering valve at tank end.
and PPC relief valve at tank end.
After disconnecting the hoses and tubes,
mark with a tag to distinguish when installing.
After disconnecting the hoses and tubes,
dust.
HYDRAULIC TANK
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY

removal.
1
Hydraulic tank filter plug
3 Plug on top of filter:
11.8 1 Nm {1.2 0.1 kgm}
23
Installation of tubes (8) and (9)
Refilling with oil

Tighten the plug on the top of the hydraulic
tank filter, and add hydraulic oil through the oil
filler to the specified level.
5
U42103
Hydraulic tank: 206
Bleeding air
For details of the bleeding air from the brake
system and the hydraulic line, see TESTING AND
ADJUSTING, PRECAUTIONS WHEN CARRYING
OUT OPERATION.
30-213
w
REMOVAL BRAKE COOLING

OIL TANK
1. Draining oil
Remove cover (1) at right side of bulkhead,
then loosen drain plug (2) of brake cooling oil
tank and drain hydraulic oil.
6 Hydraulic oil: 16
U42103
2. Disconnect tubes (3) and (4) of brake cooling oil

line.
1
3. Remove mounting bolts (5) of brake cooling oil

tank, then lift off brake cooling oil tank (6).
4 Brake cooling oil tank: 18 kg
30-214
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INSTALLATION OF BRAKE
COOLING OIL TANK

removal.
1
Installation of tubes (3) and (4)
Refilling with oil

Add brake cooling oil through the oil filler to the
specified level.
5

U42103
Brake cooling oil tank: 16
30-215
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BRAKE OIL COOLER
REMOVAL OF BRAKE OIL

COOLER
U42103
1. Draining oil
1) Loosen oil filler cap (1) slowly to release
2) Loosen mounting bolts (3) of tube (2) and
set so that oil inside cooling oil tank does
not flow out.
1
2. Drain
Loosen drain valve (3) and drain coolant.
If the coolant contains antifreeze, dispose of
it correctly.
6 Coolant: 68 (including sub-tank)
3
DEW00449
3. Brake oil cooler piping

1) Disconnect tubes (4) and (5) from brake oil
cooler (9).
The oil inside the piping is drained, so
set a container in position to catch the
oil.
30-216
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BRAKE OIL COOLER
2) Disconnect radiator hoses (6), (7) and radiator drain hose (8).
U42103
4. Brake oil cooler

Remove mounting bolts (10) of brake oil cooler
(9), then remove brake oil cooler.
30-217
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BRAKE OIL COOLER
INSTALLATION OF BRAKE OIL

COOLER

removal.
Tighten drain plug and add water through the

radiator water filler to the specified level.
5
Coolant: 68

specified level.

U42103
Run the engine to circulate the water through

the system. Then check the water level again.
30-218
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WORK EQUIPMENT, PPC, BRAKE COOLING PUMP
REMOVAL OF WORK
EQUIPMENT, PPC, BRAKE
COOLING PUMP ASSEMBLY
Stop


Operate

accumulator.
U42103
Depress

When releasing the refrigerant from the air con-
2
DEW00494
ditioner, carry out the oil return operation, then

use a gauge manifold and release the refrigerant slowly from the core of the compressor highpressure and low-pressure valves.
1. Covers
2. Ladders
30-219
w

Remove brake hose clamps at two points
under floor board.
3) Disconnect accelerator cable (7) under pedal.
1
board.
7
DEW02354
5) Disconnect hose (10) of radiator sub-tank (9).
Remove the hoses from the hose clamps.
DNW03792
Remove clamp
U42103
DEW02356

Disconnect hoses (11) and (12) at brake oil tank
end.
Loosen the mounting bolts of tube (13) and
does not flow out.
5. Bulkhead
1) Remove cover (16) at bottom front face of
bulkhead (15).
2) Remove top mounting bolts (18) holding
bulkhead (15) and hood (17).
Be careful not to lose the rubber and
washers of the mounting portion.
17
16
18
15
15
DEW02359
30-220
w
DEW01077

4 Bulkhead: 135 kg
(including accumulator, charge valve)
U42103

400 mm.
To prevent the bulkhead from falling after it is raised, place blocks on the left
and right at opposite ends.
Remove clamp
Eyebolt
17
19
400 mm
DEW01211

DEW00470
6. Pump piping
2
1) Disconnect suction tube (20) between hydraulic tank and pump at pump end.
2) Disconnect suction tube (21) between brake
cooling oil tank and pump at pump end.
3) Disconnect tube (22) between hydraulic
pump and main control valve at pump end.
4) Disconnect tube (23) between PPC pump and
charge valve at pump end.
5) Disconnect tube (24) between brake cooling
pump and axle at pump end.
After disconnecting the tubes, fit plugs to
7. Pump
3
Remove mounting bolts of hydraulic, PPC and
brake cooling pump assembly (25), then remove
pump assembly.
4 Hydraulic, PPC, brake cooling pump assembly: 33 kg
30-221
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INSTALLATION OF WORK
EQUIPMENT, PPC, BRAKE
COOLING PUMP ASSEMBLY

removal.
1
3 Accelerator cable mounting nut:
53.9 4.9 Nm {5.5 0.5 kgm}
Refilling with oil

11.8 1 Nm {1.2 0.1 kgm}

specified level.
Bleeding air
1) Bleed air from brake line.
OUT OPERATIONS.
3) Bleeding air from brake cooling oil line
30-222
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DEW00448
U42103
23
PPC VALVE
REMOVAL OF PPC VALVE

ASSEMBLY
Stop


2
DEW00494
Operate

accumulator.
U42103
1. Covers
2. Ladders
3. Hydraulic piping
hose (5) of port P4, hose (6) of port P3,
and hose (7) of port P1 at valve end.
2) Disconnect hose (8) between PPC accumulator and PPC valve at valve end.
3) Disconnect hose (9) of PPC valve drain port
at valve end.
9
6
9
8
4
4
DEW01217
DEW01218
4. Cover
Remove side cover (11) of console box (10).
30-223
w
PPC VALVE
5. PPC valve
1) Remove joints (13) and (14) of rod installed
to PPC valve assembly (12).
14
2) Remove mounting bolts (15) of PPC valve

assembly, then remove valve assembly.
4 PPC valve assembly: 3 kg
15
13
12
DEW01220

removal.
Refilling with oil

Tighten drain plugs (1) and (2) at the top of the
11.8 1 Nm {1.2 0.1 kgm}
Bleeding air
Bleed air from PPC line.
see PRECAUTIONS WHEN CARRYING OUT OPERATIONS.
30-224
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U42103
INSTALLATION OF PPC VALVE

ASSEMBLY
PPC VALVE
DISASSEMBLY OF PPC VALVE

ASSEMBLY
1. Remove bolt (1).
2. Remove plate (2).

3. Remove seal (3), then remove spool (4).
Of the 4 spools (4), make a distinguishing
mark on the boom LOWER spool and check
the mounting position.
4. Remove collar (5) from spool (4).
5. Remove valve assembly (6) from body (7).
U42103
6. Remove collar (8), then remove retainer (9),

spring (10), and shim (11) from valve (12).
10
13
7. Remove spring (13) from body (7).

The number of coils of spring (13) differs for
each hydraulic port, so check the mounting
position of each spring and make distinguishing marks.
12
7
DEW01221
8
9
9
10
10
6
11
11
12
12
13
13
DEW01222
30-225
w
PPC VALVE
ASSEMBLY OF PPC VALVE

ASSEMBLY
1. Assemble spring (13) to body (7).
The number of coils of spring (13) differs for
each hydraulic port as shown in the chart
below, so check each spring and be sure to
install in the correct position.
Port position
No. of coils of spring
P1 Fork TILT
11
P2 Lift arm RAISE
P3 Lift arm LOWER
14
P4 Fork DUMP
2
3
The position of each port is stamped on the

valve body.
5
9
2. Assemble shim (11), spring (10), and retainer (9)

to valve (12), and install collar (8).
10
13
3. Assemble valve assembly (6) to body (7).
7
DEW01221
5. Fit seal (3) and install plate (2).

6. Install bolt (1).
3 Bolt: 44.1 4.9 Nm {4.5 0.5 kgm}
8
9
9
10
10
6
11
11
12
12
13
13
DEW01222
30-226
w
U42103
12
4. Fit O-ring to collar (5), and assemble to spool

(4), then install spool (4).
For spools (4), check the mounting position
of the boom LOWER spool which was
marked with a distinguishing mark, then install the spools.
MAIN CONTROL VALVE
REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
Stop


1. Cover
Remove inspection cover (3) of front frame.
U42103
2
DEW02360
DEW00494
2. Fork cylinder
1) Disconnect connector (4) of fork positioner
wiring.
2) Disconnect grease hose (5) at front frame
end.
3) Disconnect rod hose (6) at cylinder end.1
4) Disconnect bottom hose (7) at cylinder end.
2
6
4
DEW01227
DEW01228
30-227
w
MAIN CONTROL VALVE
5) Sling fork cylinder (10), and remove lock bolt,

then remove pins (8) and (9).
3
When slinging, be careful of the center
of gravity and sling from two points.
If there are shims installed, check the
number and thickness of the shims, and
keep in a safe place.
6) Lift off fork cylinder (10).
10
4 Fork cylinder: 192.5 kg

DEW01229
4. Main control valve

Remove mounting bolt (26), then using eyebolts,
lift off main control valve (25).
5
16
17
21
15
24
20
13
14
11
12
DEW01230
18
19
22
23
DEW01231
17
24
4 Main control valve: 95 kg
16
14
15
21
13
23
11
25
12
26
DEW01232
30-228
w
U42103
3. Hydraulic piping
This section explains the procedure for the
2-spool main control valve. Remove the special piping for the 3-spool valve in the same
way.
Disconnect following hydraulic piping.
4
1) Disconnect tube (11) between hydraulic
pump and valve at main control valve end.
2) Disconnect hose (12) between cut-off valve
and main control valve at main control valve
end.
3) Disconnect tubes (13) and (14) between main
control valve and fork cylinder at valve end.
4) Disconnect tubes (15) and (16) between main
control valve and lift arm cylinder at valve
end.
5) Disconnect drain tube (17) of main control
valve at valve end.
6) Disconnect tubes (18), (19), (20), (21), (22),
and (23) between PPC valve and main control valve at main control valve end.
mark with a tag to distinguish when installing.
dust.
MAIN CONTROL VALVE
INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY

removal.
12
U42103
3
Fork cylinder
1) Align the bottom pin hole, assemble shims
so that the total for clearance a between the
cylinder and frame is within the standard
value, then install pin (9).
Clearance a: 1.5 mm
2) Align the rod pin hole and assemble pin (8).
Always use a bar when aligning the pin

a
DEW01233
4
Be careful that the O-ring does not get caught
when installing.
Before tightening fully, install the clamps that
were removed.
5
When setting the valve in the mounting position, pay attention to the balance and be
careful not to hit any other part inside the
frame.
Refilling with oil

11.8 1 Nm {1.2 0.1 kgm}
Bleeding air
DEW00448
30-229
w
MAIN CONTROL VALVE
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
U42103
This section explains the procedure for the 2-spool main control valve. For the 3-spool valve, there
is an additional set of spool (the same as for the main relief valve).
30-230
w
MAIN CONTROL VALVE
1. Tube, hose
1) Remove tube (2) and hose (3) from valve
body (1).
2) Remove tee (4), nipple (5), and elbow (6).
2. Spool assembly
1) Remove sleeve (7), then remove spacer (8),
spring (9), and piston (10).
2) Remove case (11), spring (12), and retainer
(13), then remove spool assembly (14).
Do not remove plug (16) from spool (15)
unless necessary.
3) Remove sleeve (17), then remove spacer (18),
spring (19), and piston (20).
4) Remove case (21), then remove spring (22),
retainer (23), spring (24), and retainer (25).
U42103
3. Main relief valve assembly

Remove main relief valve assembly (26).
4. Safety valve assembly with suction
Remove safety valve assembly (27).
The safety valve cannot be adjusted when it
is installed on the machine, so do not disassemble it.
5. Suction valve assembly
Remove suction valve assembly (28).
6. Selector valve assembly
Remove selector valve assembly (29).
7. Check valve assembly
Remove plate (30), then remove spring (31) and
valve (32).
8. Remove flange (33), then remove spring (34),
seal (35), and valve (36).
30-231
w
MAIN CONTROL VALVE
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
U42103
This section explains the procedure for the 2-spool main control valve. For the 3-spool valve, there
is an additional set of spool (the same as for the main relief valve).
30-232
w
MAIN CONTROL VALVE
1. Assemble valve (36), seal (35), and spring (34)

to body (1), then fit O-ring and install flange
(33).
U42103
2. Check valve assembly

Assemble valve (32) and spring (31) to body (1),
then fit O-ring and install plate (30).
3 Mounting bolt:
88.3 9.8 Nm {9.0 1.0 kgm}
3. Selector valve assembly
Fit O-ring and install selector valve assembly
(29).
4. Suction valve assembly
Fit O-ring and install suction valve (28).
3 Suction valve assembly:
225.6 9.8 Nm {23.0 1.0 kgm}
5. Safety valve assembly with suction
Fit O-ring and install safety valve assembly (27).
3 Safety valve assembly:
225.6 9.8 Nm {23.0 1.0 kgm}
6. Main relief valve assembly
Fit O-ring and install main relief valve assembly
(26).
3 Main relief valve assembly:
321.7 47.1 Nm {32.8 4.8 kgm}
7. Spool assembly
1) Push spool (14) into body (1).
2) Assemble retainer (25), spring (24), and retainer (23) to case (21).
3) Assemble spacer (18), spring (19), piston (20),
and spring (22) to sleeve (17), then fit O-ring
and assemble to case (21).
4) Fit O-ring to case (21) and install to body (1).
5) Assemble retainer (13) and spring (12) to
case (11), then fit O-ring.
6) Assemble spacer (8), spring (9), and piston
(10) to sleeve (7), then fit O-ring and assemble to case (11).
7) Fit O-ring to case (11) and install to body (1).
8. Tube, hose
1) Install elbow (6), nipple (5), and tee (4) to
body (1).
3 Elbow, nipple:
24.5 4.9 Nm {2.5 0.5 kgm}
3 Tee: 29.4 4.9 Nm {3.0 0.5 kgm}
2) Install hose (3) and tube (2).
3 Hose sleeve nut:
91.2 12.8 Nm {9.3 1.3 kgm}
3 Tube sleeve nut:
49.0 19.6 Nm {5.0 2.0 kgm}
30-233
w
FORK CYLINDER
REMOVAL OF FORK CYLINDER

ASSEMBLY
Stop


3
1
DEW01235
1. Disconnect connector (1) of fork positioner wiring.

2
2. Disconnect grease hose (2) at front frame end.
4. Fork cylinder
1) Sling fork cylinder (7), then remove lock
bolts, and remove pin (5) and pin (6). 2
When slinging, be careful of the center
of gravity and sling from two points.
2) Lift off fork cylinder (1).
DEW01236
7
5

DEW01237
30-234
w
U42103
3. Hydraulic piping
1
1) Disconnect rod hose (3) at cylinder end.
2) Disconnect bottom hose (4) at cylinder end.
FORK CYLINDER
INSTALLATION OF FORK
CYLINDER ASSEMBLY

removal.
1
2
Fork cylinder
1) Align the bottom pin hole, assemble shims
so that the total for clearance a between the
cylinder and frame is within the standard
value, then install pin (6).
Clearance a: 1.5 mm
DEW01238
2) Align the rod pin hole and assemble pin (5).
Always use a bar when aligning the pin
U42103
After completing the assembly, add hydraulic

oil through the oil filler of the hydraulic tank to
the specified level.
Bleeding air
30-235
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LIFT ARM CYLINDER
REMOVAL OF LIFT ARM

CYLINDER ASSEMBLY
Stop


2
DEW00494
1. Rod pin
1) Sling lift arm cylinder (3), then remove lock
bolt of rod pin, and remove pin (4).
1
2) Start engine, and use control lever to retract
cylinder rod on side that was removed.
Retract to a point 20 mm before the end
of the stroke.
2. Hydraulic piping
1) Disconnect cylinder rod from connecting
portion.
2
2) Disconnect cylinder bottom tube (7) and hose
(8) at connecting portion.
3
dust.

1) Remove lock bolt of cylinder bottom pin,
then remove pin (9).
4
2) Lift off lift arm cylinder (3).
Be careful of the center of gravity and
lift off slowly.
Be careful not to damage the cylinder
portion.
4 Lift arm cylinder: 222 kg
30-236
w
U42103
LIFT ARM CYLINDER
INSTALLATION OF LIFT ARM

CYLINDER ASSEMBLY

removal.
1
Start the engine, operate the control levers, and
extend the rod. Align the pin holes and assemble shims so that clearance a is uniform on the
left and right, then install the pin.
Clearance a: Max. 1.5 mm
Rod pin
DEW01243
23
4
Align the pin at the cylinder bottom, assemble
shims so that the total for clearance b between
the cylinder and frame is within the standard
value, then install the pin.
Bottom pin
Always
U42103
use a bar when aligning the pin

DEW01244
Clearance b: Max. 1.5 mm
Refilling with oil

11.8 1 Nm {1.2 0.1 kgm}
Bleeding air
DEW00448
30-237
w
REMOVAL OF GRAPPLE ARM

CYLINDER
Stop

the safety bar on the frame. Lower the work
equipment to the ground and stop the engine.
Then apply the parking brake and put blocks
under the wheels to prevent the machine from
moving.
2. Hydraulic piping
Disconnect grapple arm cylinder hoses (6) and
(7) from connection of tubes (8) and (9).

Remove bottom pin (10), and lift off grapple
arm cylinder (1).
4 Grapple arm cylinder: 78 kg
30-238
w
U42103
1. Rod pin
1) Sling grapple arm cylinder (1), and remove
rod pin (2).
2) Start engine, and operate work equipment
lever to retract rod (3).
Loosen the oil filler cap slowly to release the pressure inside the hydraulic
tank. Then operate the steering wheel
and control levers several times to release the remaining pressure in the hydraulic piping.
INSTALLATION OF GRAPPLE
ARM CYLINDER
Set grapple arm cylinder (1) in mounting position, and install bottom pin (10), then tighten
mounting bolts.
U42103
2. Hydraulic piping
Connect grapple arm cylinder hoses (6) and (7)
to tubes (8) and (9).
3. Rod pin
Tighten plugs at top of hydraulic tank filter, and
plugs of pump piping, then start engine and
operate work equipment control levers to align
pin holes. Install rod pin (2), then tighten mounting bolts.
11.8 1 Nm {1.2 0.1 kgm}
Refilling with oil

11.8 1 Nm {1.2 0.1 kgm}
Bleeding air
30-239
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HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, LIFT ARM, FORK CYLINDER
ASSEMBLY)
Steering cylinder
1. Set cylinder assembly (1) to tool N.
2. Cylinder head, piston rod assembly

Steering cylinder assembly
1) Using tool O, remove cylinder head (2) from
cylinder.
DEW01245
Steering cylinder
DEW01246
Lift arm, fork cylinder assembly

1) Remove mounting bolts of cylinder head (2).
Cylinder
Width across flats of

bolt (mm)
Lift arm cylinder
27
Fork cylinder
30
2) Pull out cylinder head and piston rod assembly (6) from cylinder (7), and lift off.
Oil will flow out when the piston rod
assembly is removed from the cylinder,
so place a container under the cylinder
to catch the oil.
DEW01248
30-240
w
U42103
2) Pull out cylinder head and piston rod assembly (3) from cylinder (4), and lift off.
Oil will flow out when the piston rod
assembly is removed from the cylinder,
so place a container under the cylinder
to catch the oil.
HYDRAULIC CYLINDER
3. Cylinder head
1) Set cylinder head and piston rod assembly
(3) to tool N.
2) Using tool P, remove nut (8).
Width across flats of nut: 55 mm
3) Remove piston (9), then remove cylinder
head (2).
P 9
N
8
DEW01249

1) Set cylinder head and piston rod assembly
(6) to tool N.
2) Remove piston mounting bolt (10), then remove spacer (11), piston (12), and cylinder
head (5).
12
10
11
U42103
DEW01250
4. Remove O-ring and backup ring (14) from piston rod (13).
Rod of lift arm, fork cylinder only.
14
13
DEW01251
5. Disassembly of piston assembly

Remove wear ring (15) and piston ring (16) from
pistons (9) and (12).
9, 12
16
15
DEW01252
30-241
w
6. Disassembly of cylinder head assembly

1) Remove snap ring (17), then remove dust
seal (18).
2) Remove rod packing (19), then remove bushing (20) from cylinder head (2).
3) Remove O-ring and backup ring (21).
HYDRAULIC CYLINDER
17
18
20
21
19
DEW01253
22
23
25
26
24
DEW01254
30-242
w
U42103

1) Remove snap ring (22), then remove dust
seal (23).
2) Remove rod packing (24), then remove bushing (25) from cylinder head (2).
3) Remove O-ring and backup ring (26).
HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, LIFT ARM, FORK CYLINDER
ASSEMBLY)
Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with engine
oil before installing. Be careful not to damage
the rod packing, dust seals or O-rings when assembling.
25
2
1. Assembly of cylinder head assembly

1) Using tool Q, press fit bushing (25) to cylinder head (2).
2) Install rod packing (24).
3) Using tool S, fit dust seal (23), then install
snap ring (22).
DEW01255
23
22
U42103
24
DEW01256
26
DEW01257
4) Install O-ring and backup ring (26).

Do not try to force the backup ring into
position. Warm it in warm water (50
60C) before fitting it.
20
Steering assembly
1) Using tool Q, press fit bushing (20) to cylinder head (2).
2
DEW01258
2) Install rod packing (19).

3) Using tool S, install dust seal (18) to cylinder head.
18
19
DEW01259
30-243
w
HYDRAULIC CYLINDER
4) Install snap ring (17).

5) Install O-ring and backup ring (21).
position. Warm it in warm water (50
60C) before fitting it.
17
21
DEW01260
R2
16
R1
16
DEW01261
3. Assemble O-ring and backup ring (14) to piston rod (13).

position. Warm it in warm water (50 60C)
before fitting it.
9, 12
DEW01262
9, 12
14
13
16
15
DEW01263
4. Cylinder head, piston rod assembly

1) Set piston rod assembly (6) to tool N.
2) Assemble cylinder head (2), piston (12), and
spacer (11) to piston rod, then tighten mounting bolt (10).
2 Mounting bolt:
3 Mounting bolt:
Cylinder
Lift arm cylinder
Fork cylinder
30-244
w
12
DEW01264
10
11
N
Nm {kgm}
110.8 12.8 {11.3 1.3}
DEW01265
U42103
2. Assembly of piston assembly

1) Using tool R1, expand piston ring (16).
Set the piston ring on the expander and
turn the handle 8 10 times to expand
the ring.
2) Remove piston ring (16) from tool R1, then
assemble to pistons (12) and (9).
3) Using tool R2, compress piston ring (16).
4) Assemble wear ring (15).

1) Set piston rod assembly (3) to tool N.
2) Assemble cylinder head (2) and piston (9) to
piston rod.
3) Assemble nut (8), and using tool P, tighten
nut (8).
2 Thread of piston rod:
3 Nut:
HYDRAULIC CYLINDER
P 9
N
8
Width across flats

Nm {kgm}
55
1422.0 142.2 {145 14.5}
U42103
5. Cylinder head
Lift arm, fork cylinder
1) Set cylinder (7) to tool N.
2) Raise cylinder head and piston rod assembly (6) and assemble to cylinder (7).
3) Install cylinder head (2) to cylinder (7).
3 Mounting bolt:
Cylinder
Lift arm cylinder
Fork cylinder
DEW01249
Nm {kgm}
343.2 34.3 {35 3.5}
490.3 49.0 {50 5}
DEW01267
4) Remove cylinder assembly (1) from tool N.

1) Set cylinder (4) to tool N.
2) Raise cylinder head and piston rod assembly (3) and assemble to cylinder (4).
3) Using tool O, install cylinder head (2) to cylinder (4).
3 Cylinder head:
784.5 78.5 Nm {80.0 8.0 kgm}
4) Bend lock of cylinder head (2) into notch at
cylinder end.
5) Remove cylinder assembly (1) from tool N.
DEW01246
1
N
DEW01269
30-245
w
WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
Stop

Put block 1 under lift and right lift arm
mounts of work equipment.

hydraulic tank filter, and prevent the oil inside the tank from flowing out.
2
DEW00494
1. Hydraulic piping
Disconnect hoses (3) and (4) between main control valve and arm cylinder
Install blind plugs in the hydraulic piping at
the chassis end to prevent the hydraulic oil
from coming out.
2. Fork link, hinge pin

1
1) Sling fork link (5), and remove mounting pin
(6).
Remove the cord ring.
Secure fork link (5) to the bellcrank with
wire.
30-246
w
U42103
WORK EQUIPMENT
2) Remove fork hinge mounting pin (7).

Never insert your fingers in the pin hole.
Check the number of shims and use

for reference when assembling.
3. Move machine to rear and disconnect fork (8).
U42103
4 Fork: 2,375 kg
4. Fork cylinder pin

2
Sling fork cylinder (9), then remove mounting
pin (10), and disconnect cylinder rod and
bellcrank (11).
Fit a lifting tool to the fork cylinder and fix it
to the rear.
30-247
w
WORK EQUIPMENT
5. Lift arm cylinder pin

3
Sling lift arm cylinder (12), and remove mounting pin (13).
Set a stand under the tip of the lift arm.
Insert a block on top of the axle, then lower
the cylinder.
If there are shims installed, check the number
and thickness of the shims, and keep in a
safe place.
4 Lift arm cylinder: 222 kg
4 Lift arm assembly: 1915 kg

(including bellcrank, fork link,
bellcrank pin)
If there are shims installed at the connection of the front frame and lift arm,
check the number and thickness of the
7. Bellcrank, fork link
5
1) Sling fork link (5), then remove mounting
pin (17), and lift off from bellcrank (11).
4 Fork link: 86 kg
2) Sling bellcrank (11), then remove mounting

pin (18), and lift off from lift arm assembly
(15).
Carry out the mounting pin removal operation with two people.
4 Bellcrank: 415 kg
4 Mounting pin: 40 kg
30-248
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U42103
6. Lift arm, bellcrank, fork link

4
1) Remove lift arm kick-out switch (14).
2) Sling lift arm assembly (15), then remove lift
arm mounting pin (16), and lift off lift arm
assembly.
WORK EQUIPMENT
8. Dust seals, bushings

6
1) Pull out dust seal (19) and bushing (20) from
lift arm (15).
U42103

bellcrank (11).

bucket link (5).
30-249
w
WORK EQUIPMENT
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
Always
use a bar when aligning the pin holes.

Never insert your fingers.
removal.
1
Fork and fork link
Be careful that the cord ring does not
get caught.
Clearance c at mount portion: 1.5 mm
Grease all the pins after completing the
assembly.
DEW01281
U42103
2
Fork cylinder
After assembling the mounting pin, remove the block.
3
LIft arm cylinder
Clearance b at mount portion: Max. 1.5
mm
Before starting the engine, place the directional lever at the N position, and
check that the parking brake is applied.
DEW01282
4
Lift arm, bellcrank, fork link
Clearance a at mount portion: Max. 1.5
mm
After assembling the pin, set a stand
under the tip of the lift arm.
a
DEW01283
30-250
w
WORK EQUIPMENT
5
Bellcrank, fork link
Secure the fork to the bellcrank with wire.
Be careful that the cord ring does not
get caught.
Bushing
12
12
DEW01284
U42103
6
Use a press to press fit the bushing to the fork
link, bellcrank, and lift arm. After press fitting,
assemble the dust seal.
2 Inside surface of bushing:
Grease (G2-LI)
Hydraulic cylinder
DEW01285
Refilling with oil

11.8 1 Nm {1.2 0.1 kgm}
Bleeding air
Bleed air from Hydraulic line.
DEW00448
30-251
w
COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT
Stop

1. Sling radiator guard, and remove 4 mounting

bolts, then disconnect connector (2) of rear working lamp wiring and radiator water level sensor
(3) at radiator end.
2. Lift off radiator guard (1).
3. Sling counterweight, then remove mounting
bolts and lift off.
1
4 Counterweight (3) : 400 kg
4 Counterweight (4) : 1,200kg
(Serial No.: 50305 52999)
(Serial No.: 53001 and up)

When removing the counterweight, be careful not to hit the battery box.
INSTALLATION OF
COUNTERWEIGHT

removal.
1
3 Mounting bolts (7, 8):
926.7 104.9 Nm {94.5 10.5 kgm}
3 Mounting bolt (9):
549 59 Nm {56 6 kgm}
When installing the counterweight, be careful not to hit the battery box.
30-252
e
U42103
: 1,600kg
FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
Stop

1. Radiator guard
1) Remove 4 radiator guard mounting bolts,
and disconnect connector (2) of rear working lamp wiring and radiator water level sensor (3) at radiator end.
2) Lift off radiator guard (1).
2. Draining fuel
Loosen drain valve and drain fuel.
6 Fuel: 400
U42103
3. Drain valves
Remove engine oil drain valve (4) and radiator
drain valve (5) from fuel tank.
DEW01289
4. Fuel tube, wiring clamp

1) Disconnect hose (6) between fuel tank and
feed pump, fuel return hose (7), and spill
hose (8) at tank end.
2) Disconnect wiring connector (10) for fuel sensor.
3) Remove clamps at fuel tank mounting bolt
for steering oil cooler hose and hose going
to transmission cooler.
DEW01290
DEW01291
4) Remove fuel tank air bleed hose (9).

10
DEW01293
30-253
w
FUEL TANK
5. Fuel tank
1) Put pallet under fuel tank (11), then put blocks
so that tank does not tilt, and support tank
with pallet truck.
11
4 Fuel tank: 250 kg
Pallet truck
Blocks
Pallet
DEW01294
2) Remove fuel tank mounting bolts (12).1

12
3) Pull out fuel tank (11) from rear of chassis.
Maintain the balance of the fuel tank,
and operate the pallet truck to remove
the tank.
DEW01295
INSTALLATION OF FUEL TANK

ASSEMBLY
11

removal.
1
When installing the fuel tank, keep it horizontal, and set it in position on the machine.
Tighten the bolts in the following order: left,
rear, right.
3 Fuel tank mounting bolt:
926.7 104.9 Nm {94.5 10.5 kgm}
Tighten the drain valve and add oil through
oil filler.
30-254
w
DEW01296
U42103
12
CAB
REMOVAL OF CAB ASSEMBLY

(OPTION)
Stop

1. Remove mounting bolts (3) of left and right dashboards (1) and (2).
DEW01297
2. Remove right cover (4).
U42103
3. Remove left cover (5).
5
DEW01298
3
4. Disconnect electric wiring at connector (6).
5. Disconnect window washer hose (7).
After disconnecting the hose, mark with a
tag to distinguish when installing.
6. Remove mounting bolts (8) of left and right dashboards, then remove left and right dashboards
(1) and (2).
DEW01299
7. Remove steering post and cab mounting bolts

(9).
DEW01300
30-255
w
CAB
8. Remove covers (10) under cab.
10
DEW01301
12
11
DNW03798
10. Lift off cab (13).

Keep the cab horizontal and lift it off slowly.
Remove the plugs on top of the cab, and
install eyebolts.
4 Cab: 300 kg
13
DEW01303
INSTALLATION OF CAB
ASSEMBLY (OPTION)

removal.
30-256
w
U42103
9. Remove 2 cab mounting bolts (11), 4 mounting

bolts (12) in the middle, and 4 mounting bolts at
the rear.
MAIN MONITOR
REMOVAL OF MAIN MONITOR

ASSEMBLY
Stop

Disconnect
1. Remove steering post cover mounting bolts (1)

and (2).
2. Remove steering post cover (3).
U42103
3. Remove mounting bolt caps (5) of steering post

cover (4), then remove bolts.
4. Remove mounting bolt caps from steering post

cover (6), then remove mounting bolts (7).
Tip the steering post cover to the front.
5. Remove bracket (8) at back of main monitor.
30-257
w
MAIN MONITOR
6. Remove mounting bolts (10) of main monitor

(9).
When removing the main monitor, be careful not to subject it to any strong shock.
U42103
7. Disconnect wiring connectors (11), (12), (13), and

(14) from main monitor, and remove main monitor (9).
1
INSTALLATION OF MAIN
MONITOR ASSEMBLY

removal.
1
Fit the connector lock securely.
30-258
w
MAINTENANCE MONITOR
REMOVAL OF MAINTENANCE
MONITOR ASSEMBLY
Stop

1. Remove cover (1) of right console box.
DEW01311
2. Disconnect connectors (2), (3), and (4) for maintenance monitor wiring and bulb wiring (5) from
maintenance monitor.
2
4
U42103
5
3
DEW01312
3. Remove mounting bolts (7) of maintenance

monitor (6), then remove maintenance monitor
(6).
DEW01313
INSTALLATION OF
MAINTENANCE MONITOR
ASSEMBLY

removal.
30-259
w
U42103
40
Engine mount, transmission mount .........

Torque converter ........................................
Transmission ..............................................
Transmission control valve .......................
Drive shaft ...................................................
Differential...................................................
Final drive ...................................................
Axle mount .................................................
Steering column .........................................
Steering valve .............................................
Steering cylinder mount ............................
Slack adjuster .............................................
Brake valve .................................................
Brake ............................................................
Parking brake ..............................................
Torque converter, transmission pump ....
Steering, switch pump ..............................
Hydraulic, PPC pump .................................
PPC valve ....................................................
Cut-off valve ...............................................
Main control valve .....................................
Lift arm cylinder .........................................
Fork cylinder ...............................................
Center hinge pin .........................................
Work equipment linkage ...........................
Fork positioner and lift arm kick-out ........
40- 2
40- 3
40- 4
40-12
40-16
40-18
40-20
40-21
40-22
40-23
40-24
40-25
40-26
40-30
40-32
40-33
40-34
40-35
40-36
40-37
40-38
40-40
40-41
40-42
40-44
40-47
40-1
ENGINE MOUNT, TRANSMISSION MOUNT

Serial No.: 50305 52999
U42103
Kgm
Kgm
279 29 Nm
(28.5 3 kgm)
123 24 Nm
(12.5 2.5 kgm)
Kgm
927 103 Nm
(94.5 10.5 kgm)
AA
Kgm
927 103 Nm
(94.5 10.5 kgm)
BB
SDW00331
Unit: mm
No.
Check item
Criteria
Remedy
Clearance between engine

bracket and adjustment bolt
1 1.5
Adjust
40-2
e
U42103
Unit: mm
No.
Check item
Criteria
Remedy
Clearance between engine

bracket and adjustment bolt
1 1.5
Adjust
40-2-1
e
TORQUE CONVERTER
U42103
TORQUE CONVERTER
Unit: mm
No.
Check item
Outside diameter of pilot
Inside diameter of retainer

seal ring contact surface
Wear of stator
shaft seal ring
Criteria
Remedy
Standard size
Tolerance
Repair limit
78
0.010
0.040
77.75
110
+ 0.035
0
110.5
Width
0.01
0.03
2.7
Thickness
4.3
0.1
3.9
Backlash between PTO

drive gear and drive gear
Replace
0.18 0.49
40-3
e
TRANSMISSION
TRANSMISSION
U42103
(1/2)
40-4
e
TRANSMISSION
Unit: mm
No.
U42103
Check item
Clearance between pump

drive shaft and bearing
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
65
+0.024
+0.011
0
0.015
0.039
0.011

drive gear bearing and
housing
120
0
0.015
+0.030
0
0
0.045

50
+0.020
+0.009
0
0.012
0.032
0.009

drive shaft bearing and
housing
90
0
0.015
+0.030
0
0
0.045
Clearance between idler

gear shaft and bearing
65
+0.012
0.007
0
0.015
0.027
0.007
Clearance between idler

gear bearing and idler
gear
120
0
0.018
0.030
0.052
0.052
0.012

40
+0.025
+0.009
0
0.012
0.037
0.009

housing
80
0
0.013
+0.030
0
0
0.043

45
+0.025
+0.009
0
0.012
0.037
0.009
10

housing
100
0
0.015
+0.030
0
0
0.045
11

90
+0.035
+0.013
0
0.020
0.055
0.013
12

housing
160
0
0.025
+0.030
0
0
0.055
13
Clearance between output

shaft bearing and housing
130
0
0.018
0.018
0.058
0.058
0
14

shaft and bearing
75
+0.030
+0.011
0
0.015
0.045
0.011
15

shaft bearing and housing
150
0
0.018
0.018
0.058
0.058
0
16

shaft and bearing
85
+0.035
+0.013
0
0.020
0.055
0.013
160
0
0.025
+0.030
0
0
0.055
160
0
0.025
+0.030
0
0
0.055
160
0
0.025
+0.030
0
0
0.055
160
0
0.025
+0.030
0
0
0.055
17
18
19
20
Clearance (R) between

FORWARD, 1st clutch
bearing and housing
Clearance (F) between
FORWARD, 1st clutch
bearing and housing
REVERSE, 2nd clutch
bearing and housing
REVERSE, 2nd clutch
bearing and housing
Replace
40-5
e
TRANSMISSION
U42103
(2/2)
40-6
e
TRANSMISSION
Unit: mm
No.
U42103
21
Check item
Clearance (R) between 3rd,

4th clutch bearing and
housing
Criteria
Tolerance
Standard
size
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
130
0
0.018
+0.030
0
0
0.048
160
0
0.025
+0.030
0
0
0.055
22
Clearance (F) between 3rd,

4th clutch bearing and
housing
23

countershaft and bearing
45
+0.025
+0.009
0
0.012
0.037
0.009
24

countershaft bearing and
housing
100
0
0.015
+0.030
0
0
0.045
25

countershaft and bearing
40
+0.025
+0.009
0
0.012
0.037
0.009
26

countershaft bearing and
housing
80
0
0.013
+0.030
0
0
0.043
Inside diameter of seal ring

contact surface
Replace
Standard size
Tolerance
Repair limit
55
+ 0.05
0
55.1
Width of seal ring groove
3.2
+ 0.076
0
3.5
Width of seal ring
3.1
0.05
2.8
Thickness of seal ring
2.29
0
0.1
2.1
105
0
0.087
104.8
105
0
0.087
104.8
27
28
29
30
31
Outside diameter (R) of

coupling oil seal sliding
surface
Outside diameter (F) of
coupling oil seal sliding
surface
shaft cover and housing
Free rotating torque of
output shaft
Standard clearance
Clearance limit
0.5 1.4
Tighten
0.1 1 Nm {0.01 0.1 kgm}
40-7
e
TRANSMISSION
U42103
FORWARD, 1ST CLUTCH
40-8
e
TRANSMISSION
U42103
Unit: mm
No.
Check item
Clearance (R) at bearing

press-fitting portion of
FORWARD, 1st clutch shaft
Clearance (F) at bearing
FORWARD, 1st clutch shaft
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
75
+0.030
+0.011
0
0.015
0.045
0.011
75
+0.049
+0.036
0
0.015
0.064
0.036
Standard size
Tolerance
Repair limit
Thickness of separator
plate
2.0
0.05
1.8
Distortion of separator
plate
0.05
0.15
Thickness of friction
plate
3.2
0.08
2.75
Distortion of friction plate
0.1
0.25
Load of wave spring (1st)

(height 3.2 mm)
2481 N
{253 kg}
224 N
{22.8 kg}
2109 N
{215.1 kg}
Load of wave spring

(forward) (height 3.2 mm)
1106 N
{112.8 kg}
57 N
{5.8 kg}
940 N
{95.9 kg}
Thickness of 1st clutch

thrust washer
0.1
3.7
Thickness of FORWARD
clutch thrust washer
0.1
3.7
3
Replace
40-9
e
TRANSMISSION
2ND, REVERSE CLUTCH
No.
Check item

REVERSE, 2nd clutch shaft
REVERSE, 2nd clutch shaft
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
75
+0.030
+0.011
0
0.015
0.045
0.011
75
+0.071
+0.061
0
0.015
0.086
0.061
Standard size
Tolerance
Repair limit
plate
2.0
0.05
1.8
plate
0.05
0.15
plate
3.2
0.08
2.75
0.1
0.25
Load of wave spring (2nd)

(height 3.2 mm)
2481 N
{253 kg}
224 N
{22.8 kg}
2109 N
{215.1 kg}
Load of wave spring

(Reverse) (height 3.2 mm)
1106 N
{112.8 kg}
57 N
{5.8 kg}
940 N
{95.9 kg}
Thickness of REVERSE
clutch thrust washer
0.1
3.7
Thickness of 2nd clutch

thrust washer
0.1
3.7
Replace
40-10
e
U42103
Unit: mm
TRANSMISSION
U42103
3RD, 4TH CLUTCH
Unit: mm
No.
Check item

press-fitting portion of 3rd,
4th clutch shaft

press-fitting portion of 3rd,
4th clutch shaft
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
75
+0.030
+0.011
0
0.015
0.045
0.011
35
+0.071
+0.061
0
0.015
0.086
0.061
Standard size
Tolerance
Repair limit
plate
2.0
0.05
1.8
plate
0.05
0.15
plate
3.2
0.08
2.75
0.1
0.25
2481 N
{253 kg}
224 N
{22.8 kg}
2109 N
{215.1 kg}
3
Replace
Load of wave spring

(height 3.2 mm)
Thickness of 3rd clutch

thrust washer
0.1
3.7
Thickness of 4th clutch

thrust washer
0.1
3.7
40-11
e
Unit: mm
No.
Check item
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
25
0.02
0.03
+0.013
0
0.02
0.043
0.06
Clearance of fill valve body
Clearance of fill valve

sleeve
25
0.02
0.03
+0.033
+0.020
0.04
0.063
0.08
Clearance of fill valve

sleeve
26
0.04
0.05
+0.041
+0.025
0.065
0.091
0.11
Clearance between sleeve

and body
38
0.025
0.050
+0.025
0
0.025
0.075
0.10
Clearance of accumulator
valve body
25
0.03
0.04
+0.013
0
0.03
0.053
0.07
Standard size
Repair limit
Free length Installed height Installed load Free length Installed load
6
Accumulator spring
22
20
9.41 4.7 N
{9.6 0.48 kg}
21.3
89.2 N
{9.1 kg}
Accumulator spring
100
78.5
605.1 30.4 N
(61.9 3.1 kg}
97.0
577 N
{58.8 kg}
Accumulator spring
66
58.5
258.9 12.6 N
{26.4 1.3 kg}
64.0
246 N
{25.1 kg}
Fill valve spring
29
15
35.0 N
{3.57 kg}
28.1
33.2 N
{3.39 kg}
40-12
e
Replace
U42103
MODULATION VALVE ASSEMBLY
U42103
UPPER VALVE ASSEMBLY
40-12-2
e
Unit: mm
No.
U42103
Check item
Clearance between pilot

valve and body
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
25
0.035
0.045
+0.013
0
0.035
0.058
0.08
Clearance between main

relief valve and body
25
0.035
0.045
+0.013
0
0.035
0.058
0.08
Clearance between main

relief valve and load piston
15
0.020
0.030
+0.018
0
0.02
0.048
0.07
Clearance between quick

return valve and body
25
0.020
0.028
+0.013
0
0.02
0.041
0.06
Clearance between torque

converter regulator valve
and body
25
0.035
0.045
+0.013
0
0.035
0.058
0.08
Clearance between
emergency spool and body
14
0.020
0.030
+0.011
0
0.02
0.041
0.06
Standard size
Replace
Repair limit
7
Main relief valve spring

163.5
132.3
306N
{31.2 kg}
158.6
290 N
{29.6 kg}
Quick return valve spring
40
30.5
1.03 N
{0.105 kg}
38.8
0.98 N
{0.10 kg}
Torque converter regulator

valve spring
65
62
70.6 N
{7.2 kg}
63.1
67.1 N
{6.84 kg}
10
Quick return valve spring
31.5
27
4.8 N
{0.49 kg}
30.6
4.6 N
{0.47 kg}
11
Pilot valve spring
74.2
49
463 N
{47.2 kg}
72.0
439 N
{44.8 kg}
12
Load piston spring
26.0
19
5.7 N
{0.58 kg}
25.2
5.4N
{0.55 kg}
40-12-3
e
LOWER VALVE ASSEMBLY
5
9
SDW00340
40-12-4
e
U42103
U42103
Unit: mm
No.
Check item
Clearance between
directional selector spool
and body
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
19
0.020
0.030
+0.013
0
0.02
0.043
0.050
Clearance between H-L

selector spool and body
19
0.020
0.030
+0.013
0
0.02
0.043
0.050
Clearance between range

selector spool and body
19
0.020
0.030
+0.013
0
0.02
0.043
0.050
Clearance between priority

valve and body
19
0.035
0.045
+0.013
0
0.035
0.058
0.065
Clearance between parking

brake valve and body
19
0.020
0.030
+0.013
0
0.02
0.043
0.050
Standard size
6
Directional selector spool

spring
H-L range selector spool

return spring
Priority valve spring
Parking brake valve spring
Replace
Repair limit
42
32
78.9 N
{8.05 kg}
40.7
75 N
{7.65 kg}
48
36.7
69.8 N
{7.12 kg}
46.6
66.3 N
{6.76 kg}
125.5
111.3
569.8 N
{58.1 kg}
121.7
541 N
{55.2 kg}
46
37
81.4 N
{8.3 kg}
44.6
77.4 N
{7.89 kg}
40-13
e
U42103
FLOW VALVE
Unit: mm
No.
Check item
Clearance between flow

valve spool and body
Criteria
Standard
size
25
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0.020
0.030
+0.013
0
0.02
0.043
0.06
Replace
Standard size
Repair limit
2
Flow valve spring

63.8
40-14
e
47
79.5 N
{8.11 kg}
61.9
75.5 N
{7.7 kg}
U42103
ACCUMULATOR VALVE
Unit: mm
No.
Check item
Clearance between
accumulator valve and body
Criteria
Standard
size
32
Tolerance
Shaft
Hole
0.035
0.045
+0.025
0
Standard size
2
FORWARD accumulator
valve spring
Remedy
Standard
clearance
0.035
0.07
Clearance
limit
0.09
Repair limit
184.8
165
319 N
{32.5 kg}
179.3
303 N
{30.9 kg}
1st accumulator valve

spring
145
135
78.5N
{8.0 kg}
140.7
74.5 N
{7.60 kg}
2nd accumulator valve

spring
157.7
155
33.3 N
{3.4 kg}
153.0
31.7 N
{3.23 kg}
Replace
40-15
e
DRIVE SHAFT
U42103
DRIVE SHAFT
40-16
r
DIFFERENTIAL
U42103
DIFFERENTIAL
40-18
r
DIFFERENTIAL
Unit: mm
No.
Clearance of side bearing

(outer race)
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
160
0
0.025
+0.054
+0.014
0.014
0.079
Clearance of side bearing

(inner race)
105
+0.059
+0.037
0
0.020
0.079
0.037
Clearance of pinion shaft

bearing (outer race)
146.05
+0.025
0
0.025
0.050
0.075
0.025
69.85
+0.064
+0.051
+0.013
0
0.064
0.038
69.85
+0.051
+0.038
+0.013
0
0.051
0.025
4
5
U42103
Check item

bearing (inside of
inner race)
bearing (outside of
inner race)
Clearance of pilot bearing

(outer race)
110
0
0.015
+0.030
+0.010
0.010
0.045
Clearance of pilot bearing

(inner race)
50
+0.050
+0.034
0
0.012
0.062
0.034
Clearance between
differential carrier and
gauge
190
0.020
0.060
+0.046
+0.010
0.030
0.106
Clearance between spider

and differential pinion gear
0.06
0.11
+0.10
+0.05
0.11
0.21
10
Thickness of side gear

washer
11
Thickness of pinion gear

washer
34.93
Standard size
Tolerance
Repair limit
0.05
3.8
1.5
+0.09
0.01
1.35
Standard size
Repair limit
12
Backlash of bevel gear
0.3 0.41
13
Backlash of differential
gear
0.25 0.55
End play of pinion shaft
Replace
Max. 0.21
14
Preload of pinion shaft
bearing
Rotating force: Max.147 N {15 kg}
15
Preload of differential
side bearing
Rotating force: 19.6 24.5 N {2.0 2.5 kg} [Target: 24.5 N {2.5 kg}]
16
Runout at rear face of

bevel gear
Max. 0.1
40-19
r
FINAL DRIVE
U42103
FINAL DRIVE
Unit: mm
No.
Check item
Clearance between
planetary shaft and bearing
Clearance between ring

gear hub and bearing
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
45
+0.013
0
0
0.012
0.025
0
180
+0.040
+0.015
0
0.025
0.065
0.015
Replace
Standard size
Tolerance
Repair limit
26
0.1
25.5
Thickness of spacer
Backlash between planet

gear and sun gear
0.19 0.43
Backlash between planet

gear and ring gear
0.19 0.53
Thickness of wheel hub

shim
2.025 1.25
40-20
AXLE MOUNT
AXLE MOUNT
U42103
Serial No.: 50305 52999
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
Thickness of thrust plate
20
0
0.15
Thickness of wear plate
+0.3
0.1
Clearance between hole

and shaft at front support
end

and shaft at rear support
end
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
275
0.056
0.137
+0.439
+0.023
0.079
0.576
170
0.043
0.106
+0.455
+0.027
0.070
0.561
Replace
40-21
r
AXLE MOUNT
U42103
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
Thickness of thrust plate
20
0
0.15
Thickness of wear plate
+0.3
0.1

and shaft at front support
end

and shaft at rear support
end
40-21-1
r
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
275
0.056
0.137
+0.439
+0.023
0.079
0.576
170
0.043
0.106
+0.455
+0.027
0.070
0.561
Replace
STEERING COLUMN
STEERING COLUMN
3 29.42.9Nm
(3.00.3kgm)
U42103
3 52.06.8Nm
(5.30.7kgm)
3 88.334.3Nm
(9.03.5kgm)
3 55.97.8Nm
(5.70.8kgm)
SAW00768
Unit: mm
No.
Check item
Clearance between
steering shaft and column
bearing
40-22
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
19
0
0.08
+0.15
0.05
0.05 0.23
Clearance
limit
Replace
0.4
STEERING VALVE
STEERING VALVE
U42103
3
SLW01253
Unit: mm
No.
Check item
Criteria
Standard size
Steering spool return

spring
Remedy
Repair limit
Free length Installed length Installed load Free length Installed load
37.2
32.0
56.9 N
{5.8 kg}
47.1 N
{4.8 kg}
20.9
13.2
9.34.9 N
{0.950.5 kg}
7.8 N
{0.8 kg}
114.7 N
{11.7 kg}
Load check valve spring
Demand spool return

spring
75.1
68.5
136.1 N
{13.88 kg}
Relief valve spring
24.0
22.19
182.4N
{18.6 kg}
145.1 N
{14.8 kg}
Check valve return spring
21.6
17.0
2.3 N
{0.23 kg}
1.8 N
{0.18 kg}
Replace
40-23
STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
1, 2
a
3, 4
AA
U42103
b
SDW00348
Unit: mm
No.
Check item
Clearance between
mounting pin and bushing
at connection of steering
cylinder rod and frame
Clearance between
mounting pin and bushing
at connection of steering
cylinder bottom and frame
Connection between
steering cylinder and
front frame
Connection between
steering cylinder and
rear frame
40-24
r
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
55
0
0.046
+0.174
+0.100
0.100
0.220
55
0
0.046
+0.174
+0.100
0.100
0.220
Replace
Width of boss
Width of hinge
65
69
65
69
Standard clearance
(clearance a + b)
Max. 0.5
(after adjusting
with shim)
Max. 0.5
(after adjusting
with shim
SLACK ADJUSTER
SLACK ADJUSTER
kgm
55.9 6.2 Nm
(5.7 0.7 kgm)
kgm
65.7 6.8 Nm
(6.7 0.7 kgm)
U42103
SEW00349
Unit: mm
No.
Check item
Clearance between
body and piston
Criteria
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
55
0.030
0.076
+0.074
0
0.030
0.150
0.25
Standard size
2
Slack adjuster spring
Spring
Repair limit
Replace
198
Remedy
38.8
38
43.2 N
{4.4 kg}
33
66.7 N
{6.8 kg}
40-25
r
BRAKE VALVE
BRAKE VALVE (SINGLE)
2
3
kgm
66.2 7.3 Nm
(6.75 0.75 kgm)
kgm
7.8 2 Nm
(0.8 0.2 kgm)
6
kgm
66.2 7.3 Nm
(6.75 0.75 kgm)
5
7
152 24.5 Nm
(15.5 2.5 kgm)
U42103
kgm
4
SDW00350
Unit: mm
No.
Check item
Clearance between pedal

mount hole and bracket
hole
Clearance between roller
and pin
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
10
0.025
0.075
+0.1
0
0.175
0.025
0.25
10
0.025
0.075
+0.1
0
0.175
0.025
0.25
Standard size
Tolerance
Repair limit
30
0
0.5
29.2
Outside diameter of roller
Standard size
Repair limit
4
Control spring
34
33.5
3.82 N
{0.39 kg}
33
Control spring
46.3
46
11.8 N
{1.2 kg}
45.3
Return spring
86.2
58
60.8 N
{6.2 kg}
78
Return spring
31.5
19.5
16.7 N
{1.7 kg}
28
40-26
r
Replace
BRAKE VALVE
BRAKE VALVE (TANDEM)
kgm
66.2 7.3 Nm
(6.75 0.75 kgm)
kgm
7.8 2 Nm
(0.8 0.2 kgm)
U42103
5
7
kgm
66.2 7.3 Nm
(6.75 0.75 kgm)
8
kgm
40-28
152 24.5 Nm
(15.5 2.5 kgm)
SDW00351
U42103
BRAKE VALVE
Unit: mm
No.
Check item
Clearance between pedal

mount hole and bracket
hole
Clearance between roller
and pin
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
10
0.025
0.075
+0.1
0
0.175
0.025
0.25
10
0.025
0.075
+0.1
0
0.175
0.025
0.25
Standard size
Tolerance
Repair limit
30
0
0.5
29.2
Outside diameter of roller
Standard size
Repair limit
4
Replace
Control spring
34
33.5
3.82 N
{0.39 kg}
33
Control spring
46.3
46
11.8 N
{1.2 kg}
45.3
Return spring
86.2
58
60.8 N
{6.2 kg}
78
Spring
17
16.5
17.7 N
{1.8 kg}
Return spring
31.5
19.5
16.7 N
{1.7 kg}
28
40-29
r
BRAKE
U42103
BRAKE
40-30
BRAKE
U42103
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
1
Return spring
75.6
66.2
Standard size
568.8 N
{58 kg}
74.7
511.9 N
{52.2 kg}
Tolerance
Repair limit
Thickness of plate
2.3
0.08
2.0
Thickness of disc
3.8
0.1
3.5
Overall assembly thickness

of plates, discs
38.9
1.16
35.0
Wear of piston seal

contact surface
420
+0.097
0
Wear of piston seal

contact surface
383
+0.089
0
Backlash between outer

gear and plate
0.21 0.65
Backlash between inner

gear and disc
0.31 0.74
Replace
40-31
PARKING BRAKE
U42103
PARKING BRAKE
SDW00353
Unit: mm
No.
Check item
Remedy
Standard size
Tolerance
Repair limit
0.05
3.9
Distortion
0.05
0.6
Thickness
3.2
0.08
2.97
Depth of
lining groove
0.45
+0.175
0
0.3
Thickness of
lining
0.7
0.075
1103.2 N
{112.5 kg}
(Height 3.2 mm)
56.9 N
{5.8 kg}
Thickness of plate
Brake disc
Load of wave spring
40-32
r
Criteria
892.4 N
{91 kg}
Replace
TORQUE CONVERTER, TRANSMISSION PUMP
TORQUE CONVERTER, TRANSMISSION PUMP

SAR(3)-100
A
1
AA
277 32 Nm
(28.5 3 kgm)
U42103
kgm
SEW00354
Unit: mm
No.
Check item
Criteria
Remedy
Model
Standard clearance
Clearance limit
Side clearance
SAR(3)-100
0.13 0.18
0.22
Clearance between inside

diameter of plain bearing
and outside of diameter
of gear shaft
SAR(3)-100
0.06 0.149
0.20
Depth for knocking in pin
Rotating torque of
spline shaft
Model
Standard size
Tolerance
Repair limit
SAR(3)-100
14
0
0.5
6.9 11.8 Nm {0.7 1.2 kgm}

Model
Replace
Discharge amount
Oil: EO10-CD
Oil temperature: 45 55C SAR(3)-100
Rotating
speed
(rpm)
2,500
Delivery
Standard deli- Delivery
pressure
very amount amount limit
[MPa {kg/cm2}]
(/min)
(/min)
2.9
{30}
241
221
40-33

SAR(3)71 + 50A
kgm
277 32 Nm
(28.5 3 kgm)
kgm
277 32 Nm
(28.5 3 kgm)
SEW00355
Unit: mm
No.
Check item
Criteria
Model
Side clearance
Standard clearance
Clearance limit
0.10 0.15
0.19
0.06 0.149
0.20
SAR(3)71
SAR(3)50

of gear shaft
SAR(3)71
Standard size
Tolerance
Repair limit
14
0
0.5
SAR(3)71
SAR(3)50
Rotating torque of
spline shaft
13.8 23.6 Nm {1.4 2.4 kgm}

Model
Discharge amount
Oil: EO10-CD
Oil temperature: 45 55C
SAR(3)71
SAR(3)50
40-34
Replace
SAR(3)50
Model
Remedy
Rotating
speed
(rpm)
2,500
Delivery Standard deli- Delivery

pressure
[MPa {kg/cm2}]
(/min)
(/min)
20.6
{210}
158
146
112
102
U42103
HYDRAULIC, PPC PUMP
HYDRAULIC, PPC PUMP

SAR(4)140 + (1) + 28A
U42103
277 32 Nm
(28.5 3 kgm)
kgm
277 32 Nm
(28.5 3 kgm)
kgm
SEW00356
Unit: mm
No.
Check item
Side clearance

of gear shaft
Criteria
Model
Standard clearance
Clearance limit
SAR(4)140
0.11 0.16
0.19
SAR(1)28
0.10 0.15
0.19
SAR(4)140
0.06 0.140
0.20
SAR(1)28
0.064 0.119
0.20
Replace
Model
Standard size
Tolerance
Repair limit
SAR(4)140
21
10
0
0.5
SAR(1)28
Rotating torque of
spline shaft
11.8 19.6 Nm {1.2 2.0 kgm}

Model
Discharge amount
Oil: EO10-CD
Oil temperature: 45 55C
Remedy
SAR(4)140
SAR(1)28
Rotating
speed
(rpm)
2,200
Delivery
Standard deli- Delivery
pressure
[MPa {kg/cm2}]
(/min)
(/min)
20.6 {210}
287
266
2.9 {30}
59
52
40-35
PPC VALVE
PPC VALVE
kgm
44 5Nm
(4.5 0.5 kgm)
17.6 3.9Nm
(1.8 0.4 kgm)
U42103
kgm
SEW00357
Unit: mm
No.
Check item
Criteria
Standard size
Centering spring
(Fork DUMP,
boom LOWER)
Remedy
Repair limit
Free length
x O.D.
Installed
length
Installed
load
Free
length
Installed
load
52.8 x 12.3
36.0
29.4 N
{3.0 kg}
23.5 N
{2.4 kg}
Centering spring
(Fork TILT, boom RAISE)
52.8 x 12.3
36.0
39.2 N
{4.0 kg}
31.4 N
{3.2 kg}
Metering spring
31.4 x 7.4
29.4
16.8 N
{1.7 kg}
13.7 N
{1.4 kg}
40-36
r
Replace spring
if damaged
or deformed
CUT-OFF VALVE
CUT-OFF VALVE
kgm
66.19 7.35 Nm
(6.75 0.75 kgm)
A
AA
kgm
kgm
2.21 0.25 Nm
(0.225 0.025 kgm)
kgm
34.3 5 Nm
(3.5 0.5 kgm)
U42103
147 10 Nm
(15 1 kgm)
BB
SDW00358
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
1
Unload valve spring
Check valve spring
36.9
30
35.3 N
{3.6 kg}
28.4 N
{2.9 kg}
33
20
1.7 N
{0.17 kg}
1.4 N
{0.14 kg}
Replace
40-37
r
MAIN CONTROL VALVE
U42103
MAIN CONTROL VALVE
40-38
r
MAIN CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
U42103
Spool return spring (large)

64.4
62.2
190.3 N
{19.4 kg}
152.0 N
{15.5 kg}
Spool return spring (small)
18.6
14.9
112.8 N
{11.5 kg}
90.2 N
{9.2 kg}
64.4
62.7
223.6 N
{22.8 kg}
178.5 N
{18.2 kg}
18.6
15.2
156.9 N
{16 kg}
125.5 N
{12.8 kg}
89.1
82.0
283.4 N
{28.9 kg}
226.5 N
{23.1 kg}
83.3
82.0
101.5 N
{10.35 kg}
80.4 N
{8.2 kg}
Replace
42.0
42.0
42.0
42.0
62.6
52.0
31.4 N
{3.2 kg}
25.5 N
{2.6 kg}
10
Spool return spring
62.6
52.0
31.4 N
{3.2 kg}
25.5 N
{2.6 kg}
11
Check valve spring
78.2
52.0
18.8 N
{1.92 kg}
14.7 N
{1.5 kg}
12
Float selector valve spring
53.0
42.1
137.3 N
{14 kg}
109.8 N
{11.2 kg}
13
Unload valve spring
82.7
47.0
49.0 N
{5.0 kg}
39.2 N
{4.0 kg}
40-39
r
LIFT ARM CYLINDER
LIFT ARM CYLINDER
kgm
kgm
343 35 Nm
(35 3.5 kgm)
113 10 Nm
(11.5 1.0 kgm)
U42103
SEW00361
Unit: mm
No.
2
3
Check item
Clearance between boom

cylinder rod and bushing
Clearance between piston
rod mounting pin and inside
diameter of insertion portion
Clearance between
cylinder bottom mounting
pin and bushing
Clearance at inside
diameter of cylinder
40-40
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
95
0.036
0.123
+0.235
+0.060
0.096
0.358
0.658
110
+0.350
+0.200
110
+0.207
+0.120
Standard size
Tolerance
180
+0.30
0
Replace
Repair limit
FORK CYLINDER
FORK CYLINDER
kgm
113 10 Nm
(11.5 1.0 kgm)
490 49 Nm
(50 5 kgm)
SEW00362
U42103
kgm
Unit: mm
No.
2
3
Check item
Clearance between fork

cylinder rod and bushing
Clearance between piston
rod mounting pin
and bushing
Clearance between
cylinder bottom mounting
pin and bushing
Clearance at inside
diameter of cylinder
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
100
0.036
0.123
+0.270
+0.060
0.096
0.393
0.693
120
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
120
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
Standard size
Tolerance
Repair limit
200
+0.30
0
Replace
40-41
r
CENTER HINGE PIN
CENTER HINGE PIN
U42103
Serial No.: 50305 52999
40-42
r
CENTER HINGE PIN
Unit: mm
No.
Clearance between upper

hinge pin and rear frame
Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
80
0.030
0.076
+0.071
+0.036
0.066
0.147

hinge and spacer (small)
80
0.030
0.076
+0.060
+0.030
0.060
0.136

hinge and bearing
80
0.030
0.076
0
0.015
0.015
0.076

hinge and spacer (large)
80
0.030
0.076
+0.030
0
0.03
0.106
Clearance between rear

frame and spacer (large)
95
0.036
0.071
+0.071
+0.036
0.072
0.142
130
0
0.025
0.048
0.088
0.088
0.023
80
0.030
0.076
+0.067
+0.027
0.057
0.143
80
0.030
0.076
0
0.015
0.015
0.076
130
0
0.025
0.048
0.088
0.088
0.023
95
+0.089
+0.054
+0.054
0
0.089 0
105
+0.17
+0.08
+0.054
0
0.17
0.026
6
7
8
U42103
Check item
9
10
11

frame and upper hinge
bearing
Clearance between lower
bushing
hinge pin and bearing
frame and lower hinge
bearing
bushing
Clearance at press-fitting
portion of lower hinge
pin seal
Replace
Standard size
Tolerance
12
Height of upper hinge

spacer (small)
36
0.1
13

spacer (large)
61.5
0.1
14
Value for shim between

upper hinge and retainer
15

2
19.6 2 Nm {2.0 0.2 kgm} (when adjusting with shim)
16
Tightening torque of
upper hinge retainer
mounting bolt
mounting bolt
Standard size
17
Standard clearance
Repair limit
Clearance limit
112.8 9.8 Nm {11.5 1.0 kgm} (final value)
205.9 19.6 Nm {21 2 kgm} (final value)
40-43
r
CENTER HINGE PIN
U42103
40-43-1
r
CENTER HINGE PIN
Unit: mm
No.

Criteria
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
80
0.030
0.076
+0.071
+0.036
0.066
0.147

hinge and spacer (small)
80
0.030
0.076
+0.060
+0.030
0.060
0.136

hinge and bearing
80
0.030
0.076
0
0.015
0.015
0.076

hinge and spacer (large)
80
0.030
0.076
+0.030
0
0.03
0.106
Clearance between rear

frame and spacer (large)
95
0.036
0.071
+0.071
+0.036
0.072
0.142
130
0
0.025
0.048
0.088
0.088
0.023
80
0.030
0.076
+0.067
+0.027
0.057
0.143
80
0.030
0.076
0
0.015
0.015
0.076
130
0
0.025
0.048
0.088
0.088
0.023
95
+0.089
+0.054
+0.054
0
0.089 0
105
+0.17
+0.08
+0.054
0
0.17
0.026
6
7
8
U42103
Check item
9
10
11

frame and upper hinge
bearing
bushing
hinge pin and bearing
frame and lower hinge
bearing
bushing
Clearance at press-fitting
portion of lower hinge
pin seal
Replace
Standard size
Tolerance
12

spacer (small)
36
0.1
13

spacer (large)
61.5
0.1
14

15

2
16
mounting bolt
mounting bolt
Standard size
17
Standard clearance
Repair limit
Clearance limit
112.8 9.8 Nm {11.5 1.0 kgm} (final value)
205.9 19.6 Nm {21 2 kgm} (final value)
40-43-2
r
U42103
40-44
Unit: mm
2
3
4
5
U42103
10
11
Clearance between pin and

bushing at joint of grapple
arm
arm cylinder bottom
bushing at both ends of
fork link
bushing at connection of
lift arm and fork
lift arm and frame
fork cylinder bottom and
frame
fork cylinder rod and
bellcrank
bellcrank and lift arm
lift arm cylinder rod and
lift arm
lift arm cylinder bottom
and frame
Tolerance
Remedy
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
70
0.030
0.076
+0.174
+0.100
0.130
0.250
1.0
75
0.030
0.076
+0.174
+0.100
0.130
0.250
1.0
70
0.030
0.076
+0.174
+0.100
0.130
0.250
1.0
95
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
95
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
110
0.036
0.090
+0.207
+0.015
0.051
0.297
1.0
120
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
120
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
125
0.043
0.106
+0.395
+0.295
0.338
0.501
1.0
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
Width of hinge
Joint of grapple arm and

fork
Standard clearance
(clearance a + b)
174 0.5
176 +1.5
0
1.5 4.0
13
Joint of fork and grapple

arm cylinder
75 +0.8
0
78 +0.8
0
2.2 3.8
14
Connection of fork
cylinder and frame
125 +0.8
0
128 0.8
1.4 3.8
15
Connection of lift arm and

frame
127 2.3
130 +2.5
0
0.7 7.8
16
Connection of lift arm and

fork
119 2.3
122 +1.5
0
0.7 6.8
17
Connection of fork link

and fork
138 +3
0.5
143 1.5
27
12
Replace
insert shims on
both sides so
that clearance
is less than 1.5
mm on both
left and right
[''''\
Width between bosses
Replace
replace if there
is scuffing on
pin
['\

arm cylinder rod
Criteria
['\
Check item
[''''\
No.
40-45
r
Unit: mm
Connection of lift arm

cylinder and frame
Criteria
Remedy
Width between bosses
Width of hinge
Standard clearance
(clearance a + b)
120 +0.8
0
+2.5
0
2.2 7.5
19
Connection of bellcrank
and fork link
138 +3
0.5
143 1.5
1 5.5
20
Connection of bellcrank
and lift arm
220 0.5
223 0.5
24
21
Connection of fork
cylinder and bellcrank
115 +0.8
0
118 1.5
1.2 3.0
22
Connection of lift arm

cylinder and lift arm
114 1.5
06
Replace
Adjust with shims

so that clearance
is less than 2.0 mm
on both left and right
U42103
111 2.5
Replace
insert shims on
both sides so
that clearance
is less than 1.5
mm on both
left and right
[''''\
18
Check item
[''''\
No.
40-46
r
U42103
kgm
88 34 Nm
(9.0 3.5 kgm)
kgm
17.2 2.4 Nm
(1.75 0.25 kgm)
AA
SEW00366
Unit: mm
No.
Check item
Criteria
Clearance at fork
positioner switch
37
Clearance at boom
kickout switch
37
Remedy
Adjust
40-47
r
90
OTHERS
U42103
Brake piping ............................................................................................................................................... 90- 3

Hydraulic piping ........................................................................................................................................ 90- 5
Work equipment hydraulic circuit diagram ........................................................................................... 90- 7
Electric circuit diagram (1/4) .................................................................................................................... 90- 9
Electric circuit diagram (2/4) ................................................................................................................... 90-11
Electric circuit diagram E.C.S.S. ............................................................................................................. 90-17
Connector pin arrangement diagram (1/3) .......................................................................................... 90-201
90-1
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Komatsu Wheel Loaders WA450-3 Shop Manual

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SEBM009904

WA450-3LL mount the S6D125 engine.

STRUCTURE AND FUNCTION ......................................

TESTING AND ADJUSTING ..........................................

DISASSEMBLY AND ASSEMBLY .................................

MAINTENANCE STANDARD .........................................

LIST OF REVISED PAGES

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are those previously revised

LIST OF REVISED PAGE

LIST OF REVISED PAGES

LIST OF REVISED PAGES

LIST OF REVISED PAGES

LIST OF REVISED PAGES

To prevent injury to workers, the symbol

Always wear safety glasses when hitting

3. If welding repairs are needed, always have a

6. Decide a place in the repair workshop to keep

PRECAUTIONS DURING WORK

19.Be sure to assemble all parts again in their original places.

STRUCTURE AND FUNCTION

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

Chassis volume: Issued for every machine model

Revised pages are shown in the LIST OF REVISED

Special safety precautions

Special technical precautions or other precautions

Weight of parts of systems. Caution necessary

Places that require special

Places to be coated with

Places where oil, water or

Places where oil or water

Heavy parts (25 kg or more) must be lifted

If a part cannot be smoothly removed from the

Slinging near the edge of the hook may cause

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

4) Do not sling a heavy load with ropes forming a

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, release

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

1) Hold the mouthpiece of the tightening portion

1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

2) Hold in the condition in Step 1), and push

3) Hold in the condition in Steps 1) and 2), and

3) Hold in the condition in Steps 1) and 2), and

Hold the mouthpiece of the tightening portion

Hold the mouthpiece of the tightening portion

Main applications, featuresr

Used to prevent rubber gaskets,

Used in places requiring an immediately effective, strong adhesive.

Features: Resistance to heat and

Used as adhesive or sealant for

Used as sealant for machined