TCM 803 804 805 806 Wheel Loader Super Silent Loader Service Manual SEW-605AE - PDF DOWNLOAD

N0．SEW・605AE

T⊂M⑧

．．．．．．．＿．

虔這符牒雷励姐純良 WHEEL LOADER 8ロコ・804

805・806

TtⅣlリー臥H■I￠l．」JD．

FOREWORD TCMisofftringawidevarietyofwheelloaderswhichenthusiasticallywelcomedbytheuserSalloverthe world．

TheModels803，804，805，and806articulatedtypewhee1loadersarethelatestproductsdevelopedb

Ofresearchandexperience．Togetthemostoftheloader，1tisrequiredtobecomefami1iarwithitsfbat COnStruCtion，Operatlngandmaintenanceprocedures・

ThisServiceManualexplainsthestructureoftheaboveloaders払rservicepersonnelandshopworkers

Wehopeitwi11beyourgoodcompanioninserv1Clngjob． ThedescrlPtlOnandspeci銭cationsdescribedinthismanualaresubjecttochangewithoutnotice．

TABLE OF CONTENTS 1．SPEC［FICAT10NS……………………‥．．．…‥．……‥．……．……1 1．10UTERVIEWS ……………………………‥．．……．……‥．．……‥1 1．2 SPECIFICATIONS ‥．．…………‥．……………………．．…………‥．5 1．3 NAMEPLATES …………………………‥．………………………‥ 9

2．ENGINEANDALuED COMPONENTS．…………．．．…‥．………．‥ 2．1ENGINE …………………………………………………………．10 2．2 LUBRICATINGSYSTEM……………………‥．．……………………‥18 2．3 COOLINGSYSTEM．…………………………………‥．……‥．……19 2．4 FUELSYSTEM．‥‥．．．．．‥‥‥．．‥‥‥‥．‥‥．………………………… 22 2．5INTAKEANDEXHAUSTSYSTEM．．．…………………………………… 25 2．6 ELECTRICALSYSTEM‥．………………．．…………………………．．28 2．7 ENGINECONTROLUNIT

30

3．POWERTRAIN…．．……‥‖……………………………………‥31 3．1HSTUNIT……………………．……．．．…………………………‥ 33 3．1．1HYDRAULICDRIVE ………………………‥．．……………．……．33 3．1．2 HSTPIPING……………………………………………………‥ 36 3．1．3 HSTCONTROL…．．……‥．……‥．……………………．……‥．．．40 3．2 HSTPUMP．．……………………………………………………… 42 3．3A HSTMOTOR（803）…………………‥・・・…………………………・54 3・3B HSTMOTOR（804，805，806）……………………・・……………・……‥59 3．4 REDUCTION GEAR ……．．……．．…………………………………‥ 64 3．5 PROPELLERSHAFTS ……………………………………．………… 67 3．6DRIVEAXLES（FRONTANDREAR）……………………………………・69 3．6．1DRIVEAXLE …………………………………………………… 69 3．6．2 AXLEMOUNT ………………………………………‥．………‥ 75

3．7 WHEELASSEMBLY ……………………．…………………．．．．．…… 76 3．7．1TIRE…………………………………………………………‥ 76 3．7．2 WHEEL ………………………………………………………‥ 78

4．BRAKESYSTEM …………．…………………‥．………．………．79 4．1BRAKELINE …………………………‥．………………………… 80 4．1．1GENERALDESCRIPTION…………………………‥．……………‥ 81 4．1．2 0PERATION………………………………………………‥‖‥．82

4・2SERVICEBRAKE …・・……・・…………‥・………‥…………・・・…‥85 4．2．1MASTERCYLINDER………‖……………………………………．85 4．2．2 DISKBRAKE…………………………………………．………… 87 4．3 PARKINGBRAKE……………………．．……………………‥．…… 88 4．3．1PARKINGBRAKEVALVE ……………………………．．…………‥ 89

5，STEERING SYSTEM．．．．‥‥．．‥‥‥．‥‥‥‥‥‥．．．．．．‥‥．‥‥‥．‥． 5．1GENERALDESCRIPTION ………………………………………．．…‥ 90 5．2 0ILCIRCULATIONROUTE…………………………………………．．．92 5．3 STEERINGWHEELUNIT‥．…………………………………………‥ 93 5．4STEERVALVEUNIT（ORBITROL）………‥・……………………………94 5．4．10RBITROL ……………………………………………………‥ 95 5．4．2VPVALVE（PRIORITYVALVE）………………………‥・……………98

5．5STEERINGCYLINDER．‥‥．．‥‥．．．‥‥．．．．．‥．………………………．

6．FRAMEAND COCKP］T ‥．．…………………………．．…………．103 6．1FRAME…………………………………………………………．103 6．2 CENTERHINGEpIN………………………………………………‥104

7．HYDRAUuC SYSTEM‥‥．．．……………………………………．．107 7．10ILCIRCULATIONROUTE．．．．‥．．‥．‥‥．‥．．‥

…‥．．．………．…

7．1．1GENERALDESCRIPTION‥‥．……………………………………‥108 7．1．2 RETURNFILTER …………．．………………．．．．………………‥111

7．2 pUMP ………………………………………．．…………………112

7．2．1MAINPUMP．‥．．．‥‥．．．．．‥‥‥．‥‥‥．．‥‥‥‥‥‥‥‥‥．………‥11 7．2．2 HSTCHARGINGPUMP……………………………………………113 7．3 CONTROLVALVE ……………………………．．．……………．…‥114 7．3．1GENERALDESCRIPTION．……………………………‥．…………114 7．3．2 0PERATION ……………………………………………………119 7．3．3 RELIEFVALVE …………．．．．…………………………………‥123 7．4 VALVECONTROLS ……‥……………………．．…．t……………‥124 7．5 0ILTANK ………………………………………………………．125

8．LOAD HANDuNG SYSTEM…………‥．．………………………‥126 8．1BOOM，BELLCRANKANDBUCKET…………．……………．・・．・・……‥・127 8．1．1GENERALDESCRIPTION．．…………………………‥．…………‥127 8．1．2 BUCKET ……………………．…………………．……………．129 8．1．3 BUCKETLEVELER …………………………………．…………‥130 8．2 CYLINDERS．．‥．‥．‥‥‥．．．……………………．…………………132 8．2．1BOOMCYLINDER ……‖……………………．…‥．．……………132 8．2．2 BUCKETCYLINDER ……‥．……………………………………‥132

9．ELECTRICSYSTEM………．．……．．……………………………．135

9・1LIGHTINGEQUIPMENT ……………‥・・・・・……・ 9．2 METERSANDSWITCHES ……………………∴……．．……………‥136

9．2．10PERATINGSTATUSMONITORS（CLUSTERGAUGES）…………………‥136 9．2．2 LIGHTINGSWITCH ………………………………………………140 9．2．3 TURNSIGNALSWITCH……．．…．．…………．．……………………140 9．3 ELECTRICCIRCUITDIAGRAM ……．．．………………………………．141

1．SPECIFICAT10NS 1．10UTERVIEWS

Unit：mm

Unit：mm

ー2−

Unit：mm

ー3−

Unit：mm

−4−

1．2 SPECIFICAT］ONS Modcl Item MachimeName

＄03

804

805

TCM803

TCM804

TCM805

TCM806

＄0

Front−endarticulatedloader withdieselenglne

町pe

Per払rmance

Bucket Type

DEB（doubleedgedbucket）

Bucket Capacity （StruCk）

0．25m3

0．34m3

0．43m3

0．51m3

（heaped）

0．30m3

0．40m3

0．50m3

0．60m3

soo kg

650 kg

800 kg

900 kg

（boomcylinder）

1490kg

2140kg

2350kg

2260kg

（bucketcylinder）

2290kg

2700kg

3610kg

3210kg

RaisingTlme（fullload）

4．3s

5．2s

5．4s

5．5s

LoweringTime

3．Os

◆−

3．2s

BucketDumpingTime

1．Os

OperatingLoad（fullturn） BreakoutForce（SAE）

1．2s

Travel Speed （forward）

15．Okm／h

（reverse）

15．Okm／b

Max．TractionForce Gradeability

◆−

1650kg

2700kg

3300kg

300

300

300

【at3．4kmnlinforward］

【at3．5kmnlinforward］

【at3．4kmnlinforward］

（frontwheel）2830mm

仲ontwbeel）3270mm

世ontwbeel）3490mm

300

【at3．3kmnlinfbrward］

Min．TurningRadius （outermostpartofloader） （outermostpartofbucket）

3120mm

3640mm

3910mm

（frontwheel）2680mm

（frontwheel）3100mm

（丘ontwheel）3280mm

（bucketonground）

（bucketedge）3520mm

（bucketedge）4045mm

（buc寧etedge）4460mm

（bucketedge）4530mm

（underno−loadconditionincarryposition）

（bucketedge）3490mm

（bucketedge）4030mm

（bucketedge）4430mm

（bucketedge）4470mm

（loaderbody）

1380mm

1505mm

1660mm

（bucket）

1390mm

1570mm

1690mm

（centerofoutermostwheel）

3930mm

Dimemsions

Overall Length

Overall Width

一5−

◆−

さ03

別）4

805

（steeringwheelknob）1780mm

（steeringwheelknob）1825mm

（steeringwheelknob）1865mn

Overa110peratingHeight（bucketfu11yraised）

3095mm

3435mm

3865mm

Wheelbase

1550 mm

1780 mm

1900 mm

仲ontwhecIs）

1100mln

1180mm

1260mm

（rearwheels）

1100 mm

1180 mm

1260 mm

（incarryposition）

1315mm

1540mm

1740mm

1780mm

（bucketonground）

1345mm

1555mm

1770mm

1840mm

RearOverbang

625mm

710mm

790mm

HoodHeight

1235mm

1280mm

1320mm

BodyHeight

（Steeringwheelknob）1780mm

（steeringwheelknob）1825mm

（steeringwheelknob）1865mm

Min．GroundClearance

（attransmissioncasebottomedge）210mm

（attranSmissioncasebottomedge）255mm

（attransmissioncasebottomedge）295mm

BucketHingePinHeight

2490mm

2765mm

3115mm

DumpHeight（at450dischargeangle）

（bucketedge）1970mm

（bucketedge）2210mm

（bucketedge）2520mm

（bucetedge）2470mm

Reach（at450dischargeangle）

（bucketedge）630mm

（bucketedge）800mm

（bucketedge）840mm

（bucketedge）890mm

Item

Overal1Height（bucketonground）

80

3930mm ◆−

Tread

Front Overhang

BucketRoll−BackAngle（underno−loadconditionin

◆・−

550

CarryPOSition） BucketDumpingAngle（bucketfu11yraised）

490

500

490

DiggingDepth（withbuckettiltedfbrwardlOO）

155mm

165mm

180mm

Towing Device Height

425mm

470mm

510mm

1850 kg

2570 kg

3100 kg

3250 kg

（underno−loadcondition）

世ont猥1e）820kg，（rearade）1030kg

（frontaxle）1050kg，（rearaxle）1520kg

（frontaxle）1230kg，（rearaxle）1870kg

（frontaxle）1200kg，（rearaxle）2050kg

（underratedload）

（frontaxle）1620kg，（rearaxle）730kg

（frontaxle）2110kg，（rearaxle）1110kg

（frontaxle）2580kg，（rearaxle）1320kg

（frontakle）2720kg，（rearaxle）1430kg

Name

D1105 Diesel engine

V1505 Diesel engine

V1505−TDieselenglne

Type

4−CyCle，Water−COOled，OVerheadvalve，in−1ine， Vertical，VOrteX−Chambertype

190mm

Weight WeightofLoader Weight Distribution

Engine

4−CyCle，Water−COOled，OVerheadvalve，in−1ine， Vertical，VOrteX−Chambertype，withexhaustturbo

Charger Battery

12V，52Ah（5−hourrate），1pc．

◆−−

Radiator （enghe） （HST）

Corrugated丘n（WaVy）＆tube Corrugated丘n＆tube

−6−

◆−

Model

803

AirCleaner

Cyclone，paper丘1tertype

Muffler

Porousandseparatortype

SO4

805

＄0

PoⅥ℃rTrain

HST Pump （Model）

A4VG28DA−980

（Type）

Variabledeliverypistonpump

A4VG28DA−981

A4VG28DA−982

A6V59DA−986

A6V59DA−987

TCM606−32

TCM608−32

TCM606−30

（front）TCM608−30，（rear）TCM606−30

HST Motor （Model）

A6VM28HA−993

（Type）

Variabledeliverypistonmotor（inc血edshaf［）

Reduction Gear （Model）

TCM605−32

（Type）

ConstantqmeSh，SPur−gearl−Stagereduction

ReductionGearandDifferential （Model）

TCM（iO5t30

（Type）

Usualtype，2−Stagereduction

FinalReductionGear （Model）

TCM（；05−30

（Type）

Planetarygeartype

TCM606−30

◆−

Axles and Wheels Driving

4−Wheeldrive

Front Axle

Frame−nXed，Semi−floating

Rear Axle

Cradle−pln−SuPPOrted，Semiーfloating

Tires（frontandrear）

10−16．5−4PR，tubeless（し2）

Rim（frontandrear）

16．5Ⅹ8．25150DC

◆−

12．5／70−16−6PR，tubeless（L−2）

16Ⅹ10LB DC

15・5／60−18−8PR，tubeless（Lt2）

18ⅩW13

Brake System Service Brake （Type）

Reduction−gear−inpuトShaftbraking，Wettype

◆−

hydraulicdiskbrake （Numberoffluidlines）

1 line

◆−

Parking Brake （Type）

Reduction−gear−input−Shaftbraking，Wettype mechanical（spring）diskbrake

−7−

◆−

Model Item

803

804

805

SO

SteeriI唱System

Type SteeringCylinder

Framearticulated Double−aCtingpistontype，1pe．

LoadHa皿dlingSystem

Linkage

InverseZtype

BucketTeeth

Typel（DEB）

Hydraulic System BoomCylinder

Double−aCtlngPistontype，2pcs．

Bucket Cylinder

Double−aCtingpistontype，1pc．

◆−

◆−

MahPump （Model）

GSP2−12

（Type）

Geartype

Steering Pump

GSP2−16

Doublesasmainpump

GSP2−19

◆−

HSTChargingPump （Model）

Gl−06

（Type）

Gear type

◆−

Control Valve （Model）

KVS−31

（Type）

Tandemtype，2−SPOOIslidingtype， 南山reliefvalve

KVS−65

−8−

◆−

1．3 NAME PUITES 1．NameIIlate

Thenameplatedescribesthemodelname，maXimum loadingcapacity，tOtalweightofloader，andserialNo・

Fig．l．1NamePlate

2．Lecation ofLoader SerialNumber Theloaderserialnumberisstampedontheleftside faceofthefrontframe，neartheboomcylinderpln・

∴鮎二一、・ ・1・・︑ゝ

￣

¶

ゞ、・・・・・・・

Fig．.2 Loader Serial Number 3．I，OCationofEngineSerialNumber TheenglneSerialnumberis stamped on the right cylinderblock（Withtheenginemountedontheloader）・

Fig．l．3EngineSerialNumber

4．SerialNumbersofMqjorComponents

ThemaJOrCOmPOnentSOftheloadercarrytheirownserialnumbersstampedthereonoronthedeca

majorcomponentsinclude：theHSTpump，HSTmotor，reductiongear，aXles（frontandrear），andco valve．

−9−

2．ENGINEANDALL暮ED COMPONENTS 2．1ENGINE 1．GeneralDescription TheenglnemOuntedonthisloaderisa4−CyCle，Water−COOled，OVerhead−Valve，in−1inevertical，VOrteXChamber

typedieselengine・On805and806，theirengines（V1505−Tdieselengine）areequippedwithanexhaust−gaS−

driventurbocharger nepoweroftheenglneistransmittedfromtheflywheelthroughthecouplingtotheHSTpump．

Fig・2・1EngineandAlliedComponents

−10＿

（1）＄03（DllO5DieselEngine） Name

DllO5dieselenglne

Type

4−CyCle，Water−COOled，OVerhead−Valve，in−1inevertical，VOrteX

Numberofcylinders−borexstroke

3−78．Ommx78．4mm

Total displacement

l．123せ

Compression ratio

22．0

chamber type

Engineperbrmance

Rated speed

2500 rpm

Rated output

22．OPS

Maximum torque

7．Okg−m（atapprox・1600rpm）

Fu11−loadmin・COnSumPtlOnratio

185gPSh（at2000rpm）

Dry weight

120 kg

Dimensions（OVera11lengthxoverallwidth

537．8mmx439．7mmx564．7mm

XOVerallheight） Firing order

1−2−3

Rotational direction

Clockwisewhenviewedfromcoolingfan

Starting aid

Withquickglowplug（autoglow）

Stopping system

Keyswitchtype

Unloadedmax．speed（Whenseparately

2700誓5rpm

血easured）

Unloadedmin．speed（Whenseparately

800±50rpm

measured） A1lowabletiltingangle

300inburdirectionswhenviewedfromflywheel

Maintenancedata

Open

Valveopenlngandcloslngtimlng Intakevalve

140bebreTDC 300afterBDC

Exhaustvalve 55ObebreBDC 140afterTDC Valve clearance

Intakevalve（COld）‥0・145−0・185mm Exhaustvalve（COld）：0・145−0・185mm

Injection timing

17to190beforeTDC

Injectionstartpressure

140kがm2

Compressionpressure

29−33kgkm2（at350rpm）

−l1−

Closed

（2）＄04（D1505DieselEngine） Name

V1505dieselenglne

T〉−11e

4−CyCle，Water−COOled，OVerhead−Valve，in−1inevertical，VOrteX

chamber type

Numberofcylinders−borexstroke

4−78．Ommx78．4mm

Total displacement

l．498ゼ

Compression ratio

22．0

Engineperbrmance

Rated speed

2400 rpm

Rated output

29．OPS

Maximum torque

9・5kg−m（atapprox・1600rpm）

Full−loadmin．consumptlOnratio

190g伊Sh（at2000rpm）

Dry weight

140 kg

Dimensions（OVeralllengthxoverallwidth XOVerallheight）

622．8mmx398．6mmx670．2mm

Firing order

1−3−4−2

Rotational direction

Clockwisewhenviewedfromcoolingfan

Starting aid

Withquickglowplug（autoglow）

Stopping system

Keyswitchtype

Unloadedmax．speed（whenseparately

260鴫5rpm

measured） Unloadedmin．speed（Whenseparately

800±50rpm

measured） Allowabletiltingangle

300inburdirectionswhenviewedfromflywheel

Maintenance data

Valveopenlngandcloslngtimlng

Open Intakevalve

140befbreTDC 300afterBDC

Exhaustvalve 550bebreBDC 140afterTDC Valve clearance

Intakevalve（COld）

Exhaustvalve（COld）

0．145−0．185mm O．145−0．185mm

Injection timing

12to140bebreTDC

Injectionstartpressure

140kg／cm2

Compressionpressure

29−33kgkm2（at350rpm）

−12−

Closed

（3）＄05and＄0

（V1505・TDieselEngine）

Name

V1505−Tdieselenglne

Tサpe

4−CyCle，Water−COOled，OVerhead−Valve，in−1inevertical，VOrteX chambertypewithexhaust−gaS−driventurbocharger

Numberofcylinders−borexstroke

4＿78．Ommx78．4mm

Total displacement

l．498ゼ

Compression ratio

22．0

Engine performance Rated speed

2400 rpm

Rated output

37．OPS

Maximum torque

ll．8kg−m（atapprox・1800rpm）

Full−loadmin．consumptlOnratio

175g仲Sh（at1800rpm）

Dry weight

145 kg

Dimensions（OVeralllengthxoverallwidth

621．3mmx439．2mmx670．2mm

XOVerallheight） Firing order

1−3−4−2

Rotational direction

Clockwisewhenviewedfromcoolingfan

Starting aid

Withquickglowplug（autoglow）

Stopping system

Keyswitchtype

Unloadedmax．speed（Whenseparately

260鴫5rpm

measured） Unloadedmin．speed（Whenseparately

800±50rpm

measured） Allowabletiltingangle

300inburdirectionswhenviewedfromflywheel

Maintenancedata

Valveopenlngandcloslngtimlng

Open Intakevalve

Closed

140bebreTDC 300afterBDC

Exhaustvalve 550be丘）reBDC 140afterTDC Valve clearance

Intakevalve（COld）

Exhaustvalve（COld）

0．145−0．185mm O．145−0．185mm

Injection timing

12to140beforeTDC

Injectionstartpressure

140kgたm2

Compressionpressure

29−33kgkm2（at350rpm）

−13−

2．OuterViewsofEngine （1）DllO5DieselEngine 1．WATER TEMPERATURE GAUGE SENSOR FITrING PORT 2．ALTERNATOR 3．CAR HEATER WATER INLET 4．COOLING WATERINLET 5．OIL PRESSURE SWITCH FnnnNG PORT 6．OIL FILTER 7．WATER DRAlN COCK 8．WATER TEMPERATURE

SENSOR（FORGLOW） 9．EXHAUSTMANIFOLD lO．STARTER MOTOR ll．FLYWHEELHOUSING 12．CRANKCASE 13．0IL PAN

1 6

1

7

1

8

1

16．INLETMANIFOLD

4 5

15．CYLINDER HEAD COVER

1

14．NOZZLE HOLDER

17．CYLINDER HEAD 18．ENGINE STOP SOLENOID 19．FUEL PUMP 20．COOLING WATER OUTLET 21．CAR HEATER WATER OUTLET

22・FUELSUCTIONPIPE（FROM FUELFILTER） 23．INJECTION PUMP 24．COOLINGFAN 25．V−BELT

26・FUELSTRAlNER（INSTALLED ONFUELTANK）

Fig・2．2DllO5DieselEngine

−14−

（2）V1505DieselEngine

1．VVATERTEMPERATURE GAUGE SENSOR FITrING P（）RT

2．ALTERNATOR 3．CAR HEATER WATER INLET 4．COOLINGWATERINI，ET 5．0ILPRESSURESWITCH nTnNGPORT 6．0ILFILTER 7．WATER DRAIN COCK 8．WATER TEMPERATURE

SENSOR（FORGLOW） 9．EXHAUSTMANIFOLD lO．STARTER MOTOR ll．FLYⅥ／HEEL HOUSING 12．CRANKCASE 13．0IL PAN

5 7

1

6

1

8

16．INLETMANIFOLD

4

15．CYLINDER HEAD COVER

1

14．NOZZLE HOLDER

1

17．CYLINDER HEAD 1

18．ENGINE STOP SOLENOID 19．FUELPUMP 20．COOIJINGWATER OUTLET 21．CARHEATER WATER OUTLET

22・FUELSUCTIONPIPE（FROM FUELFILTER） 23．INJECTION PUMP 24．COOLING FAN 25．V−BELT

26・FUELSTRAINER（INSTALLED ONFUELTANK）

Fig・2・3V1505DieselEngine

−15−

（3）V1505−TDieselEngine 1．WATERTEMPERATURE

SENSOR（FORGLOW） 2．WATERTEMPERATURE GAUGE SENSOR FITTING PORT 3．ALTERNATOR 4．CAR HEATER WATER INLET 5．COOLINGWATERINI，ET

6．0IL PRESSURE SWITCH FImNG PORT 7．OIL FILTER AND OIL COOLER 8．WATER DRAIN COCK 9．TURBOCHARGER lO．EXHAUSTMANIFOIJD ll．STARTER MOTOR 12．FLYWHEEL HOUSING 13．CRANK CASE 14．0IL PAN

15．NOZZLE HOLDER 6 8

1

9

1− 1

18．CYLINDER HEAD

7

17．INLETMANIFOLD

5

1

16．CYLINDER HEAD COVE

19．ENGINESTOP SOLENOID 1

20．FUELPUMP 21．COOLING WATER OUTLET 22．CAR HEATER WATER OUTLET 23．FUELSUCTIONPIPE（FROM FUELFILTER） 24．INJECTIONI】UMp 25．COOLINGFAN 26．Ⅴ−BELT 27．FUEl．STRAlNER（INSTALLED ONFUELTANK）

Fig．2．4V1505−TDieselEngine

−16−

3．EngineMounting

Theenglneismountedontherearframethroughbracketswithmountlngrubbersatitscoolingfansideand isconnectedtotherearframetogetherwiththereductiongearattheflywheelside・

﹁

単＝．

︶イ・1／

シー−−−や

／

し

／招畑し

Notes：D＞ぢ＝：コ8・5kgdm（61ft−1bs） B＞ぢ＝コ5・6kg−m（40ft−1bs）

B＞ぢ：：：：＝コ5．1kg−m（37ft−1bs），一4＝ゝThreadedarea‥LOCTITE262 B＞仁＝＝袖Insidesplines：Molybdenumgrease（approx・10cc）

匪＞ぢ＝コ5．1kg−m（37ft−1bs）

匡＞ぢ＝：コ4・Okg−m（29ft−1bs）

1．ENGINE

4．REARFRAME

7．COUPLING

2．BRACKET

5．WASHER

8．REDUCTIONGEAR

3．MOUNTRUBBER

6．DRAINHOSE

9．DRAlNPLUG

Fig．2．5MountlngOfEngine

−17−

2．2 LUBRICATING SYSTEM ＄03（DllO5）

＄04

805，＄0

（V1505）

（V1505−T）

Lubrication

Forcedcirculation

Lubricatingpump

Trochoidpump，directlycoupledtocrankshaft

←

Filtration

Full−flowtype，PaPer員1ter

●−

Cooling

Oil pressure adjuster LubricatlngOilcapacity

Watercooled Ballvalve，SprlngtyPe

◆・−

4．1ゼ

◆−

5．6ゼ

neenglnePartSarelubricatedbybrcedcirculationmethodbytheoilpumporbynaturallubricationby Oiloozedffomtheparts鮎rced−1ubricated．

Thecrankshaft，CamShaft，rOCkerarm，idlergears，andgovernorgearreceiveforcedlubricationwhilethef

CamShaft，tapPetS，andpushrodsarelubricatedbynaturallubricationmethod． ROCKER ARM SHAFT

ROCKER ARM

Fig・2・6EngineLubricatingSystem −18−

2．3 COOuNG SYSTEM ＄03（DllO5）

Cooling Cooling fan 「丹pe

＄04

＄05，＄0

（V1505）

（V1505・T）

Water−COOling

←

Pushertype，350mmdia・

←

Pushertype，380mmdia・

6−bladed

6−bladed

Driving

V＿beltdrive

Water pump

V−beltdriven，Centrifugal

◆−

←

◆−

◆−

●−

type Watertemperatureregulator

Type

Waxtype

OpenlngtemPerature

820C

Full−OPenlngtemperature

950C

←

Corrugated鎖n（WaVy）＆

←

◆−

7lOC 850C

Radiator r丹pe

●−

tube

CapopenlngpreSSure （Pressurevalve）

0．9kg／cm2

（Negativepressurevalve）

0．05k釘cm2

◆−

Watercapacity

3．4ゼ

←

3．7せ

Dryweight

8．2kg

←

9．5kg

Cooling water capacity

6．9Q（totalcapacity）

6・3Q（totalcapacity）

7・2Q（totalcapacity）

l．GeneralDescription TheenginecoolingsystemisawateトCOOledforced−Circulationtypebymeansofthewaterpump・

Thecoolingwaterispickedupfromtheradiatorbythewaterpumpandissenttoeachpartfbrcooling・ Whenthecoolingwatertemperatureislowenoughtokeepthethermostatclosed，thecoolingwater

recirculatesinsidetheenglneWithoutflowinglntOtheradiator・Asthecoolingwatertemperaturerisesenoug toopenthethermostat，thecoolingwaterissentintotheradiatorfbrcoolingbebreflowinglntOthewater pump・

ー19−

Note：B＞ぢ＝コTightentheboltuntiltheboltheadprotrudes2pitchesh・Omthedoublenuthead． 1．RADIATOR

5．SHROUD

9．RADIATORHOSE

2．RADIATORRUBBER

6．SOUND−ABSORBINGMATERIAL

lO．OILCOOLER

3．RADIATORHOSE

7．REARFRAME

11．ENGINE

4．RADIATORRUBBER

8．RESERVETANK

Fig．2．7CoolingSystem

ー20−

2．Radiator

A．COOLINGWATERINLET

1．RADIATOR CAP

4．VINYLHOSE

B．COOLINGWATEROUTLET

2．RADIATORSUBASSEMBLY

5．RUBBERHOSE

C．fromRESERVETANK

3．DRAlNCOCK

Fig．2．8Radiator

−21−

2．4 FUELSYSTEM

＄の（DllO5）

804

＄05，＄0

（V1505）

（V1505・T）

Injectionpump

Boschtype

Injectionnozzle

Throttletype

←

Fuel feed pump

Solenoidpump（Plungertype）

←

Fuel員1ter

Full−flowtypeofnlterpaper

←

●−

◆−

◆−

Governor

Governlng

Centrifugal，all−SPeedcontrol

Lubrication

Mist

Fuel tank capacity

◆・−

33ゼ

◆■

40ゼ

1．GeneralDescription

Thesolenoidpumpdrawsfuelfromthefueltankandforcesitunderpressurepastthewatersedimentorand

fuelⅢterintotheinjectionpump，fromwhichthefuelisdistributedtotheinjectionnozzleaccordingt lnJeCtiontimingofeachcylinder，thusbeinglnJeCtedintothecombustionchamber・

Note：Mode1803（DllO5engine）doesnothaveawatersedimentor・ lNJECT10N NOZZLE

Fig．2．9EngineFuelSystemSchematicDiagram

＿22−

2．FuelTamk

Thefueltankisboltedtotheleftsideoftherearframe，Withitsfuelhoses（SuCtionandreturn）con totheenglne・

ThefueltankisequlPPedwithafuellevelsenderunitlinkedtothefuelmeteronthedashboard．

Tankweight （803）：aPPrOX・27kg （804，805，806）：aPPrOX・33kg

1．FUELLEVELSENDER UNIT

4．ENGINE

7．FUELHOSE

2．FUELTANK

5．STRAINER

8．VVATERSEDIMENTOR

3．DRAlNPLUG

6．FUELPUMP

9．FUELFILTER

Notes：l・Theabove員gureillustratesthefuelsystemofMode1804． Mode1803does nothave awatersedimentorinitsfuelfeedline． 2・Someloadersmayhaveastrainer（5）atthefueltankside・

Fig．2．10FuelSystem ＿23−

（Unit：mm）

Float Resistance

position FULL

団 10二

3／4

（19）

1／2

32±3

1／4

（49・5）

EMPTY 80二

Fig．2．11FuelLevelSenderUnit 3．VVater Sedimentor

Thewatersedimentorseparateswaterfromthefuel・ Whenthefloatrisesuptothe

discharge一一markontheoutsideofthecase，drainwater・

ELEMENT FJLTER CUP FLOAT

Fig．2．12WaterSedimentor

−24−

ViewlookinclfromZ

2．51NTAKEAND EXHAUST SYSTEM

＄03（DllO5）

Air cleaner

Cyclonenlterpapertype

＄04

＄05，80

（V1505）

（V1505・T）

←

Turbocharger Name

Exhaust−gaS−driventurbocharger

Driving

Exhaust−gaS−driving

Lubrication

Forcedcirculation Porousseparators

Mu圧1er

◆−

l．GeneralDescription neintakesystemoftheenglneisdesignedsothattheopenairisdrawnthroughtheaircleanerintothe

inletmanifbld・Theaircleanerisequippedwithanindicator（VaCuumSenSOr）toinbrmtheoperatorth theAlRCLEANERwarnlnglamponthedashboardwhentheaircleanerelementshouldbecleaned． Theexhaustsystemisdesignedsothattheexhaustgasfromtheexhaustmanibldisdischargedthroughthe

mufflerwherethepressureandtemperatureoftheexhaustgasareloweredintotheatmosphere．

▲

Becarefu1nottotouchthemllmerandexhaustmanibldsincetheyarehotwhentheenglne

isrunnlngOrSOOnafteritisshuto嘩0therwiseyoumightburnyourhand．

TⅦrbo血arger（＄05，＄0 ） neV1505−Tenginehasaturbochargerintheintakesystem．

ItispossibletoattainhighenglneOutPutbysendinghighlycompressedairunderpressureintothecylinders

Ontheintakestroketoincreaseairsupply，thusincreaslngthequantityoffueltobeinjected．Toachi purpose，themodels805and866areequlpPedwiththeexhaust−gaS−driventurbocharger．

Theturbocharger sexhaustgasinletisconnectedtotheexhaustmanibld・neeXhaustgaSrOtateSthe

turbinewheelatahighspeed，thusrOutedthroughtheexhaustgasoutletintothemuffler．Atthistime，

impeller，mOuntedontheoppositeendofthesameshaftastheturbineismounted，alsorotatesatahighs

tocompresstheairdrawnthroughtheaircleanerandsendittotheintakemanifo1d．

＿25−

匡＞Assemblethemufflerandthetailpipeafterapplyingtheexhaustsealontheirconnections．

1．EXHAUSTTUBE

4．ENGINE

7．AIR CLEANERHOSE

2．COVER

5．MUFFLER

8．AIRCLEANER

3．BRACKET

6．TAILI）IPE

9．AIRINTAKEHOSE

Fig・2．13IntakeandExhaustSystem

−26−

2．AirCleaner

1．INDICATOR 2．BODY 3．CLAMPBAND 4．DUSTCUP

Indicatorspecincation

Operatingresistance：635±58mmH20 Circuit

：Normally−OPened

Fig．2．14AirCleaner

ー27−

5．ELEMENT 6．WINGNUT 7．BAFFLESCARF

2．6 ELECTRfCALSYSTEM

別追（DllO5）

＄04

＄05，80

（V1505）

（V1505・T）

Battery Voltage and capacity

←

12V，52Ah（5−hourrate）

Quantity

←

Weight

approx・17・1kg

◆・−

Starter motor D．C．series−WOundmotor

′丹pe

Withreductiongear Voltageandoutput

12Vandl．2kW

12Vandl．4kW

Alternator

Type

A．C．type

Voltage and output

◆−

12VandO．36kW

Driving

← ←

V−beltdrive

←

ICregulator（builtinalternator）

←

◆−

Automaticchargingregulator Name Method Cold start aid

Stoppingdevice

Thyristor（SCR）

◆−

Provided（glowplug）

◆−

←

Solenoidtype

2．6．1BAITERY

nebatteryunitisinstalledinsidetheenginehoodattherightsideoftherearframe．Wheninspectionof thebatteryunitisneeded，OPentheenginehood・

▲DANGER！！Useduecauti。nWhenhandlingthebatte，ymit． 1・Nofire・No sparks・Neversmokeorusefireornakedflamenearthebatteryunit since

flammablegasisalwaysreleasedfromthebattery・Thereisdangerofexplosion・ 2・Thebatteryelectrolyteisdilutesulfuricacid・Itwi11causePainfu1andseriousburnSifitg Ontheskin・Itcancauseblindnessifitgetsintoeyes・Ifelectrolytegetsonyoureyes†flushyour eyesoutwithwaterandgettoadoctor．

ー28−

2．6．2 ELECTRIC CIRCU］T

Note：Fortheelectriccircuitdiagramoftheenglne，reftrto

Fig．9．6ElectricCircuitDiagram．一

1．GeneralDescription

TheenglneCOldstartaidisawatertemperaturesenslngautO−glowtypeconsistlngOfaglowplugs，gl SenSOr（WatertemPeratureSensOr）whichsensesthepreheatingtimeoftheglowplug，glowcontroller，relay

andglowslgnalonthedashboard・WhenthestarterswitchisturnedtoON，thecoldstartaidautomatical

StartSOPerating． Theenglneisshutoffwiththestarterswitch．TheenglneShutoffdeviceconsistsoftheenglneStOPSOlenoid

andstoptlmer．WhenthestarterswitchisturnedtoOFF，thestopsolenoidgetsexcitedtoplacetheinje

PumPCOntrOlrackinthenon−1nJeCtionposition，thusshuttingofftheenglne・

2．Starter Switeh Thestarterswitchhas3positions：OFF，ONandSTART・

▲EngineNeu．．alS．aJ Unlesstheshiftleverisinneutral，theenglneWOn （Re飴rto

3．1．3HSTCONTROL．

tstart．

）

Terminal Position

OFF

ON START

（Rear）

（Front）

Fig．2．15StarterSwitch

−29−

B BR ACC Rl R2 C ○

2．7 ENGINE CONTROL UNIT TheenglneSpeediscontro11edbyoperatingtheacceleratorpedal・ Whentheacceleratorpedalispressed，theacceleratorleverisactuatedthroughthebellcrankandcontroI

CablesothatanenglneSPeedmostsuitedtotheworkingconditionisobtained・

1 2

ViewA（DetailofacceIerator始Ver）

2．STOPPERBOLT

4．BELLCRANK 5．SPRING

3．ROD

6．CABLE

1．ACCELERATORPEDAL

Fig．2．16EngineControIUnit

ー30−

7．ENGINE 8．ACCELERATORLEVER

3．POWERTRA］N

ThepowertrainconsistsoftheHSTunit，reductiongear，PrOPellershafts，driveaxles（ftontandrear）an tires．

ThepowerfromtheenglneistransmittedthroughtheHSTunittothereductiongearwhereitisreduced

inspeedanddistributedthroughthepropellershafttothefrontandrearaxles・Thepowertransmittedt axleisfurthersentthroughthewheeltothetiresothattheloaderruns．

（HSTMOTOR）

Fig．3．1PowerTrain

−31−

TheschematicdiagramofthepowertransmissionoftheloaderisglVenbelow・

Fig．3．2SchematicDiagramofPowerTransmission

−32−

3．1HST UNIT 3．1．1HYDRAULIC DR］VE

l．GeTleralDescription Hydraulicdrivesconvertenginepowerfirsttofluidpowerandthentomechanicalpower（1inearorrotational

motion）whichdrivesthewheelsorothercomponents・nefluidtobeusedismineralhydraulicoil・Inth

sense，yOu Can Callallhydraulic drives as a hydrostatic transmission（HST）・However，the hydros transmission（HST）generallymeansthekindofhydraulicdrivethattransmitsonlyrotationalpower・

Hydraulicdrives areclassi抗edintotwotypes‥thehydrostatictypewhichusespressureenergyand hydrodynamictypewhichuseskineticenergy・

（1）IIydrodynamicUmit

Thehydrodynamicunituseskineticenergyproducedby fluidflowing at a high speed・The high−Speed，low−

PreSSurefluidisdischargedfromthecentrifugalpumphits the turbine wheelblades to turn the turbine wheeland

thustheturbineshaftoutofwhichtherotationalpoweris taken．Thetorqueconverterisatypicalhydrodynamicunit andisusedR）rmiddle−tOlarge−Sizedwheelloadersand othervehicles．

Fig．3．3

（2）HydrostaticUnit ThehydrostaticunituseShigh−PreSSure，lowTSpeedfluid （Oilpressure）・nePreSSureOildischargedfromthepump issenttothehydraulicmotorwhichisinturnrotatedto transmit the power to the drive wheels. This kind of

hydrostaticunitiscalledahydrostatictransmission（HST）・ TheHSTpumpandHSTmotork）rmaClosedloop，Orare COnneCted throughthe hydrauliclines so that thefluid

flowsbetweenthe pump and motor．Sincethefluidis nonTCOmPreSSive，1taCtSaS arigidlinkthatconnectsthe pumptothemotor・Thiskindofunitisused丘）rSkidsteer loaders andsmall−Sizedwhee1loaders．

−33−

Fig．3．4

2・HydrostaticTransmission（IIST） Theoperatingprincipleofthegeneralhydrostatictransmission（HST）whichusesavariablecapacityaxial PistonpumpandmotorfortheHSTpumpandHSTmotor，reSpeCtivelyisglVenbelow・

（1）OperationofHSTPump

①whentheslidingsurfaceoftheswashplateisflatandpositionedvertical，thesystemstandsneutrala

nooilisdischarged・Evenifthedriveshaftrotates，thesuctionanddischargeofoilisnotperfbrme

despltetherotationofthecylinderblock．

Fig．3．5Neutral

②whentheswashplateanglecontro11everisshiftedtotheleft，thecylinderblockturnsenoughtopass

beyondthekidneyBtodrawoilintothepistonholes・Whenthecylinderblockturnstopassbeyondthe

kidneyA，preSSureOilisdischargedfromthepistonholes・Whenthecylinderblockturnscontinuous OilissuckedthroughtheportBleadingtothekidneys，beingdischargedthroughtheportA・

③Thevolumeofoiltobesuckedanddischargeddependsuponthepistonstrokeorthetiltingangleof

SWaShplate・Thedischargevolumeofoilisreducedby reducingthetiltingangleoftheswashplatean isincreasedbyincreaslngthetiltingangle． E≡≡≡ヨLow−PreSSureOll

SWASHPLATEANGLECONTROLLEVER

Fig・3・6PumpOperation（1）

ー34＿

④Astheswashplateanglecontrolleverisshiftedtotheright，theoilflowisreversed・（therotati directionofthedriveshaftremainsthesame・）

TbeoilissuckedthroughtheportAanddischargedthroughtheportB・

Fig．3．7PumpOperation（2）

（2）OperationofIISTMotor

①Thehigh−PreSSureOilfromthepumpflowsthroughtheportAandkidneyAtoactsonthepistonin Cylinderblockandpushesitagainstthedriveshaft・

②Thendriveshaftthenrotatestogetherwiththepiston．Thelow−PreSSureOildischargedfromthepis flowsthroughthekidneyBandportB・

③Incontrast，Whenthehigh−PreSSureOilffomthepumpflowsthroughtheportBandkidneyB，thedrive shaftrotatesinreverse．

④Astheinclinedshaft（driveshaft）angleObecomeslarger，thepistonstrokeincreasessothatdriveshaft speedslowstIncontrast，theinclinedshaftangleObecomessmaller，driveshaftspeedincreases・ PISTON

DRIVE SHAFT

Fig．3．8MotorOperation

−35−

3．1．2 日STPIPING

Fig．3．9HSTOilCirculation −36−

Note：Speci抗cationsandlocationsofswitchesandsensors I，OCation Designation

Specifications

Application …HSToilpressure‖

L Pressureswitch

M Sensor（builtin）

N Thermo−SWitch

OFF‥5・2±0・3kgkm2（74±4psi） ON：4・2±0・3kg／cm2（60±4psi） （ONatatmosphericpressure）

Warnlnglamp

1amp

HST員1ter

warnlng Operationpressure：（difftrentialpressurebetweenIN andOUT）0・3kg／cm2（4psi）

HSToiltemperature‖

Warnlnglamp

L HSTclosedcircuit

ON‥110±30C（230±50F） OFF：OVerlOOOC（OVer2120F）

l．HSTPUMP

6．0ILCOOLER

ControIcircuit（exceptfbr803）

2．HSTCHARGINGPUMP

Lubricationandcoolingcircuit

3．MAlNPUMP 4．HSTMOTOR 5．SUCTIONFILTER

（draincircuit）

Mainhydrauliccircuit（SuCtion） 〟〟〟ゝChargingpumpcircuit −・−Parkingbrakecircuit

Fig・3・10HSTPiping −37−

7．CHECKVALVE

8．PARKINGBRAKE VALVE 9．OILTANK

1．GeneralDescription Note： Forthehydrauliccircuitoftheentireloader，reftrtoFigs・7・2and7・3in−7・10ILCIRCULATION ROUTE．

1meHSTcircuitconsistsoftheHSTclosedcircuit，1ubricationandcoolingcircuit（draincircuit），andcha pumpcircuit．Onthe804，805，and806，theHSTmotor（DAregulator）controIcircuitisadded・

Thelubricationandcoolingcircuithasacheckvalveandoilcoolerandtheoilreturnsintotheoiltank The

chargingPumPCircuithasasuctionnlter・neOilpressurebrreleaslngtheparkingbrakesystemissuppli throughtheHSTcircuit・

2．OilCooler

Note：Fortheinstallationoftheoilcooler，reftrto

Fig．2．7CoolingSystem・

Fig．3．110ilCooler

−38−

3．Suction Filter

ThesuctionⅢterisprovidedinthechargingpumpcircuit・Theoilflowsthroughthe員1terelementfr

OutSidetoinsideandthenlteredoilisdirectedtothechargingportoftheHSTpump・Whentheoil

elementbecomesclogged，thesensorinstalledonthe filterheadsensesclogglngSOthatthe‖HSTfilt

Warnlnglamponthedashboardcomeson・

ValveopenlngPreSSure： 0・4kg尤m2（6psi）

Sensorlightingpressure： 0．3k離m2（4psi）

（PressuredifferentialbetweenIN

andOUT）

A．from OILTANKSUCTION TUBE B．to HSTCHARGINGPUMP C．fromREDUCTION GEAR BRAKE HOUSING D．fromPARKINGBRAKE VALVEPORTT

1．SENSOR 2．BYPASSVALVE 3．FILTER HEAD 4．HOSE 5．HOSE 6．FILTERCARTRIDGE 7．HOSE

Fig．3．12SuctionFilter

−39−

3．1．3 HSTCONTROL

neHSTunitisoperatedwiththeshiftleverinstalledonthesteerlngCOlumn・Whentheshiftleve

moved，theHSTpumpdirectionalcontroIvalve（SOlenoidvalve）isexcited tochangeoverthe dischar

directionsoftheHSTpumptodeterminethetravelingdirectionoftheloader・ ne traveling speed oftheloaderis controlled continuouslyfrom startlng tO aCCeleration and from decelerationtostopping・（Reftrto

3・2HSTPUMP

and

3・3HSTMOTOR：1）

A B C D E F F

N R

Fig．3．13ShiftLever

−40−

HST CONTROL ELECTRIC CIRCUIT 旺IHSTcontroI Whentheshiftleverisoperated，electricflowtothesolenoidsaandbofthedirectionalcontroIvalveis SWitchedtoactuatethedirectionalcontroIvalvesothatthetilt−rOllingplStOnOftheHSTpumpISPutinmotion toswitchoverthedischargedirectionoftheHSTpump・（Reftrto

3・2HSTPUMP・一

）

E］parkingbrakedragpreventionmechamisnT

①whentheparkingbrakeisapplied，thepressureswitchisturnedONandtheneutralrelayisturnedOFF．

（参ElectricityisnotsuppliedtotheterminalCoftheshiftlevertomakeitimpossibletododirectiona COntrOl，thusputtlngtheHSTunitinneutral・

回 Engimeneutralst叫▲ Onlywhentheshiftleverisinneutral，electricityflowsfromtheshiftleverterminalBtothestarterrelay

COil，makingltPOSSibletocrankthestartermotor・Itmeansthatunlesstheshiftleverisinneutral，theengln won tstart．

STARTER SWlTCH TERMlNAL C

Note： Thepressureswitchisbrthe一

PARKINGBRAKE

warnlnglamp．Foritsspecincations，refert

Fig・4・2・

Fig．3．14HSTControIElectricCircuitDiagram

ー41−

3．2 HST PUMP

Model

＄03

＄04

A4VG28DA＿980

A4VG28DA−981

VariabledeliverypIStOnPumP

丹pe

Driving

DirectlycoupledtoenglneCrankshaft

Discharge

0−28cc／rev

Max．workingpressure （Reliefvalvepressure）

Control

＄05，＄0 A4VG28DA−982

←

←

◆−

400＋㌘kがm2

（380＋㌘頓m2）

350＋㌘kg血2

400＋㌘kg血2

（330＋諾頓m2）

（380＋㌘頓m2）

DA（direct−driven，SPeed−reSPOnSe

←

OutPutCOnStantCOntrOl）

Weight

35kg

HST charging pump

◆−

Geartype

←

◆−

Note：ForthespecincationsoftheHSTchargingpump，reftrto一

7．2PUMP．

1．REDUCTION GEAR 2．HSTPUMP 3．BRACKET

4・（REARFRAME） 5．MOUNTRUBBER

二、＿＿＿＿＿＿二

1′￣￣￣￣￣圭一

塵」ヱ、5

ぐ哲−−、＼4

−↓l 凰−、＿、、5 （互）

Note：駐＞ぢ：：＝：コ14．4kg−m（104札−1bs） 匡＞ぢ＝コ8．5kg−m（6‖Hbs） 臣＝＞ぢ：：：：：コ9・Okg−m（65札−1bs）

Fig．3．15DriveUnitMount −42−

R X4．X2

Sol‖a■−exdted

T

Sol b excited ＝ミ＞

Al

■− Fi

AIMA x3

X4XIX2

MA

G

S2 sl

HvdrauIicCircu往Diaqram

View100kinqfromZ

（Explanationofports）

（Partname）

Al，Bl：Dischargeport

Tl，T3：DrainandBllerport

1．MAlNPUMP 2．HSTCHARGINGPUMP

T2，T4：Drainport MA：Gaugeport（Aside）

3．HIGH−PRESSURERELIEFVALVE（B） 4．HIGH−PRESSURERELIEFVALVE（A）

MB：Gaugeport（Bside）

5．DAVALVE

R ：Airbleedingport

6．LOW＿PRESSURERELIEFVALVE

7．SOLENOID a 8．SOLENOIDb 9．DIRECTIONALCONTROLVALVE lO．INCHINGLEVER

Xl，X2：Controlpressureport X3，X4：ControIpressureport G ：Gaugeport（Chargingline）

Fi：Chargepressureinletport Sl：Suctionport Fo ：Chargepressureoutletport

S2 ：Suctionport B2 ：Dischargeport Fig．3．16HSTPump −43−

Fiq．A．Pi＄tOnPump

8 2

1．ROTARYGROUP（SeeFig・B・） 2．TILT−ROLLINGCYLINDER（SeeFig・C・）

3．COVERGROUP（SeeFig・D・） ◎ ◎ ◎

4．HIGHTPRESSURERELIEFVALVE（SeeFig・E・） 5．LOW−PRESSURERELIEFVALVE（SeeFig・F・）

6．CONTROLGROUP（SeeFig・G・）

（DIRECTIONALCONTROLVALVE）

章

7．DAVALVE（SeeFig・H・）

8．HOUSING

10．PIN

9．COVER

ll．SPRING Fig．3．17HSTPUMP（1／3） −44−

1．SPRING 2．SPRING 3・SHIM（t＝0・3，0・4，0・5mm）

4．PISTON 5．ROD 6．RING （t＝5・77to6・02mm，6types）

Ficl．D．CoverGroup

Fig．3．1＄HSTPump（2／3） −45一

Fi（】．G．ControIGrou？ （DirectionaLContr01VaLve）

Fi（】．E．Hi（】h・Pres＄ure ReliefVa］ve

Ficl．F．Low−Pre＄＄ure Relie†VaLve PLUG Sト‖M

（t＝0．3，0．5，1．Omm） SPRING PLUNGER

Fiq．暮．GearPump

Fig．3．19HSTPump（3β） −46−

TheHSTpumpatandempumpconsistingofavariabledeliverypistonpumpandgearpumps（mainand

Charging）whicharedrivenbyasingleinputshaft・Itisinstalledonthereductiongearcasewithitsinputshaft

COuPledtotheenglneflywheel・BoththepIStOnPumPandgearpumpsarealwaysinoperationwhile engineisrunning・TheHSTpump（Pistonpump）brms為closedcircuitwiththe HSTmotorwithtw

high−preSSurehosesandactuatestheHSTmotorbydischarginghigh−PreSSureOil．neHSTpumpISCOntr bytheDAregulator・

1．PⅦmpFunction

Thecylinderblockislinkedtothedriveshaftandrotatesasthedriveshaftrotates・ThepIStOnSbuil

Cylinderblockmakereciprocatingmotion，bllowingthehanger（SWaShplate），SOthatthecylindervolumevar

to producesuctionanddischargeaction ofthepump・The9pistons accomplish acycleofsuction and dischargeevery time the cylinderblockmakes afu11turn to rotate the drive shaft so that a continuous

OPerationofsuctionanddischargeisobtained・Thegearpumpsareconnectedtothedriveshaftbothtosu Oiltotheclosedcircuitandtoprovidepilotfunction（excluding803）brtilt−rOllingcontrol．

（l）High・PreSSureReliefValve

Thereliefvalveisdesignedtoprotectthehigh−PreSSureCircuitbyregulatingthemaximumpressure．Italso

actsasacheckvalvebrchargingsothatiftheflowrateatthesuctioncircuitistoolow，itdirectsthecharging PreSSuretOthesuctioncircuit．

CHARGING

Fig・3・20HSTPumpHydraulicCircuitDiagram

−47−

High‑Pressure Relief Valve Operation

● RelierValve Function

①whentheoilpressurePHaCtingonthepoppetarea Aislargerthanthesprlngl

spressure，theoilin

thechamberApushesupthepoppettoflowinto themaincircuitlow−PreSSureSide・

（卦ThismakestheoilpressureinthechamberAlower thanthePHSOthattheplungerispusheduptolet

theoilatthehigh−preSSureSideflowdirectlytothe lowpressureside．Themaincircuitpressureisthus

COntrOlledsothatitmaynotexceedthepressure Settingdeterminedbythesprlngl・ Note：Fig．3．21 囲；Main？rcuithigh−PreSSureSide ［至ヨ；MainclrCuitlow−PreSSureSide

● CheckValve FⅦnCtion

WhenthemaincircuitpressurePHdropsbelowthe low−PreSSureSidepressure（Chargepressure）PL，theoil

PreSSurePLaCtlngOntheareaCofthebushing srlng PuShestheplunger，thuslettingtheoilatthePLSide

flowtothePHSide・Itmeansthatthehigh−PreSSure reliefvalvebypassesreliefvalvefunction，ifthemain Circuitflow rateislow，tO direct the oilfrom the Chargingcircuittothemaincircuit・

Fig．3．22

（2）I，OW−PressureReliefValve

Thisvalveregulatesthechargingpressureofoil・Whiletheenglneis runnlng，thevalveis alwaysi

Operation・TheoilrelievedlubricatesandcooIsthepumpandmotorandreturnsthroughtheoilcoolerint theoiltank．Thechargeoilpressureissenttheparkingbrakevalvebrthepurposeofreleaslngtheparking brake． 一48−

2．DARegulator （1）Fea血res

①switching of discharge direction with solenoids：itis possible to switch the traveling direction （brward／reverse）oftheloaderwithasingletouchoftheswitch・ ②Dischargecontrolaccordingtoenginespeed：thetravelingspeedcanbesteplesslycontrolledwitht accelerator pedal alone.

③constanttorquecontrol‥Iftheloadincreases，thedischargeislimitedtopreventoverloadiムg．

（2）Ti1t−rOllingMechanism

Thetilt−rOllingpistonisconnectedtothehanger（SWaShplateofpump）・netilt−rO11ingpistonhasaspri Whichexpandsinthedirectionthatreturnsthetilt−rO11ingpistontotheorlglnalposition・Thepositionofth

tilt−rOllingpIStOn，Or thepumpflowrate，depends upon themagnitudeofcontrolpressure routed to the tilt−rOllingcylinders．WhichcylinderreceivesthecontroIpressureisdeterminedbythedirectionalcontroIvalve，

andthusthepumpdischargedirectionisestablished・ TherelationshipbetweendirectionalcontroIvalvesolenoidsandpumpdischargedirectionisglVenbelow． Relationshipamongpressuregenerationport，traVelingdirectionandexcitationofsolenoids Excitedsolenoid

Sol．a

Sol．b

Dischargeportl） Pilotport

Al

Bl

Ⅹ1

Ⅹ2

Travelingdirection2） FonⅣard

1）Clockwise（Whenviewedfromtheendof PumPdriveshaft）

2）ForwardwhenoilisdischargedfromportAl・

Reverse

Fig．3．23Tilt−Ro11ingMechanism

−49−

CONTROL PRESSURE−→．＿ 「3

DfRECT10NALCONT O VAV

T］LT−ROLLING CYL‡NDER

TILT−ROLLING PISTON PIN

S

LAT

T−ROLLING

DISPLACEMENTVOLUME

ANGLE）

（q）

q max

CONTROL PRESSURE

Fig・3．240perationofTilt−Ro11ingMechanism

−50−

（3）Tilt・RollingRestorationForceandAdvanceAngle ThehangerreceivesoilpressurebywayofthepIStOn・Theswitchingpointbetweenhighandlowpressur

ofthecontroIplateislocatedoffket，Oradvanced，intherotatingdirectionsothatthehigh−PreSSureaCting

pointonthepIStOnisdeviatedfromthehanger，sfu1crum・Owingtothedeviationbetweenthefulcruman actingpolnt，abrcetorestorethetilt−rOllinglSPrOduced・Thisbrceiscalledthetilt−rOllingrestorationbrce・

ThedeviationplnOftheadjustingscrewendisconnectedtothegrooveofthecontrolplate・Theadvanc angleofthecontrolplatecanbeadjustedbyadjustlngthedeviationwiththeadjustlngSCreW・

Fig．3．25Tilt−RollingRestorationForceandAdvanceAngle

−51−

（4）DAValve

TheHSTpumphasthegepumP（HSTchargingpump）connectedcoaxiallysothatthegearpump

rate（discharge）variesproportlOnatelywithenginespeed・Alltheflowfromthegearpumpisdirectedthrough

theDAvalveor泊cetothechargingcircuit．Usingthedifferentialpressureproducedacrosstheorifice tothechangesinflowrate，theDAvalvereducesthechargingpressuretogeneratethecontroIpressure（P3）・

The controIpressureflows throughthe directionalcontroIvalve to actuate thetilt−rOllingcylinder，t determlnlngtheHSTpumpflowrate・Thatis，thetilt−rOllingactionofthepumplSCOntrOlledbythepre

almostproportionaltoenglneSPeed・ ・Imdling伽netion When theinchingleveris operated，the controI

PreSSure（P3）dropsduetotheinchingspring・This functionisused toincrease the speed of theload

handlingmeanswiththeloaderinchedorstopped・

Fig．3．26Changesin controIpressure during

inching operation

Fig．3．27DAValveOperation

ー52−

（5）AutomaticSpeedControl （彰ThecontroIpressureproportionaltoenginespeedisconnectedflowsfromtheDAvalvetothetilt−rOlling cylinderselectedbythedirectionalcontroIvalve・

（卦Withtheengineatidle，thecontroIpressureissmallerthanthespringpressureofthetilt−rOllingpiston

sothatthepumpISinneutralandtheloaderstationary・

③Asenginespeedincreases，thecontroIpressurealsoincreaeSSOthatthetilt．rollingpistonmoves

thepumptiltroll・SincethepumpdischargevarieswithenglneSPeed，itispossibletocontrolthetravelin SPeedoftheloadercontinuouslywiththe早CCeleratorpedal■

Displacement volume

Control pressure （P3）

qmaX

＼＿∠

（。3占符；㌣

Control pressure

≡

（N）

Engine speed

Fig．3．28EngineSpeedvs・TravelingSpeed

（6）TorqueControIFunction

（彰Withthepressureincreasing，thetilトrollingrestorationbrceincreasestoreducethetiltrollingofthe

pumpsothatthepumpperformsanapproximatelyconstanttorquecontrol・（Fig・A）

③nesettingtorqueisdeterminedbythebalanceamongthecontroIpressure，tilt−rOllingcylindersp pressure，andtilt−rOllingrestorationfbrce・Withthemaincircuitoilpressureconstant，itvarieswithenglne SPeed・（Fig・B）

③Ifaloadexceedingenginetorquewereapplied，enginespeedwoulddropfromNltON2・Ifenginespeed

drops，thepump，sabsorptlOntOrquealsodecreasessothatthetiltrollingactionofthepumpisbal

withenginetorque．（Fig．C）Thatis，Whentheloadincreases，theengineslightlysIowsdownan

pumpautomaticallycontroIsitstiltrollingaction，thusmakinggooduseOfenglnetOrqueWithoutstopplng theenglne・

Fig．A

Fig．B

Fig．C

FIow rate Fig．3．29TorqueControIFunction

−53−

3．3A HSTMOTOR（803） 803 Model

A6VM28HA−993

「丹pe

Variabledeliverypistonmotor（inclinedshafttype）

Discharge（SuCtion）

14．4−28．1cc／rev

Control

HA（COnStantPreSSureCOntrOl）

Weight

18kg

HydrauticCircurtDiaqram

（Explanationofports）

A，B‥Pressureport

T：Drainport Fig・3・30HSTMotor（803）

−54−

4

5

1．DRIVESHAFT 2．HOUSING

9101112

3．CYLINDER BLOCK 4，PISTON 5．CONTROLPLATE 6．CONTROLPISTON 7．CONNECTINGROD 8．VALVEBODY 9．REGULATORCOVER lO・GUIDE（A）

11．ORIFICE 12．GUIDE（B）

13．SPRING 14．SETSCREW 15．GUIDE 16．SPRING

■・−

18．POPPET 19．GUIDE

1

20．VALVECOVER View100kinqfromZ

Fig．3．31HSTMotorStruCture（803） −55−

5 6 7

1

17．SERVOSPOOL

TheHSTmotorisaninclinedshafttypevariabledeliverypIStOnmOtOrandisinstalledinthereductionge

ConhectedtotheHSTpumpwithtwohigh−PreSSurehoses（Closedloop），itisdrivenbytheoilpressurefr

theHSTpump・TheHSTmotordriveshaftissplinedtotheinputshaftofthereductiongearsothatthe outpqtoftheHSTmotoristransmittedtothereductiongear・（ReftrtoFig・3・41・）rmeHSTmotorconsists

oftheinclinedshafttypepistonmotorandHAregulator・

PistonMotorOperation ①sevenpistonsarearrangedinafan−1ikefashiononthecylinderblock・Whenthepressuroilisdirected tothecylinderblock，thepistonsfbrcethedriveshafttomakeitturn・TherotatingdirectlOnOfthedrive Shaftdependsuponwhichport，AorB，thepressureoilflowsto・

②Eachpistonaccomplishesonestroke，OrSuCkingoilanddischargingit，forafu11rotationofthedriveshaft・ SincethesevenpIStOnSCOntinuouslyoperate，thedriveshaftmakesasmoothrotationalmotion・

③TherotatingbrceofthedriveshaftisequaltothecomponentbrceFoftheoilpressureFpactingon piston，andthusthelargerthetilt−rOllingangle8thegreatertherotatlngtOrque・Ontheotherhand，the largerthetilt−rOllingangle，the、Slowerdriveshaftspeedbecausethepistonsuctionvolumebecomeslarger・ Incontrast，aSthetilt−rOllinganglebecomessmaller，theshaftspeedincreases・

④Thec。ntrOIplateisconnectedtothecontroIpistonwiththeconne云tingrodsothatthetilt−rOllingangle dependsuponthecontroIpistonposition・（ReftrtoFig・3・31・）

Fig．3．32PistonMotorOperation

ー56−

ⅡARegulatorOperation

TheregulatorcontroIsthetilt−rOllingactionaccordingtothehigheroneofthepressuresattheportsAand

B（HSTcircuitpressures）・Whenthepressureislowenoughtokeeptilt−rOllingsmall，itispossibletotrave

theloaderatahighspeed・Astheloadincreasesenoughtoneedalargebrce，Shifttothelargetilt−rOl sideisdone．

①withtheservOSPOOlinneutral，tilt−rOllingactionisheldbecauethecontroIpressurePcactingon

controIpIStOnlargerdiametersectionisbalancedwiththemalnCircuitpressurePHaCtingonthering SeCtlOn．

③whentheoilpressureactingontheservOSPOOlislowerthanthespringpSSure，Pcisdirectedtotheoil tank（insidethehousing）sothatthecontroIpistonmovestowardthedirectlOnOfqmin・Bycontrast，When

theoilpressureishigherthanthesprlngPreSSure，PcisconnectedtoPHSOthatthecontroIpistonmoves towardthedirectionofqmax・ Neutral（q：heldconstant）

PH・B＝F〟＋FFB

Tilt−rOlling（Changestoqmin）

PH・B＜㌦＋FFB

Tilt−rOlling（Changestoqmax）

PH・B＞F〟＋FFB

Fig．3．33HARegulatorOperation

＿57−

・Tilt・RollingStartPressure（Pi）

Thetilt−rOllingstartpressureisadjustablewiththe adjusting spring pressure FAJ‑ FJU：Small→Pi‥Small

・0verride（AP）

Theoverrideisfactorysetdependinguponthearea

BandthesprlngCOemCientofthefeedbacksprlng・ Donottrytoadjusttheoverride．

Fig．3．34

・I，OaderperbrmanceandHAcharaCteristics

Whentheloadislight，tilt−rOllinglSminimizedtoallowtheloadertotravelatahighspeed・Asthelo

increases，theHAregulatorshiftstothemaximumtilt−rOllingsidesothattheloadercanproducealarge tractionforcealthoughthetravelingspeedisslow・Thatis，tilt−rOllingactionisautomaticallycontrolled accordingtothemagnitudeoftheload・

−58−

3．3B HSTMOTOR（804，805，806） ＄05，80

＄04 Model r吋pe

A6V59DA−987

A6V59DA−986 Variabledeliverypistonmotor（inclinedshafttype）

←

15．6−58．7cc／rev

13．9−58．7cc／rev

Control

PA（Speedsensingcontrol）

←

Weight

28kg

←

Discharge（SuCtionvolume）

T2

Hvdraulic Circu旺DiaQram ∨盲ewlookinqfromY

（Explanationofports） A，B：Pressureport Tl，T2：Drainport Xl，X2‥Pilotport

Fig．3．35HSTMotor（804，805，806）

−59−

View100kinq什omY

1．DRIVESHAFr 2．HOUSING 3．PISTON 4．CYLINDERBLOCK 5．CONTROLPLATE 6．RETAINER 7．VALVECOVER

8．SERVOSPOOL 9．VALVEBODY lO．SPRING ll．SPRING

15．SELECTORVALVESPOOL 16．ORIFICE 17．GUIDE 18．ORIFICE

12．ADJUSTINGSCREW 13．CONNECTINGROD 14．CONTROLPISTON

19．GUIDE

Fig・3・36HSTMotorStructure（804，805，806）

ー60−

TheHSTmotorisaninclinedshafttypevariabledeliverypistonmotorandisinstalledinthereduction

ConnectedtotheHSTpumpwithtwohighpressurehoses（Closedloop），itisdrivenbytheoilpressurefr

theノHSTpump・neHSTmotordriveshaftissplinedtotheinputshaftofthereductiongearsothat

OutPutOftheHSTmotoristransmittedtothereductiongear・（ReftrtoFig・3・41・）TheHSTmotorcon OftheinclinedshafttypepIStOnmOtOrandDAregulator・

PistonMotorOperation

①sevenpistonsarearrangedinafan−1ikepatternonthecylinderblock・WhenthepressurOilisdirect

tothecylinderblock，thepistonsforcethedriveshafttomakeitturn・merOtatingdirectlOnOfthe

Shaftdependsuponwhichport，AorB，thepressureoilflowsto・

②Eachpistonaccomplishesonestroke，OrSuCkingoilanddischargingit，fbrafu11rotationofthedriveshaft． Sincethesevenpistonscontinuouslyoperate，thedriveshaftmakesasmoothrotationalmotion・

③rmerotatingbrceofthedriveshaftisequaltothecomponentbrceFoftheoilpressureFpactingo

Piston，andthusthelargerthetilt−rOllingangleOthegreatertherotatlngtOrque・Ontheotherhand，the

largerthetilt−rOllingangle，theslowerdriveshaftspeedbecausethepistonsuctionvolumebecomeslarge Incontrast，aSthetilt−rOllinganglebecomessmaller，theshaftspeedincreases・

④necontroIplateisconnectedtothecontroIpistonwiththeconnectingrodsothatthetilt−rOllingan dependsuponthecontroIpistonposition・（ReftrtoFig・3・36・）

Fig．3．37PistonMotorOperation

一61−

DA Regulator Operation

TheportsXlandX20ftheselectorvalvea？COnneCtedtotheportsXlandX20ftheHSTpump（A4V），

respectively・TheportsAandBofthemainclrCuitareconnectedtotheportsAiandBlOftheHSTpump neportsareswitchedoverbytheselectorvalveasshownbelowsothatoilpressureisdirectedtothe

regulator． Pressuregeneratedin簸）rWardtravel Pressuregeneratedinreversetravel

Regulatoroperationmaincircuit PH RegulatoroperationpilotpressurePx

PA

PB

Pxl

Px2

Note：Forward−−PortApushedin，Reverse

PortBpushedin

pressure

①withtheservospoolinneutral，ti！t−rO11ingactionisheldbecチuS？th？COntrOIpressur？Pcactingonthe

COntrOlpistonlargerdiametersect10nisbalancedwiththemalnClrCultPreSSurePHaCtlngOnthecontroI Pistonsmallerdiametersection． PH ＝＝

Fig．3．3＄DARegulatorOperation −62−

②whentheoilpressureactingontheservOSpOOlisIowerthanthespringpressure，Pcisdirectedtotheo

tank（insidethehousing）sothatthecontroIpistonmovestowardthedirectionofqmax．Bycontras

WhentheoilpressurehigherthanthesprlngPreSSure，PcisconnectedtoPHSOthatthecontroIpiston movestowardthedirectionofqmin・ Neutral（q：heldconstant）

Px・A−PH・B＝F心＋FFB

Tilトrolling（Changestoqmax）

Px・A−pH・B＜㌦＋FFB

Tiltqrolling（Changestoqmin）

Px・A−PH・B＞F〟＋FFB

・Ti1t・RollingStartPressure（Pi） Thetilt−rOllingstartpressureisadjustablewiththe adjusting spring pressure FAJ. FJU：large→Pi：Small

PivarieswiththechangeinPx Px＝1arge→Pi‥1arge

・Override（AP）

¶1eOVerrideisfactorysetdependinguponthearea BandthesprlngCOefncientoftheftedbacksprlng．

Donottrytoadjusttheoverride． Fig．3．3，

・IJOaderper鮎rmanceandDAcharacteristics Tbesettingvarieswithenginespeed（HSTpumpinputspeed）・Whentheloadislightandtheenginerun

atidle，tilt−rOllinglSmaXimized・AsenglneSPeedincreases，tilt−rOllingshiftstothesmallerside，a1lowlngthe

englnetOrunathigherspeeds・Astheloadincreases，tilt−rOllingalsobecomeslarge，thusmakingavailable

largertractionforce・natis，judgingtheintentionoftheoperatorfromtheenglneSPeed，theDAregu

automaticallycontroIsthegenerationoftorqueaccordingtothemagnitudeofload・

−63−

3．4 REDUCT10N GEAR

Model

＄03

＄04

TCM605−32

TCM606−32

＄05，＄0

TCM608−32

Constant−meSh，SPurgeartyPe

「丹pe

Number of reductions

◆−

Oilcapacity

1．5ゼ

Weight

93kg

102kg

（IncludingHSTmotor）

（IncludingHSTmotor）

◆−

←

TbereductiongeartransmitstheoutputfromtheIiSTmotorthroughtheoutputshafttothefrontandrear

axles・nereductiongearconsistsoftheinputshaft，OutputShaft，2gears，diskbrakeandreductiongearcase・

nereductiongearhastheHSTpumpandHSTmotor・nereductiongearcaseisnttedtotherearfr atitsbothsidesthroughmountlngrubbermaterials．nereductiongearcaseisBttedtotheengineflywheel housing．（RefertoFigs．2・5and3・15・）

Operation（Powertransmission）

Note： ThepartnumbersglVenintextcorrespondtothoseinthecrosssectionalviewofthereductiongear ShowninFig．3．41・

①The。。tp。tfromtheHSTmotoristransmittedtotheinputshaft（19）．Afterr云ducedofspeedthrou twogears（20，17），thepowerisroutedthroughtheoutputshaft（15）tothefrontandrearaxles・

③Thediskbrakeisinsta11edononeendoftheinputshaft．Fortheoperationofthediskbrake，re −−4．2．2DISKIiM．−

−64−

E．ftomOILTANK F．to HSTSUCTION FILTER G．toAlRBLEEDER BLOCK H．fromMASTER CYLINDER I．丘om PARKINGBRAXE

VALVE ViewIookinqfrom B

View100kinqfromC

A‑‑l

（Engineside）

（HSTpumpside）

Note：D＞14＝ゝMatingsurfaces：LOCTITEFMD−127 匡：＞仁＝＝袖Chamftredareasandslidingareas：Grease 1．REDUCTIONGEARCASE

4．COMPANIONFLANGE

2．BOLT，NUT（FORPARKING

5・BREATHER

8・PLUG（LEVEL，FILLER） 9・PLUG（DRAIN）

BRAKERELEASING） 3．COVER

6. HST MOTOR 7．COMPANIONFLANGE

lO・PLUG

Note： Theabovesketchshowsthereductiongearofthemode1804・Ontheothermodels，theactu

appearanceofthereductiongearmaybesomewhatdifferentthanoursketch・ Fig．3．40ReductionGear

−65−

1

2 3 4 5 6 7

Note：B＞Oilsealassemblingprocedure

正＝ゝMetallicouterring：LOCTITE262（Donotapplyrubberouterring．） 仁＝＝袖Areabetweenlips‥Grease（brliptypeoilsealsalone） 1．CAP 2．PISTON HOUSING 3．WAVESPRING 4．BRAKEDISK 5．BRAKEPLATE 6．BRAKEHOUSING 7．RETAINER

8．END PLATE 9．PISTON lO．DISKHUB ll．SPRING 12．PLATE／BALL

13．PISTON 14．PIN Fig．3．41ReductionGearStructure

−6（i−

15．OUTPUTSHAFr 16．0ILSEAL 17．GEAR 18．OILSEAL 19．INPUTSHAFr 20．GEAR 21．SPACER

3．5 PROPELLERSHAFTS

Il

ニー

＿

Thepropellershafts，locatedbetweenthereductiongearandthefrontaxleandbetweenthereductiongear andtherearaxle，tranSmitthepowerfromthereductiongeartothefrontandrearaxles・

Thepropellershaftsabsorbthechangeindriveangleandthechangeinlengthwhentheloadertravels，

ensurlngSmOOthflowofpowerfromthereductiongeartotheaxles・

Note：B＞ぢ＝＝コ10．3kg−m（74．5ft−1bs），14＝ゝnreadedarea：LOCTITE262 B＞ぢ＝＝コ2．6kg−m（19ft−1bs），正⊃ゝnreadedarea：LOCTITE262 匡＞Completely remove paint，Oil，and grease fromflange surface bebre trying to installingbolts（4points）・

駐＝＞Payattentiontothedirectionofyoke．（Seeabovesketch・）

Fig．3．42Prope11erShaftAssembly

−67一

FRONT

（reductiongearside）

（誠Ieside）

1．FLANGEYOKE 2．UJOINT 3．GREASEFITnNG 4．SPLINEDYOKE 5．SHAFrYOKE

View bokinqfromZ

REAR

GREAS∈ Fl［lNG

H YOK∈

U JOlNT

Fig．3．43PropellerShaft

−68−

3．6 DRIVEAXLES（FRONTANDREAR） ＄03 Driving Frontaxle Rear axle

＄05，＄0

＄04

4−Wheeldrive

←

●−

←

Frame一員Ⅹed，Semi−floatingtype Cradle−plnSuPPOrted，Semi−

◆−

floating type Reductiongearand difftrential Model

r丹pe

（bothfrontandrear）

（bothfrontandrear）

TCM605−30

TCM（iO6−30

（front）TCM608−30 （rear）TCM606−30

Ordinarytype，2−Stage

reduction

1トー

Difftrentialgearbox

One−PleCetyPe

Differential gears

2sidegearsand 4 pinion gears

2 side gears and 4piniongears

Differential limiter

Not provided

←

◆−

◆−

←

Finalreductiongearassembly 乃pe

Oil capacity

Planetarygear

◆−

2・5Q（eachforfrontandrear）

andrear）

←

Weight Front

108kg

131kg

134kg

Rear

108kg

126kg

←

3．6．1DRIVEAXLE

Tbedriveaxleconsistsoftheaxletube，difftrential，伍nalreductiongearassemblyandaxleshaftstowhich

wheels areattached． Thepowerfromthereductiongearistransmittedthroughthepropellershaftstothefrontandreardrive

axles・Thepoweristhentransmittedtothedifftrentialwhereitisdividedintotherightandleftaxles totheBnalreductiongearassemblyoneachshaftend，thusdrivingthewheel．

−69一

Di蝕rentialOperation

Thedifftrentialisintegralwiththereductiongear・Thespeedreductionofthepowerisaccomplished betweenthedriveplnlOnandtheringgear・Thedifftrentialoperatesasfbllows‥

Whiletheloadertravelsstraight，theringgear，di鮎rentialgearcase，andsidegearsrotatetogether，wit

thepiniongearsinsidethedifftrentialgearcasenotrotatlng・ThepowerofthesamespeedisthustranSm fromtherightandleftsidegearsthroughtheaxleshaftstothewheels・Whentheloadermakesaturn，the

rightandleftwheelsrotatesatdifftrentspeeds，theplnlOngearSinthedifftrentialgearcaserotatearound theirownaxesaccordingtothedifEerenceinspeedbetweentherightandleftsidegears・

Durinqtravelinqstraiqht

Durinq makinqtums

1．PINIONGEAR

4．DIFFERENTIALGEARCASE

2．SIDE GEAR

5．SPIDER

3．AXLESHAFr

6．DRIVEpINION Fig．3．44DifferentialGearOperation

ー70一

7．RINGGEAR

Planet Gears Operation

TheBnalreductiongearassemblyisaplanetarytypeandprovides鋭nalspeedreductionofthepowerfro theenglneinthepowertransmissionline・Thepowerfromthedifftrentialgearrotatesthroughtheshaf threeplanetgearsinsidetheringgear，therebytransmittlngtherotationoftheplanetgearsthroughtheplanet carrierto theaxleshaft．

1．DRIVEPINION

4．PLANETSHAFr

7．PLANETCARRIER

2．DIFFERENTIALGEAR

5．PLANETGEAR

8．AXLESHAFT

3．GEAR＆SHAFr

6・RINGGEAR（丘Ⅹed）

Fig．3．45PowerFlow

−71−

Note：D＞ぢ：：：：コ1．Okg−m（7・2ft−1bs）

匡＞ぢ＝＝コ2・9kg−m（21ft−1bs）

匡＞ぢ：：：：：コ10．3kg−m（74・5ft−1bs），正＝ゝThreadedarea‥LOCTITE262

B＞紹＝ゝnreadedarea‥LOCTITE572 匡＞紹＝ゝMatingsurfaces‥LOCTITEFMD−127 匠：＝＞Assemblewithbearingcagegroovepointingdownward・

5．DIFFERENTIAL

1．AXLESHAFr 2．SEAL 3．AXLETUBE

6．PIN 7．LEVELGAUGE 8．RINGGEAR

4．FINALREDUCTIONGEARASSEMBLY

9．PIN lO．BREATHER ll．COVER 12．PLUG

Note： Theabovesketchshowsthefrontaxleofthemode1804．Ontheothermodels，theappearanc thefrontaxle血aybesomewhatdifftrentthanoursketch・ Fig．3．46FrontAxle −72−

Note：B＞ぢ＝コ2．9kg−m（21ft−1bs），正＝ゝTbreadedarea：LOCnTE262 臣＝＞6：：：：：コ5・6kg−m（40ft−1bs），紹＝ゝThreadedarea‥LOCTITE262 B＞ぢ：：：：＝コ25kg−m（180托−1bs）

B＞正⊃ゝOuterdiameter：Liquidseal，〆＝＝恥Betweenlips‥Grease 匠：＞Backlashbetweenringgearandpiniongear：0．09−0．13mm 匠＞Shimadjustingprocedure ①Torqueretainerplateboltto5kg−mandpushinaxleshaftbearingcone，turningaxleshaft． ②Measurespacingbetweenretainerplateandaxleshaft．Measuredvalue＝Y． ③chooseshimssothatthespacingisY二3：圭昌．

④Installshimsandinstallretainerplateandbolt．

ぢ：：：：コ14・4kg−m（104ft−1bs），紹＝ゝnreadedarea‥LOCTITE262 （Thebearing srotationalresistancetorqueis3to5kgonthetube飢tingboltpitchcircle・）

1．PLANETCARRIER 2．BALL 3．SHAFr 4．PLANETGEAR 5．NEEDLEBEARING 6．RETAINERPLATE

9．CASEA lO．DIFFERENTIALBODY ll．RING GEAR 12，CASE B

16．SIDE GEAR 17．PINION GEAR 18・SHIM（0・1−1・Omm，5types）

19．SPACER

13．SHIM（0・1−1・Omm，5types） 20．PINIONGEAR（DRIVEPINION）

14．BEARING RETAINER

7．SHIM（0・1−1・Omm，5types） 15・PINIONPIN（803） SPIDER（804，805，806） 8．GEAR＆SHAFr

21．SEAL 22．BEARING CAGE 23．FLANGE

Fig．3．47FinalReductionGearAssemblyandDifftrential

−73一

Note：旺＞ぢ＝コ1．Okg−m（7．2糾bs）

匪＞ぢ＝コ2・9kgⅦ（2川一呵

B＞ぢ＝コ10．3kg−m（74・5ft−1bs），正＝ゝThreadedarea‥LOCTITE262

駐＝＞正⊃ゝThreadedarea‥LOCTITE572

B＞紹⊃ゝMatingsurfaces：LOCTITEFMD−127 B＞Assemblewithbearingcagegroovepointingdownward・

R

O 1 2

E

1 1

5．DIFFERENTIAL 6．PIN 7．LEVELGAUGE 8．RINGGEAR

0ノ

1．AXLESHAFT 2，SEAL 3．AXLETUBE 4．FINALREDUCTION GEARASSEMBLY

1

Notes l：1me abovesketchshowsthe rearaxleofthemodels804，805，and806．Onmode1803，

appearanceoftherearaxlemaybesomewhatdifferentthanoursketch・ 2：Forthestructureofthe員nalreductiongearandthedifftrential，refertoFig・3・47・

Fig．3．4＄RearAxle −74−

3．6．2 AXLE MOUNT

Thefrontaxleisdirectlyboltedtothefrontframe・Therearaxleisacradlepln−SuPPOrtedtypeboth ofwhicharesupportedontherearframewithaxlesupportssothatitrocksupanddownaroundthefrontand

rearcradleplnWhenthewheelsmoveupanddown．

￣…ご＿：￣て

DetaiIofareaA

Detai10farea B

Note：B＞ぢ＝＝コ10．3kg−m（74．5ft−1bs），正＝ゝnreadedarea：LOCTITE262 匡＞ぢ＝コ37kg−m（270氏−1bs） 匪＞ぢ：：：：＝コ52kg−m（380氏−1bs）

匠＞仁＝＝和げushinginnersurface：Grease（Aligngreaseholesandgroovewheninstalling） 1．FRONTAXLE 2．REARAXLE

3．AXLESUPPORT（FRONT）

4・AXLESUPPORT（REAR）

5．THRUSTPLATE 6．THRUSTCAP 7．DUSTSEAL 8．BUSHING Fig．3．49AxleAssembly

t75一

9．DUSTSEAL lO．BUSHING ll．THRUSTWASHER

3．7 WHEELASSEMBLY

Tire Wheel

＄03

＄04

＄05，＄0

10−16．5−4pR，

12．5〃0−16−6PR，

15．5／60−18−8PR，

tubeless（L−2）

tubeless（L2）

tubeless（L−2）

16．5Ⅹ8．25150DC

16Ⅹ10LBDC

18 x W13

28．3kg 19kg

45kg

Weight（perpiece） Tire

21kg

Wheel

17・1kg

Inflationpressure

1．8−2．Okgたm2

2・0−2・2kgたm2

29・6kg

2・2−2．4k亦m2

3．7．1TIRE mestandardmodelisprovidedwithtypeL−2tireswhichftaturehightraction．Selectapproprlatetiressince

thereareavarietyoftiresavailableaccordingtotheapplicationandpurposeofwork．

Thetiresizeisexpressedininches・Thestrengthoftiresareexpressedinplyrating（PR）：brexamp

PRmeansastrengthcorrespondingtothatof6piecesofcottoncords．（PRdoesnotnecessarilystandsfbr thenumberofcordspliesinthetire・）

駄ample：′ 苧

芋

Tirewidth Flatnessratio Rimdiameter Tirestrength

竿

Fig．3．50Tire

−76−

TIRE STRUCTURE 1．Tread

Thetreadistheoutermostrubberpartofthetire Whichcontactstheroadsurface，PrOteCtlngthetire CarCaSSandresistingabrasionandcutting・nePart ofthetreadwhichcontacts theroadsurfaceis ca11ed

thecrownandawidevarietyoftreadcrownpatterns areavai1ablefbrspeci伝ctireuses．

2．Rreakers Breakers arelocatedbetweenthecarcass andthe

treadareseverallayersofrubber−COatednyloncord．

Thesebreakersabsorbshock，andprotectthecarcass fromstones，nailsandothersharpobiectsthatmay

Penetratethetread． Fig．3．51TireStructure

3．Carcass Thecarcassisconstructedofspecially−treatedhighstrengthnyloncordplies，eaChofwhichiscoatedonbot

Sideswitharubbercompound．ThecarcassserveStOmaintaintheinflationpressureandsupporttheload

4．8eads

ThebeadsservetOPreVentthetirefromgettingdefbrmedduetoinflationpressureorexternalforceand

toproperlyanchorthetiretotherimsothatthetiredoesnotslipofftherimwhiletheloaderisinmotion・

5．Inner Liner

Theinnerlinerisonlyusedbrtubelesstires．Theinnerlinerisanair−tightlayerofrubberwhichco

theinsideofthecarcassofatubelesstiretomaintaintheinflationpressure．

−77−

3．7．2 WHEEL

mewheelconsistsoftherimanddisk．Thediskisboltedtotheaxleshaft． ThetireisinstalledontherimandbothserveaSaOnepleCe・ItisthusverylmpOrtanttOuSeanapPrOPrla

rimwheninstallingatireontherim・Theuseofaninapproprlaterimmayresultinashortlifeofthe andintheworstcasemightleadtoaseriousaccident・Therimsizeisalsoexpressedininches・Th numberstands fortherimwidth and thenextonetherimdiameter．

（803）

ぢ＝＝コWheelbolt‥ 27kg−m （200fト1bs）

（804）

ぢ＝コWheelbolt：41kg−m （300虹1bs）

（805，806） ぢ＝コWheelbolt：41kg−m （300虹1bs）

Fig．3．52Wheel

−78−

4．BRAKE SYSTEM ＄の，＄04，＄05，＄0 Service brake l、〉・1−e Numberoffluidlines

Reduction−gear−1nput−Shaftbraking，WettyPehydraulicdiskbrake

Master cylinder Supplytank

Single type

1 line O．1ゼ

Diskbrake Piston（0・D・XI．D．）

45．Ommx30．Omm

Effectiveradiusofdisk

43 mm

Pressuresetting

42kgkm2（60kgofdepression）

Parking brake Type

Reduction−gear−input−Shaftbraking，WettyPemeChanical（Spring）diskbrake

Disk brake

Usedincommonwithservicebrake

Fig．4．1BrakeSystem −79−

4．1BRAKE LINE

Note：Specincationsandapplicationsofswitches Position

Specifications

Application

Designation

OFF：Whenpushrodispushed ON：Whenpushrodisreleased

A Stoplampswitch

Stoplamp

B

一一BrakeoillevelMwarnlnglamp ON：1evelisabout40cc

uⅣelswitch （builtinmastercylinder）

C Pressureswitch

（belowstandardlevel）

Parkingbrake warnlnglamp OFF：5．2±0．3kg／cm2（74±4psi） ON：4．2±0．3kg／cm2（60±4psi） （Turnsonatatmosphericpressure）

1．BRAKEPEDAL

2．BELLCRANK 3．MASTERCYLINDER （W．RESERVETANK）

4．INCHINGCABLE

5．BRAKEDISK 6．PLATE 7．PISTON（SERVICEBRAKE）

8．INPUTSHAFr 9．DISKHUB Fig．4．2BrakeLine

ー80−

10．SPRING

ll．PISTON（PARKINGBRAKE）

12．PARKINGBRAKEVALVE

4．1．1GENERALDESCRIPT10N

l．ServieeBrake neservicebrakeisawettypediskbrakeinstalledonthereductiongearlnPutShaft，withthebrakeline

beingahydraulictypeuslngamaSterCylinder・

Themastercylinderisasingletypeandtheservicebrakesystemoperatesonaslnglebrakehydraulicli neservicebrakesystemconsistsofthebrakepedal，bellcrank，maSterCylinderandtubing・

2．ParkingBrake

Tbeparkingbrakesharesthewettypediskbrakewiththeservicebrakesystem・neParkingbrake

engagedmechanically（byspring）withtheparkingbrakevalveintheoperatorcabanddisengagedhydraulically bytheoilsuppliedfromtheHSThydrauliccircuit・ Whentheparkingbrakeisactuated，theHSTsystemisputinneutralbecauseoftheparkingbrakedrag PreVentionmechanism・（Refbrto7T3・1・3・HSTCONTROL・

▲

）

Iftheparkingbrakecannotbereleasedduetoade鮎ctivepumporfbranyotherreason，

ispossibletomanua11yreleasetheparkingbrakeasanemergencymeasure・Fordetail）See▼▼ PARKINGBRAKE．M

3．InchingMechanism

Theinchingpedalislinkedfromitsbe11cranktotheHSTpump（DAvalve）inchingleverwiththeinchin

Cable．Wheneitherofthebrakepedalispressed，theloaderisbrakedwiththediskbrakeswhiletheinch

leverisactuatedtoinitiatetheinchingfunctionoftheHSTpump・（Referto一一3・2HSTPUMP・

ー81−

）

4．1．2 0PERAT10N

l．ServiceBrakeiT10peration ①Asthebrakepedal（1）ispressed，thebellcrank（2）rotatestopushinthepushrodofthemastercyli

（3），PreSSurizingthebrakeoilandsendingitintotheservicebrakecylinderchamber（15）ofthereductio gear・

②neservicebrakepiston（9）shiftstoactuatethewettypediskbrake（16），PrOducingbraking良）rCe． ③Therotationofthebellcrank（2）pu11stheinchingcable（4）totilttheHSPpump（DAvalve）inchinglever

SOthattheswashplateisreturnedin theneutraldirection（SeeFig・4・2） ［HSTPUMPINCHING FUNCTION］．

Fig・4・3ServiceBrakeinOperation

ー82−

2．ServiceBrakeReleased

（彰Whenthebrakepedal（1）isreleased，thepushrodofthemastercylinder（3）ispulledouttoitsoriginal POSition，returningthebrakeoilfromtheservicebrakecylinderchamber（15）tothemastercylinder・

（卦Theservicebrakepiston（9）becomesfreesothatthewetdiskbrake（16）isreleased・ ③TheHSTpump（DAvalve）inchingleverisreturnedtotheoriginalposition，thusreleasingtheinchi mode．

Fig．4．4ServiceBrakeReleased

ー83−

3．OperationofParkingBrake

①whentheknoboftheparkingbrakevalve（14）ispulledout，thehydraulicoilintheparkingcylinder Chamber（17）isdrained・

③Theparkingbrakepiston（13）isshiftedbythespring（12）pressuretopushtheservicebrakepiston（9）， Puttingthewetdiskbrake（16）inoperation・

③Whentheknoboftheparkingbrakepiston（13）ispushedin，thehydraulicoilisdirectedintotheparki brakecylinderchamber（17）・（SeeFig・4・4・）

④Theparkingbrakepiston（13）shiftsagainstthespring（12）pressuretomaketheservicebrakepiston（9） free，thusreleasingthewettypediskbrake（16）・（SeeFig．4・4・）

Fig．4．5ParkingBrakeinOperation

ー84一

4．2 SERVICE BRAKE 4．2．1MASTER CYLJNDER

nemastercylinderisactuatedbyoperatingthebrakepedal．Whenthebrakepedalispressed，thebrak

Oilispressurizedanditisdirectedunderpressuretothediskbrake（Servicebrakepiston）inthereductiongea

Themastercylinderhasareservetankwherebrakeoilisaccumulated．Thereservetankhasalevelswitch Note： UseTCMapprovedmineraloiltypebrakeoilfbrthemastercylinderreservetank．Neveru automobile−uSenOn−mineraloiltypebrakeoil．

4 5

12 13 14 15 16

6 7 8 9 10 11

17

Note：駐＞ぢ＝コ1・7−2・5kg−m（12−18托」bs） 1．INDICATOR（LEVELSWITCH）

7．SUPPLYVALVE

13．STOP PLATE

2．RESERVOIR

8．VALVEROD

14．STOP WIRE

3．FILTER 4．CYLINDER

9．pRIMARYCUp

15．BOOT

lO．STOPPIN

16．PUSHROD

ll．PISTON

17．YOKE

5．RETURNSPRING 6．VALVESPRING

12．SECONDARYCUP

Fig．4．6MasterCylinder

−85一

Operation （1）Braking （彰Asthepistonisshiftedfbrwardbythepushrod，thecentralsupplyvalverodleavesthestoppin，Clo

the supply valve. ③partofthebrakeoilinfrontofthepistonisdischargedfromthecylindertothediskbrakeunitaccordin tothepistonstroke・

③Whenthediskbrakepistonreachestostopandthebrakeoilpressurerisesenough，thebrakeget engaged・

CYLlNDER

Fig．4．7Braking

（2）Releasing

①Tbepistonisreturnedtotheoriginalpositionbythereturnspring．

②Tbesupplyvalverodcontactsthestoppin，thusopeningthesupplyvalvetoletthebrakeoilreturninto thereservOir．

③ThebrakeoilatthediskbrakeisdepressurizedandreturnedintothereservOir，thusreleasingthebra

Fig．4．＄ReleasingBrake

−86−

4．2．2 DISKBRAKE

Thediskbrake，Whichdoublesasboththeservicebrakeandparkingbrake〉isawetmultipledisktypean

builtinthereductiongear．

Thediskbrakeconsistsofdiskhub，brakedisks，brakeplate，endplate，WaVeSPrlng，Servicebrak Parkingbrakepiston，andsprlngS・

Operation

③whenthebrakeoilpressureactsonthebackoftheservicebrakepiston，thebrakepistonshiftslocksup thebrakediskswiththebrakeplates・

（参珊einsidediametersofthebrakedisksareinmeshwiththereductiongearinputshaftthroughthedisk

hubwhiletheoutsidediametersofthebrakeplatesareinmeshwiththebrakehous1ng・ Asthebrakediskslockedupthebrakeplatesstoprotating，theloaderisbrakedthroughthediskhuband lnputShaft・

③Whenthebrakeoilpressureisreleased，thebrakepistonisreturnedtoitsoriginalpositionbythewav sprlngSOthatthebrakedisksareunlockedtoreleasethebrake・

④Theparkingbrakeisdesignedtooperatebyactuatingtheservicebrakepistonwiththeparkingb piston，Sharingthediskbrakewithbothbrakesystems・（See

4・1・20PERATION・ ） E≡：≡ヨBrakehydraulicoil

匿≡≡ヨB

rakecoolingoil

1．SPRING 2．PARKINGBRAKE PISTON 3．SERVICEBRAKE PISTON 4．WAVESPRING 5．BRAKEHOUSING 6．BRAXEDISK 7．BRAKEI〉LATE 8．DISKHUI‡

9．INPUTSHAFr Fig．4．9DiskBrakeOperation

−87−

4．3PARKINGBRAKE MANUALRELEASING Iftheparkingbrakecannotbereleasedwiththeparkingbrakevalveduetoadeftctivepumporbrany

Otherreason，manua11ymovetheparkingbrakebyuslngtheparkingbrakereleasebolttoreleasetheparking brake．

▲

TheuseofthemanualreleaslngOftheparkingbrakeshouIdnotbeabused．Itshou）db

1imited to such a case as a disabledloader needs to be moved to an out−Of・trafric area．Ifthe Parkingbrakeisreleasedwiththeloaderparkedonaslope，besuretob）ockthewheels・ procedⅦre

（彰Removetheparkingbrakereleaseboltandnut（1）

fromthediskbrakecapofthereductiongear・ ②Remove the recessed head plug（2）from the CenterOfthecap．

Fig．4．10

③Insertthereleaseboltandnut（1）removedinto the centralscrew holein the brake piston（3） throughtheplughole・Seetherightfigure・

④Holdingthereleaseboltheadwithaspanner，turn thenuttoremovethebolt．Compressthesprlng （4）toreleasethebrake・

Fig．4．11

ー88−

4．3．1PARK］NG BRAKEVALVE neparkingbrakevalve，locatedundertheoperator

sseat，1SuSedtocontroltheparkingbrake・Wh

Valveknobispulledout，theparkingbrakeisapplied・Befbrestartlngtheloader，besuretopushinth

toreleasetheparkingbrake・ThevalveisequlPPedwiththedetentmechanismtoholdeachspoolposition Operatiom

（彰Whenthevalveknobispushedin，thepressureoilattheportAflowsthroughtheoilpassageintheval

PaSttheportBintothediskbrakeinthereductiongear・

（参Whenthevalveknobispulledout，thepressureoilattheportAisblockedbythespool．Thepressure OilatthediskbrakeisdrainedthroughtheportB，PaSttheoilpassageinthevalvetotheportT・ B

10 11 12

1 2 3 4 5

6．2mm （StrOke）

6 7 8 9 Not？：ぢ＝コPortsA，B，T：3・5−4kg−m（25−29n−1bs） ぢ＝コFittingbolt：4−5・3kg−m（29−38ft−1bs） （Overtighteningwi11causethe

malfunctionofthespool・） A．fromHSTPUMP PORTG

1．CAP

7．SPRING

B．toREDUCTIONGEARDISKBRAKE

2．PIN

8．BALL（DETENT）

T．toHST畠ucTIONFILTER（IN）

3．0−RING

9．SEALPLATE

4．COLLAR

lO．SPOOL

5．HOUSING

ll．SEAL

6．SLEEVE

12．WIPER

（DRAINPORT）

Fig．4．12ParkingBrakeValve

−89−

5．STEERING SYSTEM

Mechanism

Frame−articulating Orbitro1

Framearticulatingangle

4lOtorightandleft

400torightandleft

Nhmberofrotationsofsteerlng wheel

3．3counterclockwise and4．3clockwise

3．4counterclockwise and4．5clockwise

Name

OrbitroILC−Dl−A

Orbitrol LD−Dl−A

r丹pe

Separatetype

TyllC

← ←

Powersteerlng

Pressure setting Steering pump Steering cylinder

140k帥m2 usedalsoasmainpump

Type Cylinder stroke Quantity

●−

175k亦m2 ←

← ← ◆−

◆−

Double−aCtingpiston 213．Omm l

5．1GENERAL DESCRIPT10N The steerlng SyStemis a frame−articulating type which steers the loader by operating the steering

Cylinderbetweenthefrontandrearframes．Ituses the orbitrol（fu11−hydraulic power steering）which

doesnotuseanylinkagemechanismbutoperateson hydraulicpoweralone． ThesteerlngSyStemCOnSistsofthesteerlngWheel unit，Orbitrol（Withpriorityvalve），Steeringcylinder，

andtubing．

Fig・5・10rbitroltypeSteeringSystem．

▲Ifthep，eSSu．e。ilisn。tSuPpliedfr。mthepumpwiththeengineat，eSt，the。rbit

a manualsteering system）thus makingitpossibleto steertheloader・IIowever）nOtethatt Steeringoperationisconsiderablyheavierthanus11al．

−90−

STEERlNG WHEEL

STEER VALVE （ORB汀ROリ

STEERING CYuNDER

Note：Tbeabovesketchdoesnotillustratethetubing・

Fig．5．2SteeringSystem

−91−

5．2 01LCJRCULAT10N ROUTES TheoilpickedupfromtheoiltankbythemainpumpissentunderpressuretotheVPvalve（priorityvalve） Ofthesteervalveunitwhereitisdividedintotwoportions：Onefbrthemainhydrauliccircuitandonebrthe

Steeringhydrauliccircuit・neSteeringhydrauliccircuitusestheloadsenslngSyStemWhichletsthest hydrauliccircuittakeprlOrityoverthemaincircuitsothattheorbitrolreceivesthenecessaryamountofoil ftomtheVPvalve，withtheresidualamountofoilbeingsenttothemaincircuit・WhenthesteerlngWheel isturned，theoilissentintothesteerlngCylinder．TheoildischargedfromthesteerlngCylinderreturnsinto

theorbitrolffomwhichitreturnsintotheoiltank． Note：Fortheoperationoftheloadsensingsystem，refbrto

5．4．2．VPVALVE（PRIORITYVALVE）：

Fig・53HydraulicCircuitDiagram

−92一

5，3 STEERING WHEEL UN［T nesteeringwheelunitisinstalledinthecockpit・Belowitisthesteervalve（Orbitrol）・Whenthesteerin Wheelisturned，therotationistransmittedthroughthesteerlngShaftwhichinturnactuatestheorbitrol．

Steerin WheelUnit Mountin

匡＞ぢ＝コ4．0−4．6kg−m（29−33ft−1bs）

Note：F＞ぢ＝コ1．9kg−m（14ft−1bs）

匡＞lく＝＝袖Splines：Molybdenumgrease（about3g）

匡＞仁＝＝袖Grease

匠＞一4＝ゝWater−PrOOfseal

駐＞紹＝ゝSyntheticrubberadhesive l．STEERINGWHEEL

4．STEERVALVE

7．BEARING

2．STEERINGWHEELUNIT

5．BUSHING

8．STEERINGSHAFr

3．MAT−

6．GROMMET

9．STEERINGCOLUMN

Fig．5．4SteeringWheelUnit

−93−

5．4STEERVALVEUN［T（ORBITROL）

Thesteervalveunitconsistsoftheorbitrolandadirectlyconnectedpriorityvalve（VPvalve）・The valveunitis飢tedtothesteerlngCOlumnflange・TbeorbitrolisactuatedbythesteerlngShaft・

VPvalveratedflow：

40 4/min

VPvalvereliefpressuresettlng （803）：

140k亦m2（1990psi）

（804）（805）（806）‥175k如m2（2490psi）

P EF

Fig．5．5SteerValveUnit

−94−

5．4．10RB一丁ROL

neorbitroIconsistsofthecontroIvalveandtherotorset． ThecontroIvalveisarotaryvalvetypewhichchangesoveramongoilpassagesbyrotatingitselftoactuate

thesteerlngCylinders・nerOtOrSetislocatedunderthecontroIvalve．Usuallyitactsasanoilmotort performmeteringfunction・Inanemergency，ltisusedasahandpumpandactasamanualsteerlngunit・

二幸 Sectk）nCC（Checkvarvel

（Gerotorstar mountingposition）

Deta‖0＝引

7 8 9 CrossSectionalViewAA（Orbnron

Note：B＞6：：：：：コ2．9kg−m（21ft−1bs） 1．NEEDLEBEARING

8．SLEEVE

15．LS ORIFICECHECKVALVE

2．0ILSEAL

9．SPOOL

16．CFCHECKVALVE

3．DUSTSEAL

lO．SPACERPLATE

17．CHECKBALLRETAINER

4．CENTERINGSPRING

ll．GEROTOR

18．BALL

5．SEALGLANDBUSHING

12．END CAP

19．CHECKSEAT

6．PIN

13．DRIVE

7．HOUSING

14．SPACER

Fig．5．60rbitroIStructure

−95−

ORBITROLOI〉ERATION （1）SteeringWheelinNeutral

Theoilh■OmPportflowsintothecavitybetweenthe SpOOl（2）anddriveshaft（3）throughthesmallopenings Ofthe sleeve（1）and the spool（2）・Theoilin the

CaVityflowsoutfromtheTportthroughtheupperpart Ofthedriveshaft，andnotchgrooveofthespooland

Sleeve・rmeRandLports（Cylinderports）areclosed

by the spool.

Fig．5．7NeutralState

（2）TurningSteeringWheelCounterclockwise WhenthesteerlngWheelisturned，COunterClockwise， thespool（2）isrotatedwithrespecttothesleeve（1）to Closetheneutralflowpassage（Smallopenings）・

TheoilfromthePportpassesthroughthechanged OVerSleeveopenlngS，SpOOlgrooveandsleeveopenlngS andis sent to the rotor set section throughthe oil PaSSageOfthehousing（4）torotatetherotor（5）・

Theoildischargedbyrotationoftherotorissentto the controIvalve section and thenflows from the L

POrtintothesteerlngCylinderthroughthesleeveand SpOOl． TheoildischargedfromthesteerlngCylinderreturns

totheRportandflowsoutfromtheTportthrough thesleeveandspool．

Fig．5．＄ CounterclockwiseRotation

Note：Whentherotorrotates，thedriveshaftandthe Sleeverotatetogether．Namely，ifthesteerlngWheelis

turnedtorotatethespool，thesleeveisalsorotated equally，thereby nullifying spool displacement・ Consequently，therotorisrotated，COrreSPOndingtothe

rotation angle of the steerlng Wheel，and the oil displacedbytherotorissenttothesteerlngCylinder・ In actual steering the following motion of rotor to SteerlngWheelisexecutedcontinuously・

Fig・5・9RotorSetSectioninOperation 一96−

（3）TurningSteeringWheelClockwise When the steerlngWheelis turned clockwise，the rotor rotates in a direction opposite to direction of rotor rotated when the steering wheel is turned COunterClockwise，therebyinverslng Oilintake and dischargebytherotor．

The oilflows from the R portinto the steerlng Cylinders，and the oildischarged from the steerlng CylinderreturnstotheLport．

Fig．5．10ClockwiseRotation

（4）EmergencyOperation Whenthehydraulicoilisnotsuppliedfromthepump duetoenglneStOP，theorbitroIserveSaSanemergenCy

Steerlngunit． When the steerlng Wheelis turned，rOtationis transmitted to the drive shaft（3）and the rotor（5） throughthespool（2）andcrosspin（6）．

Therotor，Putintorotation，drawsinoil．Negative

PreSSureiscreatedintheoilpassage，SOthatthecheck Valve（7）isopenedtodrawinoilfromtheTport．

The oildischarged from the rotoris sent to the SteerlngCylinderthroughthecylinderporttochange thedirectionoftheloader．

TheoildischargedfromthesteerlngCylinderreturns

to anothercylinderportsandisdrawnintotherotor throughthecheckvalve（7）・ Note：Incaseofemergencyoperation，thesteerlng

Fig・5・11Emergency Operation（Clockwise

Rotation）

Wheelisftltheavierthaninnormaloperation．

（5）OperationofCenteringSpring

WhenthesteerlngWheelisturned，thecenterlngSPrlngisdebrmed，COrreSPOndingtotheclearanceb

thecrossplnandspool．WhenthesteerlngWheelisreleasedorlocked，thesleeveisrotatedbytensiono Centeringsprlng，andrestorestheneutralposition．

Inthisstate，turnlnglSCOntinuedattheglVenturnlngangleuntilthesteerlngWheelisturnedagain・Thus，

thedeIbrmationrecoveryofthecenterlngSPrlngaCtSaSftedbackofthesteerlngmeChanism・ −97−

5．4．2VPVALVE（PR］ORrTYVALVE） TheVPvalveisapr10rityvalvedirectlyconnectedtotheorbitrol，COmbiningwiththeorbitroltobrmthe loadsenslngSyStemWhichdistributestheoildischargedfromthemainpumptoboththesteerlngandhydraulic SyStemS．TheVPvalveisprovidedwiththereliefvalvebrthesteeringhydrauliccircuit・

◆ badsenslmgSyStem

Theloadsensingsystemletstheonlyamountofoil（OutOftheoildischargedfromthemainpump）necessa forsteerlngOPerationflowintotheorbitrol，WhilelettlngalltheremalnlngOilflowtothehydraulicequlpment （COntrOIvalve）・Forexample，Whenthesteeringwheelisinneutral，mOStOftheoildischargedfromthemain

PumPisdirectedintothecontroIvalvebrtheoperationoftheloadhandlingsystem・Thissystemal

efncientuseoftheoildischargedfromthemainpump，thusmakingthehydraulicsystemmoreenergy−SaVl

◆ Dynamicslgmalsystem TheloadsenslngSyStemadoptsthedynamicslgnalsystemwhichincorporatesaLSlinecheckvalveandCF linecheckvalve（SeeFig・5・6）topreventthesteeringwheelfromkickingback・

＄ectionalViewofDDNPvahIe） ORBITROL（Fig，5．6）

Note：FortheLSlinecheckvalveandCFlinecheckvalve，reftrto Fig．5．60rbitroIStructure：． 1．HOUSING

5．DYORIFICEPLUG

9．RELIEFSPRING

2．CONTROLSPRING

6．SCREEN

lO．BALLGUIDE

3．CONTROLSPOOL

7．SEAT

ll．ADJUSTINGSCREW

4．PP ORIFICEPLUG

8・BALL（RELIEFVALVE） Fig．5．12VPValveStructure −98−

LOAD SENSING SYSTEM OPERATION

（1）SteeringWもeelinNeutral

①ThepressureoilfromthepumpflowsthroughtheportP，paStthechamberP，ChamberCF，andor CdyoftheVPvalve，intothepressurechamberB・

②ThepressureoilinthechamberBflowsthroughtheor泊ceCIsandLSlinecheckvalveintotheorb LSportandthenthroughtheportTintotheoiltank・

③ThespooloftheVPvalvemovestotherightduetoth占balanceofthepressuredifftrentialacro Or泊ceCdy（dynamicori員ce）andthespringpressure・Almostallportionofthepressureoilfromthepump isdirectedthroughtheportEFintothecontroIvalve・

④ontheotherhand，aSmallportionofoil鮎wsthroughthechamberCF，PaSttheorbitroIwheret

isusedtopreheattheunitand員nalけintotheoiltank・

（卦Withthesteeringwheelinneutral，almostallportionofoildischargedfromthemainpumpisusedbr load handling system.

Fig．5．13SteeringWheelinNeutral

−99−

（2）SteeringWheelinRotation

①Whenthesteeringwheelisturnedclockwise，theoilpassagesintheorbitrolareselectedasshowninthe 員gurebelow．

③nesteeringoperationoilwhichenterstheorbitrolisdividedintothefbllowingtwoflows： （a）：VPvalve

schamberCF→1inecheckvalveCF→Orbitrol

sportp→Or泊ceCl（Variablecontrolorince）

→Gerotor→POrtR

（b）：VPvalve schamberCF→OrinceCdy→PreSSureChamberB→OriGceCIs→1inecheckvalveLS→ Orbitrol

sportLS→Gerotor→pOrtR

Note：Withtheexceptionofthelow−SPeedsteeringrotationarea，theflowrateat（a）isextremelygre

thantheflowrateat（b）sothatthepressure−flowcharacteristicsofoilpassingthroughtheori抗ceCl ismostimportant．

③Atthistime，theVPvalvespoolmovestotheleftduetothebalancebetweenthepressuredifferential （PreSSureChambersAandB）andthespringpressure．nespoolisheldatapositionwheretheamount

OfoilnecessaryfbrsteerlngOPerationflowstothesteeringhydrauliccircuit，dependingupontheopenlng areaofthevariablecontrolor泊ceCl．

④whenthesteeringwheelisturnedfromneutral，theamountofoilnecessarybrsteeringoperationflows

intotheorbitroIwiththeremalnlngamOuntOfoilbeingroutedtotheloadingsystem・

Fig・5・14WhileSteeringWheelisTurned −100−

（3）Ⅵ≠enSteeringCylinderisatStrokeEnd

①Whenthesteeringwheelisturnedtoitsstrokeendateitherofitsrotationaldirections，thereliefv intheVPvalveunit．

②TheoilrelievedfromthereliefvalveflowsthroughthechambersPandCfoftheVPvalve，PaSttheorinc

Cdy，PreSSureChamberB，Ⅲterandreliefvalve，backintotheoiltank．nereliefflowrateisamou to21iters／minsothatalmostallportionofoilisusedbrtheloadhandlingsystemevenwiththerelief valveinactuation．

③nepositionoftheVPvalvespoolisdeterminedbythebalancebetweenthepressurediffbrentialacross theorinceCdyandthesprlngPreSSure．

Fig．5．15SteeringCylinderisatStrokeEnd

ー101−

5．5 STEERING CYLINDER nesteeringcylinderisadouble−aCtingpistontypewhosepistonrodandcylindertubeconnectedtothe 丘ontframeandrearframe，reSPeCtively・Theloaderissteeredbythepistonrodextendingandcontractlng・

1

9 10

7

lnside View

匡＞3

Note：旺＞ぢ：：：：：コ24kg−m（170ft−1bs），FnThreadedarea：nreeBond1901 匡＞ぢ：＝コ17kg−m（120糾bs） B＞ぢ＝コ0．70kg−m（5・1ft−1bs）（Aftertightening，Calktwoparts・） 匡＞ Pressurecheckport（PTl／8） 1．PINBUSHING

7．CYLINDERHEAD

13．SHIM

2．WIpERRING

8．0−RING

14．PISTON

3．PLUG

9．BUSHING

15．SEALRING／0−RING

4．WIPERRING

lO．U−RING

16．SLIDERING

5．LOCKWASHER

ll．PISTONROD

17．SETSCREW

6．0・RING

12．CYLINDERTUBE

18．STEELBALL

Fig．5．16SteeringCylinder

ー102−

6．FRAMEAND COCKPLT

6．1FRAME Theframeisasteel−plateweldedtypeanddividedintotwoparts‥ftontandrear丘ames・Thecockpit OPeratOr

sseataremountedontherearframe．

A Donottrytomodi heROPS（Roll・OVerPmt∝tionstruCture），ifmounted，withoutp

Permission鉦（）mthemanu払cturer・IftheROPSshouldgetdamagedorde伽rmedduetottlrnlng

OVerOrCOllision，itisadvisabletoreplaceitwithanewone，becauseadamagedorde伽rmedROP

hasalowstructuralstrength・BebretryingtomountanewROPS）besuretowIPeaWayPainta lubricantfromthemountingsur払cesofthe畠tructureandthe蝕−ame．

Note：D＞ぢ：＝コCockpitmountingbolt‥9・Okg−m（65ft−1bs） P＞ぢ＝コBalanceweightmountingbolt：mOrethan16kg−m（120ft−1bs） Fig．6．1Frame −103−

6．2 CENTER HINGE PIN neloaderisaframe−articulatedtype：theh■Ontframeisjoinedtotherearframewithtwohingepinsar Whichtheloaderisbentforsteerlng．

▲ whenladerissteered，thea代anearthe Center hinge plnS becomes so na汀OW仙at yoⅦ

might get caught between the n．ont and rear 什ames．Be鮎retryingtoserrvicetheloader，make

sure toset the sabtylink・Priorto starting （traveling）theloader，makes11rethesa鮎tylinkis

SettOtheoriginalposition．

Fig．6．2SafetyLink

＿104−

Note：D＞仁＝＝袖Innersurface：Grease （beforepinsareinstalled）

匡＞14＝ゝOuterring‥LOCTITE262 匡＞Press抗tsleeveandbushingtobe

flushwiththissurface（No Prqjectionallowed）（2points）

駐＝＞Makesuretoinstallcenterhinge

Pinbushingsindirectionindicated （2pointsattopandbottom）

O／iewIookingfromrearofthe10ader．）

1．FRONTFRAME

4．CENTER PIN

7．THRUSTWASHER

2．REARFRAME

5．SLEEVE

8．BUSHING

3．GREASEFITnNG

6．SEAL

9．DUSTSEAL

Fig．6．3CenterHingePin（803）

−105−

Note：旺＞ぢ＝コ33．2kg−m（240ft−1bs） −4＝ゝnreadedarea：LOCTITE262

3 4

匡＞ぢ：：：：コ5．1kg−m（37鋸bs） B＞ド＝＝ねInnersurface‥Grease （beforepinsareinstalled）

匡＞正＝ゝOuterring：LOCTITE262 匠＞Makesuretoinstallcenterhinge Pinbushingindirectionindicated・ （upperhingepinalone）

医 CrosssectionatviewAA

O＿00kingfromrearofthebadeO

1．FRONTFRAME

6．DUSTSEAL

11．DUSTSEAL

2．REARFRAME 3．GREASEFITrING

7．BUSHING

12．SHIM（t＝0・2，0・4mm）

8．WASHER

13．CAP

4・CENTERPIN（UPPER）

9．COLLAR

14．COLLAR

5．SLEEVE

lO．BUSHING

15・CENTERPIN（LOWER）

Fig．6．4CenterHingePins（804，805，806）

−106t

7．HYDRAUuC SYSTEM

Thehydraulicsystemusesthemainpumpasitspowersourceandchangesoveroil flowswiththec Valveaccordingtotheworkyouwanttodo．

Thehydraulicsystemconsistsofthemainpump，COntrOIvalve，ValvecontroIs，Oiltankandhydraulicplplng

Notesl： Theabove伝gureincludesthesteeringhydraulicpIPlng．

2： Forthesuctioncircuit（includingthemainpump）andreturncircuit（includingthereturnⅢter） referto…3．1．2HSTPIPING：

Fig．7．1HydraulicSystem

−107＿

7．101LCIRCULAT10N ROUTES 7．1．1GENERALDESCRIPTtON

Thehydrauliccircuitoftheloaderconsistsofthemainhydrauliccircuit，SteeringhydrauliccircuitandHST hydrauliccircuit．

Main Hydraulic Circuit Theoilpickedupffomtheoiltankbythemainpumpisdirectedintothesteervalvewhereitisdividedinto

twoportions‥theonefbrthemainhydrauliccircuitandtheonebrthesteeringhydrauliccircuit．rmeoi

themainhydrauliccircuitisroutedtothecontroIvalve・WhenthecontroIvalveisinneutral，theoilpa

throughthecontroIvalvebackintotheoiltank・WiththecontroIvalveinanoperatlngPOSition，theoil

throughtheoilpassagechosenbythespoolintothecylinder・neOildischargedfromthecylinderreturns thecontroIvalvewhichinturnsendstheoilthroughthereturnⅢterintotheoiltank．

Notesl： Forthesteeringhydrauliccircuit，reftrto

5・STEERINGSYSTEM（5．2）．

2： FortheHSThydrauliccircuit，reftrto一 3．1HSTUNIT（3．1．2）．

−108−

Fig・7・20ilCircuitDiagram（803） −109−

Fig・7・30ilCircuitDiagram（804，805，806） −110−

7．1．2 RETURN FILTER

ThereturnⅢterislocatedinthereturncircuitofthemainhydrauliccircuit．neoilflowsthroughth element ftom outside toinside and the員1tered oilreturnsinto the oiltank．Asthe return玩1ter element

becomesplugged，thepressureattheinletportsideincreasessothattheoilbypassestheⅢterelement

Opensthebypassvalvetoflowdirectlytotheoutletport・ne鎖1terisacartridgetype・Whentheelemen needstobereplaced，rePlacethecartridge．

Fig．7．4ReturnFilter

−111＿

7．2 PUMP ト

・、

、

＼

Theloaderusestwopumps：mainpump（Steeringpump）andHSTchargingpump・

neHSTpumpunithasdoublepumpsatitsrear‥thefrontoneofthedoublepumpsisusedasthe pumpandtherearoneisusedastheHSTchargingpump・Sincethedrivegearofthedoublepumps COuPledtotheHSTpumpdriveshaft，italwaysrotatesastheenglnerunS・

Fig．7．5Pumps

ー112−

7．2．1MAIN PUMP

ThemainpumpdoublesasthesteerlngPump・nemainpumppicksuphydraulicoilfromtheoiltanka

Sendsittothesteervalve（VPvalve）whereitisdividedintotwoportions：theoneforthesteeringhyd Circuitandtheonebrthemainhydrauliccircuit．

7．2．2 HSTCHARG［NG PUMP

neoildischargedfromtheHSTchargingpumplSuSedforthebllowlngthreepurposes：ChargingtheHST Closedloop，pilotoiltbrtilt−rOllingcontrol（804，805，806）andreleasingtheparkingbrake．

Note：FortheHSThydrauliccircuit，refbrto

3・1HSTUNIT（3．1．2）．

Fig．7．6DoublePumps

−113−

7．3 CONTROLVALVE ＄03

804，＄05，＄06

Model

KVS−31

KVS−65

Type

Tandemtype，2−SpOOIslidingtype

◆−

（W／reliefvalve）

Mainreliefpressuresettlng

210k釘cm2

Portreliefpressuresettlng

230kgたm2

← ●−

（Bucketcylinderrodside）

7．3．1GENERALDESCRIPT10N

necontroIvalveisastacked，2−SPOOIslidingtype，COnSistingoftheinletsection，tWOSPOOIsections，an

Outletsection・TbeoilpassagesinsidethevalveisatandemtypeandthebucketoilpassagehasprlOrltyO theboomoilpassagesothatthepressureoilissuppliedtotheboomsectiononlywhenthebucketspoolis inneutral．

Note：ForthecontroIvalveinstallation，SeeFig．7．20．

（1）RelierValYe necontroIvalvelSPrOVidedwithareliefvalveandserveStOPrOteCtthe entirehydrauliccircuitoftheload

handlingsystemwhilecontrollingtheoperationpressure・Thecylinderportleadingtothebucketcylin Sideis員ttedwithaportreliefvalvewhichrelievesthepressureoilwhenthecylinderreceivesaloadhea enoughtoletthepressureatthecylinderportrisebeyondthespeci6edvalue，thusprotectlngthecylinderand

thepIPlng．

（2）DetentMechanism Onallmodels，thedetentmechanism払rthesecond（boom）sectionisamechanicaltype・Thefirst（bucket）

SeCtionisasolenoidtypeon804，805，and806．

−114−

Tandem circuit

1．MAlNRELIEFVALVE 2．OUTLETSECTION

3・SPOOLSECTION（BOOM） 4．INLETSECTION 5．SPOOLSECTION（BUCKET）

6．PORTRELIEFVALVE

（CircuitDiagram）

Fig．7．7ControIValve（803）

−115−

（BUCKET）

8 7 6

1．HOUSING 2．SPOOL 3．WIPER 4．0−RING

5．SPRING 6．CAPSCREW 7．CAP 8．SEALPLATE

9．0−RING

lO．LOAD CHECKVALVE ll．SPRING

（迅00M）

1．HOUSING

6．SI）RING

2．0−RING

7．DETENTSPRING 8．DETENTPIN 9．STAINLESSBALL lO．SPACER

3．WIPER 4．SPOOL 5．SEALPLATE

11．DETENTSLEEVE 12．CAP 13．0−RING

14．LOADCHECKVALVE 15．SPRING

Fig．7．8SpooISection（803）

−116−

Tandem circu往

1．MAlNRELIEFVALVE 2．OUTLETSECTION 3．SPOOLSECTION（BOOM）

4．INLETSECTION

5・SPOOLSECTION（BUCKET） 6．PORTRELIEFVALVE

（CircuitDiagram）

Fig．7．，ControIValve（804，805，806）

−117−

（丑UCKET）

1．SPOOL 2．SEALPLATE 3．WIPER 4．0−RING

5．VALVEHOUSING

6．SPRING 7．CAP 8．SLEEVE 9．PIN lO．pLATE

11．COILTUBEASSEMBLY 12．CHECKVALVEPOPPET 13．SPRING 14．0−RING

（BOOM）

131415

1．VALVEHOUSING 2．0−RING

3．WIPER 4．SPOOL 5．SEALPLATE

6．SPRING 7．DETENTSPRING 8．DETENTPIN 9．STAlNLESSBALL lO．SPACER

11．DETENTSLEEVE 12．CAP 13．0−RING

14．CHECKVALVEPOPPET 15．SPRING

Fig・7・10SpooISection（804，805，806） −118−

7．3．2 0PERAT10N

Whenthecontrolleveris actuated，theoilpassagesareswitchedoverbythespooIsslidingsothatthe

pressureoilfromtheprlOrltyValveisselectivelysenttothebucketorboomcylinder・neboomspoolhas detentmechanismwhichautomaticallyholdsthe一

floating一

position，keeplngthespoolftomreturnlngtOneutral

Whentheoperatorremoveshishandfromtheleveronceitisshiftedintothe

floating

leverautomaticallyreturnstoneutralfromoperationpositionsotherthanthe

floating Tposition・

Note：On804，805，and806，thesolenoiddetentisprovidedonthe

roll−back

1position・neCOntrOl

一positionofthebucketspoo

fortheoperationoftheautoleversystem．

l．ControIValvein Neutral

①whenthespooIsofthebucketspooIsectionandtheboomspooIsectionareinneutral，boththecylinder POrtSA（rodside）andB（tailside）areclosedbythespool・

②ThepressureoilwhichhasreachedthecontroIvalveflowsthroughtheinletsection，PaSttheneutral PaSSageSinthebucketspooIsectionandtheboomspooIsection，tOtheoutletsectionfromwhichitis directedtothelow−PreSSureOilpassageandleavesthecontroIvalvethroughtheinletsection．

Note：ThesketchgivenbelowshowsatypicalKVS−65seriesvalve．

Fig・7・llControIValveinNeutral（BucketSpooISection）

−119−

2。迅ⅦCktSp0010peration （1）Roll−back

①whenthecontrolleverisplacedinthe

roll−back

：position，thebucketspoolmovesinthedirect

indicatedbythearrow・

（参Theneutraloilpassageisclosedbythespoolandthepressureoilpushesopentheloadcheckvalvetofl

tothecylinderport（Bl）fromwhichitisdirectedintothebucketcylindertail・

③Tbeoildischargedfromthebucketcylinderrodsideflowsthroughthecylinderport（Al）tothelow− PreSSureOilpassageandbacktotheoiltank・

■l Rollback

Fig．7．12Bucketin、Roll−back （2）D廿mp

①whenthecontrolleverisplacedinthe−Tdump position，thebucketspoolmovesinthedirectionindicated bythearrow． （参Theneutraloilpassageisclosedbythespoolandthepressureoilpushesopentheloadcheckvalvetofl tothecylinderport（Al）fromwhichitisdirectedintothebucketcylinderrodside．

③Theoildischargedfromthebucketcylindertailsideflowthroughthecylinderport（Bl）tothelow−PreSSure Oilpassage． BI

Al

Fig．7・13BucketinDump

−120＿

3．BoomSpoolOperation （1）RaiseandDown

neoilpassageintheboomspooIsectionisidenticalwiththatinthebucketspooIsection．Tberefore，

ralSlngOperationisidenticalwithbucketroll−backoperationwhereasboomlowerlngOPerationisidenticalwith

bucketdumpoperation．Forthedetailsofboomoperation，Seethepertinentsectionsofbucketoperati Note：PressureoilisnotsuppliedtotheboomspooIsectionunlessthebucketspoolisinneutralsincethe oilpassagesinthecontroIvalveformatandemcircuit．（Theboomcylinderdoe這notactuated．）

（2）Float

①whenthecontro11everisfurtherpusheddownfromthe一一Down，一positiontotheT−Float一一pos草tion，theboom SpOOlmovesasindicatedintheillustration． ②Duetothismotiontheneutralpassageisopened．Thepressureoilflowsasinneutralposition．

③mecylinderports（A2）and（B2）areconnectedtothelowpressureoilpassage．Asaresult，theboo floatoverthegroundsurfaceaccordingtoitsirregularities．neoildischargedfromtheboomcylinderrod Sideissenttothetailsideandtheoilfbrcedoutfromitstailsideissenttorodsiderespectivelythrough thelowpressureoilpassageinthecontroIvalve．

Fig．7．14BoominFloating

−121−

4．DetemtOperatiom （1）BoomSide

③whenthecontro11everispusheddownfu11ytothe．一noat一一position，theboomspool（1）ispulledoutfu11y Duetothisthedetentpin（2）員ttedtothespoolendisalsopulledout，andthedetentballs（3）fallinto thegrooveofdetentsleeve（4）・

②sincethedetentballsarepushed becomesoperative．

bythedetentspring（5），theboomspoolholdsitsposition，andthedetent

（卦Toreleasethedetent，Setthecontro11everin一一Neutral−Ipositionbyhand． 5 2 3

1

4

◆ ‖FIoating

Fig．7．15BoomSideDetentinOperation （2）8ⅦCketSide（＄04，＄05，＄0 ）

①Theelectromgneticdetentisusedatthebucketside・Theelectricalcircuitisconnected＆omthebatt

totheproximltySwitchofthebucketlevelerthroughthecoilassemblyofthebucketspooIsection・

③whenthebucketistiltedforward，theproximityswitchiskeptclosedsothatthecoilassembly（4）is excited．

③whenthecontrolleverispulledoutfu11ytothe Roll−back一一position，thebucketspool（1）isfu11ypushed

in，andthepin（2）Ⅲtedtothespoolendisalsopushedin，SOthattheplate（3）contactsthecoil（4）・As aresultthebucketspoolholdsitsposition，andthedetentbecomesoperative・

④Toreleasethedetent，OPentheproximityswitchtodeenergizethecoilassemblyoroperatethecontrol leverbyhand． 1

2

3

4

pR。Xw．TCH

■■Rolトba

Fig．7．16BucketSideDetentinOperation −122−

7．3．3 REuEFVALVE ThecontroIvalvehasamainreliefvalveandaportreliefvalve・

Themainreliefvalveislocatedbetweentheneutraloilpassageandthelow，preSSureOilpassage（re

PaSSage）intheinletsection．neportreliefvalveislocatedbetweentherodcylinderportandthelow− pressureoilpassage（returnoilpassage）inthebucketspooIsection・

Operation （l）InInoperativeState

①Thepressureoilinthehigh−PreSSureOilpassage

LP

2

LP

1 3

（HP）flows through thethrottle hole（2）in the mainpoppet（1）toⅢltheinternalcavity（3）・

②0wingtothedifftrencein ．

SeatStOthesleeve（4）・

Fig・7・17InInoperativeState （2）Operation（A）

①whenthepressureinthehigh−PreSSureOilpassge （HP）risesandexceedsthereliefpressuresettlng， thepilotpoppet（5）opens・

③Thepressureoilflowsfromthepilotpoppetinto thelowpressureoilpassage（LP），PaSSingbetween

thesleeve（4）andthehousing（6）． LP

5

Fig．7．180peration（A）

（3）Operation（8） Asthepilotpoppet（5）opens，thepressureinthe

internalcavity（3）lowerstomovethemainpoppet（1）

SOthatthepressureoilintheoilpassage（HP）flows directlyintothelowerpressureoilpassage（LP）・

HP

Fig．7．190peration（B）

一123一

7．4 VALVE CONTROLS

rnleValvecontroIsystemisasinglelevertype・Whenthecontrolleverismanlpulated，thecontroIval

SPOOIsareoperatedtoslidethroughthecable；ShiftingtheleverbackandbrthwillactuatetheboomspooI

Whileshiftingtheleversidewayswillactuatethebucketspool・

▲AsasabtydevCebrthevalvecontroIsystem，aStOPlinkisprovided・mSethestopli lockthecontrolleverlnneutralwhentheloadhandlingsystemdoesnotneedtobeused．

1 2 3＜＝＝刀 4

5

亡己∩二、てヾ 画一ナーー壷攣

（HOODSUPPORl〕

2 8

イ ／一−、、、＿一

′イ。／／／ふ ⑳

D＞〆＝：＝袖Outerdiameter：Grease （bebreassembly）

1．CONTROLLEVER

7・（PIN）

2．BUSHING

8．BOSS

3．PIN

9．BALLLINK

4．STOP LINK 5．SpRING

lO・CONTROLCABLE（BOOM） 11・CONTROLCABLE（BUCKET）

6．BOOT

12．CONTROLVALVE

Fig．7．20ValveControISystem

−124一

7．5 01LTANK ＄03 Tank capacity

Weight（Dry）

＄04，＄05，＄0

33Q（totalcapacity）

40Q（totalcapacity）

20Q（levelcapacity）

24Q（1evelcapacity）

29kg

34kg

Theoiltankholdshydraulicoilbrthemainhydrauliccircult，Steeringhydrauliccircult，andHSThydraulic Circuit．Itisboltedtotherightsideoftherearframe・

A to MAINPUMP B．fromRETURNFILTER

（MAlNHYDRAULIC CIRCUIT）

C．from CHECKVALVE

（HSTPUMPT2PORT） D．丘om OILCOOLER

E．toDISKBRAKE

（COOLINGCIRCUIT）

1．COVER 2．0ILTANK 3．OILGAUGE 4．DRAlNPLUG 5．FILLERCAP 6．SCREEN 7．COVER

Fig．7．210ilTank

＿125−

8．LOAD HANDuNG SYSTEM Theloadhandlingsystemisoperatedbyhydrauliccylindersandisusedtodig，loadandunload，andtransport

loads・nelinkageemployedfortheloadingsystemisaninverseZ−Shapetypewhichissimplerindesignan PrOducesmorepowerfu1bucketbreak−Outfbrcethantheduplextypeandothers・

Fig・＄・1I・OadHandlingSystem

■126−

8．1BOOM，BELLCRANKANDBUCKET ＄03 Linkage

InverseZ

Bucket

DEB，1type

＄04

＄05

＄0

◆−

Bucket capacity Heaped

0．30m3

0．40m3

0．50m3

0．60m3

Struck

0．25m3

0．34m3

0．43m3

0．51m3

Bucketleveler

Visual

Solenoid

Boom kickout

Not provided

◆−

←

◆−■

Weight Boom（PerPiece）

98kg

162kg

234kg

234kg

Bellcrank

33kg

45kg

52kg

52kg

pushrod

7．9kg

9・6kg

10kg

10kg

Bucket（double−edged）

120kg

169kg

195kg

207kg

8．1．1GENERALDESCRIPTION

Theloadhandlingsystemconsistsofbooms，bellcrank，Pushrod，bucket，bucketcylinder，boomc

andpins・Thebucketlevelerhelpsprovideefncientloadhandlingoperation・A11connectingplnSOfth

handlingsystemhavedustsealstopreventtheentranceofwater，mudordustintothesystem．Theyareal

securedwithlockbolts．

ー127−

Detai10ftvDicaIDin

Note：D＞仁＝＝袖Allpins，bushing，andbosses：Grease（applybebreinsta11ingpins） 匡＝＞Dustsealmustbenttedwithlipfacingoutward・ 1．BUCKETCYLINDER

7．STOPPERPLATE

12．SHIM（t＝1・Omm）

2．BELLCRANK

8．STOPPERPLATE

（805and806alone）

3．STOPPER

9．SPACER

4．PUSHROD

（t＝1・0，1・6，2・3mm）

5．BOOM

10．GREASEFITnNG

6．BUCKET

ll．BOOMCYLINDER Fig．8．2Boom，Be11crank，andbucket

ー128−

13．PIN

14．BUSHING 15．DUSTSEAL

8．1．2 BUCKET

Thedouble−edgedbucketisstandard・Inadditiontothestandardtype，thetypellightbucketandty bucketarealsooptlOnalけavailable．

Thebucketshouldbeselectedwithduecare，COnSideringtheconditionofjobsites，thenatureofloa

behandled，andtheoperatingcondition・Awrongbucketwi11causeanine抗cientoperationand

malfunctionoftheloadhandlingsystemaswell．

DOUBLEEI）GEDBUCKET

Note；匡＞（妄＝コ29・1kg−m （210ft−1bs）

1．SIDECUTnNGEDGE 2．MAlNCUmNGEDGE 3．DOUBLEEDGE

mE・3BUCKET Note：旺＞ぢ＝コ29．1kg−m （210虹1bs）

1．SIDECUTnNGEDGE 2．MAINCUTnNGEDGE 3．BUCKETTOOTH 4．SPACER

1．SIDECUTnNGEDGE 2．MAINCUTnNGEDGE

Fig．8．3Bucket −129−

8．1．3 BUCKETLEVELER

l．Visual取peIiⅦCketI止Yeler（＄03）

The803isequlppedwithavisualtypebucketleveler・Thebucketstandslevelwhenthematch−markonthe levelerpIPematChesthematchmarkonthebucketcylinder・

Fig．8．4BucketLeveler（br803）

−130一

2．SolenoidTypeBucketAutoleveler（＄04，805，806）

WiththecontrolleverputinRoll−backafterdumplngthebucket，thebucketautolevelerautomatica

returnsthecontrollevertoneutralwhenthebucketisputinhorizontalposition・

Operation ①Asthebucketisrolledback，thebucketcylinderpistonrodextendsenughtoletthelevelerplateleav thesensingsurfaceoftheproximityswitch（thusopeningtheelectricclrCuit）・

②rmeproximityswitchisconnectedtothesolenoiddetentcoilofthecontroIvalvebucketsection．The SOlenoid detentis thus released tolet the controllever return to neutral，StOPPlng the rolling back Operationofthebucket・

Note：nebucket spoolis a solenoiddetent mechanism．When thebucketis ro11ed backbeyond the

horizontalline，nOfurtherelectrlCltywi11nowtothesolenoiddetentcoilso thatthecontro11ever detent mechanismwon

twork．

1．BUCKET CYLINDER 2．LEVELERPLATE 3．BRACKET 4．pROXIMITY SWITCH 5．CONTROLVALVE

Note：On805and806，thelevelerplatepositiononthebucketcylinderisdifftrentfromthatintheabov 坑gure．

Fig・8・5BucketLeveler（804，805，806）

ー131−

8．2 CYLINDERS ＄04

＄03

＄05，＄0

Boomcylinder r吋pe

Double−aCtlngpiston

Q ty

2

Cylinderstroke Weight（PerCylinder）

◆−

438．Omm

479．Omm

505．Omm

15 kg

20 kg

23 kg

Bucket cylinder

Type

Double−aCtingpIStOn ←

Q ty

Cylinderstroke Weight

300．Omm

382．Omm

380．Omm

15kg

15．5kg

27kg

8．2．1BOOM CYuNDER

Thetwoboomcylindersofadouble−aCtlngPIStOntyPeareuSed．Astheboomcylindersareextend

COntraCted，ralSlngOrlowerlngthebooms・Theboomcylinderconsistsofthecylindertube，Cylinderh

plStOnrOd，Piston，andpackings・

8．2．2 BUCKETCYuNDER

nebucketcylinderisadouble−aCtingpIStOntyPe・Asthebucketcylinderisextendedorcontracted，

bucketisdumpedorrolledbackthroughthebellcrankandpushrod・Thebucketcylinderconsistso Cylindertube，Cylinderhead，pistonrod，Pistonandpackings．

ー132−

」8＿こ

」

Note：旺＞ぢ＝：コ（803）：28kg−m（200ft−1bs），（804）‥35kg−m（250ft−1bs），（805，806）：39kg−m（280ft−1bs）

正＝ゝThreadedarea：ThreeBond1901 B＞ぢ＝コ（803）：29kg−m（210ft−1bs），（804）：52kg−m（380ft−1bs），（805，806）：68kg−m（490ft−1bs）

B＞ぢ：：：：：コ0・70kg−m（5・1ft−1bs）（Aftertightening，Calk2parts・） 1．pINBUSHING

7．0−RING

13．PISTON

2．WIPERRING

8．BUSHING

14．SEALRING／0−RING

3．LOCKWASHER

9．URING

15，SLIDERING

4．0−RING

lO．PISTONROD

16．SETSCREW

5．PISTON

ll．CYLINDERTUBE

17．STEELBALL

6．BACK−UP RING

12．SHIM

Note：The abovesketchshows theboomcylinderofthe804．Thesizeand appearance aresomew difftrentfromthoseoftheothermodels． Fig．＄．6BoomCylinder −133一

Note：D＞ぢ＝コ（803，804）：35kg−m（250ft−1bs），（805，806）：46kg−m（330ft−1bs）

紹＝ゝThreadedarea‥nreeBond1901 E＞往＝コ（803，804）‥52kg−m（380ft−1bs），（805，806）：105kg−m（760ft−1bs） 匡＞ぢ：：：：：コ（803，804）：0．70kg−m（5・1ft−1bs），（805，806）：1・65kg−m（11・9ft−1bs） （Aftertightening，Calk2PartS・） 1．PINBUSHING 2．WIpERRING 3．LOCKWASHER 4．0−RING

5．PISTON 6．BACK−UPRING

7．0−RING

13．PISTON

8．BUSHING 9．U RING lO．PISTONROD ll．CYLINDERTUBE 12．SHIM

15．SLIDERING 16．SETSCREW 17．STEELBALL

14．SEALRING／0−RING

Note：Theabovesketchshowsthebucketcylinderofthe804．nesizeandappearancearesome difftrentfromthoseoftheothermodels． Fig．8．7BucketCylinder

−134−

9．ELECTRIC SYSTEM 9．1LIGHTING EQUIPMENT Name

Specification

Q ty

Headlights

12V 35W

2

Turnsignals世Ont）

12V 23W

2

Turnsignals（Side）

Remarks

Usedincommonwithfrontturnslgnals．

Brakelamps 12V 23侶W

2

Taillamps

Rearcombinationlamp

Back−uPlamp

12V18．4W

2

Instrumentlamp

12Vl．4W

3

−135一

9．2 METERSANDSWITCHES

9・2▲10PERATINGSTATUSMONITORS（CLUSTERGAUGES） FUEL METER

MON［TORLAMPS

PVARN［NGLAMPS）

（Front）

CONN．B

CONN．A

CONN．B

CONN．C

CONN．D 23 756iPl−49

（Loaderside）

Connectedto

No． O1

Starterswitch

No．

Connectedto

四 （HSTnlter）

2 （Parkingbrake）

12

3 （Engineoilpressure）

13 Ground

4 （Brakeoillevel）

14 Lightingswitch

5

15 Starterswitch

6 （Glow）

16 Fuel level sender unit

7 （Charge）

17 Thermosenderunit

8 （Aircleaner）

18

9 （HSToiltemperature） 19 Hourmeter（＋） 10 （HSToilpressure） （Internalwiringdiagram）

Fig．9．1ClusterGaugeUnit

−136−

20 Ground

TheoperatlngStatuSmOnitorsystemmonitorstheloaderoperatlngStatuSWiththesensorsandswitches

installedontheloaderanddisplaystheinbrmationontheinstrumentPanelintheoperator scompartme toinbrmtheoperatorofthecurrentoperatlngStatuSOftheloader． TheoperatlngStatuSOftheloaderisdisplayedbyacombinationoftheclustergaugeunitandmonitorlamps （andwarninglamp）wi1ichindicatewhethereachsystemisoperatingproperly・

1．Meters

¶1emeterSincludethefuelmeter，englneWatertemPeraturegaugeandhourmeter・ Engine water temperature gauge

Meter

770C

Fuelmeter

l130C

￣訂

1710F 0C 60

Scale

『′ RedGreen

WhiteGreenRed

Measurementpolnt

600C（1400F）十 1130C（2350F）†

EI

F十

15．8Q

80Q

10日

Standardvalue

84．3Q

Fig．9．2Meters

Table9．1Specincationsandlocationsofsensors Name

Application

Spec泊cation Float

E 1佗 F

Resistance【）

80 32 10

Insidefueltank

Fuellevelsenderunit Fuelmeter TemperatureOC Tbermosenderunit

Location

Engine water

OF

temperaturegauge

ResistanceE2

ー137−

80 4（1．b 10

2．MonitorLamps（Warninglamp） Theloaderisprovidedwithatotalof9monitorlampswhichmonitorthecurrentoperatlngStatuSOfthe loader・Ifanyoftheb1lowlngCOnditionsoccurs，thecorrespondinglampwi11comeon．

Note：Whenthestarterswitchisturnedon，allmonitorlampsshouldcomeon・Ifanylampwon，tcomeon，

itissusPeCtedthatthebulbisblownout・NotethattheTTGlow一一1ampwillgooutwhentheenglneh beenpreheated・

DescrlPtlOn

Name

，恩G Parkingbrake 盈

Parking brake applied

Oilpressurebelowspec泊ed

L

■

B．ak。。ill。，el

Levelisbelowspeci丘ed

BRAKE

亡∃ charge

Batteryundercharged

CHG

⑨

Ai，C．eane，

Clogged

AIRCJEANER

：］慧IISToiltemperature

Temperatureoverspeci員ed

HSTIISToilpressure 0ルPRESS

Oilpressurebelowspeci員ed

HST爪1ter

で甘 Gl。W

Clogged

Enginebeingpreheated・

GJOW

Fig．9．3MonitorLamps

−138−

Table9・2Specincationsandlocationsofswitches（SenSOrS） Name

Application

OFF‥5・2±0・3kgkm2（74±4psi）

Pressureswitch

Oilswitch

IJeVelswitch

Parkingbrake

Location

Speci員cation

ON‥4・2±0・3kg尤m2（60±4psi）

（Turnsonatatmosphericpressure）

BrakeplplngOfparking brakevalve

Engineoil

TurnsofFwhenoilpressuredropsbelow Leftsideofenglne

PreSSure

0・5kgkm2（7psi）

Brake oil level

ON：Turnsonbelowstandardlevel （about40cc）

（topofoilⅢter）

Inside master cylinder

Turnsonwhennegativepressureexceeds

Indicatqr

Aircleaner

635±58mmH20・

Aircleaner

（Turnsoffatatmosphericpressure）

Thermoswitch

Pressureswitch

Sensor

ON‥110±30C（230±50F） temperature OFF：OVerlOOOC（2120F）

HSToil

HST oil preSSure

IISTmter

OFF：5・2±0・3kがm2（74±4psi）

ON‥4・2±0・3kgkm2（60±4psi）

（Turnsonatatmosphericpressure） TurnsonwhendifftrentialpressureIN

andOUTexceedsO・3kgkm2（4psi）

一139−

Pipingofoilcooler

HSTpumppIPlngOf

parking brake valve InsideHSTsuctionfilter

9．2．2 uGHTINGSWITCH

ST

Fig．9．4LightingSwitch

9．2．3 TURN SIGNALSWITCH

L

3

2

○

○

N R

○

○

Fig．9．5TurnSignalSwitch

−140−

H

OFF

○

1st

○

○

2nd

○

○

○

9，3 ELECTFl］CCJRCUIT DIAGRAM Note：Cordcolors：

Thecordsareclassinedbycolor．neBrstsymboIshowsthecablecolorandthe2ndthemarking color．

B；Black BW：BlackWhite BY：BlackYe110W BR：BlackRed

BG：BlackGreen BL：BlackBlue

W；White WR：WhiteRed WB：WhiteBlack WL：WhiteBlue VVY：WhiteYe1low WG：WhiteGreen RW：RedWhite RB：RedBlack

R；Red

RY：RedYellow RG：RedGreen RL：RedBlue

G；Green GW：GreenWhite GR：GreenRed GY：GreenYellow GB：GreenBlack GL：GreenBlue Y；Yellow YR：YellowRed YB：YellowBlack YG：YellowGreen YL：Ye1lowBlue YW：YellowWhite Br；Brown BrW：BrownWhite BrR：BrownRed BrY：BrownYellow BrB：BrownBlack L；Blue

LW：BlueWhite LR：BlueRed

LY：BlueYellow LB：BlueBlack LG：BlueGreen

Lg；Light

LgR：Lightgreen

LgB：Lightgreen

LgW：Lightgreen

Green

Red

Black

White

P；Pink 0；Orange Gr；Gray

▲

BebretⅣingtoworkontheelectricsystem，besuretodisconnectthebatteryconnectors

Whendisconnectingthebatteryconnectors，firstthedisconnectthegroundside（−）terminalbe鮎r

removlngtheotherterminals．

一141−

◎

22B

10GR

（Option）

20YB

61BY

5BW

8WL

Fig・9・6ElectricCircuitDiagram −142−

No．SEW−605AE

lssued：March，1993

Tl▼lllH剛■l￠l．，u■． TRADINGOFFICE：

15・5，Ni＄hi・＄himbashil・Chome，Minato・ku，Toky0105，Japan

TELEX：J・23991TCM TOK A＝HghtsreseⅣed

FAX：JAPAN3・35918152 0−0503040（F−204）

TCM TW011H払H■l￠l．，uD．