TCM 866 Kubota Wheel Loader Service Manual SEW-669AE - PDF DOWNLOAD

No．SEW−669AE

＿

T⊂M⑧

盛返狩靴励姐蝿藍 WHEELLOADFR ●

866

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TlⅣlりH臥H■l￠l．，uD．

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FOREWORD

TCMisofferingawidevarietyofwheelloaderswhichar与enthusiastica11ywelcomedbytheusersallov theworld．

neMode1866articulated typewheelloaderis thelatest productdevelopedbyyearsofresearch and experience・

Togetthemostoftheloader，1tlSrequiredtobecomefami1iarwithitsfeatures，COnStruCtion，Operatlngan maintenanceprocedures・

nisServiceManualexplainsthestructureandmaintenanceproceduresoftheMode1866wheelloaderbr

servicepersonnelandshopworkers・Wehopeitwillbeyourgoodcompanioninserv1Clngjob・ Tbedescriptionandspecincationsdescribedinthismanualaresubjecttochangewithoutnotice・

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TABLEOFCONTENTS 1．SPECIFICAT10NS……………．…………………‥・……………・・1 1．1MACHINESPECIFICATIONS…………………・…………………‥・…‥1 1．20UTERVIEWS …………………………………………………・…・4 1．3NAMEPLATE …………‥．…………………………………………

5

2．ENGINEANDALLIEDCOMPONENTS…………．．…………………・6 2．1ENGINE…………………………………………………………‥

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6

2．2LUBRICATINGSYSTEM．．．．……………・・・‥・・・・・・‥・‥・・‥・・・・・‥‥‥‥‥10

2．3COOLINGSYSTEM…………………………………………‥・……・11 2．4FUELSYSTEM．……‥・……・・………………・，‥・・・・・・…………‥・‥13

2．5INTAKEANDEXHAUSTSYSTEM ………・‥・・…………………………・15 2．6ELECTRICALSYSTEM………………………………………………・17 2．7ENGINECONTROLUNIT ……………………………………………・18

3．POWERTRAIN………………………………………………‥・‥20 3．1DRIVEUNIT‥‥‥．．．．‥‥．．．‥．．．‥‥・・・・・・………………・…………

21

3．2TORQUECONVERTER………………………………………………24 3．30VERDRIVEGEARBOX…‥．……・‥・・・・………・，……………‥，…‥29 3．4TRANSMISSION……………………………………………………・30 3．50ILCIRCULATIONROUTES．．…………………………‥・……………49 3．6PROPELLERSHAFTS………………………………………………‥51 3．7DRIVINGAXLES（FRONTANDREAR）‥・・…・・…………………………‥53 3．8WHEELS（TIRESANDWHEELS）……………・………………………‥62 4，BRAKESYSTEM ………………………‥．………………………64 4．1BRAKELINE………………………………………………t……・・

65

4．2SERVICEBRAKE ………………．．………………‥・………………71 4．3PARKINGBRAKEANDEMERGENCYBRAKE……………………………・・82

5．STEERINGSYSTEM…………………．……………………‥．…‥86 5．1GENERALDESCRIPTION ‥．…‥．………………‥．．………‥．………86

5・20ILCIRCULATIONROUTES…………………………………………‥88 5．3STEERINGWHEELUNIT‥‥‥．．．．．‥．……．…………．………………．89

5・4＄TEERINGVALVE………．．．．‥‥．．．‥．．．．．‥．‥．．‥‥．‥．．‥‥‥‥‥‥‥ 5・5 CONTROLLINKAGE ……………‥．……．．…………………………97 5・6STEERINGANDASSISTPUMP．．．．……………‥．……………………．100 5・7STEERINGCYLINDERS…………………………．……………．‖…．103

6．FRAMEANDCOCKPIT．…‥．………．………………………‥．．．］04 6・1FRAME ………………………………………………………‥．104 6．2COCKPIT ………………………………………………………‥107

7．HYDRAULICSYSTEM…………‥．………………．．…‥．．．……‥108 7・10ILCIRCULATIONROUTES…………………．……………………‥．109 7・2PUMP ‥‖………………………………………………………．111 7・3VALVE…………………………………………………………．114 7・4VALVECONTROLS …………．．…．．．……………．．．．……………‥127 7・5 0ILTANK ………………………………………………………．133

8．LOADJNGSYSTEM………………………………………………135 8・1BOOM，BUCKET，ANDBELLCRANK …．．………………………………．136 8・2CYLINDERS……………‥．．．………．．…………‥．．……………．144

9．ELECTRICSYSTEM．．．．．‥‥．．‥‥．．．．．．‥．．．．‥‥．．‥． 9・1LIGHTINGEQUIPMENT …………………………．………．．…．．…‥147 9・20PERATINGSTATUSMONITORINGSYSTEM．．‥．………………………‥148 9・3SWITCHES……………………………………．…………………153

9・4ELECTRICCIRCUITDIAGRAM．…………‥．…………………………155

1．SPECIF］CAT10NS 1．1MACHINESPECIFICAT10NS TCMMode1866

Machine Name

Front−endarticulatedloaderwithdieselenglne

恥pe

Per鮫ImanCe

Double−edged

Bucket Type BucketCapacity（heaped） （StruCk）

2・9m3

Breakoutforce（SAE）（bucketcylinder）

18000 kg 15800 kg

（boomcylinders） OperatingLoad（fullturn）

5300 kg

RaisingTime（fu11load）

6・2S

I．owerlngTime BucketDumplngTime

l・6S

Travel Speed

（帥d）

（rev）

1stspeed

7・6kmn1

8・2kmnl

2ndspeed

13・Okm仙

14・Okmnl

3rdspeed

21・5kmn1

23・Okmnl

4thspeed

34・5km／h

36・5kmnl

17400 kg

Max．TractionForce

300（at3・5kmnlinfbrwardlstspeed）

Gradeability Min．TurningRadius（OutermOStpartOfloader）

（COunterWeight）6520mm

（OutermOStPartOfbucket）

7090 mm

（CenterOfoutermostwheel）

6120 mm

Dimensions 8080 mm

OverallLength（bucketonground） （underno−loadconditionincarryposition）

8000 mm

2850 mm

OverallWidth（body）

3050 mm

（bucket）

（attopofcab）3410mm

OverallHeight（bucketonground）

OverallOperatingHeight（bucketfu11yraised）

5440 mm

Wheelbase

3300 mm

Tread（frontandrearwheels）

2200 mm

FrontOverhang（incarryposition）

2730 mm 2785 mm

（bucketonground）

1995 mm

RearOverhang

−1−

Hood Height

2360 mm

Body Height

（tai1pipe）3280mm （Centerhingepin）445mm

Min．GroundClearance

BucketHingePinHeight

4070 mm

DumpHeight（at450dischargeangle）

2930 mm

Reach（at450dischargeangle）

1170 mm

BudketRoll−BackAngle（underno−loadcondition，incarryposition）（SAE）

480

BucketDumpingAngle（bucketfu11yraised）

500

DiggingDepth（WithbuckettiltedhrwardlOO）

315 mm

TowingDeviceHeight

1070 mm

Ⅵbight

WeightofLoader（WithROPScabandanoperatorweighing80kg） WeighDistribution

18500 kg （frontaxle）（rearaxle）

（underno−loadcondition）

9230kg

9270 kg

（underratedload）

17530kg

6270 kg

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NF6TDieselEngine 4−CyCle，Water−COOled，in−1ine6−Cylinder，directlnJeCtiontypewithturbocharger

12V，120Ah（5−hourrate），2pcs・

Battery

Plate巨nandtubetype

Radiator（engine） （torqueconverter）

Multi−Platetype

（hydraulicoil）

Stackedfintype

Air Cleaner

Drypapernltertype

Muffler

Porousseparatortype

PowerTrain TorqueConverter 8FCN−1350−5（MS370）

Name

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3−element，Single−Stage，Slnglephase

r丹pe

Transmission TCM6（i8−25

Electromagnetictypefu11power−Shift，COnStantmeShtype，fu1lmodulate Reduction GearandDifftrential TCM668−30 Ordinarytype，2−Stagereduction Final Reduction Gear

Planetarygeartype

Ⅰ）・1−e

−2−

Axles andⅥⅧeels 4−Wheeldrive

Driving

Frame一触ed，Semi−floating

Front Axle

Center−PlnplVOted，Semi−floatlng

Rear Axle

23．5Ⅹ25−16PR，L−3（OR）

Tire（frontandrear）

19．50Ⅹ25WTB

Rim（frontrear）

BrakeSystem Service Brake

Type

Front−rearWheelseparate

braking，Wetdisk，air−OVerhydraulic

Numberoffluidlines

ParkingBrake Type

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FrontTaXleinputbrakingdiskbrakewithsprlngCylinder

Usedincommonwithparkingbrake

Emergency Brake

Steering System Frame articulation

Type

Double−aCtlngPIStOn，2units

SteeringCylinder Loading System

Z type Type 1

Linkage BucketTeeth

HydraulicSystem Pilotoperationtype

Hydraulic Unit BoomCylinder

Double−aCtlngPiston，2units

BucketCylinder

Double−aCtlngpiston，1unit

MainPump KFP4156

Name

Gear type T〉■llビ

SteeringPump Name

KFP5190

Type

Gear type

AssistPump KPlO13

Name

Gear type

Type MainValve

J7000

Name

2−SpOOIslidingtypepilotoperationcontrol

TI−11し

PilotValve MPPC−MD

Name

2−SPOOIslidingtype

−3−

1．2 0UTERV］EWS Unit：mm

⊂）

N N

Note：The伝guresshowMode1866witha3・3m3double−edgedbucketandaROPScab・ Thespec摘cationsaresutカecttochangewithoutnotice．

−4−

1．3 NAME PUITE l．NameIIlate

A name plate describing the modelname， maximumloadingcapacity，tOtalweightofmachine，

and serialNo．is attached at theleft side of the 丘ont丘ame．

Fig．l．1NamePlate ㌍考

2．I，OCationofSerialNumtnrofbader

Theloaderserialnumberisstampedontheright frontframeneartheboomcylinderpln・

Fig．l．2IJOaderSerialNumber 3．I，OCationofSerialNumberofEngine TheenglneSerialnumberisstampedontheleft Cylinderblock（With the engine mounted on the loader）・

Fig．l．3EngineSerialNumber

4．SerialNumbersofMqiorComponents

ThemaJOrCOmpOnentSOftheloadercarrytheirownserialnumbersstampedthereonoronthedecal

ThemajrCOmP？nentSinclude：thetorqueconverter，tranSmission，aXles（frontandrear），COntrOIvalv PumpS（maln，Steerlng，andcharging）・

−5−

2．ENGINEANDALLIED COMPONENTS 2．1ENGINE l．GeneralDescription TheenglnemOuntedonthisloaderisa4−CyCle，Water−COOled，in−1ine6−Cylinder，directlnJeCtiontypediesel englne・

Thepoweroftheenglnetransmitted丘omthenywheelthroughthedriverlngtOthetorqueconverter・

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Fig．2．1EngineandAlliedComponents

ー6−

Name Tサpe

NF6TO4dieselenglne 4−CyCle，Water−COOleddirectlnJeCtiontypewith

turbocharger Numberofcylinders−borexstroke

6−120mmx135mm

Total displacement

9．160ゼ

Compression ratio

16．8

Engineperbrmance

Rated speed

2200 rpm

Ratedoutput Maximum torque

220 PS 85kg−m（atapprox・1400rpm）

Fullloadmin．fuelconsumpt10nratio

approx．153gn）Sh（atapprox・1600rpm）

Dry weight

approx・820kg

Dimensions（OVeralllengthxovera11widthx

OVerallheight） Firing order

1374mmx872mmx1571mm

Rotational direction

Clockwisewhenviewedfromcoolingfan

Starting aid

Preheating（ribbontypeairheater）

Stopping system

Keyswitchtype（Wiremotortype）

Torquecuttingdevice

Provided（Wiremotortype）

l−4−2−6−3−5

Unloadedmax．speed（Whenseparatelymeasured）2400±50rpm Unloadedmin．speed（whenseparatelymeasured）720＋呂Orpm（underaloadof8kg−m）

Allowabletiltingangle

300infourdirectionswhenviewedfromflywheel

Maintenancedata Valveopenlngandclosingtimlng

Open Intakevalve 220bebreTDC 490afterBDC Bhaustvalve 520bebreBDC 20OafterTDC

Valve clearance

Intakevalve（COld）：0・4mm

Exhaustvalve（COld）‥0・6mm

Injection timing

17ObebreTDC

Injectionstartpressure

200kg／cm2 31kgkm2（200rpm）

Compressorpressure

−7−

Close

2．OuterViewsorEngine 1．INJECTION NOZZLE 2．ROCKER COVER 3．CYLINDER HEAD 4．GEAR CASE 5．COOLINGFAN 6．FRONTCOVER 7．TACHOMETERDRIVER 8．0ILPAN 9．FUELSTRAlNER lO．FUELFILTER ll．INTAKEMANIFOLD 12．STARTERMOTOR 13．INJECTION PUMP

14．MUFFLER 15．TURBOCHARGER 16．EXHAUSTMANIFOLD 17．FLYWHEELHOUSING 18．FLYWHEEL 19．WATERMANIFOLD 20．GENERATOR 21．WATERPUMP 22．0ILCOOLER 23．CAMCHAMBER COVE 24．0ILFILTER 25．CYLINDERBLOCK

Fig・2・20uterviewsofenglne

−8一

3．EngineM皿nting

Theenglneisconnectedtothedriveunitandmountedontherearframewithmountingrubbers・

Notes：臣＞ぢ＝＝コ3．1kg−m（22氏−1bs） 臣＞ぢ：：：：：コ5．1kg−m（37ft−1bs），正＝ゝThreadedarea：LOCTITE B＞ぢ＝コ22・8kg−m（165ft−1bs） 匡＞ぢ＝＝】9kg−m（65ft−1bs） 匪＞ぢ＝コ33・4kg−m（24＝Hbs）

1．ENGINE

4．REARFRAME

7．DRIVEUNIT

2．BRACKET（FANSIDE）

5．PLATE

8．GASKET

3．MOUNTRUBBER

6．BRACKET

9．DRIVERING

Fig．2．3MountlngOfEngineandDriveUnit

＿9−

2．2 LUBRICATING SYSTEM Lubrication

Forced circulation

Lubricating pump LubricatlngOilnlter LubricatlngOilcooler Oilpressureadjuster Lubricatingoilcapaclty

Geartype，directlydrivenbygeartrain Full−flowmterpaperelement Built−inwatercooling Regulator valve Max・（H）：20Q Min・（L）：15Q

TheenglnelubricatlngSyStemisabrcedcirculationbymeanstheoilpump． TheenglneOilispickedupfromtheoilpanbytheoilpumpandflows，paSSlngthroughtheoilcoolerand

Oi用1ter，tOthecylinderblockoilgallery，andthenisfedtoeachpartoftheenglne．

FAN PULLEY

Fig．2．4EngineLubricatlngSystem

−10−

2．3 COOLING SYSTEM Cooling Cooling fan

Water，COOling

乃pe

Plate，puShertype，740mmdia・6−bladed

Driving

Belt drive

Geardriven，Centrifugaltype

Water pump

Water temp. regulator 「吋pe

Wax pellet

Openlngtemp・−Full−OPenlngtemp・

76・50C−900C（1pc・），82OC−950C（1pc・）

Radiator Core

CapopenlngPreSSure Weight Coolingwatercapaclty

pF2−6（G−6） 0・5k多／cm2

190kg（includingoilcooler）

Total：58Q（14Qbrengine，41・5Qbrradiator，2・5Q

brreservOirtank）

TheenglneCOOlingsystemisawater−COOledbrced−Circulationtypebymeansofthewaterpump・ ThecoolingwaterlSPickedupfromtheradiatorbythewaterpumpandissentunderpressurethroughthe

Oilcoolerandcylinderblocktothecylinderheadbrcoolingeachpart・ ThecoolingwaterleavlngthecylinderheadflowsthroughthewatermanibldandisagalnSentagalninthe

Samemannerbythewaterpumptothecylinderblock（Whenthethermostatisclosed）・ Whenthethermostatopensasthecoolingwatertemperaturerisestoapolnt，thecoolingwaterwhichhas

reachedthewatermanitbldissenttotheradiatorbrcoolingbebrefl0winglntOthewaterpump．

● Fig．2．5CoolingSystemSchematicDiagram

−11−

7

3

Radiator Core

Plate員n＆tubetype PF2−6（G−6）

CapopenlngpreSSure 0．5kg／cm2 Vacuumvalve 0−0．05kgたm2

Weight Watercapacity

A：fromRESERVOIRTANK B：COOLINGWATERINLET C：COOLINGWATER OUTLET D：fromRELIEFVALVE E：tO OILTANK F：fromTORQUECONVERTER G：tOTRANSMISSION

approx・1（i7kg

Oilcooler（brtorqueconverteroil）

approx・40せ

Core

Multi−Platetype（PTO−LS）

Weight Oilcapaclty

approx・11kg

Remarks

builtinlowertank

approx・l・5kg

1．UPPER TANK 2．RADIATOR CORE 3．LOWERTANK

4・OILCOOLER（FORHYDRAULICOIL）

5・OILCOOLER（FORTORQUECONVERTEROIL） 6．DRAIN COCK 7．SHROUD Fig．2．6Radiator

ー12−

2．4 FUELSYSTEM Injection pump Injection nozzle Injectiontimlngadjuster Fuelftedpump

Bosch type Enclosed，POrOuStyPe Centrifugal type Plunger type

Fuel員1ter

Filterpapertype（Cartridge）

Governor

Governlng

Centrifugal，all−SPeedcontrol（RSV−Stype）

Lubrication

Forced circulation

Fueltankcapaclty

290ゼ

Thefuelinthefueltankisdrawnupbythefuelftedpump，hlteredthroughthefuelⅢter，andsenttoth lnJeCtionpump・

ThefuelissentunderpressurefromtheinJeCtionpumptotheinJeCtionnozzlethroughwhichitislnJeCted intoeachcylinder・

−−−−

Feedline

＞Overflowline

E Fig．2．7FuelSystemSchematicDiagram

−13一

Fuel tank capacity: 316 4 Usabletankcapacity‥ 290Q Tankweight‥ 200 kg

1．FUELTANK 2．FUELHOSE 3．FUELHOSE 4．ENGINE 5．FUELSTRAlNER 6．FUELFILTER 7．CAp 8．STRAINER 9．FUEL METER SENDER UNIT lO．DRAlN COCK

Fig．2．8FuelTankandFuelLine

−14−

2．51NTAKEAND EXHAUSTSYSTEM Air cleaner Turbocharger Name Driving Lubrication

Cyclone巨1terpaper，FHG14

Exhaust−gaS−driveturbocharger

Exhaust−gaSdriving Forced−Circulation

neintakesystemoftheenglneisdesignedsothattheopenairisdrawnthroughtheaircleanerintothe turbochargerwhereitiscompressed，andthensentintotheintakemanibld・

Theexhaustsystemisdesignedsothattheexhaustgasfromtheexhaustmanibldisdischargedtothe

atmosphereafterpasslngthroughtheturbochargerandthemumerthepressureandtemperatureofthe exhaustarelowered．

▲ Becarefu1nottotouchthemumerandexhaustmani伽1dsincethcyarehotwhenthee isrunnlngOrSOOna魚eritisshutofnOtherwiseyoumightburnyourhand・

Turbocharger Tbeenglneisprovidedwiththeturbochargerattheintakesystem・

ItispossibletoattainhighenglneOutPutbysendinghighlycompressedairunderpressureintothecylinders

ontheintakestroketoincreaseairsupply，thusincreaslngthequantltyOffueltobeinjected・ Toachievethispurpose，themode1866isequlPPedwiththeexhaust−gaS−drivingturbocharger・ Theexhaustgasinletoftheturbochargerisconnectedtotheexhaustmanibld・Theexhaustgasrotates turbinewheelatahighspeedandthenissentfromtheexhaustgasoutlettothemuffler・ Atthistime，theimpeller，mOuntedontheoppositeendofthesameshaftastheturbineismounted，al

rotatesatahighspeedtocompresstheairsuckedthroughtheaircleaner，andtosendittotheintake manibld．

−15−

⑳⑫

ー∵（二

6

1．TAILPIPE 2．MUFFLER 3．ENGINE 4．TURBOCHARGER 5．RAIN CAP

6・INDICATOR（［AlRCLEANER］ ALARM） 7．MOUNTBAND A AlR CLEANER 8．BODY 9．INNER ELEMENT lO．OUTER ELEMENT ll．CUP 12．BAFFLE 13．CLAMP

Fig．2．9IntakeandExhaustSystem

−16−

2．6 ELECTRICALSYSTEM Battery Voltageandcapaclty

12V，120Ah（5−hourrate）

Quantity

2

Weight（Perunit）

about39．5kg（includingelectrolyte）

Starter motor 「トーllし、

Wet，reductiontype

Voltageandoutput

24V，5．5kW

Starting method

Pinion−Shift

Generator T）−lle

Voltageandoutput Driving Automatic charging regulator

AC 24V，50A Belt drive

Name

Regulator

Type

ICtype（builtingenerator）

1．BatteⅣ

Twobatteriesarehousedinthebatteryboxesattherearrightandleftpartsoftheloader・ Wheninspectionofthebatteriesisneeded，Openthebatteryboxcover・ ▲

DANGER！！Useduecautionwhenhandlingthebattery・

1．Notire・Nosparks・Neversmokeorusefireornakedflamenearthebatterysinceflamm gasisalwaysreleased蝕・Omthebattery・Thereisdangerofexplosion・

2．Theelectrolyteisdilutesulfuricacid・Itwi11causepainfu1andseriousburnsifitgetso skin．Itcancauseblindnessifitgetsintoeyes・Ifelectrolytegetsonyourskin）flushitoffat

oncewithcoplOuSamOuntOfwater・Ifitsgetsintoyoureyes，nuShyoureyesoutwithwateran get to a doctor.

2．ElectricCircuitDiagram Fortheelectriccircuitdiagramoftheenglne，See Fig・9・8ElectricCircuitDiagram：．

ー17−

2．7 ENGINE CONTROL UN．T l．AcceleratorPedal

TheenglneSPeediscontro11edbyoperatingtheacceleratorpedal・ Whentheacceleratorpedalispressed，theacceleratorrodandleverworktoshifttheinJeCtionpumpcontrol

leversothatanenglneSPeedmostsuitedtotheworkingconditionisobtained・

ENGINE

3 4

Note：D＞ぢ＝：：コ2・3kg−m（17ft−1bs）

1．PEDALASSEMBLY

5．PEDAL

9．LEVER

2．二BALLJOINT

6．PUSHROD

lO．RETURN SPRING

3．ACCELERATORROD

7．BELLOWS

ll．HANGERPLATE

4．BRACKET

8．BODY Fig．2．10AcceleratorPedal

−18−

2．EngineStopMotor Theenglneisshutoffwiththestarterswitch・

Whenthestarterswitchisplacedinthe一一STOP

position，theinjectionpumpisshutoffbyoperationofth

englneStOPPlngmOtOr，thusshuttingofftheenglne・

Note（X）：tOACCELERATORPEDAL throughROD・

1．STOPMOTOR

5．CONTROLLEVER

9．ROD

2．BRACKET

lO．STOP LEVER

3．SHAFr

6．BEARING 7．SPACER

ll．SPEED LEVER

4．BRACKET

8．BALLJOINT

12．INJECTIONPUMP

Fig．2．11EngineStopMotor

＿19−

3．POWERTRAIN

Thepowertrainconsistsofthedriveunit（torqueconverter，OVerdrivegearbox，andtransmission），PrOPe

Shaft，frontaxle，rearaXle，andtires． nepowerfromtheenglneistransmittedfromthedriveunitthroughtheprope11ershafttothefrontand rear axles．

nepowertransmittedtotheaxlesisfurthersenttothetiresthroughthewheels，SOthattheloaderruns・

TheschematicdiagramofthepowertrainisglVenbelow・

〉 PropeIIershaft

Front axle

Propellershaft

Rear axle

Fig．3．1PowerTrain

ー20一

3．1DRIVE UN汀 Model

TCM668−25

Torqueconverter Name

8FCN−1350−5（MS370） 3−element，Single−Stage，Slngle−Phasetype

Type Pressure setting Chargingpump

2．8kgたm2

Name

2P3146AR

Tサpe

Gear type

Driving

Geartype

Transmission

Type Speeds

Electromagneticfu11−pOWer−Shift，COnStant−meSh，fu11modulatetype 4brward／4reverse

Clutch（transmission） r吋pe

Wetmultiple−diskclutch

Hydraulic

Operation Pressure setting Quantityofoil

35￠

Weight（driveunit）

766kg

17−20k亦m2

Thedriveunitconsistsofthetorqueconverter，OVerdrivegearbox，andtransmission・

Thepowerfromtheenglneistransmittedthroughtheengineflywheeltothetorqueconverter，andthenis sentthroughtheoverdrivegearboxtothetransmission・

Theenglneisconnectedtothedriveunitbylinkingtheenginenywheeltothetorqueconvertercoverwhe through the drive ring.

Thedriveunitismountedontherearframethroughthemountbracketacrosstheengineflywheelhouslng andtransmissioncase． Note：ForthemountlngOfthedriveunit，SeeFig・2・3・

＿21−

卜．■1■

：￣了F］ †

．

l

二r

「こ

「−「

ノ

汀ORQUECONVERTER）

DRIVE RING

GASKET ′￣

￣＼

＿JJ￣

l ll （∈NG】NE）

Notel：Installationprocedure

① cleanupdustandrustpreventivefromtheconvertermountingsurfaceontheengineflywheelus solvent．

②Instal1thedriveringontheflywheelandsecurewith24bolts・ ③ Liftthetorqueconverterassemblywithahoist．Aligningtheconverterassembly

sprqjectionswit

matlngSOCketsintheflywheel，Putthemtogetherbyhand・

④ Aftermakingsuretheconverterhousingprqjectionshaventintotheflywheelhousingsocketscompletely， SeCuretheconverterhouslngWith12nuts・

Note2：D＞ぢ＝コ5．1kg−m（37ft−1bs），紹＝ゝThreadedarea‥LOCTITE 臣＞ぢ＝コ3・1kg−m（22鋸bs）

Fig．3．2ConnectionofEngineandTorqueConverter

一22−

● TORQUE CONVERTER

●

ViewIookingfromA Fig．3．3DriveUnit −23−

3．2 TORQUE CONVERTER

Convertersupplyoilpressure：aPPrOX・2・8−3・2kgkm2（40−45psi）

Safttyreliefpressure：

9・8kg／cm2（140psi）

Masterclutchoilpressure：11・5−14・Okgkm2（163−199psi） S．CONVERTEROILINLET

1．CONVERTERWHEEL

7．CHARGINGPUMP

8・PUMPDRIVEGEAR（51T）

T．CONVERTEROIL

ASSEMBLY

OUTLET

2．AlRBREATHER

9．REGULATORVALVE

3．BEARINGSUPPORT

lO・PLUNGER（SAFETY

U．MASTERCLUTCHOIL INLET

4・PUMPDRIVEGEAR（53T）

V．OVERDRIVEGEARBOX

5．CONVERTERHOUSING

LUBE．0ILpORT

6．PUMPDRIVESLEEVE

Fig・3．4TorqueConverter

−24＿

VALVE） 11．SPRING

3．2．1GENERALDESCRIPT10N

Thetorqueconverterconsistsoftheconverterwheelassembly，pumpdrive，Chargingpump，andregul valve．

Theconverterwheelassemblyiscomposedoftheimpeller，turbine，reaCtionmember，andmasterclutch・ ThemasterclutchislocatedbetweentheimpellerwheelandclutchcarrierandcoupletheenglnetO，Or uncoupletheenginefrom，thetorqueconverter・Themasterclutchhydraulicoilflowsfromthetransmi controIvalve，PaSSlngthroughthehouslngandstatorsupport，tOthebackofthemasterclutchpiston・

ThepumpdrivedrivesthecharglngPumP，mainpumpandsteerlngpumpbymeansofthepumpdrivegear 抗ttedontheclutchcarrier．

Theregulatorvalve，installedontherightsideoftheconverterhouslng，regulatestheconverteroilpressu 1ettingexcesshydraulicoilflowtotheoilcooler・ t00JLCOOLER †

Crackingpressure‥2・8kgkm2（40psi）

1 2 3

4

5

1．ROLLpIN 2．OUTERSPRING 3．INNER SPRING 4．BODY 5．PISTON 6．SPRINGRETAlNER

6 7 DRAIN＿ニーー」

† from STATOR SUPPORT

」＿＿÷．＿DRAIN

7．

0

−RING

Fig．3．5RegulatorValve

1．powerTransmission ¶lepOWerfromtheenglneistransmittedfromtheflywheelthroughthedriverlngtO‥thetorqueconver

coverwheel→Clutchcarrier→maSterClutch→impe11er→turbine→turbineshaft・Thepowerisfurtherfrom theturbineshafttotheoverdrivegearbox・

−25−

2．OilFlow

Thetorqueconverterhydraulicoil，SentfromthetransmissioncontroIvalve，flowsthroughthestatorsuppor Oilpassageintotheconverterwheel・

AstheenglnerunS，theimpellerrotates．Theoilflowsalongthebladesoftheimpe11erwheeltowardth

Peripheryoftheimpe11erandgetsintotheturbinewheel・Thisoilflowhitstheturbinewheelbladestotu

theturbinewheelandthusturbineshaft．Thereactionbrceobtainedbytheoilflow，Whoseflowdirectio

hasbeenbrcedtochangebyhittingtheturbinewheelblades，becomestheoutputtorqueoftheturbineshaf

rIbereactionmemberrect泊estheoilcomlngfromtheturbinewheelinafixeddirectionandletsitflowint theimpellerwheeltoincreasethetorque・

Partoftheoilinsidetheconverterwheelflowsthroughthestatorsupportoilpassagetotheoilcooler・ Thesafttyvalveislocatedatthetorqueconverterhydraulicoilinlettorelieveexcessoilintotheconverter houslng・

Fig．3．60ilnowinTorqueConverter

−26−

●

1112 13141516 1718

Note：D＞ぢ＝コ2・36−2・70kg−m（17・1−19・5ft−1bs）駐＞ぢ：：：：コ4・22−4・82kg−m（30・5−34・8ft−1bs） 駐＝＞ぢ＝コ5・21−5・95kg−m（37・7−43・0丘−1bs）

1．COVERWHEEL

8．TURBINESHAFT

15．SNAPRING

2．CLUTCHCARRIER

9．OILSEALRING

16．BACKPLATE

3．CLUTCHPISTON 4．OILSEALRING

lO．INPUTGUIDE

17．SINTEREDPLATE

ll．TURBINEWHEEL

18．STEELPLATE

5．0ILSEALRING

12．STATORWHEEL

19．SEALRACE

6．PUMPDRIVEGEAR

13．STATORHUB

20．SEALCARRIER

7．STATORHOLDER

14．IMPELLER WHEEL

21．0ILSEALRING

Fig．3．7ConverterWheelAssembly

一27−

3．2．2 CHARGING PUMP

Thechargingpumpisnttedattherearsideoftheconverterhouslng・neCOnVerterPumPdrivegear COnneCtedtothechargingpumpdrivegearthroughthepumpdrivesleeve．

Forthisreason，thechargingpumprotatesastheenglnerunS，drawinghydraulicoilthroughthestrainerfrom

thetransmissionsumptank． TheoildischargedftomthechargingpumplSSuPPliedthroughtheoilⅢtertothetransmissioncontroIvalve．

7

8

9 10

8．DRIVEGEAR

1．COVER

5．− 0

2．BUSHING

6．0ILSEAL

9．BUSHING

3．DRIVENGEAR

7．BUSHINGSEAIノBACKINGRING

lO．MOUNTINGFLANGE

−RING

4．BODY

Fig．3．8ChargingPump

ー28−

3．3 0VERDRIVEGEAR BOX

Tbeoverdrivegearbox，locatedbetweenthetorqueconverterandthetransmission，lnCreaSeStheout Speedofthetorqueconverterandsendsittothetransmission・

nepoweristransmittedfromthetorqueconverterturbineshafttotheoverdrivegearboxlnPutShaft， PaSSlngthroughtheidlershafttotheoutputshaft・

CrossSectionalViewA−A

C．fromCONTROLVALVEto

1．GEAR（40T）

6．OUTPUTSHAFr

MASTER CLUTCH

2．INPUTSHAFT

7．IDLERSHAFr

D．fromCONTROLVALVEto

3．BEARING

8．GEAR（30T）

TORQUECONVERTER

4．CASE

9．GEAR（33T）

INLET

5．GEAR（36T）

Fig．3．90verdriveGearBox

■29−

3．4 TRANSMISS10N 3．4．1GENERALDESCRIPT10N

Thetransmissionchangesthespeedanddirectionofthepowersentfromtheoverdrivegearbox・

netransmissionconsistsoftheclutchshafts（forward／reverse，1st／2nd，and3rd／4th），backgear，idlershaft，

OutPutShaft，COntrOIvalve，andsolenoidvalves．

●

Note：D＞ぢ：：：：コMountingbolt‥0．6−0．8kg−m（4．3−5．8ft−1bs） A．from CONTROLVALVE to MASTER CLUTCH

1．TRANSMISSION CASE

B．fromCONTROLVALVEtoTORQUECONVERTERINLET

2・DISTRIBUTOR（3RD／4TH）

C．CONTROLVALVEINLET D．TRANSMISSION LUBE OILINLET

3．SINGLE SOLENOID VALVE 4．MAGNETSTRAINER

E．FWD CLUTCH PRESSUREMEASUREMENTPORT

5・DISTRIBUTOR（1ST／2ND）

F． REVCLUTCH PRESSUREMEASUREMENTPORT

6．ACCUMULATOR 7．CONTROLVALVE 8．DOUBLE SOLENOID VALVE

G．1ST−SPEED CLUTCH PRESSUREMEASUREMENTPORT H．2ND−SPEED CLUTCH PRESSUREMEASUREMENTPORT

I． 3RD−SPEED CLUTCH PRESSURE MEASUREMENTPORT 9・BEARINGCAP（lST／2ND） J． 4TH−SPEED CLUTCHPRESSUREMEASUREMENTPORT K．INCHINGAIR PRESSUREFEED PORT

10．REAR CASE ll．REAR COVER 12・DISTRIBUTOR（FWD／REV）

13．IDLER SHAFTCAP

14・BEARINGCAP（3RD／4TH） Fig．3．10Transmission

ー30−

●

CrossSectionalView B−B

19 20

1st／2nd driveshaft

庭 Detai10fsection C

● Notes：駐＞（乞：：＝コ28−35kg−m（200−250氏」bs）

匡＞〆＝＝袖Betweenoilseallips：Grease，紹＝ゝOuterring‥LOCTITE241 1．FWD／REVCLUTCHSHAFT

8．GEAR（36T）

15．SPEEDOMETERGEAR

2．IDLERGEAR（55T）

9．GEAR（52T）

3．IDLERSHAFr

10．BACKGEAR（35T）

16．OILSEAL 17．BEARINGCAP

4．3RD／4THCLUTCHSHAFr

11．BACKGEARSHAFT

18．OILBAFFLE

5．OUTPUTFLANGE

12．IDLERGEAR（43T）

19．1ST／2NDCLUTCHSHAFr

6．RETAlNER 7．OUTPUTSHAFr

13．HIRANGEGEAR

20．LORANGEGEAR／SHAFT

14．SPEEDOMETERGEAR

Fig．3．11StructureofTransmission

−31−

3．4．2 CLt）TCH SHAFr Therearethreeclutchshaftassemblies：forward／reverse，1st／2nd，and3rd／4th． Eachclutchshaftassemblyincorporatesafixednumberofclutchdisksandinterruptstheflowofpowerfbr Shiftinggears・

Operation Theclutchisactuatedbythepressureoilsenth・OmthetransmissioncontroIvalve． ThepressureoilfromthecontroIvalveflows，PaSSlngthroughthedistributorcapandtheoilpassageinthe

Clutchshaft，tOtherearoftheclutchpistontoactivatetheclutchpiston・Theclutchpistonaggregatestheinne

andouterclutchdiskstomaketheclutchshaftandclutchhubintoonepleCetOallowtheflowofpowerfrom

theenglne．

Whennopressureoilisappliedtotheclutchpiston，however，theclutchpistonisreturnedbackbythe

returnsprlngtOunlocktheinnerandouterclutchdisks，thus1ettlngtheclutchshaftandclutchhubrotate

SeParatelysothattheflowofpowerfromtheenglneisinterrupted． 2

14 15 16 17

3

4 5 6 7 8 9 10 11 12 13

20

18 19

21・1j

Note：D＞疋＝ゝnreadedarea‥LOCTITE572 1．FRONTBEARING

8．OUTERCLUTCHDISK

2．FWD CLUTCHHUB GEAR

9．INNERCLUTCHDISK

3．BACKINGPLATE

lO．REVCLUTCHHUBGEAR17．SPRINGRETAINER

4．CLUTCHPISTON

ll．REARBEARING

18．RETURNSPRING

5．PISTONOUTERSEALRING

12．SHAFrASSEMBLY

19．PISTONINNERSEALRING

6．BALL

13．SEALRING

20．SPACER

7．BLEEDVALVESEAT

14．SEALEDBEARING

21．PLUG

Fig．3．12Fwd／RevClutchShaft

−32−

15．SPACER 16．BEARING

1．FRONTBEARING

3．1ST−SPEEDCLUTCHHUBGEAR

2．2ND＿SPEEDCLUTCHHUBGEAR

5・ORIFICE

4．REARBEARING

Fig・3・131st−and2nd−SPeedClutchShaft

1

3

2

4

3．3RD−SPEEDCLUTCHHUBGEAR 1．FRONTBEARING 2．4TH＿SPEEDCLUTCHHUBGEAR 4．REARBEARING Fig・3・143rd−and4th−SpeedClutchShaft

＿33−

5

5・ORIFICE

3．4．3 CONTROLVALVE

necontroIvalveislocatedontheupperleftareaofthetransmissioncover． ThecontroIvalveincorporatestheclutchpressureregulatingvalve，tranSmissionclutchpressurebooster Valve，maSterClutchpressureboostervalve，flowsenslngValve，andcut−Offvalve．

ThecontroIvalvelSPrOVidedwithaninchingvalvewhichshutsoffthedrivingpowertemporarilybrinching

Operation．

View100kingfromZ

A．丘omOILFILTER

B・fromBRAKELINE（AIRPRESSURE）

※Drain

Transmission clutch

C．toMASTERCLUTCH

Oilpressure：

D．toTORQUECONVERTER E．toTRANSMISSIONCLUTCH F．TRANSMISSIONCLUTCHOIL

17−20k亦m2（240−280psi）

Master clutch

PRESSURECHECKPORT（PTl／8）

G．MASTERCLUTCHOILPRESSURE CHECKPORT（PTl侶）

Oilpressure： Inching start

11・5−14・Okg／cm2（163−199psi）

preSSure：

1・5kgkm2（21psi）（airpressure）

Fig．3．15ControIValve −34＿

8 91

0

3 4 5 6

（lnchingvalve）（Clutchpressure

regulatingvalve） Cross SectionalViewA−A

5

1 1

6 7 8

1 1

●

（F［owsensingvaIve）

（Cut−0汗valve）

CrossSectionaIViewC−C

CrossSectionaIView B−B

Note：Forthenamesofthenumberedparts，Seethenextpage・ Fig．3．16StructureofControIValve

−35−

（menamesofthepartsgiveninFig・3・16） 1．VALVESPACER

12．SPRING

23．SPRING

2．VALVEBODY

13．SPRING

3．PISTON

14．PISTON

24．STOppER 25．SpACER

4．SPRING

15・THROmEPLUG（D）

5．AIRPISTON

16．STOPPER

6．AlR CYLINDER

17．PISTON

7．THROmEPLUG（C）

18．SPRING

28．STOPPER 29．SPRING

8．SPRING

19．COVER

30．THROmEPLUG（B）

9．PISTON

20．STOPPER

31．PISTON

lO．SpRING

21．PISTON

32．THROmEPLUG（A）

ll．STOPPER

22．SpRING

Note：Thethrottleplugs

26．PISTON 27．COVER

symboIs（A）−（D）correspondtothoseinFig・3・17HydraulicCircuitDiagram．

●

from OIL FllTER ぴromCHARGINGPUMP）

Fig．3．17HydraulicCircuitDiagram

＿36−

OperationofControIValve

ThecontroIvalve，afull−mOdulationtypewhichprovidesmodulationfunctionwhengearsareshifted（fwd／r

andinallspeeds），regulatesthetransmissionclutchhydraulicoilandmasterclutchhydraulicoilpressures・

Ithasalsoinchingfunctionwhichshutsoffthepowertransmissionfromtheenginebydisengaglngthetorque COnVertermaSterClutchwhenthebrakesareapplied・

ThecontroIvalveregulatesthepressureofhydraulicoilsentthroughtheoilⅢterfromthechargingpu

andsendsittothefwd／revclutchsolenoidvalve，3speed−rangeClutchsolenoidvalves，andmasterclutch・

Excessoilissentbacktothetorqueconverterwhereitisusedastorqueconverterhydraulicoil・ 1．Modulation

①nepressureoil，SentfromthechargingpumptothecontroIvalve，isregulatedbytheclutchoilpressu

regulatedvalveandsenttothemasterclutchpressureboostervalveandtransmissionclutchpres吏ur boostervalve．Thehydraulicoilrelievedbytheclutchpressureregulatingvalveisdeliveredtothetorque

COnVerter． ● ②Themaster？1てtChpressureboostervalveiscomTunicatedthroughtheinchingvalvewiththemasterclutch・ ThetransmlSSlOnClutchpressureboostervalvelSCOmmunicatedtoboththeftvd／revclutchsolenoidvalve andspeed−rangeClutchsolenoidvalves・

③whenanyofthesolenoidvalvesisactivatedwiththeshiftlever，thepressurefromthetransmissioncl

PreSSureboostervalveflowstotheclutchunitandputitinoperation・ Note：Boththe transmissionclutch pressureboostervalve and masterclutch pressureboostervalve are

reducingvalves．Asthesecondarypressureoftheoilpasslngthevalveexceedsthesprlngk）rCe，

PaSSagegetSClosed・Whenthesecondarypressuredropstoacertainlevel，theoilpassageopensa bythespringforce・

Theflowsensingvalveisputinactuationbythepressuredifftrential（Pl−P2）acrossthethrottle（A）

●

一37−

（1）DⅦdmgTraveling

①SincethecontroIvalveisinequilibriumduringtraveling，thereisnopressuredifftrentialacrossthethrott （A）・【Pl＝P2】

②Theflowsensingvalvepistoniskeptshiftedtotheleftbythespringbrce，keepingtheoilpassageopen tothetransmissionclutchpressureboostervalve一一1arge．．piston・Tbepressureoilthusflowstothe‖1arge．一

plStOninthetransmissionclutchpressureboostervalveandshiftsittotheleftmostsothattheareaabove theplStOnbeⅢledwithpressureoil・

③Thecut−Offvalvepistonisalsoshiftedtotheleftbyoilpressure（P2），thus員11ingthe一一1arge‖pistonport Ofthemasterclutchpressureboostervalvewithpressureoil・

④undertheabovecondition，theclutchunitisinactuationsothattheloadercancontinuetotravel．

Note：neCOntrOIvalveinneutralhasalsothesameschematicdiagramglVeninFig．3．18，Whereanysole

Valveisnotenergized．

● fromCHARGING PUMP

Fig. 3.18 During Traveling

一38−

（2）SwitchingofClutchPacks

①Whengearsareshifted，brinstance，fromhrwardtoreverse，thefwdh eVClutchsolenoidvalveisswitched frombrwardtoreverse．

ThehydrauliclinefromthecontroIvalvegetsintocommunicationwiththereverseclutchpackwhilethe pressureoilinthebrwardclutchisdrainedfromthesolenoidvalve・

②ThepressureoilfromthecontroIvalveflowsintothereverseclutchpacksothatthepressure（P2）in clutchoilpressurelinedrops，thusproducingapressuredifftrential（Pl＞P2）acrossthethrottle（A）・ TheflowsenslngValvepIStOnthusmovestotheright，drainingthepressureoilfromthetransmissionclutch pressureboostervalve一一1arge−fpiston・

③Asthepressure（P2）intheclutchoilpressurelinedrops，thecut−ffvalveshiftstotheright，thusdrain

thepressureoilfromboththemasterclutchandthemasterclutchpressureboostervalve−11arge−TpIStOn・

Note：ThemasterclutchisglVenaSmallinitialpressuretoresisttheinnerpressureofthetorqueconve ④Asmentionedabove，thehydraulicpressureforthetransmissionclutchandthemasterclutchdropsas

●

asgearsarechanged・

●

from CHARGING PUMP

Fig・3・19SwitchingofClutchPacks

ー39−

（3）ClⅦtChEngagememt ①Asthereverseclutchpackgetsnlledwithoil，theoilpressure（P2）rises，thusreducingthepressu difftrentialacrSSthethrottle（A）・

TheflowsenslngValvespoolisthusshiftedtotheleftbythesprlngbrce・Thetransmissionclu PreSSureboostervalve．．1arge

pistonopenscommunicationthroughthethrottle（B）withtheclutchoi

PreSSureline． ②Thecut−Offvalvepistonisshiftedtotheleftbytheoilpressure（P2）toletthemasterclutchpressu boostervalveT

③Asthe

1arge

1arge

7pistoncommunicatethroughthethrottles（C，D）tothemasterclutchoilpressureline．

pistonsofthetransmissionclutchpressureboostervalveandthemasterclutchpressu

boostervalveget丘1ledwithoil，theoilpressurerises，engaglngthetransmissionclutchandthemaster Clutch，reSpeCtively．

TbeschematicdiagramoftheclutchengagedisshowninFig・3・18・

from CHARGING PUMP

Fig・3・20ClutchbeingFilledwithOil 2. Inching Operation Note：neinchingoperationisinterlockedwith theoperationoftheservicebrake・（See BRAKELINE・

4．1

）

①As theleft brake pedalis pressed，the

COmpreSSedairissent fromthebrakelineto theinchingvalve．

②TbeinchingpistonmovestodrainthepeSSure Oilfromthemasterclutch，thusdisengaglngthe masterclutch． Whiletheleftbrakepedaliskeptpressed，the flowofpowerffomtheenglneistemporarily Shut offby the master clutchin the torque

Fig・3・21InchingOperation

COnVerter． −40−

●

3．4．4 ACCUMULATOR

Theaccumulatorisinstalledonthelst／2nd−SPeeddistributorcapatthefrontofthetransmissionca hasthe2nd−Speedsolenoidvalvefittedonitsbody・

Theaccumulatorisincorporatedinthehydrauliccircuitbetweenthe2nd−SPeedclutchpackandthe2nd

〇」 ◎

ニ1

◎

AT⊥A

SPeedsolenoidvalve・

＿＿⊥1 rL＿⊥「

B

（Solenoidvalvesjde）

A→・」

Cross SectionalViewA−A

● Note：D＞fCLThreadedarea‥LOCTITE572 1．BODY

4．ORIFICE（1．Ommdia・）

7・BALL

2．ROD

5．GUIDE

8．PISTON

3．SPRING

6．SPRING Fig．3．22Accumulator

−41−

neaccumulatoralleviatesthedropinthe2nd− speed clutch oil pressure to attain a smooth transitionintotheriseofthelst−SPeedClutchoil pressure when speed gears are shifted from 2nd intoIstwithDSSduringdiggingoperation・ Withouttheaccumulator，ittakeslonger（tl）to

Shutoffthedrivingforce・TheloaderequlPped Withtheaccumulatorcanshutoffthedrivingfbrce

morequickly（t2）sothatitispossibletoprevent theloaderftombackingunintentionally．

Theaccumulatoralsoactsinthesamewayasin usualspeedgearshifting（2ndtoIst，2ndto3rd）

whereDSSisnotused． Fig．3．23Speedgearshifting（2ndtoIst）

Operation ①Whengears are shiftedinto2ndspeed，the

pressure oil leaving the solenoid valve flows

throughthe check valve bothinto the2nd− SPeedclutchpackandintotheaccumulator． ②when gears are shifted from the2nd．speed

intootherspeeds，the pressureoilisdrained throughthethrottlefromtheaccumulatorso thatthe2nd−SPeedoilpressuredropsgradually．

Fig．3．240perationofAccumulator

−42−

3．4．5 SOLENOIDVALVE

netransmissionisequlpPedwithbursolenoidvalves：Onedoublesolenoidvalvetbrdirectioncontroland 3singlesolenoidvalvesforspeedcontrol・

Tbedoublesolenoidvalveis抗ttedonthe知d／revdistributorwhiletwosinglesolenoidvalvesareont

lst／2nd−SPeeddistributorandonesinglesolenoidvalveisonthe3rd／4th−SPeeddistributor・ Note：ThesolenoidvalvehaspushcontroIsbrmanualoperationatitsbothends，Whichallowmanu switchingofoilpassagesinthevalvewhencheckingtheinitialoperationoranytroubleoccurs・ Note：臣＞ぢ＝コ0・6−0・8kg−m（4−6n−1bs）

（SINGLESOLENOIDVAINE）

（DOUBLESOLENOIDVAINE） Spoofmovesinthisdirection

SpooImovesinthisdirection

When aSOL．is exc汁ed．

When bSOLis excjted．

Fig．3．25StructureofSolenoidValve

一43−

3．4．6 POWERTRANSM［SS］ON

ThepoweristransmittedbyactuatlngaSPeCi員cclutchpackwiththeshiftlever・

Thepowerfromthetorqueconverterisnrsttransmittedtothefwd／revclutchshaft・Itissenttoeithe

thehrwardorreverseclutchpacksandpassesthroughtheidlershaft，OneOfthespeed−rangeClutchpack OutPutShaft，prOpellershafttothefrontandrearaxles・

nereareninepowertransmissionpatterns：1stto4thspeedsinhrwardandlstto4thspeedsinreverse and neutral．

ThegearsinthetransmissionareinconstantmeshwitheachotherasshowninFig・3・26・

Note：Viewlookingfromtherearsideof thetransmission．

6 7 8

A．FWD／REVCLUTCHSHAFT

B．BACKGEARSHAFr C．IDLERSHAFr D．1ST／2ND−SPEEDCLUTCHSHAFT E．3RD／4TH−SPEEDCLUTCHSHAFT

F．OUTPUTSHAFr

1．FWD CLUTCHHUB GEAR

6．1ST−SPEED CLUTCHHUB GEAR

11．HIRANGEGEAR

2．REVCLUTCHHUBGEAR

7．2ND−SPEED CLUTCHHUB GEAR

12．OUTPUTSHAFr

3．BACKGEAR

8．LO RANGEGEAR

4．IDLERGEAR（55T）

9．3RD−SPEED CLUTCHHUBGEAR

13．OUTPUTSHAFr

5．IDLERGEAR（43T）

lO．4TH−SPEED CLUTCHHUB GEAR

GEAR（52T）

GEAR（36T）

Fig．3．26GearEngagement

ー44−

3．4．7 TRANSMISS10N CONTROL

l．GeneralDescription ThetransmissioncontroIsystemisanelectrictypewhichactivatesthesolenoidvalvesinthetransmissionby

OPeratingtheshiftlever（transmissioncontroIswitch）toswitchoilpassagesforeachclutchpack，thusprovi SPeedcontroloftheloader．

TheelectrictransmissioncontroIsystemconsistsofthetransmissioncontroIswitch，down−Shiftswitch（D anddownTShiftbox．

ThetransmissioncontrolisprovidedwiththeDSS（down−Shiftswitch）mechanismandthetransmissioncuト offmechanism．

Note：（X）toRELAYBOX（BTERMINAL） （Y）toRELAYBOX（FTERMINAL） 1．DOWN−SHIFTBOX

5．PARKINGBRAKELOW−PRESSURESWITCH

2．SOLENOIDWE

6・FUSE（FORTRANSMISSION：6A）

3・TRANSMISSIONCONTROLSWITCH

7・FUSE（FORNEUTRAL：2A）

4．DOWN−SHIFrSWITCH

Fig．3．27ElectricCircuitDiagrambrTransmissionControl

ー45−

（l）TransmissionControISwitch（shiftlever）

⑥ （Redwhite）N

⑨ （White）2

④

（Red）COM

⑨

（White）R

①

（White）1

Deve10PmentOfcontactpoints Fig．3．28TransmissionControISwitch

（2）Down・Sh的Box

3P

←A

Ln

く）−−−」」こアニ￣￣￣￣￣￣￣一

（Y）③

⑥（W）

二夢二 Empty

㊥（R）

（B）（D

□ 巴

「

冥￣†

◎（RB）

（Br）◎

①（RY）

（G）⑧

疋）（RW）

（LW）⑥

⑧（L）

l

＿

View100kingfromA

Circuitdiagram

Fig．3．29Down−ShiftBox

−46−

（3）NeⅦtralSwitchRelayBox

。J

。

（、しB）⑧

（W）⑧

View100kingfromA

Circuit diagram

Fig．3．30NeutralSwitchRelayBox

2．DSS（Dowm・Sh汎switch）Mechanism

TheDSSmechanismchangesloaderspeedsimply bypresslngthedown−Shiftswitch・Withthisfunction，

●e tti shi托1ever．

The DSS mechanism consists of the down−Shift switchincorporatedintheboomleverknob，andthe down−Shiftbox．

Fig．3．31Down−ShiftSwitch

−47−

Operatiom Asthedown−Shiftswitchispressedduringdiggingoperation，Withtheshiftleverinlbrward2ndspeed

transmissionshiftsintoIstbyoperationofthedown−Shiftboxsothatthethrusting丘）rCeOftheloadermaybe increased． A氏erdigging，WhentheshiftleverlSplacedinthereverseposition，thetransmissionreturnsinto2ndspeed byoperationofthedown−Shiftbox，thusquickeningthereversetravelspeed・

Thatis，theoperatorisabletochangethethrustingforceandtravelingspeedoftheloadersimplybyshifting

theboomlever（down−Shiftswitch）alone，Withtheshiftleverink）rWard2nd，duringdiggingoperation・ 3．TransmissionCut・OfrMechamism ThetransmissioncontroIsystemlSPrOVidedwiththetransmissioncut−0ffmechanismwhichisinterlockedwith theparking（emergency）brake・ Betweenthehandvalveandquickreleasevalveintheparkingbrakelineisthelowpressureswitchwhich iswiredtothedown−Shiftbox． Withtheparkingbrakeapplied，thebrakelinepressureequalsatmosphericpressuresothatthelow−preSSure

SwitchisON．Forthisreason，nOelectricityflowstothetransmissioncontroIswitchbyfunctionofther inthedown−Shiftbox．

nerebre，Whiletheparkingbrakeoremergencybrakeisbeingapplied，thetransmissionisinneutralso

theloaderwon tstartevenifthetransmissioncontroIswitch（Shiftlever）isoperated・Thisfunctionprevent theoccurrenceofanaccidentthattheoperatortriestostarttheloaderwithoutnrstreleaslngtheparking brake．

ー48一

3．5 01LCIRCULATlON ROUTES 3．5．1GENERALDESCRIPT10N

nechargingpumppicksuphydraulicoilbrthedriveunitfromthetransmissionsumptankanddischarges itunderpressure・

TbepressureoildischargedffomthechargingpumpflowsthroughtheoilmtertothetransmissioncontroI

valvewhereitisdividedintothreeflows＝forthemasterclutch，tOrqueCOnVerter，andtransmissionclutch・ l．TorqueConverter

ThehydraulicoilforthemasterclutchisregulatedofpressurebythecontroIvalveandsenttothetorque converter master clutch piston.

nehydraulicoilforthetorqueconverterflowsfromthecontroIvalvethroughthetorqueconvertersaftty

valveintotheconverterwheelanditspressureiscontro11edbytheregulatorvalve■Somehydraulicoil throughtheregulatorvalveissenttotheoilcoolerforcooling・

Note：（A）fromENGINE FLYWHEEL HOUSING

9

1．RADIATOR 2．0ILCOOLER 3．CHARGINGPUMP

4．TORQUECONVERTER

7．TRANSMISSION

5．REGULATORVALVE 6．CONTROLVALVE

8．OILFILTER 9．CAP

Fig．3320ilCirculationRoute ＿49−

2．Transmissiom Thehydraulicoilcooledbytheoilcoolerisreturnedtothetransmissionbrthelubricationandcoolingof theclutchshafts． ThehydraulicoilfbrthetransmissionclutchisregulatedofpressurebythecontroIvalveandsenttotheeach

SOlenoidvalve・Itisusedbroperatingtheclutchpackswhenshiftinggears・ 3．5．2 01LF暮LTER

TheoilⅢterislocatedinthesuctionline・Oilflowsintothemterelementfromoutsidetoinside，and

nlteredoilisdeliveredtothecontroIvalveofthetransmission．

WhentheⅢterelementbecomesclogged，theoilpressureattheinletportsiderisestoputthebypassva inactuation，SOthattheoilbypassesthe抗1terelementandflowsdirectlytotheoutletportside・

●

Bypassvalveworkingpressure：1・75±0・18kgkm2 （24・9±2・6psi）

1．HEAD

●

2．BYPASS、VALVE

3．ELEMENT

CrossSectionalViewA＿A

Fig．3330ilFilter

ー50−

3．6 PROPELLERSHAFTS Universal joint

Cross

Length（SpaCingbetweenpins）

Front Center

755 mm

Rear

360−380mm

812−872mm

Note：D＞ぢ：：＝コMountingbolt（20pcs・）：14・6kg−m（106ft−1bs），正＝ゝThreadedarea‥LOCTITE262 臣＞ぢ＝＝コMountingbolt（2pcs・）：22・8kg−m（165ft−1bs） Fig．3．34PropellerShaftArrangement

ー51−

nepropellershafts，locatedbetweenthetransmissionandfrontaxle，andbetweenthetransmissionan axle，tranSmitthepowerfromthetransmissiontothefrontandrearaxles． Thepropellershaftsabsorbthechangeindriveangleandthechangeinlengthwhenthewheelsmoveup anddown，enSurlngSmOOthflowofpowerfromthetransmissiontotheaxles．

（TransmissiontoFrontaxle）

1・GREASEFITrING

Note：D＞ぢ＝コ14・6kg−m（106ft−1bs）

5．SPLINEDYOKE

匡＞ぢ＝コ23±1kg−m（166±7fLlbs）2・CROSSBEARING

6．ENDPLATE

3．SHAFrYOKE

7．SLEEVEYOKE

4．PILLOWBLOCKUNIT

8．SHAFrYOKE

（TransmissiontoRearaxle） 1

2

3

Note‥臣＞ぢ＝：コ14・6kg−m （106丘−1bs）

1．SPIDERBEARING 2．SLIPYOKE 3．STABYOKE 汀RANSMISS10NSIDE）

（AXLESIDE）

Fig. 3.35 Propeller Shaft

ー52＿

3．7 DRIVINGAXLES（FRONTANDREAR） Driving

4−Wheeldrive

Front axle

Frame−fixed，Semi−floatingtype Centerpln−Pivoted，Semi−floatingtype

Rear axle

Reductiongearanddifferential（frontandrear） Model

TCM668−30

Type

0rdinary，2−Stagereduction

Differential gear box

Banjo type

Differential limiter

Provided（torqueproportioningdifferential）

Final reduction gear T）■ド

●

Oilcapacity（inc・finalreductiongear）

Planetary gear 50Q（eachbrfrontandrear）

Weight Front axle

1221 kg

Rear axle

1186 kg 156 kg

Frontdifftrential Reardifferential

Finalreductiongearandbrake

143 kg 320 kg

3．7．1GENERALDESCRIPT10N

Thedrive axleconsistsoftheaxlehouslng，difftrential，aXleshaft and玩nalr早ductiongear andbrake assemblies．newheelisinstalledonthewheelhubwherethe伝nalreductiongearandbrakeassemb housed．

Thepowerfromthetransmissionistransmittedthroughtheprope11ershafttothefrontandrearaxles・

poweristhentransmittedtothedifEtrentialwhereitisdividedintotherightandleftaxleshaftstothehal reductiongearandbrakeassembliesontherespectiveshaftends，thusdrivingthewheels・

＿53−

●

Notes：D＞ぢ＝コ15kg−m（110ft−1bs）（nedowelpinisusedbr3pointsmarkedT・X・一．） 匡＞ぢ：：＝コ23kg−m（170ft−1bs），紹⊃ゝThreadedarea：LOCTITE262

●

B＞紹＝ゝMatingsurface：LOCTITEFMD−127 B＞正＝ゝPlugthreadedarea：LOCTITE572 匠：＞Procedureforadjustingparkingbrake Afterscrewlnginthehandbrakeboltuntilthepadbecomesinclosecontactwiththedisk，turn itoffl／30faturn．

1．DIFFERENTIAL

3．AXLESHAFr

7．THREE−WAY

ASSEMBLY

4．COOLINGPLATE

8．HOUSING

5．GUARD

9．BREATHER

2．FINALREDUCTIONGEAR ANDBRAKEASSEMBLY

6．HANDBRAKEBOLT Fig．3．36FrontAxle

ー54−

●

Notes：D＞ぢ＝コ15kg−m（110ft−1bs）（Tbedowelpinisusedbr3pointsmarked TX一一・） 臣＝＞ぢ：：：＝コ23kg−m（170ft−1bs）・紹＝ゝThreadedarea‥LOCTITE262

B＞正＝ゝMatingsurface：LOCTITEFMD−127 B＞正＝ゝPlugthreadedarea：LOCTITE572

B＞14＝ゝAdapterthreadedarea‥LOCTITE572 1．DIFFERENTIAL

3．AXLESHAFr

7．BREATHER

ASSEMBLY 2．FINALREDUCTIONGEAR ANDBRAKEASSEMBLY

4．COOLINGPLATE

8．SENSORGUARD 9．THERMOSENSOR（br．7Brake

5．THREE−WAY

Temperature

6．HOUSING Fig．3．37RearAxle

−55−

warninglight）

3．7．2 AXLE MOUNT

rmefrontaxleisbolteddirectlytotheftontftame． TherearaxleissupportedthroughthecradleontherearframecradlesupportbycradleplnS．Therearaxle

thusrocksupanddownaroundtheffontandrearcradleplnSWhenwheelsmoveupanddown・

Note‥ 臣＝＞ぢ＝＝コ180kg−m（1300丘−1bs）

1．FRONTFRAME

5．CRADLE

8．DUSTSEAL

2．FRONTAXLE

6．PIN

9．BUSHING

3．REARFRAME

7．SpACER

lO．CRADLEPIN

4．REARAXLE

（t＝1・2mm，2・3mm，3・2mm）

Fig．3．38AxleMount

−56−

3．7．3 D．FFERENTIAL

nedifftrentialofthisloaderconsistsofthereductiongearandthedifftrentialgear．

Thepowerfromthepropellershaftpassesthroughthedrivep）nlOntOtheringgeartothedifftrentialc

andfromtheredividesintotherightandleftthroughthesidegearstotheaxleshafts・ ThespeedreductionofthepoweriscarriedoutbetweenthedriveplnlOnandringgear・ Operationofdi恥rentialgear

Whiletheloadertravelsstraight，theringgear，difftrentialcase，andsidegearsrotatetogether，witht

PlnlOngearSinthedifftrentialcasenotrotating・Thepowerofthesamerotationalspeedistransmitte therightandleftsidegearsthroughtheaxleshaftstothewheels・

Whentheloadermakesaturn，therightandleftwheelsrotateatdifftrentspeeds，theplnlOngearSint differentialcaserotatearoundtheirownaXeSaCCOrdingtothedifferenceinspeedbetweentherightandleft

Sidegears． DuringtraveIingstraight

Duringmakingaturn

1．PINION GEAR 2．SIDEGEAR 3．AXLESHAFr d 4．DIFFERENTIALCASE 5．SPIDER 6．DRIVEpINION 7．RINGGEAR

Fig．3．390perationofDifftrentialGear

TorqueProportionI）i恥rential

Tbewheelloaderoftenneedstoworkonabadgroundconditionlikeonsandorswampyplace・

Whenworkingonsuchabadgroundcondition，loadersequlPPedwiththeconventionaldifftrentialcans

makingltimpossibletodeliveritsperbrmance・Inaddition，thetireswillalsowearoutprematurely・ preventthisfromhappenlng，themode1866loadercomesequlPPedwiththetorqueproportioningdifftrential・

Thetorqueproportionlngdifferentialissimilarindesigntotheautomotivedifferentialexceptthat the difftrentialhasanoddnumberofpiniongearssothattheengagementpositionbetweenthepiniongearsand Sidegearschangesaccordingtothedifftrenceinroadresistance，thuschanglngthetractionforceoftheright andlefttires．

＿57−

●

Notes：B＞ぢ＝コ5kg−m（36ft−1bs）匡＞ぢ：：：：：：コM12：9kg−m（65fLlbs），M16：23kg−m（170ft−1bs）

B＞ぢ＝コ15kg−m（110ft−1bs），正＝ゝnreadedarea：LOCTITE262

●

匡＞ぢ＝コ32kg，m（230ft−1bs），正＝ゝThreadedarea‥LOCTITE262 B＞ぢ＝コI・OCknut：43kg−m（310ft−1bs），一4＝ゝnreadedarea‥LOCTITE572 匡＞ぢ＝コ55kg−m：（400ft−1bs）

匠＞ぢ：：：：：コ43kg−m（310ft−1bs）

匡＞Afterassembling，SelectaproperspacersothatarotationaltorqueofO．15toO．26kg−m（1．1to l・9ft−1bs）canbeobtained・（Oilsealresistanceisexcluded．）

1．COVER 2．BRAKEDISK 3．BRAKEFLANGE 4．0ILSEAL 5・SHIM（t＝0・1，0・2，0・25mm）

6．THRUSTSCREW 7．THRUSTWASHER 8．SIDE GEAR

9．CAP lO．FLANGEHALFCASE ll．RING GEAR 12．PARKINGBRAKE 13．BRAKE CARRIER 14．SPACER 15．BEARING CAGE 16．DRIVEPINION Fig．3．40FrontDifftrential −58−

17．CASE BOLT 18．DIFFERENTIALCARRIER 19．PLAIN HALFCASE 20．ADJUSTINGNUT 21．ADJUSTINGNUTLOCK 22．PINION GEAR 23．THRUSTWASHER 24．SPIDER

Notes：B＞ぢ＝コM12＝9kg−m（65ft−1bs），M16‥23kg−m（170ft−1bs）

匡＞ぢ＝コ15kg−m（110ft−1bs），14＝ゝnreadedarea‥LOCTITE262 B＞ぢ＝：：：コ32kg−m（230ft−1bs），rCLThreadedarea：LOCTITE262 B＞ぢ：＝コIJOCknut：43kg−m（310ft−1bs）・紹＝ゝThreadedarea：LOCTITE572 臣＞ぢ＝コ55kg−m（400糾bs）

駐＞ぢ＝：：コ43kg−m（310氏亜s）

匝＝＞Afterassembling，SelectaproperspacersothatarotationaltorqueofO・15toO・26kg−m（1・1t l．9ft−1bs）canbeobtained・（Oilsealresistanceisexcluded・） 1．COMPANION FLANGE 2．OILSEAL 3．OILSEALRETAINER 4．SHIM（t＝0・1，0・20・25mm）

5．THRUSTSCREW 6．THRUSTWASHER 7．SIDEGEAR

8．CAP 9．FLANGEHALFCASE lO．RINGGEAR ll．SPACER 12．BEARING CAGE 13．DRIVEPINION 14．CASEBOLT Fig．3．41RearDifferential −59−

15．DIFFERENTIALCASE 16．PLAINHALFCASE 17．ADJUSTING NUT 18．ADJUSTING NUTLOCK 19．PINION GEAR 20．THRUSTWASHER 21．SPIDER

3．7．4 FINALREDUCT10N GEARANDBRAKEASSEMBLY

ne伝nalreductiongearandbrakeassemblyconsistsofthefinalreductiongearandthebrake・ The伽alreductiongear provides員nalspeed reductionofthepower from theenglnein the power transmissionline・Itistheplanetarygeartype・

ne sun gear splined to the axle shafts rotates the three planet gearsinside the rlng gear，thereby transmittlngtherotationoftheplanetgearsthroughtheplanetcarriertothewheelhubs．

Thebrakesarethewetdiskbraketype，andinstalledontheaxleshafts・neyareuSedasservicebrakes．

theoperationofthebrakesystem，See

4．BRAKESYSTEM．

Cross SectionalViewA−A （Operationofplanetarygears）

く＋powerFLow 5．PLANETSHAFr 6．PLANETCARRIER 7．WHEELHUB

1・RINGGEAR（nxed）

2．SUNGEAR 3．PLANETGEAR 4．AXLESHAFr

Fig．3．42PowerFlow

ー60−

● Note：D＞ぢ：：：：コ23kg−m（170ft−1bs），紹＝ゝThreadedarea：LOCTITE262 医＞（妄＝コ26kg−m（190ft−1bs），紹＝ゝThreadedarea‥LOCTITE262

B＞紹＝ゝMatingsurface：LOCTITEFMD−127 匠＞Shimadjustmentprocedure‥

①Tightenwheelhubholdingbolttoatorqueof5kg−m（36ftrlbs）andpushinhubbeari COne．

②Measurethespacingbetweenretainer plateandwheelhub・Selectapropershim（S）soth thespacingbecomesO・15toO・25mm・

③Installtheshim（S）andtightenwheelhubholdingbolt・ （nehubbearingrotationaltorqueshouldbel・Otol・6kg，m（7・2−12ft−1bs）・）

ぢ＝コ162kg−m（1170ft−1bs），紹＝ゝThreadedarea：LOCTITE262 1．INNER■ 0 −一RING

9．GEAR HOUSING

17．BRAKE DISK

2．OUTER MO

lO．BUSHING

18．END PLATE

3．BRAKE HOUSING

ll．PLANETCARRIER

19．DISKHUB

4．PIN

12．HUB OILSEAL

20．SUN GEAR

5．PLANETSHAFr

13．W11EELHUB

21．RETAINERPLATE

6．RING GEAR

14．SEALRETAINER

22．SHIM（t＝0・1，0・2，0・25，0・5，1・Omm）

7．PLANETGEAR

15．BRAKE PISTON

23．WHEELHUB HOLDING BOLT

8．NEEDLE ROLLER

16．BRAKE RING

−RING

Fig．3．43FinalReductionGearandBrakeAssembly

−61−

3．8WHEELS（TLRESANDWHEELS）

Tires Wheels

23．5Ⅹ25−1（iPR，し3（OR），t†1beless 19．50Ⅹ25WTB

Weight（PerPiece）

approx. 300 kg 234 kg

Tire Rim Inflationpressure

3・25霊kかCm2

3．8．1TIRE

ThestandardmodelisprovidedwithrocktypeL−3tireswhichftatureexcellentresistancetodamageand Wear．

Selectapproprlatetiressincethereareavarietyoftiresavailableaccordingtotheapplicationandpurpose

●

ofwork． netiresizeisexpressedininches・¶leStrengthoftiresareexpressedinpryrating（PR）．Forexample，

16PRmeansastrengthcorrespondingtothatof16piecesofcottoncords・（PRdoesnotnecessarilystands forthenumberofcordsofthetire・）

16PR

Ⅹ

23．5

25

Tirewidth（inch）Rimdiameter（inch）Tirestrength

Tread Pattern

Fig．3．44Tire −62−

3．8．2 WHEEL

newheelconsistsoftherimanddisk．Thediskboltedtothewheelhub． netireisinstalledontherim，andbothserveaSOnePleCe・Wheninstallingthetireontherim，itisv importanttouseanapPrOprlaterim・

Theuseofaninapproprlaterimmayresultinashortliftofthetireandintheworstcasemightcausea serious accident．

Therimsizeisalsoexpressedininches・The丘rstnumberstandsfortherimwidthandthenextonetheri diameter．

ぢ＝コWheelbolt：88kg−m（640ft−1bs）

CrossSectionalViewA−0−B

1．RIM

4．LOCKRING

2．DISK

5．SIDERING

3．BEADSEATBAND

6．LOCKRINGDRIVER

7．−−0−−−RING

Fig．3．45Wheel

−63−

4．BRAKE SYSTEM SenricebTake Tサpe：

Frontandrearwheelindividualbraking，Wetdisk，air−OVer

Operatingline：

2 lines

Brakevalve： Diskbrake： Servounit：

E−2singlebrakevalves

Aircompressor‥

Reciprocatlng，air−COOledtype

Pressureregulator：

D−2governor

Airtank：

40せ（20せⅩ2）

hydraulic braking

4＿Wheelwet−diskbrakes

Chamberandcylinder

Parkingbrakeandemergencybrake 乃pe‥

Frontaxleinputbraking，diskbrakewithsprlngCylinder

Diskbrake：

Dry type

Fig．4．1BrakeSystem

ー64−

4．1BRAKE LINE

（X）‥tOTRANSMISSIONCONTROLVALVE

AIRLINE（ServiceBrake） ZZZZZZEAlRLINE（ParkingBrake）

（AlRLINEforINCHING）

（Y）：tODISKBRAKE（forPARKINGandEMERGENCY） ＋HYDRAULICPRESSURELINE

Note：SeethenextpageaboutspecincationsandinstallationpositionsofthesensorandtheswitchesA− 1．AlR COMPRESSOR 2．AIR GOVERNOR 3．CHECKVALVE 4．AlRTANK 5．SAFETYVALVE

6．DRAIN COCK

11．BRAKEOILRESERVOIR

7．RIGHTBRAKEVAI」VE

12．CHAMBER＆CYLINDER

8．LEFrBRAKEVALVE 9．DOUBLECHECKVALVE lO．QUICKRELEASEVALVE

13．WETDISKBRAKE 14．HANDVALVE 15．SPRINGCHAMBER

Fig．4．2BrakeLine

−65−

Notes：Specincationsandinstallationpositionsofthesensorandtheswitches Position

Designation

A I．owpressureswitch

Specification

Use

Warninglamp

andthealarmbuzzer

airpressure一

OFF：5．2±0．3kgkm2（74±4psi）

ON：4．2±0．3kgたm2（60±4psi） （ONinatmosphericpressure）

B Pressuresenderunit

C Airswitch

Brakeairpressuregauge

Stoplamp

Operationpressure

Resistance

k亦m2（psi）

（Q）

0（0）

80

5（70）

32

10（140）

10

oN‥belowO．3±粥kgkm2（4t3psi）

D hⅣelswitch（built−in） Waminglamp一一brakeoil

ON：belowthespec泊edlevel

1evel −

E Lowpressureswitch

Warninglamp parking brake

F Lowpressureswitch

For transmission control

G Thermosensor

WarninglampMbrake

OFF：1．2±0．3kgkm2（17±4psi） ON：0．5±0．3kgkm2（7±4psi） （ONinatmosphericpressure） Temperature（OC）

temperature

Resistance（E2）

20

2470

40

1150

80

310

4．1．1 0UTLINE

l．ServiceBrake neservicebrakeisa4−Wheelwetdiskbrakeandinsta11edinthedriveaxle．Thebrakelinesareanair− hydraulictype・

Thisloaderhastwobrakelineswhichuseapairofchamberandcylinderassemblies；Oneforthefrontline andtheotherbrtherear．Evenifoneofthetwolinesisdisabled，theotherlinecanoperatetobra loader．

Theservicebrakelineisdividedintotheairlineandthehydraulicline．Itconsistsoftheaircompres airgovernor，brakevalve，Chamberandcylinderassemblyanddiskbrake・

2．ParkingBrakeandEmergenqrBrake

neparkingbrakeisthesprlngtyPeandusesthedrydiskbrakeintheinputpartofthefrontaxle・ 珊e parking brakeis operated by the hand valveinstalled on theinstrument panelofthe operator COmPartment・

neemergencybrakeactsautomatically，iftheairpressureoftheservicebrakeairlinedropsbelowthe

specinedlevel．Ifthebrakeairlineisbroken（e・g・hosedamage），theemergencybrakeoperatestoe

Sakty．

Thisemergencybrakeisalsousedastheparkingbrake・

ー66−

4．1．2 0PERAT10N

l． CompressedAirCharglng ① Astheenginestartsrunning，thecompressedairdischargedfromtheaircompressor（1）issuppli theairtank（2）tothehandvalve（5）throughthelowerchambersoftherightandleftbrakevalve 4）・

② Whenthehandvalve（5）ispushedin（toreleasetheparkingbrake），COmPreSSedairflows，PaStthehand valveandthequickreleasevalve（6），tOthespringchamber（7）・

ThesprlnginthesprlngChamberiscompressedbycompressedairtoreleasethediskbrakefbrparkin ③ Whenthehandvalve（5）ispulledout（toapplytheparkingbrake），COmPreSSedairisshutoffbyt handvalve，thebrakelineafterthehandvalveisopenedtotheatmosphere，andthediskbra ParkinglSaCtuated・ （Seer．4・ParkingBrakeinOperation一 ・）

●

Fig．4．3CompressedAirCharging（toReleaseParkingBrake）

ー67−

2． ServiceBrakeOperation

① whenthebrakepedalispressed，COmPreSSedairissentfromthelowerchamberofthebrakevalve（3）

totheupperchamber・Itflowsthroughthedoublecheckvalve（8）toactuatechamberandcylinder assembly（9）．

②Inthechamberandcylinderassembly（9），thepressureofcompressedairisconvertedintobrakeoil

PreSSureandboostedtoactuatethewetdiskbrakes（10）insidethedriveaxles，therebybrakingth

loader． ③ whenthebrakepedalisreleased，theupperchamberofthebrakevalve（3）isopenedtotheatmospher

andtheairpressureoftheairlinetothequickreleasevalve（11）isreducedtodischargethecompr airinthechamberandcylinderassembly（9）totheatmosphere．

Thechamberandcylinderassemblyisreturnedtotheinitialposition，therebyreleaslngthediskbrakes （10）・

④ meleftbrakevalve（3）performsinchingoperation．Whentheleftbrakepedalispressed，theload isbrakedand，atthesametime，COmPreSSedairis ．

⑤whentherightbrakevalve（4）ispr？SSed，thedoublecheckvalve（8）isputin？perationsothat COmpreSSedairisnotsenttothetransmlSSioncontroIvalve・Hence，inchingoperationlSnOtPerfbrmed．

Fig・4・4ServiceBrakeOperation（LeftBrakePedalDepressed）

ー68−

3． EmergenqrBrakeinOperation

①Iftheairpressureofthecompressedaircharginglinereducesbranyreasonsuchasruptureof

hose，theknobofthehandvalve（5）isautomaticallypushedup・neCOmPreSSedairinthelineaft thehandvalveisdischargedtoreducetheairpressure・

ThecompressedairwhichiscompreヲSingthespringinthespringchamber（7）isdischargedfromt quickreleasevalve（6）totheopenalr・

② Thespringinthespringchamber（7）isreturnedtotheinitialpositiontoshiftthediskbrake（Pa brake）1everbrproducingbrakingbrce・

●

Fig．4．5EmergencyBrakeinOperation

ー69−

4． ParkingBrakeinOperation ① whentheknobofthehandvalve（5）ispulledout，thecompressedairfromthebrakevalve（4）isshut

Offbythehandvalve．

② necompressedairinthebrakelineafterthehandvalve（5）isdischargedfromthehandvalveandthe quickreleasevalve（6），thecompressedairwhichiscompressingthespringinthespringchamber（7）

beingreleasedtotheatmosphere．

③ mespringinthespringchamber（7）restoresitsinitialstatetoshiftthediskbrake（parkingbrake）lever forproducingbrakingbrce．

●

Fig・4・6ParkingBrakeinOperation

ー70−

4．2 SERVICE BRAKE 4．2．1 BRAKEVALVE

Whenthebrakepedalisdepressed，thepressureofcompressedairwhichpassesthroughthevalveis controlledandsenttothechamberandcylinderassembly・

Sincethebrakevalveusesarubbersprlng，thebrakingpressurecanbecontrolledaccordingtothepedal

presslnganglewhenthepressureislow，andthebrakepressurecanbecontrolledaccordingtothepedal presslngbrcewhenthepressureishigh・

ニ／

ク∴

／

Note：匡＝＞〆＝＝袖

●

SlidingParts‥Grease

5

l． PEDAL 2． ROLLER 3． STOPRUBBER 4． PISTON 5． VALVE 6． VALVESEAT 7． BOOTS 8． PLUNGER 9． PLATE lO． RUBBERSPRING ll． BODY 12． DIAPHRAGM

6

Fig．4．7BrakeValve

一71−

0peration l・ Rm最ng Whenthebrakepedal（1）is㌣eSSed，theplunger （2）isactuated，therubbersprlng（3）pushesthe piston（4）down，andtheexhaustvalveseatatthe pistonendclosely6tstotheinletkxhaustvalve（5）， therebyclosingtheexhaustvalve（a）．

When the brakepedalisfurther pressed，the inlet／exhaustValve（5）isfurtherpushed，SOthatthe

inletvalve（b）isopenedtoallowcompressedairto flowfromthesupplyportintodeliveryport（upper Chamber）・

Fig・4・8Braking

2・ Balanclng Ifthebrakepedal（1）ispessedandheld，the

PreSSure Ofcompressed airln the deliveryport （upper chamber）acts on thebottom surfhce of piston（4）．

Whenthepressureofcompressedairisraised， the plStOnis pushed up，OVerCOmlng the brake Pedalpresslngforce，with the result that the

inlet／exhaustValve（5）ismovedtoclosetheinlet Valve（b）・

mesupplyportandthedeliveryportareshut

O托thepressureofcompressedairinthedelivery port（upperchamber）iskept，therebyestablishing

abalancedstate．

Fig・4・9Balanclng

ー72−

3． Releaslng Whenthebrakepedal（1）isreleased，thepiston （4）ispushedupbythereturnspring（6），andatthe

Sametimethebrakepedalisreturnedtoitsinitial POSition・

When the piston（4）moves up to open the exhaustvalve（a），thecompressedairofthedelivery

port（upper chamber）is discharged from the exhaustcheckvalve（7）throughtheinletkxhaust Valve（5）・

Fig．4．10Releaslng

●

−73−

4．2．2 CHAMBER＆CYuNDER

nechamberandcylinderassemblyisaportlesstype．Sincethecylinderdoesnothaveacylinderport，t Pistoncupisfreeftomthepossibilityofbeingdamaged，thusensuringgreaterdurability・

nechamberandcylinderassemblyconsistsofapneumaticchamberandahydrauliccylinder．Itconverts

thepressureofcompressedairintobrakehydraulicpressureandboostsit・

●

1． PUSHPLATE 2．PRESSUREPLATE 3．DIAPHRAGM 4． RETURN SPRING 5． NON−PRESSUREPLATE

6． DUSTCOVER 7． PUSHROD

8． PISTON STOPPER 9． SECONDARYCUP lO． PISTON ll．VALVESTOPPER 12．INDICATOR 13． PRIMARYCUP 14． VALVEROD

Fig．4．11ChamberandCylinderAssembly

−74−

15．SUPPLYVALVE 16． RETURNSPRING 17．RETURNSPRING 18．CYLINDER BODY 19．BLEEDERSCREW

Operation

l．Rraking

Whencompressedairissenttothechamber，apreSSureisappliedtotherearofthediaphragm，andthepu

rodispushedfbrwardtomovethepIStOninthecylindersection． AstheplStOnismovedbrward，thesupplyvalverodleavesthevalvestoppertoclosethesupplyvalveso thatthebrakeoilinthecylinderisdischargedinthequantltyCOrreSPOndingtothedistancethepIStOnhas moved． Afterthebrakepistonofeachdiskbrakereachesitsstrokeend，thebrakehydraulicpressureisincreased

toputthebrakesinaction．

田AIR 「 「 BRAKEOlし

● 1 2 つJ 4

DIAPHRAGM PUSH ROD VALVE STOPPER PISTON SUPPLYVALVE

：＝＝

from BRAKE VAい／E

5

Fig・4・12Braking 2・Releaslれg

Whenthecompressedairfbdintothechamberisdischarged，thepushrodandpistonarerespectivelypushed backbythereturnsprlng・

Whenthepistonismovedback，thesupplyvalverodhitsthevalvestoppertoforcethesupplyvalveopen， SOthatthebrakeoilisreturnedtotheoiltank，andthebrakesarereleased．

●

⊂：コA旧 BRAKE OIL

二＝

1．RETURNSPRING 2． PUSHROD 3． PISTON 4．VALVESTOPPER 5．RETURN SPRING 6．SUPPLYVALVE

to BRAKE VALVE

Fig・4・13Releaslng

ー75−

4．2．3 D霊SKBRAKE

Theservicebrakeisawetsinglediskbrakeandisinstalledinthe鋭nalreductiongearandbrakeassembl ofthe drive axle．

nediskbrakeconsistsofdiskhub，brakedisk，brakerings，endplateandbrakepiston・Foritsstructure， see‖3．7DRIVEAXLE−−．

Operatiom

Whenthebrakepedalispressed，thebrakeoilpressureactsontherearofthebrakepistontoclampthe brakediskbythebrakerings． Theinnerperipheryofthebrakediskissplinedtotheaxleshaftthroughthediskhubwhereastheouter

Peripheryofthebrakeringis丘ⅩedtothebrakehouslngWiththep）n，SOthatthebrakediskclampedbyth

brakeringsstopsrotatlngtObraketheloader・ Whenthebrakeoilpressureisreleased，thebrakepIStOnisreturnedalittlebytherestoringfbrceofthe

一

0一

−ring，Creatingagapbetweenthebrakediskandthebrakeringtocausethebrakedisktofreewheel．

2 3 4 5 6 7 8 9

1．AXLESHAFr 2． DISKHUB 3．ENDPLATE

4．BRAKEDISK 5． PIN 6．BRAKERING

Fig．4．14DiskBrakeinOperation

ー76t

7．OUTER．

0

RING

8．BRAKEPISTON 9．INNER−−0

RING

4．2．4 AIRCOMPRESSOR

TheaircompressorisinstalledontheenglnetOPrOducecompressedairfbrthebrakesystem・Itisdrive

bytheenglnegeartrain・ Whentheenglneisrunnlng，theaircompressoralsooperatestosupplycompressed airtotheairtanks・

Whenthepressureintheairtankreachesthespecinedlevel，theunloadervalveispushedinbyoperation

ofthegovernortoreleasethesuctionvalve，SOthattheaircompressorisputintono−loadstate・ Whenthepressureinthe airtankdropsbelowthespeci鮎dlevel，theunloadervalveisreturne

OPerationofthegovernortooperatethesuctionvalvesothatcompressedairissupplied・

A． SUCTIONPORT

（fromAlRCLEANER） B．UNLOADER PORT

世OmAIRGOVERNOR）

C．DISCHARGEPORT （toAlRTANK）

1．UNLOADERVALVE 2． CYLINDERHEAD 3．SUCTIONVALVE 4． PISTON 5． PISTONpIN 6．CYLINDERLINER 7． CONNECTINGROD 8．BEARINGCASE 9．CRANKSHAFr lO．DELIVERYVALVE ll．CRANKCASE

●

Fig．4．15AirCompressor

＿77−

4．2．5 AIR GOVERNOR

Theairgovernorisdesignedtomaintaintheairpressureintheairtankinthespeci員edrange．Itcontro

theoperationoftheaircompressor．

Whentheaircompressorruns，itsuppliescompressedairintotheairtank・Whentheairpressureinthe airtankrisesabovethespecinedlevel，thegovernorstartsoperatlngtOunloadedthecompressor・ Whenthepressureintheairtankdrops，thegovernorallowsthecompressortorununderload．Thisway，

thepressureintheairtankisautomatica11ykeptwithinthespecinedpressurerange．

‖ON

PRESSURE：

5・0±0・3kg／cm2（71±4psi） OFF PRESSURE： 6．1±0．3k

1．RETAININGRING 2．UPPER SPRINGSEAT 3． SPRING 4． LOWERSPRINGSEAT 5．EXHAUSTSTEMSPRING 6．

0 RING

7．EXHAUSTSTEM 8．VALVE 9．VALVESPRING lO． COVER ll． NUT 12．ADJUSTINGSCREW 13． SPRING GUIDE 14． FILTER 15．WASHER 16． PISTON 17． BODY

Fig．4．16AirGovernor

−78−

87±4psi

Operation

l．WhenPressureinAirTankDropsBelow Speci蔦edI尤Vel

Thecompressedairintheairtankflowsfromthe

rServOirport（1）andactsonthebottomofthe plStOn（2）・

Whenthepressureintheairtankdropsbelow thespecinedlevel，thepistonispusheddownby thespring（3）toclosetheinletvalve（a）・The exhaustvalve（b）issti1lopen・

Thecompressedairfromtheairtankisshutoff bytheinletvalve（a）・

The line from the unloader valve of the air compressor is communicated to the open air throughtheunloaderport（4），eXhaustvalve（b） andexhauststem（5）・

Inthis state，airpressuredoes not acton the unloadervalveoftheaircompressor，SOthattheair COmpreSSOrisin ON

state（loadedstate）・

Fig．4．17 一ON Position 2． When Pressurein Air Tank Exceeds Speci瓜edI尤Yel

Whenthepressureintheairtankincreasesand thepiston（2）moves，OVerCOmingthespringforce （3），theexhaustvalve（b）is closed・When the

PreSSureisfurtherincreasedtoexceedthegovernor

● 一票雲慧e￡1宝￡芸三雲i㌘￡慧諾ふ st。

theunloadervalveoftheaircompressorthrough the reservOir（1），inletvalve（a），Piston（2）and unloaderport（4）・

Thecompressedairpressureactsontheunloader valve ofthe aircompressor to brcethesuction valveopensothattheaircompressorisputinto idlingstate・（no−loadstate）・

Fig．4．18 −79−

OFFPosition

4．2．6 0THER DEVICES

l．Sa鮎曙ValYe Thesafttyvalveisprovidedontheairtank．It isdesignedtopreventthedevelopmentofabnormal

pressure risein theairtankor airline due to a defectivegovernororunloadervalve． Whenthepressureintheairtankrisesabovethe SetPreSSure，theballvalveispushedupandthe COmPreSSed airis dischargedfrom the discharge port・

Whenthepressureinthetankdrops，thesprlng brces theballvalvetoseat to stopdischarging

COmPreSSedair． BLOW−UPPRESSURE‥10．5±0．4kdcm2

（149±6psi）

Fig．4．19SafttyValve

2． DoubleCheckValve nedoublecheckvalvelSPrOVidedatthejunctionbetweentherightandleftbrakevalvesandthechamber

andcylinderassemblies・Itsendscompressedairfromeithertherightorleftbrakevalvetothechamberan Cylinderassemblies． Whentherightbrakepedalispressed，COmPreSSedairissentfromtherightbrakevalvetothedoublecheck Valvetopushtheshuttletotheleft，therebycloslngtheleftsideinletandsendingbrcescompressedairtothe Chamberandcylinderassemblies．

Whenthebothbrakepedalsarepressed，thecompressedairh・Omeithertherightorleftpedalwh PreSSedearliertheshuttletotheoppositeinlet，gOlngtOthechamberandcylinderassemblies．

fromBRAKEVALVE（LEFT）．，

◆■fromBRAKEVALVE（RIGHT）

SHUTTLE

l toCHAMBER＆CYLINDERASS，Y

Fig．4．20DoubleCheckValve

ー80−

3．q血ekReleaseValve

Thedistancefromthebrakevalvetothechamberandcylinderassemblyissolongthatitwilltakealong timetoreleasethebrakesifthecompressedairinthechamberandcylinderassemblyisdischargedthrough

thebrakevalve． Onthisloaderaquickreleasevalve，throughwhichthecompressedairisdischarged，isprovidednear ChamberandcylinderassemblytospeedthereleaslngOperationofthebrakes． Inaddition，anOtherquickreleasevalveisinsta11edintheairlinebetweenthehandvalveandthesprlng Chambertoquickenbrakingoperation・

Operation

①whenthebrakepedalisreleased，theupperchamberofthebrakevalveisopenedtotheairtored

theairpressureintheairlinebetweenthebrakevalveandthequickreleasevalve・

②Thediaphragminthequickreleasevalveoperatestoletthecompressedairinthechamberandcy assemblydischargefromthedischargeportofthequickreleasevalve・ ③Thechamberandcylinderassemblyreturnstotheinitialstatetoreleasethebrakes．

from BRAKE VALVE ↓

→ O CHAMBER＆CYLINDERASS Y

to CHAMBER＆CYuNDER

l DISCHARGE PORT

●

Fig．4．21QuickReleaseValve

−81−

4．3 PARKING BRAKEAND EMERGENCY BRAKE 4．3．1 HANDVALVE

Thehandvalveisusedtocontroltheparkingbrake．Italsoactuatesautomaticallytheemergencybrake

Whentheairpressureinthebrakeairlinedropsbelowthesettlng・

Ifthehandvalveknobispulledout，theparkingbrakesareapplied・Befbrestartingtheloader，make

topushintheknobtoreleasetheparkingbrakes・

▲

l．The parking brake cannot be released when the brakeair pressureislower than 3．9kg／cm2（55psi）．Whenstartingtheloader，makesuretheairpressureishigherthan 3．9kg／cm2（55psi）andpushintheknobtoreleasetheparkingbrakes．

2．Theemergencybrakeoperatesautomaticallywhenthebrakeairpressuredropsbelow

2．8kg／cm2（40psi）．（meknobofthehandvalveisautomaticallypushedup．）Ifth

loadercomestoastopduetotheapplicationoftheemergencybrakes，IowerthebtlCket Onthegroundandchecktheloadercompletely．Donottrytostarttheloadert）ntilthe troubleis remedied．

Notes：臣＝＞ぢ＝コ0．35toO．45kg−m

匪ぢ＝コ

1．KNOB 2．SPRINGPIN 3．BODY 4．PLUNGER 5．SPRING 6．VALVE 7．CASTLENUT 8．COmR PIN 9．0ILSEAL lO．SEALINGNUT ll． 0

RING

12．SEALINGRING 13．COVER

Fig．4．22HandValve −82一

●

Operation

l．CharglngOperation

Iftheknob（1）ofthehandvalveispushedin

withtheairpressureinthebrakeairchargingline above3．9±0．4kgkm2（55±6psi），the knob holdsitsposition・

Thevalve（2）ismoveddownbytheplunger（3），

sothatthecompressedairfromthesupplyportis ledtothedischargeport・ Note：Whenthehandvalveknobispushedin，the

knobisautomaticallyreturnedtotheinitial POSitionbytheplungerspring（4）brce，if

the airpressureinthebrakeaircharglng lineislowerthan3．9±0．4kgkm2（55± 6psi）・

Afterincreaslngtheairpressureintheair line，OPeratethehandvalve・

Fig．4．23ChargingOperation

2．ExhaustOperation Whenthehandvalveknob（1）ispulledup，the knobholdsitsposition．Thiscausestheplunger（3）

tomVethevalve（2）upwardsothatthesupply linelSClosedandthedischargelineisopenedto theatmosphere・

●

Note：Ifthepressureinthebrakeairlinedrops below2．8±0．4kgkm2（40±6psi）with

thehandvalveknobpushedin，theplunger

SPring（4）forceovercomestheairpressure actingontheuppersurfaceofthevalve（2）， CauSingthevalve（2），tOmOVepWard・

Therebre，thedischargelinelSOPened to the atmosphere and parking brakes are applied（emergencybrakeoperation）・

Fig．4．24ExhaustOperation ー83一

4．3．2 SPRING CHAMBER

ThesprlngChamberincorporatesapowerfu1springbywhichthebrakesaremechanicallyapplied・ SincethepushrodfrontendofthesprlngChamberislinkedtothebrakecaliperlever，theparkingbrake

iscontrolledbyturnlngOnandoffthesupplyofcompressedairtothesprlngChamber・ Operation

WhencompressedairissenttothesprlngChamber，airpressureactsatrearofthediaphragm，tObrcethe pushrodout（brakereleasing）・

WhenthecompressedairsuppliedtothesprlngChamberisdischarged，thediaphragmandthepushrodare PuShedbackbythepowerfu1spring（braking）・

6

l

ll

（70mm）

7

Notesl：（芯：＝コClampingboltandnut：1．75kg−m（12．7ft−1bs） 2‥▲ D11eCareShouldbeexercisedwhendisassemblingatldassemblingthespnngchamber bcaⅦSethe叩血1spnnglSⅦSd． 1． CLAMP RING 2．DIAPHRAGM 3．PUSHPLATE

4．PRESSUREPLATE 5． SPRING

7．NON−PRESSUREPLATE

6．FUSf壬ROD

Fig．4．25SpringChamber

−84−

4．3．3 PARKING BRAKE

Tbeparkingbrakeisamechanicaldrydiskbrake・

Thebrakediskisinstalledonthebrakeflange（rotarypart）ofthefrontdifftrential・nebrakecali 触edtothebrakecarrier（non−rOtaryPart）instal1edonthedifftrentialcarrier・（See 37DRIVINGAXLES brinstallation・）

nebrakecaliperleverislinkedtothesprlngChamberrod・ Operation

Whentheleverforthebrakecaliperispulledup，thepivotseatnttedtothelevercausesthepadstoclamp thebrakediskfrombothsides，therebyproducingbrakingbrce・

Whentheleverisreturnedtotheinitialposition，theclearanceiscreatedbetweenthepadsandbrakedisk toreleasethebrakes．

Thicknessofthepad： 13．7mm（Withbackingplate） 8

9

Notes：D＞ぢ：：：：コ0・22toO・56kg−m（1・6to4・Oft−1bs） 1．（BRAKEDISK）

2．HANDBRAKEBOLT 3．OUTERPADCARRIER 4．PADASSEMBLY 5．RETRACTIONPLATE

Wearofthepad‥6・7mm

10

医＞6：＝：コ0・5kg−m（3・6ft−1bs）

6．PADCARRIERBOLT 7．TABWASHER 8．TRUNNION 9．PIVOTSEAT lO． LEVER

Fig．4．26BrakeCaliper

−85一

ll．SELF−LOCKNUT

12．RETURNSPRING 13．INNERPADCARRIER

5．STEER（NGSYSTEM Mechanism

Frame−articulating Follow−uplinktype

Framearticulatingangle

370torightandleft

SteerlngWheelreductiongear Oilpressuresetting

Ballnuttype 190k亦m2

Oilflowsetting

100 Plmin

Tサpe

Steerlngandassistpump Model

m5190−KPlO13

ll−lle

Gearpump，tandemtype

Discharge（loaded）

Front：192．4dmin（dischargepressure：210kdcm2） Rear：27．8ymin（dischargepressure：30kg／cm2） （engine‥2330rpm）

Weight

approx・25・2kg

Steering cylinder 「丹pe

Double−aCtlngpiston

Cylinderstroke

450 mm

Q ty

2

Weight（PerPiece）

approx. 32 kg

5．1GENERALDESCRIPT10N The steerlng SyStemis a frame−articulating type whichsteerstheloaderbyoperatlngthetwosteerlng cylindersbetweenthefrontandrearframes・

ThesteerlngmeChanismis afbllow−uPlinktype actuatlngthesteerlngValvespooIwiththelinkage・

ThesteerlngSyStemCOnSistsofthesteerlnggear， steerlngValve，SteerlngCylinders，SteerlngPumP，and hydraulicplplng・

Fig．5．1Follow−uPLinkSteerlngSystem

ー86−

●

Note：TTlehydraulicpIPlnglSnOtShowninthisdrawlng・

Fig．5．2SteeringSystem

●

ー87−

5．2 0ILCIRCULAT10N ROUTES

TheoildrawnfromtheoiltankbythesteerlngpumPISSentunderpressuretothesteerlngValve・ nesteerlngValveregulatesthepressureandnowrateofthepressureoilforsteerlngtheloader・Sincet loaderadoptstheprlOrltySySteminwhichthesteerlngCircuittakesprlOrityoverothercircuits，eXCeSSOilissent to themaincircuit． WhenthesteerlngWheelisturned，thesteerlngValveisputinactuationtosendthepressureoilfromthe PumPtOthesteerlngCylinders，therebysteerlngtheloader・

TbereturnoilfromthesteerlngCylindersflowsthroughthesteerlngValvebacktotheoiltank．

●

Fig・5・3HydraulicCircuitDiagram

−88−

5．3 STEERING WHEELUNIT

nesteerlngWheelunitconsistsofthesteerlngWheel，SteerlngShaft，SteerlngCOlumn，andsteerlnggear・

nesteerlngWheelunitisatiltabletypewhichisadjustableinnvestepswithinafu11160・ nesteerlnggearisaballnuttype・Theballnuttypeisalsocalledastherecirculatingba11type・Thi OfsteeringftatureslightsteerlngOPeration・

Theballnuttypesteerlnggearhassteelballsinsertedbetweenthescrewshaftandtheballnut・ rotationofthescrewshaftisconvertedintotheaxialmovementoftheballnutbythero11ingcontactofthe steelballs．

Operation ①whenthesteeringwheelisturned，thescrewshaftofthesteeringgearisrotatedthroughthesteeringshaft・

②neballnut，inmeshwiththescrewshaft，isalsoinmeshwiththebevelgearofthesectorshafta

outerrack．職erebre，Whenthescrewshaftisturned，theballnutmovesintheaxialdirectionwith

●

rotatlng・

（9Theaxialmovementoftheballnutisconvertedintotherotationalmovementofthesectorshaftbymeans oftheouterrack．

④¶lerOtationalmovementofthesectorshaftistransmittedfromthepitmanarmthroughthelinkagetot SteerlngValve・

●

−89−

Notes：駐＝＞忙＝＝袖Slidingarea：Grease DetaiIofAreaA

匡＞ぢ＝コ3．83kg−m（28鋸bs） 駐：＞Iftwoshimsaretobeused，Putthem，Onebreachside．

1．STEERING WHEEL

2・（TURNSIGNALSWITCH） 3．BEARING 4．PIN 5．STEERING SHAFr 6．UNIVERSALJOINT 7・（SHIFrLEVER）

8．STEERING COLUMN 9．COVER lO．LINK

17．STEERING WHEELSUPPORT

ll・SHIM（t＝1・Omm）

18．STEERING GEAR

12．SPACER 13．STEERING WHEELSTOPPER 14．RETURN SPRING

19．CLAMP

Fig・5・4SteeringWheelUnit

一90−

15．STEERINGWHEELSUPPORT 16．U BOLT

20．HORN SWITCH

Weight：15kg

Note：臣＞ぢ＝コ2kg−m（14ft−1bs）（Aftertightening，bendthelockwasher

Gearoil：0．5Q

alongthelocknutgroove・）

1．SECTORSHAFr

8．FILLERNIPPLE

15．SCREWSHAFr

2．0ILSEAL

9．BEARINGSUPPORT

16．BALLNUT

3．NEEDLEBEARING

10．LOCKWASHER

17．THRUSTBEARING

4．SIDECOVER

ll．LOCKNUT

18．NEEDLEBEARING

5．ADJUSTBOLT

12．DUSTSEAL

19．CAP

6．DRAINPLUG

13．CAPNUT

7．LEVELPLUG

14．GEARCASE

Fig．5．5SteeringGear

−91−

5．4 STEERING VALVE Model

HUSCO 7520

「丹pe

ControIvalvewithpressurecompensation

Flowrateatcylinderport

100 4/min

Mainreliefvalvepressuresetting

190k亦m2

Portreliefvalvepressuresetting

210k帥m2

（PortsAandB）

approx. 25 kg

Weight

AB‥ Cylinderport

P： Pumpport PB：Carry−OVerpOrt （tomaincircuit） T‥ Tankport

MAIN REuEFVALVE

（SpooIstroke） PORTREuEFVALVE

GAUGEPORT（PTl／8）

Note：Forthesectionalviews，Seethenextpage・

Fig. 5.6 Steering Valve

ー92−

ThesteerlngValveisacontroIvalvewiththepressurecompensationmechanism・Regardlessof

pressure（Steeringcylinderpressure），thisvalvedeliversoiltothesteeringcylindersataflowratecorres tothedisplacementofthesteerlngSpOOl・

nesteerlngValveconsistsofthevalvehouslng，SteerlngSPOOl，Carry−OVerPlunger，mainreliefvalve，an reliefvalve．

nemainreliefvalveadjuststhehydraulicoilpressurefbrthesteerlngCircuit・Whenthehydraulicoi pressureexceedsthepresetvalue，thisvalverelievessomeofthepressureoiltotheoiltank・

meportreliefvalve，insta11edoneachcylinderport，prOteCtSthecircuitstothesteerlngCylinder OVerloading・

●

CrossSectionalViewX−X

1．VALVEHOUSING

6．CAPSCREW

11．SEAL

2．POPPET

7．SHIM（foradjustingspooIcenter

12・CARRY−OVERPLUNGER

3．SPRING

13．MAlNRELIEFVALVE

POSition）

4．STEERINGSPOOL

8．COVER

14．SPRING

5．SPRING

9．SPACER

15．SHIM（fbrflowadjustment）

lO．WIpER Fig．5．7StructureofSteeringValve（CrossSectionalViewofSteeringValveShown Fig・5・6）

−93−

Operation

Note：neinternaldesignoftheactualvalvemaybesomewhatdifftrentthanourartisticsketchgivenbelo 1．In Neutral ①whenthesteeringspool（1）isinneutral，theportsAandBtothesteeringcylindersareclosed．

②ThepressureoilfromthepumpflowsfromtheportP，PaSSingthroughtheorince（3）ofthecarry−OVer Plunger（2），intothechamber

③Thechamber−1a

b

．

一iscommunicatedthroughasmallholewiththeloadcheckvalve（4）ofthesteeringspool

（1）・Whenthepressureinthechamber a

la

risesenough，theloadcheckvalveopenssothatthechamber

getscommunicationwiththelow−PreSSureOilpassage（T）．

④Nowthatthechamber

b becomesequaltothepumppressureandthatthepressureinthechamber ar7

drops，thecarry−OVerPlunger（2）shiftsfu11ytotheright，OPeningthecarry−OVerpOrt（PB）．

⑤A11thepressureoilfromthepumpflowsh・OmtheportPtotheportPB（maincircuit）．

† from PUMP

Fig．5．＄InNeutral

−94−

2．WhenSteeringWheelisTtlrnedCounterclockwise

．

（1）Whensteeringwheelisturnedalittlefrom PuShedinbymeansofthecontro11inkage・

②ThepressureoilffomthePortPflowsintothesteeringspool（1），PaSSingthroughtheoilpassagesi variableori員ce（5）and丘Ⅹedori抗ce（6）andfbrcingopentheloadcheckvalve（4）inthesteeringspool， pastthecylinderportBintothesteerlngCylinders・

③Atthistime，theopeningareaofthevariableori巨ce（5）isproportionaltothedistancethesteeringspool （1）hasmoved．Thepressureoil（POrtB）down−Streamthevariableorinceisdirectedtothechamber一 ofthecarry−OVerPlunger（2）whilethepressureoilupstreamthevariableorinceisledtothechamber一一b一 ・ ④Thecarry−OVerPlunger（2）shiftsaccordingtothepressuredifferentialbetweenthechambers一 a and b

，

sothatthepressuredi鮎rentialacrossthevariableori員ce（5）ismaintainedconstantatalltimes・

Forthisreason，regardlessofthemagnitudeofpressureloadedtothecylinderport，thefl proportionaltothestrokeofthesteeringspool（1）isdeliveredtotheportB・

● ⑤Theexcessoilnotusedfbrtチesteeringcircuitflowspastthecarq−OVerpOrt（PB）tothemaincircuit・

⑥ThereturnoilfromthesteerlngCylinderflowsthroughtheportA，brcingopentheloadcheckvalve（4 ofthesteeringspool（1），PaStthelow−preSSureOilpassageandtankport（T），backtotheoiltank・

ぐ］ Pushedin

Fig・5・9WhenSteeringWheelisTurnedCounterclockwise

ー95−

（2）WhenSteeringWheelisTurnedtoStop ①whenthesteeringspool（1）iscompletelypushedin，theopeningareaofthevariableor泊ce（5）becomes

maximumsothattheflowofoilfromthecylinderportBtothesteerlngCylindersincreasesaccordingly （thatis，Steeringbecomesspeedier）・

Note：The鮎edori丘ce（6）serveStOkeeptheoilflowfromtheportPtothecylinderportconstantwhenthe SteerlngSpOOlisshiftedtothestrokeend・

② whenthesteeringwheelisturnedtostop，OrWhenthefrontframehitsagainsttherearframe，t

pressureinthesteeringcircuitrisestoactuatethehigh−PreSSurereliefvalve（7），relievingpressureo throughthelow−PreSSureOilpassagetothetankport（T）・

③ Thecylinderportisclosedbytheloadcheckvalve（4）ofthesteeringspool（1）・

くコ Pushedin

↑ from PUMP

Fig．5．10WhenSteerlngWheelisTurnedtoStopCounterclockwise （High−preSSurereliefvalveinoperation）

3．WheJISteeringWheelisTurnedClockwise WhenthesteerlngWheelisturnedclockwise，thesteerlngSPOOlispulledoutofthevalve・

ThepressureoilfromthepumpportflowstothecylinderportAwhilethereturnoilffomthesteerlng

CylindersflowspastthecylinderportBandlowTpreSSureOilpassage，andtankport，backtotheoiltank・

＿96−

5．5 CONTROLLINKAGE

ThesteerlngCOntrOllinkageisconnectedfromthepitmanarm員ttedtothesteerlnggearSeCtOrShaft， throughtherodandlink，tOthesteerlngValvespool・

Thesteerlnglinkissupportonthepivot，Whichisinstalledonthefrontframe・SincethesteerlngVal

mountedon the rear frame and the steerlnggearisinstalled on thefl00rboardin the cockpit，both COmPOnentSmOVeaSdoestherearframe・

職econtro11inkagenotonlyactuatesthesteerlngValveaccordingtothemovementofthesteerlngWheel butftedsthearticulationoftheframebacktothesteerlngValvewhentheloaderisturned・

（Adjustment）

Notes：臣＞ぢ＝コ9kg−m（65氏」bs） 匡＞Adjustwithrodendbearingtoalign CenterhingeplnCenter・ B＞（Stopperboltadjustment）

AdjuststopperboltsothatthespaclngOntherightsketchislmm eachwhensteerlngValvespooliscompletelypushedinwithloader in straight position.

1．PITMANARM 2．STEERING GEAR 3．ROD 4．PIVOT

5．LINK 6．SEAL 7．NEEDLEBEARING 8．BUSHING

Fig．5．11ControILinkage −97−

9．PUSH ROD lO．ROD END BEARING ll．STEERING VALVE 12．STOPPERBOLT

A

with

Operation l．In Neutral WhenthesteerlngWheelstandatthecenterposition，thesteerlngValveisinneutral・

ThesteerlngValvecylinderportisclosedandthusthereisnooilflowtothesteerlngCylinders・ Theloadercontinuestorunstraight．

（FRONTFRAME）

／

＼

（REARFRAME）

Fig．5．12InNeutra1 2．WhenSteeringWheelisTurnedClockwise

（1）LinkageMoYement

①whenthesteeringwheelisturnedclockwise，thesteeringgearsectorshaftrotates，therebyletting

PltmanarmrOlltowardtherearoftheloader．

②Themovementofthepitmanarmrotatesthelinkthroughtherodtopullthespooloutofthesteerin valve． ③Asthesteeringvalveactuates，thepressureoilfromthesteeringpumpisdirectedtothesteeringcylinders， therebyturnlngthefrontframetotheright，thusturnlngtheloadertotheright．

●

④TherotationalangleofthesteeringwheelcontroIstheanglesofboththesectorshaftandthepitmanarm

Orthedisplacementofthelinkposition・Therebre，theturnlngradiusOftheloaderchangesaccord

tothesteerlngWheelrotationalangle・

⑤nerotatingspeedofthesteeringwheelchangestheworkingspeedofthelinkage，tlmschanging

OPenlngOftheoilpassageto thecylinderport・IfthesteerlngWheelisturnedslowly，Slowsteerl OPerationwi11result，andifitisturnedrapidly，quicksteerlngOPerationwi11result・

（2）Feedingbackoflinkagemovement ①Afterthesteeringwheelisturnedclockwiseandheld，thesteeringlinkagestopsitsmovement．

②Thesteeringvalvespoolisleftpushedout，Whilethesteeringcylinderkeepsitsactionsothatthefro framecontinuetoturntotheright・

③Thearticulationofthefrontframeletsthelinkrotatethroughthepivot，therebypushinginthesteer Valvespooltoreturnittoneutral・

●

④Thefrontframestopsturningsothattheloadercontinuestoturnatthatsteeringangle． Asdescribedabove，thearticulationangleoftheloaderisfedbacktothesteerlngValve，thuskeeplngthe

turnlngradiuscorrespondingtotherotationalangleofthesteerlngWheel・

／

／／、・・／ ＼

（F。。N，F。AME，／

（REARFRAME）

Fig・5・14Feeding−backofLinkageMotion

3．WhenSteeringWheelisTurnedCounterclockwise

WhenthesteerlngWheelisturnedcounterclockwise，thesteerlngValvespoolispushedin・Thepressu

flowsinthedirectionoppositetotheonethatitflowswhenthesteerlngWheelisturnedclockwiseandturns thefrontframetotheleft，thusturnlngtheloadertotheleft．

ThelinkagemotionisalsokedbacktothesteerlngValveinthesequenceoppositetotheonecarriedout WhenthesteerlngWheelisturnedclockwise，thusreturnlngthesteerlngValvespoolintoneutral．

一99−

5．6 STEERINGANDASSIST PUMP nesteerlngandassistpumpISatandemtypegearpump，WhosefrontsectionisusedasthesteerlngPumP

andrearsectionastheassistpumpbrthehydraulicsystem・ ThesteerlngandassistpumpISmOuntedontheconverterhouslngandisdrivenbytheconverterpumpdrive ThesteerlngPumPSeCtionrotatesastheenglneStartSrunnlnganddrawshydraulicoilfromtheoiltank， deliverlngittothesteerlngValve． Note：Fortheprocedurebrinstallingthepump，SeeFig・7・3・

、ヽ■」

一一

Rotational direction

醇

Suction side

Fig・5・15SteerlngandAssistPump

ー100−

7 6 5

3 2

4

● 18 19 20

CrossSectionaIViewB−B

19 20 18

14 13 121110

CrossSectionalViewA−A

1．DRIVEGEAR

8．ADAPTERPLATE

15．SNAP RING

2．DRIVENGEAR

9．］REARPUMI）

16．−−0−−−RING

3．MOUNTINGFLANGE

10．SNAPRING

17．−−0−−−RING

4．PRESSUREPLATE

ll．OILSEAL

18．PLATESEAL

5．−−0

12．SPECIALWASHER

19．BACK−UP

6．COVERPLATE

13．GEARPLATE

20．ISOLATIONPLATE

7．SPLINECOUPLING

14．DOWEL

−RING

Fig．5．16StructureofSteeringPump

−101−

9 8 7 6 5 4

● 1．DRIVEGEAR

6．MOUNTINGFLANGE

ll．一一07一−RING

2．SNAP RING

7．GEARPLATE

12．GASKETA

3．0ILSEAL

8．SIDEPLATE

13．GASKETB

4．DRIVEN GEAR

9．COVER

14．BALANCESEAL

5．SIDEPLATE

lO．DOWELpIN

15．BOLT

Fig・5・17StructureofAssistPump

●

−102−

5．7 STEERING CYLINDERS

Twosteenngcylindersofdoubleactingtypearemountedontheloader・職eircylindertubesaremounte totherearframeandpistonrodstothefrontframe，reSPeCtively・

WhenonesteerlngCylinderrodisextendedbythepressureoilfromthesteerlngValve，theotheroneis contractedsothattheloaderturnstothesideatwhichthecylindercontracts・

necylindershaveacushioningmechanismwhichalleviatesshockincurredwhenthecylinderisextended

uptothestrokeend・Thisisattainedbyreducingtheflowofdischargeoilwithuseofthecushion mountedtothepistonrodtoreducetheworkingspeedofthecylinder・

22く司

View100kingfromZ

1415 17

7 8 9 Notes：距＞（乞＝コ52・5±5・3kg−m（380±38丘−1bs） 医＝＞Pressuremeasurementport（PTl／8） 1．PINBUSHING

9．SNAP RING

17．SHIM SET

2．WIPER RING

lO．BACK−UPRING

18．一一0一一−RINGand SEALRING

3．CYLINDERHEAD

ll．−−OM−RING

19．SLIDERING

4．LOCKWASHER

12．CYLINDERTUBE 13．PISTONROD 14．CUSHIONINGPLATE 15．SPRING 16．PISTON

20．SNAP RING

5．BACK−UPRING 6．U−RING 7．BUFFER RING 8．BUSHING

Fig．5．18SteeringCylinder −103−

21．PIN 22．PLUG

6．FRAMEAND COCKPIT 6．1FRAME meframeisasteel−Plateweldedtypeanddividedintotwoparts：frontandrearffames・neCOCkpitand OPeratOrSeataremOuntedontherearframe．

▲Don？tfrytOmOdiMeROPS（Roll・OVerPrOteCtionstruCtu代），ifmounted，withoutprior pemlSSlOn触）mthemanu蝕c血rer．

IftheROPSshouldgetdamagedorde払rmedduetoturn1ngOVerOrCO11ision〉itisadvisa toreplaceitanewone，becauseitsstrengthmightdrop．

Be伽rebyingtomountanewROPSIbe suretoⅥpeaWayPaintandlubricant魚・Omth mountingsur払cesofthestruCtureandthe鉦ame．

Note：ぢ＝コBalanceweightmountingbolt‥154kg−m（1110ft−1bs）

Fig．6．1Frame −104−

Theloaderisaframe−articulatedtype：thefrontframeisjoinedtotherearframewithtwohingeplnS，

aroundwhichtheloaderisbent払rsteerlng．

▲

Whentheloaderissteered，theareanear thecenterhinge pin beomes so narw

that you might get caught between the

一 言こ、「ドー■

鉦omtand rear蝕・ameS．

Whentryingtoservicetheloader，besure tosetthesa鮎伊1imk． Prior to starting（traveling）theloader， make sure the sa飴tylinkis replaced to therear肋me．

Fig．6．2SafttyLink

●

●

−105−

（UPPERHINGE）

8．BUSHING

15．CAP

2．BEARING

9．−−0−−−RING

16．SHIM（t＝0・4mm）

3．DUSTSEAL 4．UPPERHINGEPIN

lO．BUSHING ll．DUSTSEAL

17．BEARING 18．CAP

5．CAP

12．BUSHING

19．SHIM（t＝0．4mm）

6．SHIM（t＝0・4mm）

13．RETAINER

20．WASHER

7．CAP

14．LOWERHINGEPIN

1．

0 −−RING

Fig．6．3ViewofCenterHingePinsAssembled

−10（i−

6．2 COCKPIT TYleCOCkpitismountedontherearframeby4−pOintrubbermountfloatingmethodwhichreducesthe amountofvibrationandnoisetobetransmittedtotheoperator・

Note：D＞Applyscrewlockingagentandtighten theboltuntiltheclearancebetweenthe bushingandbracketiseliminated・

ぢ＝＝コBolt：30kg−m（220糾bs）

●

Fig．6．4Cockpit −107−

耶脚m

3．SEATBASE PLATE

4．SEAT 5．SUSPENSION 6．BOLT

U

2．COCKPIT

7 00 ∩フ

1．DASHBOARD

7．HYDRAULIC SYSTEM ThehydraulicsystemuseSthemainpumpasitspowersourceandchangestheflowsofoilthroughthemain Valveaccordingtotheworkyouwanttodot nehydraulicsystemisapilotoperationcontrolmethod，Whichconsistsofacombinationofthepilotvalve andmainvalve，tOlessenthevalveoperationbrce． Thesystemconsistsofthepump，Valve，ValvecontroIs，OiltankandhydraulicpIPlng．

OILCOOLER

STEERING PUMPANDASSISTPUMP

（FORHYDRAULICOIL）

STOP VALVE

PlLOT VALVE

● OILTANK

0］LCOOLER

RELlEF VALVE

（FORCONVERTEROIL）

MAIN PUMP

（DRIVEUNlll

MAIN VALVE

Note：Tbe抗gureaboveincludesthesteerlngandtransmissionhydrauliccircuits．

Fig．7．1HydraulicSystem

−108−

7．101LCIRCULATION ROUTES Thehydrauliccircuitconsistsofthemaln，pilot，andsteeringhydrauliccircuits・ Note：Forthesteeringhydrauliccircuit，See．．5．STEERINGSYSTEM・

f

l．MainⅡydraulicCircuit

Themainpumpdrawshydraulicoilfromtheoiltankandsendsitunderpressuretothemainvalve・E PreSSureOilnotusedbrthesteerlngCircuitisreturnedfromthesteerlngValvetothemainvalve・ Whenthemainvalveisinneutral，thepressureoilreturnsthroughthevalveintotheoiltank・

Whentheoilpassagesinthemainvalvearechanged，thepressureoilissenttoeithertheboomcylinders

Orthebucketcylinder，andletsitoperate．meoilfbrcedoutthecylinderreturnstothemainvalveandth flows totheoiltank．

2．Pilot町draulicCircuit

ne assistpump drawshydraulicoilfromtheoiltank・Thepressureoildischargedfromthepump regulatedofpressurebythereliefvalveandissent，PaStthestopvalve，tOthepilotvalve・

Whenthepilotvalveisoperatedwiththeloadinglever，thepressureoilissenttothepilotportofthemain Valvetoshiftthemainvalvespool．Theoillbrcedoutoftheoppositeendofthevalvereturnstothepilot Valve，andaftercooledbytheoilcooler，itflowstotheoiltank． Theoilswhichreturnedfromthemaln，Steerlngandpilothydrauliccircuitsminglewitheachotherintoone flow．Itflows，PaStthereturn巨1terintotheoiltank． Note：¶1eOilcoolerisintegratedwiththeradiator．Foritsstructure，Seel−2．ENGINEANDALLIED

COMPONENTS（2・3）：

−109−

Fig・7・2HydraulicCircuitDiagram −110−

7．2 PUMP Mainpump Model

KFP4156

Type

Gear pump

Discharge（loaded）

l19．7色／min

Weight

（Engine：2330rpm，dischargepressure‥210kgkm2） approx・13，9kg

Notes：1・Forthespecincationsandstructureofthechargingpump，See一一3・POWERTRAlN・ 2・Forthespecincationsandstructuresofthesteerlngandassistpump，See一一5・STEERINGSYSTEM・‖

●

Note：D＞Befoeinstallingthepumpontheconverter

6

7

houslng，mOuntthesplitflangetemporarily・

Viewl00kingfromA

1．STEERINGANDASSISTPUMP

4．MAINPUMP

7．DRIVESLEEVE

2．（TORQUECONVERTER）

5．SPLITFLANGE

8．GASKET

3．CHARGINGPUMP

6．GASKET

9．DRIVESLEEVE

Fig．7．3PumpArrangement

−111−

．l

1．GeneralDescription nreepumpsareusedfortheloader：maln，Steerlngandassist，andchargingpumps・

Tbeyaremountedontheconverterhous1nganddrivenbythepumpdriveoftheconverter・Astheeng StartSrunnlng，thepumpsalsorotate． 2．MainIIump ThemainpumpISageartypeSlnglepump．

AstheenglnerunS，thepumpalsorotates，drawinghydraulicoilfromtheoiltanktosendittoth

valve．

DischaFge side

、t−− 一一一′

Rotation direction

Suction side

Pig. 7.4 Main Pump

−112−

●

CrossSectionalViewB−B

CrossSectionalViewA−A

1．DRIVE GEAR 2．MOUNTINGFLANGE 3．DRIVEN GEAR 4．−−0 −RING

5．PRESSUREPLATE 6．COVER 7．0ILSEAL 8．SNAP RING

9．DOWEL 10．PLATESEAL ll．BACK−UP 12．ISOLATIONPLATE

Fig．7．5StructureofMainPump

−113−

7．3 VAい／E Mainvalve Model

J7000

Type Mainreliefpressuresettlng Portreliefpressuresetting

2−SPOOIslidingtype，Pilotoperationcontro1

210kg／cm2

AIPOrt

160k亦m2

BlpOrt

235kg尤m2

B2pOrt

250k亦m2 approx．67kg

Weight Pilotvalve Model

MPPC−MD

Type

2−SPOOIslidingtype

7．3．1MAIN VALVE

l．GeneralDescription

Themainvalveisastacked，2−SPOOIslidingtypeconsistlngOftheinletsection，2spooIsandoutletsection・

nevalvehasatandemoilpassagecircuitinwhichthebucketlinetakesprlOrlty，SOthatonlywhenthe bucketspooIsectionisinneutral，thepressureoilisdeliveredtotheboomcircuit・

ThebucketprlOrltyCircuit a1lowstheoperatortooperateboththebucket and theboomssimplyby

manlPulatingthebucketleveriftheboomleverisplacedinRAISEorDOWN・ nemainvalveselectivelysendsthepressureoilfromthemainpumptothebucketcylinderortotheboom

Cylinders． neoilpassagesinthemainvalveareselectedbypilotoperationcontrolus1ngtheoilpressurefromthe Pilotvalve・（Fordetai1s，See

7・4VALVECONTROLS．

）

●

2．RelierValve

ThemainvalveuseSOnemainreliefvalveandthreeportreliefvalves・ （1）MainRelierValve

nemainreliefvalve，1nCOrPOratedbetweentheportsPandTintheinletsection，COntrOIstheworking

pressurewhileprovidingprotectionbralldevicesinthehydrauliccircuit・ Whenthepressureinthehydrauliccircuitexceedsthemainreliefpressuresettlng，themainreliefvalve

relievespressureoiltothereturnoilpassagetoprotectthecylindersandpiplng・

−114−

（2）PortRelierValYe

TheportreliefvalveislocatedbetweenthespooIsectioncylinderportandthereturnoilpassage・

Ifthepressureatthecylinderportsideexceedstheportreliefpressuresettingduetotheapplicationofan abnormalloadonthecylinderwiththemainvalveinneutral，theportreliefvalverelievesthepressureatthe cylinderportsidetothereturnoilpassagetoprotectthecylindersandpiping・

6 Pb2

●

1．INLETSECTION 2．SPOOLSECTION（BUCKET） 3．SPOOLSECTION（BOOM）

4．OUTLETSECTION 5．MAlNRELIEFVALVE 6．PORTRELIEFVALVE 7．ANTI−VOIDVALVE

Fig．7．6MainValve

−115−

（迅UCKET）

4

2．SPRING

／LU

3． 0−−−RING

7

（LOADCHECKVALVE）

8．SPOOL

5

1．POPPET

9．VALVEHOUSING

（BOOMl

●

Fig・7・7StructureofSpooISection

−116−

OperationofMainValve l．In NeⅥtral

① Whenthebucketisinneutral，nOPilotpressureactsonthebucketspooIsectionandontheboom section，SOthateachspooliskeptintheneutralpositionbythereturnsprlng・ Thecylinderports（A）and（B）areclosedbythespool，Whiletheneutraloilpassageisopen・

②Thepressureoilflows，PaSttheneutralpassageofeachsection，Outletsection，low−PreSSureOilpassage （returnpassage），pOrtToftheinletsection，andbacktotheoiltank・

CYL［NDERPORT（Al）

CYLINDERPORT（Bl）

Fig．7．＄InNeutral（BucketSpooISection）

−117−

2．OperationofBucketSpool （1）Roll・Back

①Thepressureoilflowsfromthepilotvaletothepilotport（Pbl）ofthebucketspooIsection．Thebuck SpOOlmovesinthedirectionindicatedbythearrowtothe

bucketroll−back

Tposition．

Note：Thespoolmovesproportionatelywiththeoilpressureatthepilotport．

②whenthebucketspoolisinthe

roll−back一一position，theneutralpassageisclosedbythespooIsothatthe

pressureoilflowspastthehigh−PreSSureOilpassageandfbrcestheloadcheckvalveopen，andflows

throughthePortBltOthetailsideofthebucketcylinder・

③TheoilbrcedoutoftherodsideofthebucketcylinderflowspasttheportAlandlow−PreSSureOi PaSSage，backtotheoiltank． neoilbrcedoutofthepilotport（Pal）bythemovementofthespoolreturnstothepilotvalve．

● ■−SpooIshiftingdirection

く−−Pilotpressureflow 一←Oilflowtocylinder ＜−−Returnoilflowfromcylinder

Fig．7．9RollTBackofBucket

−118−

（2）Dump

①nepressureoilflowsfromthepilotvalvetothepilotport（Pal）ofthebucketspooIsection・Thebuc spoolmovesinthedirectionindicatedbythearrowtothe一一dump‖position・ Note：Thebucketspoolmovesproportionatelywiththeoilpressureatthepilotport・

②whenthebucketspoolisinthe一▼dump position，theneutralpassageisclosedbythespooIsothatt pressureoilflowspastthehigh−preSSureOilpassage，forcingtheloadcheckvalveopen，andent bucketcylinderrodsidefromtheportAl・

③TheoilbrcedoutofthetailsideofthebucketcylinderflowspasttheportBlandlow−PreSSure PaSSage，backtotheoiltank・

Theoilforcedoutofthepilotport（Pbl）duetothemovementofthespoolreturnstothepilotvalve・

●

● ■−SpooIshiftingdirection ・fl−−Pilotpressureflow

←Oilflowtocylinder くトーReturnoilflowfromcylinder

Fig．7．10DumplngOfBucket

−119−

3．Operatiomor丑00mSpool

（1）RaiseamdDoⅥⅦ neoilpassagearrangementintheboomspooIsectioniscompletelythesameasthatinthebucketspooI

SeCtionsothattheboomspooIsectionoperatesinthesamemannerasthebucketspooIsection． The

raise

operationintheboomspooIsectioncorrespondstothe

andtheT downl tothe

roll−back

inthebucketspooIsection

dump：

Note：SincethemainvalvehasthetandemcircuitinwhichthebucketlinetakesprlOrltyOVertheotherone， thepressureoilisnotsuppliedtotheboomspooIsectionunlessthebucketspoolisinneutral（Orthe boomwon toperate）・

（2）Floating ①meboomspool，withastrokedifftrentfromthatofthebucketspool，hasitsfloatingpositionfurther downthe

down position．

Whentheboomspoolisin

floating一

，theneutralpassageisopenedsothatthepressureoilflowsin

samemannerasinneutral．

②Sincethecylinderports（A2）and（B2）arecommunicatedwitheachotherthroughthelow−preSSureOi passage，theboomsdropbytheirownweightandcanfreelyundulatealongupsanddownsontheground・

●

−120−

7．3，2 PILOTVALVE

Thepilotvalveisastacked2−SpOOIslidingtypeconsistingoftwovalvebodyassembliesconstructedbytwo tierodbolts．

Whentheloadinglever（boomorbucketlever）ismanipulated，theplungerinthepilotvalveisshift

changetheoilpassagesofthepressureoilsentfromtheassistpumptoselectivelysendthepressureoiltothe Pilotportinthemainvalve，tlmscauslngthespooltoactuate・

Eachpilotvalveplungerisprovidedwithasolenoiddetentmechanism・Whentheboomplungerisshifte tothe raise

or． float orwhenthebucketisshiftedtothe17roll−back

position，the、Plungerisheldinposition

duetothesolenoiddetentmechanismsothattheloadingleverwon treturntoneutralifthehandisremov fromthelever． Whentheleverisinotherpositions，ltWillreturntoneutralwhenthehandisremovedfromit・

●

AI BI

A2 B2

（BUCKEl〕

T

（BOOM）

Fig．7．11PilotValve

−121−

●

●

1．NUT

8．SPRINGPIN

15．PIN

2．LINKASSEMBLY

9．SPRING

16．SI〉ACER

3．ADJUSTER

lO．SHUTTLE

17．BOOT

4．pLATE

ll．VALVEBODY

18．PLATE

5．COILTUBEASSEMBLY

12．TUBEASSEMBLY

19．

6．PLUNGERASSEMBLY

13．STEELBALL

7．SPRINGSEAT

14．SOCKETHEADBOLT

Fig・7・12StructureofValveBodyAssembly（fbrBucket）

−122−

0

−RING

1 2 2 2

●

●

1．NUT

9．SPRINGSEAT

17．STEELBALL

2．LINKASSEMBLY

lO．SPRINGSEAT

18．SOCKETHEADBOLT

3．ADJUSTER

ll．SPRINGPIN

19．二PIN

4．PLATE

12．SPRING

20．SPACER

5．COILTUBEASSEMBLY

13．SHUTTLE

21．BOOT

6．PLUNGERASSEMBLY

14．VALVEBODY

22．PLATE

7．SPRINGSEAT

15．COILTUBEASSEMBLY

8．SPRING

16．PLUNGERASSEMBLY

Fig．7．13StructureofValvebodyAssembly（fbrBooms）

ー123−

Operation ThepilotvalveconsistsoftwovalvebodyassemblieswhoseoperatlngprlnCiplesarebasical1ythesame．Each Valvebodyassemblyhastwodischargeports（A，B）communicatedtothemainvalvepilotport． Thevalvebodyassemblybroperatingtheboomspoolhasthepumpport（P）andthepumpportoilpassage， andtheoneforoperatingthebucketspoolhasthetankport（T）andtankportoilpassage．

nepilotvalveoperationisdividedintotwoparts：theoneofthehydraulicpressureregulatingsectionand theoneofthesolenoiddetentsection．

l．OperationofIIydraulicPressureRegulating Section （1）NeⅦtral

① Whentheloadingleveris neutral一 ，thepressure

Oilfromthepumpport（P）isblockedoffbythe shuttle．

②Thedischargeport（OUT）iscommunicatedto the tank port（T）through the center of the Shuttle，SOthatnooilpressureisappliedtothe mainvalvepilotport・

Fig．7．14InNeutral

−124−

（2）Operation ①Astheloadingleverisshiftedfromthe 一neutral POSition，theplunger（2），plate（3），andplunger（4） arepushedin bytheplate（1）to compress the Spring（5）・

（∋Theshuttle（7）isshifteddownwardbythebrceof thespring（5）throughthespringseat（6）・ ③Asthe shuttle（7）shifts，the circuit from the discharge port（OUT）to the pump port（P）is

Openedwhilethecircuittothetankport（T）is closed．

④The pressureoilfromthe pumpport（P）flows through theinside of the shuttle（7），PaSt the dischargeport（OUT），tOthemainvalvepilotport・

O When a load is applied on the circuit of the dischargeport（OUT），theshuttle（7）receivesan upwardk）rCe（loadinPreSSureplusreturnspring （8） sbrce）actsontheshuttle（7）andadownward brce（Spring（5） sforce）・

⑥whentheloadingpressure（＝SPring（5）

sbrce−

returnspring（8） sk）rCe）exceeds，theshuttle（7）

Shifts upward，thus blocking offthe oilpassage from the pump port（P）to the discharge port

（OUT）toregulatethehydraulicpressureinthe circuit．

neoilpressureatthedischargeport（OUT）is PrOpOrtionaltothedistancetheplungerispushed

●

in，Ortheangleoftheloadinglever・ Fig．7．150peration

⑦Astheloadingleverisfurthershiftedtothestrokeend，theplunger（4）directlypushestheshuttle（7）s thattheoilpressureatthepumpport（P）andtheoneatthedischargeport（OUT）becomesequal・ ⑧whentheloadingleverisreturnedto neutral

position，theshuttle（7）isreturnedbytheloadingpressure

plusthereturnspring（8），thusblockingofftheoilpassagefromthedischargeport（OUT）tothe POrt（P），Whileopeningtheoilpassagetothetankport（T）・

−125−

（3） YFeel

position（Fig．7．16）

①Astheboomleverispushedforwardnearthestrokeend，theplunger（4）contactstheshuttle（7）whi thespringseats（9）and（10）contactseachother・

②Theplate（1）receivestheforceofthespring（11），thusmakingtheoperatingfteloftheleverdiff thanbefore． nispositionmeansthe

floating

positionoftheboomlever・

2・OperationofSolenoidI）etent（Fig・7・17）

①Astheplate（1）tilts，theplunger（2

）andplate（3

）attheoppositesidemovesupwardduetothespring

（12）・

②whentheloadingleverisshiftedtothestrokeend，theplate（3

）isattractedtotheoilassembly（13）．

Thisstateiscalled MdetentholdT ．

Atthistime，thedischargeport（OUT）isopenedtothepumpport（P）sothattheoilpressuresatbot

portsbecomesequalandthisstateisheld．

●

Fig・7・170perationofSolenoidDetent

Fig．7．16 Feel tPosition

−126一

7．4 VALVE CONTROLS 1 2

Note：（Pipingbetweenmainvalveandpilot Valve）

Tagtheendsofthehosesinadvance・ 二＝ Front ofthe10ader

① PしOT VALVE

MAIN VALVE

⑨

1．BOOMLEVER

3．PILOTVALVE

6．RELIEFVALVE

（DOWN−SHIFrSWITCH） 4・STOPVALVE 7・BOOMCYLINDERTAlL−SIDEPIPING 2．BUCKETLEVER

5．ASSISTPUMP

8．MAlNVALVE

Fig．7．18ValveControIs ＿127−

7．4．1GENERALDE＄CRIPT］ON

ThevalvecontroIsystemadoptsapilotoperationcontrolmethod．

TYlelargertheloaderbecomes，thelargerthehydraulicequlPmentisneeded・SincethequantltyOfoi

PaSSlngthecontroIvalvebecomesasgreatasaftwhundredlitersperminute，largespooIsarerequiredto Changetheoilpassages，andaccordinglyalargek）rCeisneededtooperatesuchlargespooIs・ Toreducethevalveoperatingbrce，thepilotoperationcontrolmethodisused．

Inthepilotoperationcontrolmethod，thepilotvalveiscombinedwiththemainvalve，WhosespooIsar

Operatedbytheoilpressuresentfromthepilotvalvetochangetheoilpassagesinthemainvalve・

ThevalvecontroIsystemconsistsofthepilotvalve，loadinglevers（boomleverandbucketlever），reliefva

andstopvalve． Note：Forthepilotvalve，See

7．3VALVE．

▲Thesa叫de血ヤrthevalvecontro］ 野Stem，aStOpValvelSprOVided． Ⅵ職em仙eloadingworkis二nOtperbmed，

theknoborthestopvalvesho山dbep山1ed OⅦt．

Thisk恍pSthemaimYalveinneutraleYem if theleveris umintentionally shifted， PreVentingtheloadingmeanshmmovlng

aecidently． Fig・7・，StopValve（Knob）

−128−

7．4．2 SYSTEM OPERAT10N

l．OperationUnderNormalCoTldition

nespooIsectionsofthemainvalvehavepilotports（Pal，Pa2，PblandPb2）attheirbothends，reSPeCtively Thesepilotportsarecommunicatedwiththeirrespectivepilotvalvedischargeports（B2，Bl，A2，andAl）・

Whentheloadingleverisshifted，theoilpassagesinthepilotvalvearechanged，thepressureoilfl throughtheselecteddischargeporttothepilotportofthemainvalve，thusmovlngthespool・

AsthespooIshiftsinthemainvalve，theoilistbrcedoutoftheoppositepilotportflowstothepilotvalve andreturnstotheoiltank．

Hydraulic Control Method Thepilotoperationcontrolishydraulicallycontrolled・

Astheloadingleverisshifted，theoilpressureatthedischargeportofthepilotvalveincreases，t Valvespoolmovesfurtherasthepilotoilpressureincreases・

●

Therebre，thespeedoftheloadingmeansincreasesordecreasesproportionatelywiththeshiftingangleof the loading lever.

●

to OILTANK

from ASSIST PUMP toOILTANK

Fig．7．20HydraulicCircuitDiagramofValveControISystem

−129−

2．IJOWenngOfBoomswithEnginenotRunnlng

Whentheenglneisnotrunnlng，theassistpumpalsostopsoperation，deliverlngnOOilpressuretothe

Valve．Ifnooilpressureisdeliveredtothepilotvalve，1tWillbenotpossibletolowertheboomsbecaus

mainvalveisinoperative．

Tomakeitpossibletolowertheboomswhentheenglneisnotrunnlng，however，theloaderhasthepressu

Oilattheboomcylindertailbranchedthroughthereliefvalvetothepilotvalve．

Thatis，Whentheenglneisnotrunnlng，thepressureoilattheboomcylindertailispressurereducedb

reliefvalvetothespecinedpressureanddirectedtothepilotvalve．

Ifthepilotvalveoperates，thepressureoilfromthepilotvalveshiftsthespoolinthemainvalve，th

makingltPOSSibletolowerthebooms． 3．Sa飴けDeYice

Thestopvalveisprovidedatthesuctionsideofthepilotvalve． Whenthestopvalveknobispulledout，thestopvalveshutsofftheflowofoiltothepilotvalvesothatno PreSSureOilisdeliveredfromthepilotvalvetothemainvalveeveniftheloadingleverisunintentiona11y Shifted・（Thispreventstheloadingmeansfromoperatingaccidentally・）

BeforetrylngtOdoloadingoperation，besuretopushinthestopvalveknob．

●

−130−

7．4．3 RELIEFVALVE

Thereliefvalve，PrOVidedinthepilothydrauliccircuit，doublesasareliefvalveandareducingvalve・ Asthereliefvalve，1tregulatesthepressureofoildeliveredtothepilotvalve・

Asareducingvalve，itreducestheprlmaryPreSSuretOthesecondarypressure，OrCOnVertSthepress

attheboomcylindertailintothepilotvalvehydraulicpressure，keeplngthesecondarypressurealwaysconstant regardlessofwhethertheprlmaryPreSSurefluctuates・ Note：D＞ぢ：：：：：：コ6−7kg−m（43−51fLlbs） 医＞ぢ＝コ2・8−3・2kg−m（20−23札」bs） 臣＝＞ぢ：：：：コ5−5・5kg−m（36−40侶bs）

3 4

匡＝＞2 1

5 6 7 8

9

PoTANK）（fromPUMP）

l

灯「OmBOOMCYuNDER）

「 −

‖ 」

し 「 ‖ c」せ

（toVALVE）

Reliefvalvepressuresetting：36±3kgkm2（510±40psi）

Reducingvalveper飲）rmanCe：Primaryside（Pc）maximumpressure250kg／cm2（3600psi） Secondaryside（Pp）generatingpressure：15±3・5kgkm2（210±50psi）

1．VALVEHOUSING

4．SPRING

7．SI）RING

2．RELIEFVALVEASSEMBLY

5．SPRING

8．SPRING PIN

3．POPPET（CHECKVALVE）

6・SPRINGSEAT

9．SHUTTLE

Fig．7．21ReliefValve

ー131−

7．4．4 STOPVAい／E

ThestopvalvecontroIsthedeliveryofpressureoiltothepilotvalve． Whenthestopvalveknobispulledout，theoilpassageleadingtothepilotvalveisblockedofftoprevent

thepressureoilfromfl0wingtothepilotvalve． Whenthestopvalveknobispushedin，theoilpassageopenstoallowtheflowofoiltothepilotvalve・

ThestopvalveisprovidedwiththedetentmechanismwhichholdseachspooIposition． Thestopvalveconsistsofthehouslng，SPOOl，anddetentmechanism．

Note：ぢ＝＝コMountingbolt： 4−5．3kg−m （29−38虹1bs）

1．PIN 2．CAp 3．COLLAR 4．SEALPLATE 5．HOUSING 6．

0− −RING

7．WIPER 8．SLEEVE 9．SPRING lO．BALL ll．SPOOL 12．KNOB

Fig．7・22StopValve

ー132−

7．5 01LTANK Steel−Plateweldedtype

Type Oiltankcapaclty Weight

85ゼ

Returnnlter

1pc・

196kg（excludingaccessories）

Cap working pressure Pressurevalve

0．4−0．6kがm2

Vent valve

（negativepressure）0・04rO・05kgkm2

neoiltankholdshydraulicoilforthemaln，Pilot，andsteeringhydrauliccircuits・

TbereturnlngOilsfromthehydrauliccircuitsmlnglewitheachotherintoaslngleflowanditisled，PaSt

●

throughthereturnⅢter，1ntOtheoiltank・

Thereturnnlterislocatedinsidetheoiltank．WhenthereturnBlterbecomesplugged，thepressureo returnoilactsontheBltertoshiftit，SOthattheoilbypassesthenltertotheoiltank．

Theoiltankisanenclosed，PreSSurizedtype・Thepressureinsidethetankisregulatedbythecaptop

thedevelopmentofpumpcavitationandtheentryofdustintothetank・ Theoiltankislocatedontherightsideoftherearframe．

●

ー133−

Note‥臣＝＞ぢ：：：：コ16．7kg−m（120氏」bs）

E＞14＝ゝらThreadedarea：LOCTITE572 1．SUPPORTPLATE

6．CAP

11．COVERPLATE

2．SPRING

7．nLTER

12．MAGNET

3．SPRINGRETAlNER

8．OVERFLOWHOSE

13．

4． −0− −RING

9．0ILTANK

14．COVERPLATE

5．RETURN FILTER

lO．OILGAUGE

15．DRAlNPLUG

Fig．7．230ilTank

−134−

0

−RING

8．LOADING SYSTEM Theloadingsystemisoperatedbythehydrauliccylindersfordigging，loading，andtransportlngloads・

nelinkageemployedfbrtheloadingsystemisaninverseZ−Shapetypewhichissimplerindesignother duplexlinkagesandafbrdsmorepowerbucketliftingk）rCe・

Fig．8．1IJOadingSystem

−135−

8．1BOOM，BUCKETANDBELLCRANK Linkage type

Z−Shape

BucketlⅥ）e

Double−edgedbucket

Bucketcapacity Heaped Struck Bucket leveler Boom kickout

3．3m3 2．9m3 Provided，nOn−COntaCttype Provided，nOn−COntaCttyPe

Weight Boom

llso kg

Bellcrank

300 kg

Pushrod Bucket

63 kg 1680kg（withdoubleedge）

8．1．1GENERALDESCRIPT］ON

Theloadingsystemconsistsofthebooms，bellcrank，puShrod，bucket，bucketcylinder，boomcylin

PlnStOmOuntlngthesecomponents・

Formoree租cientloadingoperation，theloaderisequlPPedwiththebucketlevelerandboomkick

mechanism．

AllconnectingplnSOftheloadingsystemhavedustsealstopreventtheentranceofwater，mudordustinto thesystem．珊econnectingpinsfbrthebucketareprovidedwith170

−rings・

●

−136−

1

1

1

0

一一∴∴l、 ●

1．BOOM

7．STOP BLOCK

13．SPACER（t＝2．3mm）

2．BUCKETCYLINDE

8．DUSTSEAL

3．BELLCRANK

9．BUSHING

14．BUSHING 15．DUSTSEAL

4．PUSHROD

lO．SPACER（t＝2・3mm）

16．SPACER（t＝1・6mm）

5．BOOM CYLINDER

11．PIN

17．− 0 −−RING

6．BUCKET

12．BUSHING

18．PIN

Fig．8．2Boom，Bucket，andBellcrank

−137−

（Boomathighestposi（ion）

駐＝＞8

3

Fl

（Boomin carry position

Note：駐＝＞Extendthebucketcylindertoitsstrokeendandcontractit5mmbebregaugewelding．

Note：〆＝＝袖Bushinginnersurface，dustseal，boss：Grease（bebreinstallingpins．） 1．BUCKET

4．BOOM

7．FRONTFRAME

2．PUSHROD

5．BUCKETCYLINDER

8．STOPBLOCK

3．BELLCRANK

6．BOOMCYLINDER Fig・8・3AssembledViewofLoadingSystem（1佗）

−138−

1 2 3 CrossSectionalViewC−C

CrossSectionalView F−F

CrossSectionalView D−D

CrossSectionalViewG−G

7 8＜＝司

CrossSectionalView H

1．PIN 2．DUSTSEAL 3．BUSHING 4．GREASEFITTING 5．SPACER（t＝2・3mm）

CrossSectionalViewJ−J

7．−−0

Cross SectionalView E−E

CrossSectionalView H−H

7 8＜司

CrossSectiona暮ViewK−K

−RING

8．SPACER（t＝1・6mm）

Note‥駐＞Maximumspacモng：1essthan2・5mm（SPaCeradjustment） 匡＞Maximumspaclng：1essthanl・5mm（SPaCeradjustment）

6．SPACER（t＝2・3mm）

Fig．＄．4AssembledViewofIJOadingSystem（2／2） −139一

8．1．2 BUCKETLEVELERANDBOOMK］CKOUT

l．BucketLeYeler ThebucketlevelerisarmedwhenthebucketleverlSplacedintheroll−backpositionaftertiltingthebucket

fbrward・Whenthebucketbecomelevelfromthedumpposition，thebucketlevelerautomaticallyshiftst bucketleverintoneutral，thuskeeplngthebucketatthehorizontalposition・

ThebucketlevelerconsistsofthelevelerbarmountedtothebucketcylinderrodandtheproximltySWitch

mountedtothecylindertube・neprOXimityswitchiswiredtothedetentsolenoid（bucketlevelersoleno 良）rthepilotvalvebucketsection．

Note：圧＞ぢ＝コ5．1kg−m（37糾bs） 1．BUCKETCYLINDER

6．FRONTFRAME

2．LEVELERBAR

7．BRACKET

3．BRACKET

8．LEVELPLATE

4・PROXIMITYSWITCH（FORBUCKETLEVELER） 5・PROXIMITYSWITCH（FORBOOMKICKOUT）

9．BOOM

Fig．＄．5BucketLevelerandBoomKickout

−140−

Operation

①whenthebuckettiltshrwardfromthehorizontalposition，thesensingsurfaceofthebucketl

PrOXimityswitchissoclosetothelevelerbarthattheswitchisinON・

Whenthebucketleverisshiftedintotheroll−backposition，theleverisheldatthatpositionbyoperation Ofthebucketlevelersolenoidofthepilotvalve・

（∋Asthebucketrollsback，thebucketcylinderpistonrodextends・Whenthebucketbecomeslevel，t levelerbarleavesofftheproximltySWitchsens1ngSurface，thusturnlngtheswitchOFF・

③ThepilotvalvebucketlevelersolenoidisdeTenergizedsothatthebucketleverdisengagesitselffro detenttoreturntoneutral．Thebucketstopstiltingandstandsatthehorizontalposition・

Note：SincethebucketlevelerproximltySWitchisinOFFwhenthebucketrollsbackfromthehorizontal position，thebucketleverroll−backpositiondetentdoesnotwork・

ingdistance：1essthan7mm

﹂

●

﹁−−t−−■一一−■一■

Standardoperat− Detection： Whendetected，LEDcomesON．

＿＿＿＿＿＿＿＿−＿＿」

Output： Outputcircuit

Whenobjectcomescloseto SWitch，OutPuttranSistorturnsON．

Fig．8．6ProximitySwitch

−141−

2．B00m Kickout

neboomkickoutisdesignatedtostopthebucketatapresetheight． Whentheboomsareraisedtoapresetheightwiththeboomleverin．一raise，一，theboomleverautomatically returnstoneutral，therebystopplngtheliftingofthebooms・

TheboomkickoutconsistsofthelevelplatemountedtotheboomsandtheproximltySWitchmountedto

thefrontframe・Theproximityswitchiswiredtothedetentsolenoid（boomkickoutsolenoid）ofthepil valveboomsection．

Operation

①whentheboomsarelowerthanthepresetboomkickoutheight，thesensingsurfaceoftheboomkic PrOXimityswitchissoclosetothelevelplatethattheswitchisinON． Whentheboomleverisplacedintheraiseposition，theboomleverisheldatthatpositionbyoperation Oftheboomkickoutsolenoidofthepilotvalve．

②whntheboomsareraisdtotheboomkickoutpresetheight，thelevelplateleavestheproximitys SenSlngSurface，thusturnlngtheswitchOFF．

●

③nepilotvalveboomkickoutsolenoidisde−energizedtodisengagetheboomleverfromthedetenttolet itreturntoneutral・neboomsstopsliftingandisheldatthepresetposition．

Note：Whentheboomsarehigherthantheboomkickoutheight，theboomkickoutproximltySWitchisOFF，

SOthattheboomleverraisepositiondetentdoesnotwork．

ー142−

8．1．3 BUCKET

Typelbucketisstandard・Type3bucketisalsoavailableasoption・

ItisnecessarytoselecttherightbucketbrthejobrequlrementS，1nCludingjobsite，loadstobehandled，a WOrkingconditions・

mEIBUCKET （doⅦble・edgedbucket） Note：距＞ぢ＝：：：コ198kg−m（1430托−1bs） 匡＞ぢ：：：：コ109kg−m（788托−1bs）

mE3BUCKET Note：臣＞ぢ：＝＝コ198kg−m（1430丘−1bs）

駐＝＞ぢ＝コ109kg−m（788鋸bs）

mE3丑UCKET （Witbspaceedge）

Note：B＞ぢ＝：コ198kg−m（1430ft−1bs） 医＞ぢ＝：：：コ109kg−m（788nJbs）

Fig．＄．7Bucket ＿143−

8．2 CYLJNDERS Boomcylinder

Type

Double−aCtlngPIStOn

Q ty

2

Cylinderstroke

930 mm

Weight（OneCylinder）

approx．146kg

Bucketcylinder

Type

Double−aCtlngPiston

Q ty

1

Cylinderstroke

550 mm

Weight

approx．174kg

l．BoomCylinder

Theloaderisequlppedwithtwoboomcylindersofdouble−aCtlngpistontype・Whencontracted，theboo

CylinderrocksaroundtheconnectlngPlnatthecylindertail，ralSlngOrlowerlngthebooms・

Theboomcylinderconsistsofthecylindertube，Cylinderhead，Pistonrod，Pistonandpackings． 2．もⅦCketCylinder

nebucketcylinderisadouble−aCtingpIStOntyPe・Whencontracted，thebucketcylinderdumpsorroll

thebucketthroughthebellcrankandthepushrod・ nebucketcylinderconsistsofthecylindertube，Cylinderhead，pistonrod，Piston，andpackings・

●

ー144−

3 4 8 9

1213141516＜司

1011

＿」

匡＞1718

5 6 7

View100kingfromZ

Detail of inside

● Notes；臣ぢ＝コ45・1±8・4kg−m（326±61糾bs）匪ぢ：：：：：コ5・22±0・98k㌢m（37・7±7・川血）

B＞ぢ：：：：コ3．21±0・6kg−m（23・2±4・3ft−1bs）B＞ぢ＝コ362kg−m（2620ft−1bs） 匝＞ぢ＝：：コ5・80±1・09kg−m（41・9±7・9fLlbs）（Aftertightening，PunChtwopoints・） 1．PINBUSHING

7．BUSHING

13．SLIDERING

2．WIPERRING

8．U−RINGANDBACK−UP

14．SEALRINGAND

3．CYLINDERHEAD

RING

RING 9．BUFFERRING

15．SHIM

RING

lO．CYLINDERTUBE

16．SETSCREW

5．WIPERRING

ll．PISTONROD

17．NUT

6．SNAPRING

12．PISTON

18．STEELBALL

4．一一0‖−RINGANDBACK−UP

Fig．8．8BoomCylinder

−145−

70

一

ViewfookingfromX−X

3 4 8 9

1011

5 6 7

Detait。fi。Side

1213141516＜＝：司

駐＝＞1718

』＞X

Notes：F＞ぢ＝コ116±21kg−m（839±152ft−1bs）医＞ぢ：：：：コ3．21±0．6kg−m（23．2±4．3ft−1bs） 匡＞ぢ：：：：：コ9．42±1．76kg−m（68．1±12．7ft−1bs）B＞（忘＝コ1416kg−m（10240ft−1bs） 匠＞ぢ：＝：コ5．80±1．09kg−m（41．9±7．9fLlbs）（Aftertightening，PunChtwopoints．） 1．PINBUSHING

7．BUSHING

13．SLIDERING

2．WIPER RING

8．U−RINGANDBACK−UP

14．SEALRINGANDf−0一一一RING

3．CYLINDERHEAD

RING

15．SHIM

9．BUFFER RING

16．SETSCREW

RING

lO．CYLINDERTUBE

17．NUT

5．WIPERRING

ll．PISTONRING

18．STEELBALL

6．SNAP RING

12．PISTON

4．．．0

一−RINGAND BACK−UP

Fig．＄．9BucketCylinder

−146−

9．ELECTRIC SYSTEM 9．1uGHTING EQUIPMENT Name

Specincation Q ty

Remarks

Headlights

24V 85／65W

2 Sealedbeamtype

Auxiliary head lights

24V 70W

2 （Spec・WithROPScab：OnrOOftop）Sealedbeamtype

Clearancelamps

24V 5W

2

Turnsignals（front）

24V 25W

2

24V 25／10W

2

Front combination lamps

Stoplamps Taillamps

Rearcombinationlamps

Back−uplamps

24V 25W

2

Turnsignals（rear）

24V 25W

2

Rear work lamps

24V 70W

2 Sealedbeamtype

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−147−

9．2 0PERATING STATUS MONJTORING SYSTEM TheoperatlngStatuSmOnitoringsystemmonitorstheloaderoperatingstatuswiththesensorsandswitches instal1edontheloaderanddisplaystheinbrmationontheinstrumentpanelinthecompartmenttoinfbrmthe OPeratOrOfthecurrentoperatlngStatuSOftheloader． Theoperatingstatusoftheloaderisdisplayedbyacombinationoftheclustergaugeunitandmonitorlamps

（andawarninglamp）whichindicateswhethereachsystemisoperatingproperly・ 1．ClusterGaugeUnit A B

C D E F

（tnternalwiringdiagram）

A．SPEEDOMETER B．WORKLIGHT INDICATION LAMP C．FUELMETER D．ENGINE OILPRESSURE E．HOURMETER F．BRAKEAIR PRESSURE GAUGE

No．

Connectedto

No．

Connectedto

口 （＋）24V

7 N．C

2 Worklightswitch

8 （＋）24V

3 Lightswitch（brSM）

9 Engine oil pressure sensor

4

Grounding（brSMlight）

10

Airpressuresensor

田 Lightingswitch

6 Hourmeter（−）

Fig．9．1ClusterGaugeUnit

ー148−

12 Grounding

Engineoilpressuregauge

BrakeairpressⅦregaⅦge

FⅦelmeter

kgkm2（psi）

kg／cm2（PSi）

Red

棄F Measurement 1k〆cm2J 8kg尤m2† Measurement 4．2kgたm2J 8．5kgたm2† Measurement point

（14psi）

Standardvalue 66．1n

（110psi） Pint 17．3【1

（60psi）

Standardvallle

36．9n

（120psi） poinl

15．3n Standardvalue

EJ

F†

80Jl

10Jl

Fig．，．2Meters

Table9．1Specincationsandlocationsofsensors Name

Specification

Application

Pressure

Workingpressurekgkm2（PSi）

1（14）

6（85）

Rightsideof

66．1

26．4

englne

Sendingunit Pressure Sendingunit

Workingpressurekgkm2（PSi）

Fuel level

Floatposition

Sendingunit Fuelmeter

Resistance（2

一149−

IJOCation

0

5（71）

10（140） Leftbrake

80

32

valve

E

1／2

80

32

F Insidefuel tank 10

2．MomitorLamps（WarningLamp）

Theloaderisprovidedwith8monitorlampswhichmonitorsthecurrentoperatingstatusoftheloaderand onewarnlnglampfbr．．englneStOP・

IfanyofthebllowlngCOnditionsoccurs，thecorrespondinglampwillblink・ DescriptlOn

Name

Engineoilpressure drops below specified level:

Enginestop

0．5kg／cm2（7psi）

匝巨

abovespecined r。

旺惇

田

1evel：1100C

nt abovespec泊ed 1evel：1058C

・

・・一

匝】Batte叩1tage

belowspeciBed VOltage below specified preSSure：

◎喜怒re

4．2kg尤m2 （60psi）

匝】Brakeoi11evel belowspecined 1evel

園 地r 巨〕 Fig．9．3MonitorLamps

−150−

parkingbrake

Whenclogged

When parking brakeisapplied

Tab）e，．2Specincationsandlocationsofswitches（SenSOrS） Name

Oil pressure switch mermosensor Thermosensor

IJOCation

Workingpressure‥0・5±0・1kg／cm2

Enginestop

（7・1±1・4psi）

Rightsideofenglne

（Turnsonatatmosphericpressure） Brake oil temperature

Temp．

OC 20 40 80 JLeftbrakehouslngOfrear axle E2 2470 1150 310

Resistance

Engine coolant

Enginewatermanibld

temperature

Tbermosensor

Converter oil temperature

IJOW−preSSure

Air pressure

switch

SpeciBcations

Applications

Rightsideoftorque COnVerter

OFF：5．2±0．3kg／cm2（74±4psi）

ON：4．2±0．3kdcm2（60±4psi）

（brake）

（Turnsonatatmosphericpressure）

Levelswitch

Brake oil level

Turnsonbelowstandardlevel

Indicator

Aircleaner

exceeds 635 mmH20. （Turnsoffatatmosphericpressure）

Insidebrakeoilreservoir

Turnsonwhennegativepressure

Low pressure switch

Parkingbrake

OFF：1．2±0．3kg／cm2（17±4psi） ON：0．5±0．3kg／cm2（7±4psi） T （urnsonatatmosphericpressure）

＿151−

Aircleaner

3．MonitorControIBox necontrolboxsupplieselectricpowertothemonitorlampsanddetectsthesignalfromeachsensorand SWitch，1ettlngthemonitorlampsturnon．

C B A

Connectiondiagram

由

D F Empty f d

（Sensorside）

J K

￠

J

（bmpside）

Empty h

a b g

与＝二

e3）（Powersourceside）

Coupler terminals （C10S8SWhentestswi（Chispressed．）

（C10SeSWhenparkin9brakeairpressuredropsbe10WO．5kg／Cm2Ppsり．） （C10SeSWhenaircleanernegath，ePreSSUreeXCeeds635mmH20） （C10S8SWhenbrakeoiIleveldropsbe10WSP8C粥edleveL） （CIosesbe10W24Ⅵ （C10SeSWhenconvertcroiltemperaturerisesabove1200C，）

（OpenswhenbrakeoiltemperaturerisesabovellOn．＊Lamp暮ights．） （C10SeSWhenradiatorc00lanttemperaturerisesabovelO50C，） （C）oseswhenbrakeairpressuredropsbeIow4．2kg／cmZ（60psO．）

（C［oseswhenengineoilpressuredropsbeIowO，5kg／cm2Ppsi）．） ＿

Note：＊Thereisaninversioncircuitatthecircledareainbrakeoiltemperaturecircuit・ Fig．9．4MonitorControIBox −152−

9．3 SWITCHES l．Starter Switch

Thestarterswitchhasfourpositions：ON，OFF，START，PREHEAT・ WhenthestarterswitchisplacedintheONposition，theelectriccircuitisconnected・Whenthestart switchisplacedintheOFFposition，theenglneStOpSOlenoidisenergizedtoshutofftheenglne・

Terminal

B BR ACC Rl R2 C

Position＼ PREHEAT OFF ON

START

（F「0nt）

（Rear）

Fig．9．5StarterSwitch

2．LightingSwit血

2

3

4

○

○

OFF ○

2ndstage

○

○

Fig．9．6LightingSwitch

−153−

3．TurnSignalSwitch Theturnslgnalswitchdoublesasthedimmerswitch．

Whentheleverispushupward，theheadlights，beamsbecomedim・Toreleasethedimmer，PuShtheswit up agaln・

（Turnsignalswitchconnectiontable） Connectedto

Flasher unit

TerminalNo．

6

L

TF O

L￡丘

（Dimmerswitchconnectiontable）

Right

Connectedto MAIN DIMMER BATT

5

TerminalNo．

OTL

DIMMER

N R

7

TF O

MAIN

OTL

Fig・9・7TurnSignalSwitch

ー154一

○

3

2

○

○ ○

9．4 ELECTRIC CIRCUIT DIAGRAM Front combination lamp

Rear combination lamp

Down−Shift box

JD E F G K C B AH

Transmission solenoidvalve

Parking brake low−PreSSureSW Rearworklight

Down−Shiftsw・，

License number

plate lamp （Option）

Pilot lamp （Option）

Stoplampsw

Back−upbuzzer Starter switch

Monitor sensor sw V

Alternator

E B

Monitorcontrolbox

nasher， parking

FE

Aircleaner

HJ

Parkingbrake

CD

AR︼

Engineoilpress・

Brakeoi11evel Converter oil temp.

Radiator coolant temp・

Brake oil temp.

Brake air Battery charge V K

Monitor test sW

Transmission

Monitorlamp

」 ＿ Starter motor

Monitor

（W／safetyrelay）

Bucket leveler

Oilpressure Airpressurebuzzer Oilpressuresensor

Rearworklight Cluster meter illuminationlamp

Air pressure SenSOr

Speedometer Rear work lightsw

Crosssectionalareaofcord Crosssectionalarea Symbol

Bucket leveler SOlemoid

Rearworklight indicatorlamp

60mnゼ

BatteIγ

Proximity switch Boom kickout SOlenoid

Boom

noat solenoid

Fig．9．＄ElectricCircuitDiagram −155＿

l

8mrrP 3mm2

0＿＿＿

1．25mrIゼ

○・・−・−−−−−・・・・・く〉

15mnゼ

l J

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No．SEW−669AE lSSUED：Janリ1993

TIYlllH■■H■l￠l．け川． TRADINGOFFICE：

15−5，1・Chome，Nishi−＄himba＄M，Minato−ku，Toky0105，Japan

TELEX：J・23991TCMTOK AFlrightsreserved

FAX：Japan3−35918152 0−0501040（F−168）

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