TCM L20-3 Wheel Loader Service Manual SEW-648CE - PDF DOWNLOAD

No．SEW−648CE

丁℃J明⑧ 至≡三「二●二3≡＝二三二＝こ二三＿＝

WHEJ：L LOADER

上〜1フ＿き

TCMCORPORAT［ON

No．SEW−648CE

FOREWORD TCMofftrsawidevarietyofwheelloaderswhichhavebeenenthusiasticallywelcomedbyusersallover

theworld・TCMModelL20−3，anarticulatedtypewheelloader，isthelatestproductdevelopedfromyea researchandexperience・Togetthemostoftheloader，itisrequiredthatyoubecomefamiliarwi ftatures，COnStruCtion，OPeratlngandmaintenanceprocedures・

ThisServiceManualexplainsthestructureoftheL20−3Wheelloaderforservicepersonnelandshop WOrkers．Wehopeitwillbeyourreferenceguideduringserviclngjobs・

Forstandardservicevaluesandtheprocedurefbrinspection，SeetheInspectionManualandbrtheprocedure brmaintalnlngeaChcomponentunit，SeetheShopManualoftheirrespectivecomponents・

ThedescrlPtlOnSandspecincationsdescribedinthismanualaresubjecttochangewithoutnotice・ July，2004

丁伽c。R，。RÅ，．。

ThisServiceManualappliestothefollowlngloader： L20＿3：＃03101andafter

No．SEW−648CE

（Emptypage）

No．SEW−648CE

TABLEOFCONTENTS l 1

0．SPECIFICAT］ONS 0．1 0UTERVIEWS

2

0．2 SPECIFICArIONS

5

1．ENGINEANDRELATEDCOMPONENTS

5

1．1 ENGINE

1

2 4

2

′0 0 1 02

2．POWERTRAIN

1

1．7 ENGINECONTROLUNIT

1

1．6 ELECTRICALSYSTEM

0

1．5 INTAKEANDEXHAUSTSYSTEM

1

l．4 FUELSYSTEM

1

1．3 COOLINGSYSTEM

0ノ

1．2 LUBRICArINGSYSTEM

2

2．2 TORQUECONVERTER

2

2．3 TRANSMISSION 2．3．1CLUTCHSHAFT 2．3．2 POWERFLOW 2．3．3 TRANSMISSIONCONTROLVALVE

2．4 0ILCIRCULArIONROUTE 2．5 PROPELLERSHAFTS

2．6 DRIVEAXLES（FRONTANDREAR） 2．6．1DRIVEAXLE 2．6．2 DIFFERENTIAL 2．6．3 FINALREDUCTIONGEAR

2．7 WHEELASSEMBLY（TIREANDWHEEL） 2．7．1TIRE 2．7．2 WHEEL

3．BRAKESYSTEM 3．1 SERVICEBRAKE

3．1．1GENERALDESCRIPTION（BRAKELINE） 3．1．2 BRAKEVAIJVE 3．1．3 SPLITCYLINDER

7 史U7 ︵X︶1 U 3 O 3 455 0′ノ 4 3 5 7 7 5 0070ノ んU ′0 ′0 ′ 07 77 7 7 7

2．3．5 AUTOMArICTRANSMISSION（ArM）［OPTION］

3

2．3．4 TRANSMISSIONCONTROL

73 03 0 3

2．1 DRIVEUNIT

No．SEW−648CE

3．1．5 0THERCOMPONENTS

0ノ

つJ

0ノ

2

3．1．4 DISKBRAKE

5

qノ

3．2 PARKINGBRAKE

0ノ

／LU

3．2．1GENERALDESCRIPTION（BRAKELINE） 3．2．2 PARKINGBRAKEVALVE

1 1 1 1 1 1

4．4 STEERINGVALVE（ORBITROL）

1

4．3 STEERINGWHEELUNIT

0 l 1 3 4 5 0 5

4．2 0ILCIRCULATIONROUTES

00 0 0 0 0 1 1

4．1GENERALDESCRIPTION

Oノ

4．STEERINGSYSTEM

0ノ

1

3．2．3 DISKBRAKE

4．5 PRIORITYVAINE

4．6 STEERINGCYLINDER l

1

7

1

l 1

1

7

5．FRAMEANDCOCKP［T 5．1FRAME

qノ

5．2 CENTERHINGEPIN

l

7

l l

0ノ つ﹂ 2 2 2 2 21 2 J7 つ J4 4 4 4 4 4 4 1 2 235 つ ′0 8J00つ4

7．2．1BOOMCYLINDER

4

7．2 CYLINDER

l

7．1．4 BOOMKICKOUT（OPTION）

0

7．1．3 BUCKETLEVELER

l

7．1．2 BUCKET

7

7．1．1GENERALDESCRIPTION

l

7．1BOOM，BELLCRANKANDBUCKET

7

7．LOADHANDLINGSYSTEM

l

6．5 0ILTANK

4

6．4 VAI二VECONTROLS

3

6．3．3 RELIEFVALVE

l

6．3．2 0PERATION

l

6．3．1GENERALDESCRIPTION

つJ

6．3 CONTROLVAINE

l

6．2．2 CHARGINGPUMP（BRAKEPUMP）

l

6．2．1MAINPUMP

l

6．2 PUMP

l

6．HYDRAUL］CSYSTEM 6．10ILCIRCULATIONROUTES（HYDRAULICCIRCUITDIAGRAM）

1 1 1 1 1

No．SEW−648CE

4 1

2

5

1

7．2．2 BUCKETCYLINDER 1

7．3 ANTI−PITCHINGSYSTEM（APS）［OPTION］

l

7

l

つJ

′んU

7

／んU U ／0 ∠U 7 7 7 7 7 1

史U 8

1

02 314

1

9．1．6 AIRCONDITIONERPIPING

つ﹂

9．1．5 CONDENSER

／LU

9．1．4 RECEIVERTANK

′0

9．1．3 COMPRESSOR

l

9．l．2 AIRCONDITIONERUNIT

l

9．1．10PERArINGPRINCIPLE

5

9．1 GENERALDESCRIPTION

1

9．AIRCONDmONER（OPT10N）

l

8．4 ELECTRICCIRCUITDIAGRAM

1

8．3 RELAYMOUNTINGLOCATION

5

8．2．3 TURNSIGNALSWITCH

00

l

8．2．2 LIGHTINGSWITCH

8

l

8．2．1MONITORLAMPS（CLUSTERGAUGEUNIT）

5

8．2 METERSANDSWITCHES

7

l

8．1LIGHTINGEQUIPMENT

5

8．ELECTRICSYSTEM

1 1 1 1 1

No．SEW−648CE

（Emptypage）

0．SPECIFICAT10NS

0．SPEC］FICAT10NS 0．10UTERVJEWS Unit：mm［in．］

︻寸．ト讐一望OS

Note：TheROPScabshownintheabovesketchesisoptlOnal．

Fig．0．10uterViews −1−

0．SPECIFICATIONS

0．2 SPECIFICAT10NS LoaderModel

L20−3，LXllO・7

Front−endarticulatedloaderwithdieselenglne

乃pe

Bucketcapacity，heaped

2．0［2．6］

m3［y3］

Breakoutforce，bucketcylinder

98．0（10000）［22050］

kN（kgf）【lbf］

SAEratedoperatlngload，fu11turn

3200［7056］

kg［1bs］

Risingtlme，fu11load

s

5．9

Lowerlngtlme

S

3．0

Bucketdumplngtlme

S

1．4

TYavelspeed，fwdlst

km／h［mph］

8．0［4．97］

fwd2nd

km几［mph］

13．5［8．39］

fwd3rd

km／h［mph］

21．5［13．36］

fwd4th

km／h［mph］

34．5［21．44］

revIst

km／h［mph］

8．5［5．28］

rev2nd

kmnl［mph］

14．5【9．01］

rev3rd

km／h［mph］

23．0［14．29］

rev4th

kmnl［mph］

35．0［21，75］

a, U ⊂d

．．L ∈

丘 l＿． q） h

Max．tractionforce

kN（kgf）［1bf］

Gradeability，fwdlst

250tilt

Minimumtumingradius outermostpartofbucket mm［in．］

Overal11ength，

Overallwidth， （′）

○ ！＝

99、0（10100）［73050］

5720［225．2］

CenterOfoutermostwheelmm［in．］

4990［196．5］

bucketonground

mm［in．］

6750［265．7］

incarryposition

mm［in．］

6715［264．4］

loaderbody

mm［in．］

2410［94．9］

bucket

mm［in．］

2480［97．6］

mm［in．］

3050［120．1］

mm［in．］

5015［197．4］

mm［in．］

2900［114．2】

frontwheels

mm［in．］

1960【77．2］

rearwheels

mm［in．］

1960［77．2］

●

1＝ U

Overallheight，tailpipe

∈

云 Overalloperatingheight，bucketfullyraised

Wheelbase Tread，

−2−

0．SPECIFJCAT10NS

RearOVerhangangle

O

12

Min．groundclearance，Centerhingepln

mm［in・］

400［15．7】

Buckethingepinheight

mm［in・］

3715［146．3］

○ ●蒜 ⊂ Dumpingheight，at450dischargeangle

mm［in・］

2760［108．7］

∈

mm［in．］

1070［42．1］

‡＝

q）

Reach，at450dischargeangle Bucketroll−backangle，incarryposition

Bucketdumplngangle，bucketfullyraised TbwlngPinheight

50

O

48

mm［in．］

1040［40．9］

kg［lbs］

9450［20840］

WithROPScab（OPtion）

9940［21920】

＋■〉 ，．⊂：

b月 WeightofLoader

ざ

O

−3−

0．SPECIFICAT10NS

NOTE

−4−

1．ENGINEANDRELATEDCOMPONENTS

1．ENGINEANDRELATEDCOMPONENTS 1．1ENGINE l．GeneraIDe＄Cription

TheenglnemOuntedonthisloaderisa4−CyCle，Water−COOled，OVerhead−Valve，in−1inedirect，1nJeCti typedieselenglne・TheenglneisequlPPedwithaturbocharger・ Theenglneismountedattherearoftheloaderanditspoweristransmittedthroughtheflywheelandplate intothetorqueconverter・

−5一

1．ENGINEAND RELATEDCOMPONENTS

ISUZU BB−6BGIT DieselEngine 4−CyCle，Water−COOled，OVerhead−Valve，in−1inevertical，direcト

1It）eCtiontypewithturbocharger Numberofcylinders−borexstroke

6−105mm［4．13in．］x125mm［4．92in．］

Total displacement

6．494L［396．3in．3］

Compression ratio

17．5

Engineperformance Ratedspeed

2200 rpm

Ratedoutput

96kW（130PSi

Maximumtorque

471N−m（48kgf−m）［3471bf−ft］（atapprox．1600rpm）

Full−loadmin．fuelconsumptionratio242g／kWhi177g車Sh）（at1800rpm）

Dry weight

About533kg［11801bs］

Dimensions（overalllengthx OVerallwidthxoverallheight）

1185mmx732mmx1324．5mm［46．65in．x28．82in．x52．15in．

Firing order

1−5−3−6−2−4

Rotational direction

Clockwisewhenviewedfromcoolingfhn

Starting aid

Quickglowplug

Stopping system

Key switch type

Unloadedmax．speed （Whenseparatelymeasured）

2470rpmorless

Unloadedmin．speed （whenseparatelymeasured）

A1lowabletiltingangle

800二言0叩m

300infrontandreardirectionsand250inrightandleft

directionswhenviewed丘■Omflywheel Maintenancedata Valveopenlngandclosingtlme

Valve clearance

Open

Closed

Intakevalve 190beforeTDC

470afterBDC

Exhaustvalve 570beforeBDC

150afterTDC

Intakevalve（COld）：0．4mm［0．016in．］

Exhaustvalve（COld）：0．4mm［0．016in．］ Injection timing

90beforeTDC

Idectionstartpressure

18．1MPa（185kgf／cm2）［2631psi］

Compressionpressure

3．04MPa（31kgf／cm2）【441psi］（at200rpm）

Note：ForthemaintenanceoftheenglnePrOPer，SeetheWorkShopManualforIsuzuIndustrialDies EnginesAA−4BGIT，AA−6BGl，BB−4BGIT，BB−6BGIT（IDE−2370）publishedbyIsuzuMotors

Limited．

−6−

1．ENGINEAND RELATEDCOMPONENTS

2．OuterViews

1．THERMOSTArHOUSING 2．OILFILLERCAP 3．AIJERNATOR 8

4．OILLEVELGAUGE

9

5．0ILPAN 6．MUFFLER 7．TURBOCHARGER 8．AIRBREATHER 9．EXHAUSTMANIFOLD lO．STARTERMOTOR ll．FIXWHEELHOUSING

12．NOZZLEHOLDER 13．INLETMANIFOLD 14．0ILFILTER 15．0ILFILTER

（FORDIVIDEDFLOW） 16．0ILPRESSURESWITCH 17．WERDRAINCOCK 18．FUELFIIJER 19．WERSEDIMENTER 20．INJECTIONPUMP 21．COOLINGFAN

Fig．1．1BB−6BGITDieselEnglne −7−

1．ENGINEAND RELATEDCOMPONENTS

3．EngineMounting

Theenglneisconnectedtothedriveunitandsupportedtotherearframeat4polntSOntherightandleft sides，Withmountlngrubbersatbothsidesofthecylinderbody・

笹紅−−−−−−5 （詰〉

㊥

‥ 25

Note：区＞ぢ＝コ42to48N−m（4・3to4・9kgf−m）［31to351bf−ft］ 駐＞ぢ＝：コ131to196N−m（13・4to20・Okgf−m）［97to 1451bf−ft］

4．（REARFRAME）

8．EYEBOIJ

Fig．1．2 MountlngOfEngine −8−

T N I O EYE

6．ADAPTER 7．PACKING

5．PLATE

9 0 L l l

1．ENGINE 2．BRACKET 3．CUSHIONRUBBER

1．ENGINEAND RELATEDCOMPONENTS

1．2 LUBRICAT］NG SYSTEM Lubrication

Forcedcirculationbyoilpump

Lubricating pump

Gearpump，CamShaftdriven

Filtration

Combinationoffu11−flowpapernltertypeanddivided−flownltertype

Cooling

Internalwater−COOlingtype

Oilpressurea句uster

Piston spring

LubricatlngOilcapaclty

13L［3．43U．S．gal．］

TheenglnePartSarelubricatedbyforcedcirculationmethodbytheoilpump．TheenglneOilispickedup

fromtheoilpanbytheoilpumpanddirectedunderpressure，throughtheoilnlterandtheoilcooler，tOth

galleryfromwhichtheenglneOilisdeliveredtoeachsectionfbrlubrication，beforereturnlngbackintothe

Oilpan． TheoccurrenceofanabnormalenglneOilpressureismonitoredbytheoilpressureswitchanddisplayed bywayofthe

englneOilpressure

warnlnglightoftheclustermeteronthedashboard．

FllTER ASSEMBLY

Fig．1．3 SchematicDiagramofEngineLubricatlngSystem

−9−

1．ENGINEANDRELATEDCOMPONENTS

1．3COOLINGSYSTEM Water−COOlingtype

Cooling

Coolingfan Pushertype，550mm［21・7in・］dia・，7−bladed

乃pe

Belt driven

Drivlng

Beltdriven，SPiraltype

Water pump VVaterthermostat

Type

Waxpellettype

Tbmp・atWhichvalvestartsopenlng

820C［1800F］

Tbmp・atWhichvalvefu11yopens

950C［2030F］

Radiator わrenglne

Corrugatedfin（wavy）＆tube

fortorqueconverteroil

Water−COOledmultipleplate

Cap opening pressure

49kPa（0．5kgf／cm2）［7・1psi］

Dry mass

Approx．65kg［1431bs］

Coolingwatercapacity（totalcapacity）

31L【8．2U．S．gal．］

Fig・1・4SchematicDiagramofEngineCoolingSystem

ー10−

1．ENGINEAND RELATEDCOMPONENTS

TheenglneCOOlingsystemisawater−COOlingforced−Circulationtypebymeansofthewaterpump・

Thecoolingwaterisdrawnupfromtheradiatorbythewaterpumpandissenttoeachpartbrcooling・ thecoolingwatertemperaturerisesenoughtoopenthethermostat，thecoolingwaterissentintotheradiator

forcoolingbeforeflowlnglntOthewaterpump・

Thethermosenderunitinstalledinthethermostathouslngalwaysmonitorsthecoolingwatertemperature andthetemperatureisindicatedbywayofthe englneWatertemperaturegauge oftheclustermeteronth dashboard． 11

≡計」

Note：B＞ぢ＝：：コ34．3N−m（3．5kgf−m）［25．31bf−ft］ 匡＞ぢ＝コ225N−m（23kgf−m）［1661bf−ft］

1．RADIATOR 2．CAP

5．FANGUIDE 6．RADIATORUPPERHOSE

3．CUSHIONRUBBER

7．FUNGUARD 8．HOSE

4．（REARFRAME）

Fig．l．5 EngineCoolingSystem −11−

9．RADIArORLOWERHOSE lO．RESERVOIRTANK 11．BRACKET

1．ENGINEANDRELATEDCOMPONENTS

1．4 FUELSYSTEM Irtjectionpump

Boschtype（1ine）

Injection nozzle

Porous type

Fuelftedpump

Plungertype（W／manualpump）

Fuelfilter

Papertype

Governor

Governlng

Centrifugal，all−SPeedcontrol（RSV）

Lubrication

Forcedcirculationtype

Fueltankcapaclty

170L［44．9U．S．gal．］

l．GeneraLDescription Thefeedpumpdrawsfuelfromthefueltankthroughthewatersedimenterandforcesitunderpressure throughthefuelnlterintotheinJeCtionpump・

Thefuelisthendistributedunderpressuretotheinjectionnozzleandiqjectedintothecombustioncharhber・

1．FUELTANK

4．FUELFILTER

2．WERSEDIMENTER 3．FEEDPUMP

5．INJECTIONPUMP 6．INJECTIONNOZZLE

7．OVERFLOWVALVE 8．OVERFLOWVAINE

Fig・1・6 SchematicDiagramofEngineFuelSystem −12−

1．ENGINEAND RELATEDCOMPONENTS

2．Fuel職nk

Thefueltankisweldedtotherearinsideoftherearframe，Withitsfuelhoses（suctionandreturn）connected totheenglne．

ThefueltankisequlPPedwithafuellevelsenderunitlinkedtothefuelmeteronthedashboard・ 哲

4．FUELHOSE，SUCTION 5．FUELHOSE，RETURN

6．BREArHERHOSE 7．CAP 8．STRAINER 9．PLATE lO．PLUG Fig．1．7 FuelUnitofEngine

1 2 13 4 1 1

1．REARFRAME 2．FUELSENDERUNIT 3．FUELTANK

−13−

蓋m

④FromINJECTIONPUMP （診TbWERSEDIMENTER（FEEDPUMP）

1

1．ENGINEAND RELATEDCOMPONENTS

1，51NTAKEANDEXHAUSTSYSTEM Air cleaner

Cyclonepapertype（10

Mu甜Ler

Porous separators

）

Turbocharger Name

RHG（1

Driving

Exhaust−gaSdriven

Lubrication

Forced lubrication

1．GeneralDescription Theintakesystemoftheenglneisdesignedsothattheoutsideopenairisdrawnthroughtheaircleaner intotheinletmanifold．TheaircleanerisequlPPedwithadustindicatortoinformtheoperatorwhentheair cleanerelementshouldbecleaned． Theexhaustsystemisdesignedsothattheexhaustgasfromtheexhaustmanifbldisdischarged，PaSSlng throughthemufflerwherethepressureandtemperatureoftheexhaustgasarelowered，andthetailpipeinto theatmosphere．

ABecarefuInottotouchthemumerorexhauヲtmanihldsincetheyarehot；hentheengin runnlngandfbrawhileafteritisshutoff；OtherwISe，yOumightburnyourhand．

Ttlrbocharger ItispossibletoattainhighenglneOutPutbysendinghighlycompressedairintothecylindersontheintake StrOketoincreaseairsupply，thusincreaslngthequantityoffueltobeiqected・Tbachievethispurpose，the loaderisequlPPedwithanexhaust−gaS−driventurbocharger・

Theturbocharger sexhaustgasinletisconnectedtotheexhaustmanifold・Theexhaustgasrotatesth turbinewheelatahighspeed，befbrebeingroutedthroughtheexhaustgasoutletintothemuffler・

Therefbre，theimpeller，mOuntedontheoppositeendofthesameshaftasthetufbine，alsorotatesat

SPeedtocompresstheairdrawnthroughtheaircleanerandsendittotheintakemanifold・

−14−

1．ENGINEAND RELATEDCOMPONENTS

1．AIRCLEANERHOSE

4．AIRCLEANER

2．EXTENSIONTUBE

5．BAND 6．TAILPIPE

3．RAINCAP

Fig．1．8IntakeandExhaustSystem

−15−

7．（MUFFLER） 8．（ENGmE）

1．ENGINEAND RELATEDCOMPONENTS

1．6 ELECTRICALSYSTEM Battery Ⅵ）1tageandcapaclty

12V，80Ah（5−hourrate）

Quantity

2

Weight（PerCaSe）

25．5kg［56．21bs】

Starter motor 「吋pe

Engagemagnettype

Ⅵ）1tageandoutput

24V4．5kW

AlternatOr

Ⅵ）ltageandoutput

A／Ctype 24V50A

Driving

Belt−drive

r吋pe

Automaticcharglngregulator ICtype（builtinalternator）

lサpe

Coldstartaid

Glowplug，Standardtype

Stopping device

Fuelshut−0ff，mOtOrtyPe

1．Battery Twobatteriesareinstalledinsidethebatteryboxattherearpartoftherearframe・．Wheninspection batteryunitisneeded，OPenthebatteryboxcover・

ADanger！Useduecautionwhenhandlingthebatteryunit・

（1）Nofire．Nospark．Neversmokeorusefireornakedflamenearthebatteryunitsinceflammab

gasisalwaysreleasedfromthebattery・

（2）Thebatteryelectrolyteisdilutesulfuricacid．Itwi11causepainfu1andseriousburnsifitgetso theskin．Itcancauseblindnessifitgetsintoeyes・Ifelectrolytegetsontoyourskin）fLushoffwi acoplOuSamOuntOfwaterandgetmedicalhelp・Ifelectrolytegetsintoyoureyes†flushyoureyes OutWithacoplOuSamOuntOfwaterandgettoadoctoIl

−16−

1．ENGINEANDRELATEDCOMPONENTS

2．ElectricCircuit Fortheelectriccircuitdiagramoftheenglne，rekrto㍑8・4ElectricCircuitDiagram・H （1）Generaldeseription

①Theengine

scoldstartaidisaglowplug．Ifacoldenginewon，tstart，turnthestarterswitchtothe

GLOWpositiontoenerglZetheglowplug，thuspreheatingtheenglne・Then，turnthestarterswitcht

theSTARTpositiontocranktheenglne・ ②Theengineshut−0ffdeviceisafuelshut−0fftype．TumingthestarterswitchtoOFFwi11shutoffthe engine・（EngineShut−0ffDevice） FormoreinformationontheenglneShut−0ffdevice，referto

1．7ENGINECONTROLUNIT．

（2）Starterswitch Thestarterswitchhas4positions：GLOW，OFF，ONandSTART．

AEngineNeutraSart UnlessthetransmlSSlOnCOntrOIswitch（Shiftlever）isinneutral，theenginewon，tstart．（Reftrto

TRANSMISSIONCONTROL．

）

ThispreventstheloaderfrommovlnguneXPeCtedlywhenthestarterswitchisturnedon．

B BR ACC Rl R2 C TART

GLOW OFF ON R2 （REAR）

START

（FRONT）

Fig．1．9 StarterSwitch

−17−

○

2．3．4

1．ENGINEAND RELATEDCOMPONENTS

1．7 ENGLNECONTROLUNIT l．AcceleratorPedaI TheenglneSPeediscontrolledbyoperatlngtheacceleratorpedal・

Whentheacceleratorpedalispressed，thegovernorcontrolleveroftheenglneisactuatedthroughthe controIcablesothatanenglneSPeedmostsuitedtotheworkingconditionisobtained・

1．ACCELERATORPEDAL 2．CABLE 3．BRACKET 4．（ENGINE）

5．PEDALCOVER 6．PEDAL 7．PIN 8．BRACKET

Fig．1．10 AcceleratorPedal

一18−

9．STOPPERBOIJ lO．ROD ll．BELLCRANK 12．SPRING

1，ENGINEAND RELATEDCOMPONENTS

2．EngineShut−OffDevice

AdieselenglnedoesnothaveanyelectriclgnltlOndevicelikeagasolineenglne，SOitcannotusua11ybe

Shutoffsimplybyturningthemainswitch（StarterSWitch）0ff．Forthisreason，thewheelloaderhasa englneShut−0ffdeviceuslngaStOPmOtOr・

WhenthestarterswitchisturnedOFF，englneStOPmOtOraCtuateSthegovernorstoplever・Thisreduce

thequantltyOffuelinJeCtedfromtheinJeCtionpumptotheinJeCtionnozzletozero，thusshuttingoffthe englne・

−19−

1．ENGINEAND RELAJEDCOMPONENTS

NOTE

−20−

2．POWERTRAIN

2．POWERTRAIN

Thepowertrainconsistsofthedriveunit（torqueconverterandtransmission），PrOPellershafts，h．ontan rearaxles，andtires．

Powerfromtheenglneistransmittedtothedriveunitwhereitisconvertedinbothrotationalspeedand

directionanddistributedthroughthepropellershaftstotheh・Ontandrearaxles・Thepowertransmitt eachaxleisfurthersentthroughthewheeltothetiresothattheloadermoves・ TheschematicdiagramofthepowertransmissionoftheloaderisglVenbelow・

ニニー

ー ー

G D：PROPELLERSHAFT

Note：ThetiresshowninthesketchareL−2type． Fig．2．1PowerTrain

−21−

2．POWERTRAIN

2．1DRIVEUN［T Tbrqueconverter Name

TCM642−25（Niigataconverter12・5 ）

Type

3−element，1−Stage，Slngle−Phasetype

Oilcooler

Water−COOling，multipleplatetypel）

Pressuresetting（reftrencevalue）

0．39MPa（4．Okgf／cm2）［56．9psi］

CharglngPumP2） SDYIA36・16

Name Transmission Name

TCM648−25

Type Speeds

Solenoidtypefu11powershift，COnStant−meShtype 4fwdノ4rev．

Clutch（transmission）

Type

Wetmulti−disktype

Operation

Hydraulic

Pressure setting

l．96to2．35MPa（20．Oto24．Okgf／cm2）［284to341psi］

Oil capacity

20L【5．3U．S．gal．］

Weight（driveunit）

532kg【11731bs】

Note：1）Theoilcoolerisinstalledintheradiatorlowertank・ForitsspecincationsandconstruCtion，refer to

1．3COOLINGSYSTEM．

2）Forthespecincationsandconstructionofthechargingpump，reftrto

6・2PUMR

1．GeneralDe＄Cription

Thedriveunitconsistsofacombinationofatorqueconverterandatransmission，fbrmlngaCOmPaCtOn pleCebody，WiththeconverterhouslngCOnneCtedtothetransmissioncase・ Powerfromtheenglneistransmittedthroughtheflywheelandtorqueconvertertothetransmission・ Theenglneandthedriveunitareconnectedtoeachotherbylinkingtheengineflywheeltotheconverter frontcoverwithadrytypelnPutPlate・

−22一

2．POWERTRAIN

Note：区＞ぢ＝コ42．1to48．ON−m（4．3to4．9kgf−m）［31・1to35・41bfLft］ 紹＝ゝThreadedarea：LOCTITE＃262 臣＞ぢ＝＝コ178to269N−m†18．2to27．4kgf−m）［132to1981bf−ft］ 1．（ENGⅡヾE）

2．DRIVEUNIT 3．MOUNTBRACKET

4．MOUNTRUBBER（UPPER） 5．MOUNTRUBBER（LOWER） 6．WASHER Fig．2．2 DriveUnitMount

−23−

7．STOPPERBOIJ （DOWNWARD）

2．POWERTRAIN

（Emptypage）

ー24−

2．POWERTRAIN

Clutchoilpressure：

1．96to2・35MPa（20to24kgf／cm2）

1．fromBRAKEVALVE 2．fromOILCOOLER

［284to341psi】

3．0ILFILLPORT

Safttyvalvereliefpressure：0．71MPa（7・2kgf／cm2）【102psi］

18．，OILTEMPERATURE

GAUGEFITTINGPORT 19．CONVERTEROUT PRESSURECHECKPORT 20．CONVERTERINPRESSURE CHECKPORT

4．PARKINGBRAKERELEASEPRESSURE 5．toOILCOOLER 6．丘omFILTER

191l・REVCLUTCHPRESSURECHECKPORT

31．CHARGINGPUMP 32．SUCTIONTUBE 12．FWD．CLUTCHPRESSURECHECKPORT 33．STRAINER 1813．1STCLUTCHPRESSURECHECKPORT 34．CONTROLVALVE 14．2NDCLUTCHPRESSURECHECKPORT 35．0ILGAUGE 15．3RDCLUTCHPRESSURECHECKPORT 36．PLUG 16．4THCLUTCHPRESSURECHECKPORT 37．BREATHER 17．PRESSURESWITCHFITTINGPORT 38．SPRING 39．PLUNGER（SAFETYVALVE）

Note：B＞超＝ゝThreadedarea：LOCTITE＃572

匪＞正＝ゝOuterdiameter：LOCTITE＃572 駐＞ControIvalvesolenoidoperationtable ●：ON F sol

Rsol

A sol

B sol ●

F4

●

F3

●

F2

●

●

Fl

●

●

●

N

Rl

●

●

R2

●

●

R3

●

R4

●

● ●

Note：紹＝ゝThreadedareasofplug： LOCTITE＃572

Note：ForthesectionsB−B，C−C，E−EandG−Grefertothenextpage・ Fig．2．3 DriveUnit（1）

−25−

2．POWERTRAIN

1．CHARGINGPUMP 2．PUMPSLEEVE 3．GEAR 4．BEARINGSUPPORT 5．CONVERTERWHEEL 6．CONVERTERHOUSING 7．PLUG

14．BACKGEAR 15．BALL 16．SHAFT 17．FWD／REVSHAFT

8．BOLT（FORRELEASING

PARKINGBRAKE） 9．PLUG 10．FLANGE ll．OILSEAL 12．BEARINGCAP 13．DRAINPLUG

18．DISTRIBUTORCAP 19．GEAR 20．GEAR 21．IDLERSHAFT 22．1ST／2NDSPEEDSHAFT

23．DISTRIBUTORCAP 24．GEAR 25．GEAR 26．FLANGE 27．OUTPUTSHAFT

28．OILBAFFLE 29．TRANSMISSIONCASE 30．BRAKEHOUSING 31．CAP 32．SPRING 33．PISTON 34．ENDPLATE 35．DISK 36．PLATE 37．3RD／4THSPEEDSHAFT

38．DISTRIBUTORCAP 39．ROTARYSENSOR（FOR

SPEEDOMETER） 40．GEAR

Note：B＞紹＝ゝMatingareawithconverterhousing‥LOCTITEFMD−127 臣＞紹＝ゝThreadedarea：LOCTITE＃262 駐＞14＝ゝThreadedarea：LOCTITE＃572 匡＞紹＝ゝOuterdiameter：LOCTITE＃572 匪＞ProcedurefbradjustinggapD：Afterthesensortouchesthegear，backitoffby2turns． 医＞MeasurethedifftrenceinheightXbetweenflangeandshaftwithoutshims，andselectand installappropriateshimssothatthedifftrenceinheightisX：‡；二？5mm．（Makeclearance．）

D

→←

㊥Green ㊤BIack

二

39＜こ司 0 1 2 3 3 3

SectionG−G

Note：Oilsealassemblingprocedure

紹＝ゝOilsealouterdiameter（metal）：LOCTITE＃262 1⊂＝恥Areabetweenlipsofliptypeoilseal‥Grease Section B−B

l⊂＝：恥Chamftredareaandslidingareaofcompanionflange：Grease

Section C−C

Fig．2．4 DriveUnit（2）

−26−

2．POWERTRAIN

2．2 TORQUECONVERTER

Thetorqueconverterconsistsofaconverterwheelassembly，aPumPdrive，andaturbineshaft

COnVerterWheelassemblyconsistsofanimpellerandaturbinelocatedoppositetoeachother，Withastator Wheelinbetween，andhousedinthetorqueconvertercasefilledwithoil．

ThepumpdrivedrivesthecharglngPumPandthemainpumpthroughthepumpdrivegearinstalledonto theimpellerhub．

−27−

2．POWERTRAIN

Note：B＞ぢ：：：：：コ42to47N−m（4・3to4・8kgf−m）［31to351bf−ft］

匡＞ぢ＝：コ21to23N−m（2・1to2・3kgf−m）【15to171bf−ft］

匡＞ぢ＝コ51to58N−m（5・2to5・9kgf−m）［38to431bf−ft］

B＞Theconverterwheelassemblyshouldbeinstalledwiththeballmountinggroovepointed towardoutputside． 1．COVERWHEEL 2．INPUTPLATE 3．TURBINEWHEEL 4．STATORWHEEL 5．INPUTGUIDE 6．BUSHING 7．STATORHUB

8．KEY 9．TAPERPLUG lO．IMPELLERWHEEL 11．SEALCARRIER （OILBAFFLE） 12．IMPELLERHUB

13．PUMPDRIVEGEAR Fig．2．5 ConverterWheelAssembly

−28一

14．OILSEAL 15．PUMPDRIVESLEEVE 16．GUIDECARRIER （STATORSUPPORT） 17．TURBINESHAFT

2．POWERTRAIN

Powertransmission

Powerfromtheenglneistransmittedthroughtheflywheel，inputplate，丘ontcover，impeller，tur

turbineshaft，andtothetransmission． Oilnowroute ThetorqueconverteroildeliveredfromthetransmissioncontroIvalvepassesthroughtheoilpassagein thestatorsupportintotheconverterwheel． Astheenglneisstartedandtheimpellerrotates，theoilbetweenthevanesoftheimpelleristhrownoutby

Centrifugalfbrce，flowlnglntOthevanesoftheturbine．Ithitsthevanesoftheturbineatananglewhic turnrotatetheturbineshaft．Thereactiontorqueortheoilproducedbytheoilflowhittingthevanesofthe turbinebecomestheoutputtorqueoftheturbineshaft． ThestatorcontroIstheoilflowleavlngthevanesoftheturbineinacertaindirection，directlngltintothe impeller，thusincreaslngthetorque．

Partoftheoilinsidetheconverterwheelpassesthroughtheoilpassageinthestatorsupporttotheoil

COOler．Asafetyvalveisinstalledatthetorqueconverteroilinletport，tOreleaseexcessoilintotheconverte

houslng．

toOILCOOLER

Fig．2．6 0ilFlowInsideTbrqueConverter

−29−

2．POWERTRAIN

2．3TRANSMLSS10N Thetransmissionconvertsthespeedanddirectionofpowertransmittedfromthetorqueconverter・

Thetransmissionconsistsofthreeclutchshaftassemblies，abackgear，anOutPutShaft，aParkingbrake， andacontroIvalve． 2．3，1CLUTCHSHAFT

Theclutchshaftassemblyhasclutchdisksforeachspeed，andturnspowertransmissiononandoff・

Note：B＞l⊂＝鞠Slidingsurfaces：Grease （Payattentiontothedirectionofassembly・ Seetheenlargedviewsontheright・） B＞ Deta‖ofare摘

1．SHAFT＆DRUM

8．SPACER

2．GEAR 3．ENDPLATE 4．DISK 5．RETURNSPRING 6．PLATE 7．PISTON

9．SEALRING（OUTER）

10．BLEEDVALVE ll．sEALRING（INNER）

12．GEAR 13．SEALRING 14．PLUG

Fig・2・7 ClutchShaftStructure −30−

⊂竺フ 匿＝＞ 酬areaB

2．POWERTRAIN

（Fwd／Revshaft）

（1st／2nd＄Peedshaft）

（3rd／4thspeed＄haft）

Fig．2．8 ClutchShaft −31−

2．POWERTRAIN

Operation

TheclutchisoperatedbypressurizedoilfromthetransmissioncontroIvalve・Thepressurizedoilfro thecontroIvalveflows，PaSSlngthroughthedistributorcapandtheoilpassagesintheclutchshaft，tO backoftheclutchpistontomovetheclutchpiston・Theclutchpistonthenlocksuptheclutchdisk clutchplates，thusengaglngtheclutchshaftandclutchhubtogethertotransmitthepowertothedrivesh 1 2 3

4

5

園Pressurizedoil

l．CLUTCHSHAFT 2．CLUTCHPISTON 3．CLUTCHDISK 4．CLUTCHPLATE 5．CLUTCHHUB

Fig．2．9 ClutchinEngagement

WithnopressurizedoildeliveredfromthecontroIvalve，theoilinthepistonisdischargedfromthebleed

valvesothattheclutchpistonispushedbackbythereturnspringbetweentheclutchplates・Thisunlocks clutchdisksandclutchplatestoallowtheclutchshaftandclutchhubtorotateindependently，SOthatno poweristransmittedtothedriveshaf［・

1 2 3 4 5 6

7

1．BLEEDVALVE 2．CLUTCHSHAFT 3．CLUTCHPISTON 4．CLUTCHDISK 5．RETURNSPRING 6．CLUTCHPLATE 7．CLUTCHHUB

Fig．2．10 ClutchinDisengagement

−32−

2．POVVERTRAJN

2．3．2 POWER FLOW （1）Shiftleverinneutral Withneitherthefbrwardnorthereverseclutchengaged，thepowerfromthetorqueconverterrotatesthe fbrwardandreverseshaft，butisnottransmittedanyfurther．

（2）Shiftleverinn）rWard Whentheshiftleverisputintooneofthefourforwardspeeds，thepowerfromthetorqueconverteris

transmittedthroughtheforwardclutchandtheselectedspeedclutchtotheoutputshaft．

Fig．2．11PowerFlowinForward

−33−

2．POWERTRAIN

（3）Shiftleverinreverse

Whentheshiftleverisputintooneofthefourreversespeeds，thepowerfromthetorqueconverteris

transmittedthroughthereverseclutch，thebackgearandtheselectedspeedclutchtotheoutputshaf［・

Fig．2．12 PowerFlowinReverse

−34−

2．POWERTRAJN

2．3．3 TRANSMrSSION CONTROLVALVE

ThetransmissioncontroIvalveselectivelysendsoiltoeachclutchsoastochangeoverthetraveling directionsandspeedsoftheloader． ThecontroIvalveconsistsofavalvebodyand4solenoidvalves．Thesolenoidvalvesareengagedand

disengagedbythetranSmissioncontroIswitch（Shiftlever），tOShiftthespoolinthevalvetocontroltheclutc lock−uPOil．

ThecontroIvalvealsohasamodulationmechanismwhichoperatesdifferentlyaccordingtothespeed ranges・ItispossibletooperatethecontroIvalvemanuallyiftheelectricsystemfailstooperatenormally・

ーーーー→◎○−−−−−−−−

−−−−一−

3

1．PLATE（FORMANUAL

OPERATION） 2．COVER 3．COVER 4．COVER 5．SOLENOIDVAINE 6．ADAPTER 7．VALVEBODY（LOWER） 8．F／RSELECTORSPOOL

9．ADAPTER lO．SPRING

4

ll．SPOOLA 12．SELECTORSPRING 13．SPOOLB 14．SELECTORSPRING

21．SPRING 22．FLOWSENSINGSPOOL 23．SPRING 24．PIN 15．ORIFICE，0．8mm［0．031in．］dia．25．ROD

（FORSOLENOIDVALVE） 16．ORIFICE（W） 17．ORIFICE（Z） See Note 18．ORIFICE（Y） nextpage・ 19．ORIFICE（Ⅹ） ） 20．VALVEBODY（UPPER） Fig．2．13 TransmissionControIValve（1） −35−

26．SPRING，INNER 27．SPRING，CENTER 28．SPRING，OUTER

29．LOADPISTONH 30．REGULATORSPOOL 31．PISTON

2．POWERTRAIN

7 8 91 12 0 1314

SectionA−A

1 2 3 5 3

3

4 3 6 3 8 3

3

7 3

Section D−D

3

Note：Orificediameter，mm［in．］ Orince（Y）

Orince（Z）

Or沌ce（W）

Or泊ce（Ⅹ）

formain

brlst／2ndgears

for 2nd gear

fbr3rd／4thgears

6．0【0．24］

0．9［0．035】

0．9［0．035】

1．5［0．059】

32．SPRING

35．SPRING，INNER

38．LOADPISTONL

33．MODULArIONSPOOL 36．SPRING，CENTER 39．MANUALSPOOL（FOR

34．ROD

37．SPRING，OUTER

EMERGENCYTRAVELSPOOL）

Fig．2．14 TransmissionControlⅥ11ve（2） 一36−

2，POWERTRAIN

①〜④，①，㊥：CLUTCH l

I

F／RSELECTOR SPOOL

l

I

．」

「￣1 1」⊥」 「￣●「

血〟 「−1 l」⊥」 l l i

遣［紆

！し⊥ 亭RSOL・…よⅡ加

BSOL．！

；FSO」．；

rr光一−◆一一一− 1

l

； ロ」 ミき＿．じ

toT／C l

l L＿＿嬰三q但し＿⊥」

ナ

十ーーーーーーー 川川

｝−−−−−−−−−−−一一

−一一▲−＞㌢−−1一−−−−−

l

SPOOLA

l

l

l

し＿＿

l

REGULA￣「OR 「￣￣￣「 ） l l

MODULAT10N SPOOL

FLOWSENS［NG SPOOL

from PUMP HydraulicCircuitDiagram ACCUMULATOR （LOADPISTON）

Fig．2．15 TransmissionControlValve（3）

Operation The modulation mechanismofthis controIvalve

D

Changesthetimetheclutchlock−uPOiltakestobuild LU

up，Ortheclutchoilpressurewaveform，aCCOrdingto⊃ 江：

thespeedranges，thusmakinggearshif［ingsmoother・

∽ （乃 LU

Theoperationofthemodulationmechanismis

【＝

L

explainedonpolntSA−E・Inaddition，theoperationof

円 5

thesolenoidvalvesandmanualspool（emergencytravel

SPOOl）isalsoexplainedinpagesthatfollow・ O

TIME・

Fig．2．16 ClutchOilPressureWaveform

−37−

2．POWERTRAIN

（1）Neutral，3rdspeedinNeutral（PointAinFig．2．16） ①Theoilwhichhasenteredtheinletport（1）ofthecontroIvalve，flowsthroughthesmal1hole

a

i

regulatorspoolintothechamber（2）atthebackofthespool，tOShiftthespooltotheleftinthefigu Theoilwhosepressurehasbeenregulatedfbrtheclutchlock−uPPreSSure，flowsthroughthecircuit（3）

intothemodulationspooIcircuit（5）．Excessoilflows，PaSSingthroughthecircuit（4），tOthetorque COnVerter．

②Theoilwhichhasreachedthecircuit（5）flowsthroughthetaperedoilpassageintothemodulationsp Circuit（6），Whichleadsthroughthemainorince（W）tothecircuits（8，9，12）． ③Theoilwhichhasbeendeliveredtothecircuit（8）nowsthrough（8），（16），（17），（18）andtothe3rdspeed Clutchchamber・Theclutchportsotherthanthatofthe3rdspeedclutchareconnectedtothedrain．

④Theoilwhichhasreachedthecircuit（8）flowsthroughthedrilledholeinthespooIAtothecircuit（19）．

Theoilthenpassesthroughthethrottle（Z）totheloadpistonchamber（20）・Therearetwoloadpistons：

low−PreSSureandhigh−PreSSureOneS・Afterthelow−PreSSureloadpistonmovestothestopper，thehigh−

PreSSureloadpistonstartsmovlng．

⑤Theoilwhichhasflowedintothecircuit（12）isstoppedbytheF／Rselectorspool．Boththebrwarda thereverseclutchesaredisengaged（neutral）．

⑥Thesolenoidvalvesareinthe OFF statesothattheoilwhichhasreachedthroughtheorific占toeac solenoidvalveisdrained．

−38−

2．POWERTRAIN

Fig．2．17 Neutral（3rdSpeedinNeutral）

−39−

2．POWERTRAIN

（2）ShiftingintoIstfbrward（PointBinFig・2・16） ①SolenoidvalvesFandAareturned

ON・

②WiththesolenoidFturnedON，theoilflowisstoppedbythesolenoidvalveFsothattheoilsent theoilpassage（1）flowstothecircuit（26）wheretheF／Rselectorspoolisthenshiftedduetotheoil PreSSuretOtherightinthengure・

③Ontheotherhand，aSthesolenoidAisturnedON，thespooIAmovestotherightinthefigure・

④AstheF／Rselectorspoolmoves，theoilinthecircuit（12）flowstothecircuit（21）wherethefwdclutch islocated・Astheemptyfwdclutchchamberisfi11edwithoil，adifferenceinpressurebetweenthe precedingcircuits（6，22）andthesubsequentcircuits（8，9，12）ofthemainorince（W）iscreated・（The PreCedingcircuitshaveahigheroilpressure・）

⑤Thepressuredifferentialbetweenthecircuit（9）andthecircuit（22）movestheflowsensingspooltothe rightinthefigure，Withtheoilinthecircuit（20）beingdrained・

⑥Themodulationspoolmovestotherightinthefigurebecausetheoilpressureinthecircuit（25）drop tocontroltheoilflow丘・Omthecircuit（5）tothecircuit（6），thusdeliveringonlythenecessaryamoun oil．

−40−

2．POWERTRAIN

Fig．2．18 ShiftinglntOIstForward −41−

2．POWERTRAIN

（3）Clutchinengagement（PointCinFig・2・16）

①Whentheselectedclutchesarenlledwithoil，thepressuredifferentialacrossthemainorince（W）drops

sothattheflowsenslngSPOOlismovedtotheleftinthefigurebysprlngforce，thusclosingthedrain ClrCult．

Theoilinthecircuit（23）flowsthroughthedrilledholesinthespooIAtothecircuit（24），thenpassing throughtheorifice（X），tOtheloadpistonchamber（20）・

②Ontheotherhand，theoilflowsfromthemodulationspool，PaSSingthroughtheoilpassages（5，6） thedrilledholesinthespool，tOthechamber（7）atthebackofthespool・Therefore，themodulat spoolmovesduetotheoilpressureinthechambers（7）and（25）orthatintheloadpistonchamber（20）， graduallyincreaslngtheclutchoilpressure・

③Whentheclutchoilpressurereachesthespecinedvalue，theloadpistonstopsatthestopperposition （4）Afterclutchengagement（PointDinFig・2・16）

①Assoonasboththefwdclutchandlstspeedclutcharelockedup，theloadpistonmovestothesto toincreasetheoilpressureintheloadpistonchamber（20）rapidlyuptotheregulatorpressure・

②ThemodulationspooIcircuits（7）and（25）havethesameoilpressure，butthecircuit（25）hasaspring・ Forthisreason，themodulationspoolmovestotheleftinthefigure・

−42−

2．POVVERTRAIN

Fig．2．19 ClutchesinEngagement（1stSpeedForward） 一43−

2．POWERTRALN

Fig．2．20 AfterClutchEngagement（1stSpeedForward） −44−

2．POWERTRA［N

（5）Fwdand2ndspeed・Clutchesinengagement（PointEinFig．2．16）

①SincethesolenoidsAandBareintheONstate，thespeedspooIsAandBmovetotherightinthengur ②Theoilwhichenteredcircuit（8）flowsintocircuit（23）．Itthenpassesthroughthedrilledholesinthe

SPOOl，tOCircuit（24），fromwhichsomeoftheoilpassesorifice（X）intotheloadpistonchamber（20）・ Atthesametime，theotherflowsfromcircuit（24）intocircuit（27）ofthespooIB．Theoilleavingthe Circuit（27）flowsthroughthecircuit（28）andorifice（Y）ofcircuit（29），intotheloadpistonchamber

（20）． Inotherwords，Whentheshiftleverisputin2ndspeed，theoilflowsthroughorinces（X，Y），SOthatthe

timeneededfortheclutchoilpressuretobuildupisshorterthanwhenthelstspeedclutchwhichlets theoilpassthroughtheori卓Ce（X）aloneisselected・

−45−

2．POWERTRAIN

Fig．2．21ClutchesinEngagement（2ndSpeedForward） −46−

2．POWERTRAIN

（6）Solenoid■valveoperation

Fsol Rsol Asol Bsol

Foursolenoidvalvesareinstalledonthelowervalve

4th ●

body．

●

3rd ●

Thesolenoidvalvesareoperatedbyshiftingtheshift

Fwd

leverintheoperator scompartment，tOCOntrOltheF／R

2nd ●

●

Thetableontherightshowstherelationshipsin Neutral OPerationbetweeneachspeedrangeandthesolenoids・

1st ●

●

（●：SOlenoidinON．）

1st

●

●

2nd

●

●

3rd

●

4th

●

SelectorspoolandspeedspooIsAandB．

Rev

a．SolenoidinOFFstate

Theoilwhosepressurehasbeencontrolledbythe regulatorisalwaysflowlngthroughtheorificeintothe SOlenoidvalve．WhenthesolenoidisintheOFFstate， theoilpassesthroughinsidethesolenoidvalveandis drained．TheoilpressureatthepointPisOMPa（Okgf／ Cm2）［Opsi］．

Fig．2．22

b．SolenoidinONstate Whenthesolenoidisexcited，theinsideofthevalve isblockedtooilflow．Theoilisnolongerdrained．The

OilpressureatthepointPbecomesequaltotheregulator PreSSure．Thetransmissionspeedisswitchedoverby

theF／RselectorspoolandthespeedspooIsAandB uslngthisoilpressure．

Fig．2．23 −47−

●

●

●

2．POWERTRAIN

（7）Manual（emergencytravel）spooloperation

Ifthesolenoidvalvesfailtooperateproperlyduetoabrokenwireoranyotherelectricalfailure，itis

possibletomechanicallyswitchthecontroIvalveto3rdforwardorreversewiththisspool・Itisadvisab usethisspooIwhentheloaderneedstobemovedtoanout−Of−trafncareaforrepalr・

AMakesuretheeTgineisヲhutoffb血etryingtouse！hemanualspool・Ifthemanualspoolis operatedwiththeenglnerunnlng，theloadercanjerk，CauSlnganaCCident・ a．Switchingto3rdfwd・

Toswitchto3rdfwd，PulloutthemanualspoolaboutlOmm［0・39in・］・

①Theoilwhosepressurehasbeencontrolledbytheregulatorflowsthroughtheorificeintothem

spooIcircuits（31，32）・Sincethecircuit（31）isblockedbythespool，theoilisroutedfromthecircui （33）totheFrRselectorspooIcircuit（26），thusshiftingthespooltotherightinthe員guresothatthefw Clutchoilpressureincreases・

②Theoilinthecircuit（32）flowsthroughthespoolandtheRsolenoidvalvetodrain・

③SinceboththesolenoidsAandBofthespeedspooIsareOFF，the3rdclutchpressureincreases，（See Fig．2．17）thusmakingitpossibletotravelinforward3rdspeed・

fromREGULATORVALVE

Fig．2．24 ManualSpoolOperation（Fwd）

b．Switchingto3rdrev．

Toswitchto3rdreverse，PuShinthemanualspoolaboutlOmm［0・39in・］・ TheoperatlngPrlnCipleisthesameasinthecaseof3rdforward・ −48−

2．POWERTRAIN

2．3．4TRANSMISS10NCONTROL

ThetransmissioncontroIsystemisanelectrictypewhichturnsonandoffthesolenoidvalveofthe

transmissioncontroIvalvebytheoperationoftheshiftlever（transmissioncontroIswitch），tOSWitchoverth PaSSageSOftheclutchoil，thuscontrollingthetravelingspeedoftheloader・ ThetransmissioncontroIsystemconsistsofashiftlever，downshiftswitch（DSS），DSSrelaysandneutral

relay．

＋

DSSRELAY2

DSSSWITCH

TRANSMISS10N CONTROLSWITCH

S■D

￣￣

B sol I

l

F＄0

Rs H

u

」＿＿＿．●＿＿＿＿＿

」＿− （ENGINENEUTRALSTART）

ロ3］：fromPARKINGRELAY（POWERSOURCE）［至：］：tOBACK−UPLAMPRELAY ロ］‥ffomSTARTERSWITCH

［亘］‥tOSAFETYRELAY S

C

Fig．2．25 ElectricCircuitDiagramofTransmissionControl −49−

2．POWERTRAIN

ThetransmissioncontroIsystemhasanengineneutral−StartSafbtysystemandaDSS（downshiftswit Note：Fortheinchingmechanismandtransmissionclutchcut−0ff，reftrto＝3・BRAKESYSTEM ， 3・1・1 GENERALDESCRIPTION

，and

3．2．1GENERALDESCRIPTION．

1．Shif（Lever（TransmissionControISwitch）

F（BLUE）

4 3 2 1

● こ

Ⅶ−■■■■■■−■■二二こ

Fig．2．26 ShiftLever −50−

喜

一■■

壬

2．POWERTRAIN

2．EngineNeutral−StartSafbtySystemA

Theneutral・StartSafbtysystempreventstheenginefrombeingstartedunlesstheshiftlever neutral．ThispreventstheloaderfrommovlnguneXPeCtedlywhenthestarterswitchisturnedto START． Makesuretheshif［1everisneutralbefbrecrankingtheenglne．

Theengineneutral−StartSafttysystem（neutralrelay）isincorporatedintheenginestartingcircuit． Operation（SeeFig．2．25）

①WhenthestarterswitchisturnedtoSTARTwiththeshiftleverinneutral，theneutralrelayisclosedt allowanelectriccurrenttoflowthroughthesafttyrelay，thusstartingthestartermotor（engine）．

②WhenthestarterswitchisturnedtoSTARTwiththeshiftlevernotinneutral，theneutralrelayremain OPen，SOthatnocurrentflowsthroughthesafetyrelay．Consequently，theenglneWOn tstart．

3．DSS（DownShiftSwitch）Mechanism With the downshift switch pressed，the DSS

mechanismprovides speedier，mOreefficientload handlingwithouthavingtooperatetheshiftlever． TheDSSmechanismconsistsofadownshiftswitch

builtintheboomleverknobandtwodownshiftrelays．

Fig．2．27 DownShiftSwitch

DSSOperation WhentheDSSispressedin2ndgearfbrward，thetransmissionisautomaticallyshiftedintothelstgear POSitionbytheoperationofthedownshiftrelays，allowlngmOrehorsepowertobeconcentratedonloading OPeration． WhentheshiftleverlSPlacedinthereversegearaf［erscooplngOrdigglng，thespeedrangeisautomatically

Shiftedinto2ndgearforquickerdrivingback．

Thatis，uSlngtheDSS，itispossibletocontrolboththebucketthrustingfbrceandthetravelspeedof

loaderbyoperatingtheboomlever（downshiftswitch）alone，Withtheshiftleverkeptin2ndgear，dur

SCOOPlngOrdigglngOPeration．

−51−

2，POWERTRAIN

0perationofDSSelectriccircuit

（1）WhenthetransmissioncontroIswitchisinfwd 2ndspeedgearposition ①WhenthetransmissioncontroIswitchismovedto

thefwd2ndspeedgearposition，thesolenoidFis excitedbytheelectricflow a・＝Andtherelay 1 isoperatedbytheelectricflow b・

②ThesolenoidAisexcitedbytheelectricflow

c

andthesolenoidBisexcitedbytheelectricflow d． Then，thetransmissioncontroIswitchshifts intothefwd2ndspeedgear・

Fig．2．28

（2）WhentheDSSswitchisturnedon ①WhentheDSSswitchisturnedon，therelay2is operatedbytheelectricflow e・＝Then，theelectric

flow dMtothesolenoidBiseliminatedandthe SOlenoidBisdemagnetized・

Thetransmissionshiftsintothefwdlstspeedgear・

Fig．2．29 ー52−

2．POWERTRAIN

②Theelectricflow

P

generatesintherelay2sothat

therelay2remainsexcitedeveniftheDSSswitch

isturnedoff．

Thetransmissionremainsinthe丘）rWardnrstspeed gear・

Fig．2．30

（3）WhenthetransmissioncontroIswitchismoved torev．position

①WhenthetransmissioncohtroIswitchismovedto rev．position，theelectricflow

b

iseliminatedand

theoperationofrelay 1 isreleased． Then，theelectricflow f totherelay 2 is eliminatedandtherelay2isalsoreleased・

②Theelectricflow d isrevivedandthesolenoid B

isexcited．Thenthetransmissionisreturned

tothe2ndspeedgear． ③Meanwhile，thesolenoidRisexcitedbytheelectric

flow g andthetransmissionshiftsintotherev 2ndspeedgear．

Fig．2．31 −53−

2．POWERTRAIN

2．3．5AUTOMATICTRANSM］SS10N（ATM）［OPT10N］

TheautomatictransmissionsystemdetectstravelingspeedandenglnerPmuSlngtheATCunitand automaticallyshiftsthetransmissionaccordingtothespeedrangeselected・

／ ／ ／

＼ ＼ VALVECONTROLBOX

、、 ⊂￠＼＼

／ ￣￣「二

ROPSCAB

Fig．2．32 ArM（Option） −54−

2．POWERTRAIN

1．ATCfunctions TheATC（AutomaticTransmissionController）unithasthefbllowingfunctions：

・Automaticspeed−rangeChangeofthetransmissionaccordingtothetravelingspeedoftheloader（SWitchin

Ofautomaticandmanualtransmissionmodes） ●Speed−rangeChangebyswitches

●Outputofthesignaltothespeedometerandtachometer

・SenslngOferrorsandoutputofwarnlngaboutthetransmissionsolenoid Figure2．33showstherelationshipbetweentheATCunitandotherdevices・

Fig．2．33I／ORelationshipofArC

−55−

2．POWERTRAIN

2．Relationshipbetweenshiftleverpositionsandgearshiftpatterns

TheArC（AutomaticTransmissionControl）unitautomatica11ycontroIsthespeedrangeofthetransmi basedonthetruck

stravelingspeedandenglnerPm．TheATCfunctionsasfollows：

（1）Gearshiftpatterns

A．Relationshipwiththeshiftleverpositions

Usually，the2nd−SPeedgearisselectedfordigglngandscooplng，3rd−SPeedgearfbrload＆carryoperation

and4th−SPeedgearfortravelingandmovlng．Theautomaticspeed−rangeischangedaccordingtotheshif leverpositions．（SeeFig．2．34．） Speedrange 1st

2nd

3「d

Applicablework

4th

Workusinglst・SPeedrange

1ST

Shiftlever

Diggingandscooping （ 、．

POSjtjon

Load＆carrywork （ 、＿ Travel ng ヽ＿′′r

4TH

○：Speedrangeinmanualmode．

Fig．2．34 Relationshipbetweenshiftleverpositionandgearshiftpatterns

B．DSS（Downshiftswitch）operation（bothforATandMT） ①WhentheDSSispressedwiththegearsinthe4thspeed，thetransmissionshiftsfrom4thspeedto SPeed（PressDSSonce）．

②WhentheDSSispressedwiththegearsinthe3rdspeed，thetransmissionshiftsfrom3rdspeedto

SPeed（PressDSSonce）．

③WhentheDSSispressedwiththegearsinthe2ndspeed，thetransmissionshiftsfrom2ndspeedto

SPeed（PressDSSonce）．

④WhentheDSSispressedandhelddownwiththegearsinthe4thspeed，thetransmissionshiftsfro SPeedto3rdandthento2nd．Forthelstspeed，releasetheDSSswitchandthenpre＄Sitonce．）

WhenthetransmissionhasbeenshiftedintothelstspeedbytheDSS，yOuCanreleasetheDSSIstspeed uslngeitherofthefollowlngtWOmethods： ●Usetheshiftlever．

●Morethan3secondsafterthetransmissionisshiftedintothelstspeedbypresslngtheDSSswitch，th

transmissionautomaticallyshif［suptothe2ndspeedwhenthetravelingspeedexceeds6km／h［3・7 mph］（COmmOntOallmodels）．

−56−

2．POWERTRAIN

（2）Relationshipbetweenenginespeedandgearshiftpatterns Shiftingdownisquickenedwhenenginespeedishighinclimbingaslope（kickdownfunction）・Inaddition，

thetransmissionisdesignednottoshiftupwhendescendingadownhilltoallowtheuseofenglnebraking・

Figure2・35showstherelationshipbetweenenglneSPeed，traVelingspeedandgearshiftpatterns・T

englneSPeedisdetectedbytheenglneSPeedsensorwhentheenglnerunSathighrpmanditisdetectedbya SWitchattachedtotheacceleratorpedalwhentheloaderdescendsadownhill．（Thetransmissionwon

upwhenthisswitchisnotturnedonorwhenthepedalisnotpressed・） TS32

TS43

−

H＝dle

一 L G

︻ヒ

︵∈d﹂︶p冨ds浮島じ山

￣−

一・

q TH32

TH23

TH43

TH34

Travelingspeed（km／h）

Fig．2．35 RelationshipBetweenEngineSpeed，TravelingSpeedandGearshiftPatterns

−57−

t

2．POWERTRAIN

（3）GearshiftpatternsfromFtoRorviceversa WhentheoperatortriestoreversethedirectionoftravelwhiletheloadinglSrunnlngat3rdspeedor4th

speed，thewarnlngbuzzersoundsand4th−SPeedindicatorcomeson・Thedirectionoftravelcannotbereversed whentheloaderisrunnlngat4thor3rdspeed・Itisnotuntilthetransmissionautomaticallyshiftsdownt

2ndspeedandtheloaderslowsdowntoaspeedwhichmakesitpossibletoswitchoverthedirectionoftravel thatthedirectionoftraveloftheloadercanbeperformed・

Ifthedirectionoftravelistriedwhentheloaderisrunnlnginfbrwardat4thspeedwiththeshiftlever inthe4thspeedposition： Directionof travelis reversed

S10WSdown

S10WSdown ＞

＞

＞

When traveling SPeedisless thanSD43．

When traveling SPeedisless thanSD32

WhentravelLngSPeedisless than FR2 （Less！hanFR2when reverslngfromrevtofwd）

（km／hHmphl SD43 SD32 FR2 RF2

86．9r54．01 28．Or17．41 13．5r8．41 14．6「9．11

Tbble2・1Gearshiftpolntinreverslngdirectionoftravel （4）APS（Anti・Pitchingsystem）operation（option）

Travelingspeed（km／h）

APSH

APSH（TravelingspeedatwhichAPSisactivated）：7km／h［4・3mph］ APSL（TraveIingspeedatwhichAPSisreleased）：5km／h［3・1mph］

Fig・2・36 TravelingSpeedsatwhichAPSisActivatedandReleased

−58−

2．POWERTRAIN

（OuterViews）

Sightg（ass

（Board）

Fig．2．37 ArCUnit −59−

2．POWERTRAIN

4

3

2 】

R N F

Fig．2．38 ShiftLever（ATMspecification）

−60−

2．POWERTRAIN

Fig．2．39 ClusterGaugeUnit（ArMspecification）

−61−

2．POWERTRAIN

●Metercircuitdiagram

口 Brakeoilpressure

2 EnglneOilpressure 3 Watertemperaturesensor

1

CN卜4 1

¶。CNト6・ 2Ⅹ

「1扇面「正す商ENT

CN2−24

∨ぐ。（DC24V）

4 Shiftindicatorl

ノm

5 TurnSignal（L）

5

BRAKE OILJE〉EL CN2−22I

6 Shiftindicator2 7 Mainlamp 8 Shiftindicator3

′n

Dl． CN2−25 1

EMG STE：ER

｛・h

8

CN2−18 ユ

）

CNl

cN2−19l

∨ぐC（DC24V）

CNト7

L8

CNト■3I

四

」

13 Aircleaner

14 Notconnected 15 Shiftindicator4

n E／GOILPRESS CNト2トーーーーーー⑲

L5

PARKINGBRAKE CNL−‖ ⊥

Parkingbrake

12 Charge

⑲ L

T／MCUTOFF CN2−23

9 Ground 10 Fuelsensor

。HIBEAM トー・−−−−−−−→ WORK川GLAMP CN2−261 L9 A昭CLEANER

Connectedto

CONN． No． l1000−MM51】0

16 Turnsignal（R）

17 Speedsensor 18 Emergencysteerlng 19 Powersource（24VDC）

CN2

20 Instrumentlamp 21 Oiltemperaturesensor 22 Brakeoillevel 23 TransmissioncuトOff 24

Powersource（24VDC）

25 OPT−1

CN3

26 Workinglight 27 HourmeterGND 28 Hourmeterpowersource

CN卜9

￠ ‖ 」

＿

● Connector 8 7 6 5

4 3 2

17 16 15 14 13 12

10 9

（ConnectoratcLuster gaugeunitside）

21 20 × 19 18 26 25 24 （Ctter

（t

Fig．2．40ClusterGaugeUnit（ATMspecification） 一62−

2．POWERTRAJN

2．4 01LCIRCULATION ROUTE l，GeneralDescription

Theoilusedforthedriveunitissuppliedfromthetransmissionsumptank・ AstheenglneStartS，thecharglngPumPPicksupoilfromthetransmissionsumptankthroughthestrainer andsendsitunderpressuretothetransmissioncontroIvalve．TheoildischargedffomthecharglngPumP

PaSSeSthroughtheinlinenltertothetransmissioncontroIvalve・ThecontroIvalvedividestheoilinto fbrtorqueconverteroperationandonefortransmissionclutchoperation・

Theoilsentintotheconverter，afterleavlngtheconverter，flowsintotheoilcoolertogetcooleddo

Afterleavlngtheoilcooler，itlubricatesandcooIseachclutchshaftassembly，beforereturnlnglntO

transmissionsumptank． Theoilcoolerisincorporatedinthelowertankoftheradiator．Reftrto

1．3COOLINGSYSTEM

theoilcooler．

／（十 to BRAKE VALVE

from BRAKE VALVE

SUCTION SUPPLY LINE LUBRICArIONLINE BRAKE LTNE 7

1．0ILCOOLER 2．TORQUECONVERTER 3．DISTRIBUTORCAP

（FORFWD／REVSHAFT）

4．TRANSMISSION 5．CHARGINGPUMP 6．TRANSMISSION CONTROL VALVE

Fig．2．410ilCirculationRoute −63−

7．STRAINER 8．INLINEFILTER 9．DISTRIBUTORCAP （1ST／2NDSHAFT）

for

2．POWERTRAIN

2．LnlineFilter

Theinlinenlterisprovidedinthesupplylineofthedriveunitoilcirculationroute・Theoilflowsthr thenlterelementfromoutsidetoinsideandthefilteredoilisdirectedtothetransmissioncontroIvalve Whentheoilnlterelementbecomesclogged，thepressureattheinletportsideincreasessothattheoil

bypassesthecloggedfilterelementandforcesopenthebypassvalvetoflowdirectlytotheoutletportsid

BypassvalveoperatlngPreSSure：

0．172MPa（1．75kgf／cm2）【24・9psi］

SectionA−A

l．HEADASSEMBLY 2．ELBOW 3．ELEMENTASSEMBLY 4．BYPASSVALVE Fig．2．42InlineFilter

ー64−

2．POWERTRA［N

2．5 PROPELLERSHAFTS UniversaljolnttyPe

CrossJOlnt

Length（inter−Pinlength）

Front

710mm［28in．］

Center

612mm［24．1in．］

Rear

229mm［9．Oin．］

Ⅵねight

Front＋Center

38kg［841bs］

Rear

8．7kg［19．21bs］

Thepropellershaf［s，locatedbetweenthetransmissionandthefrontaxleandbetweenthetransmissi andtherearaxle，tranSmitthepower丘omthetransmissiontothefrontandrearaxles・

ThepropellershaftatthefrontaxlesideisequlPPedwithacenterbearingwhichisattachedtothefront frametoserveasastopperwhentheloaderisarticulated・

Thepropellershaftsabsorbthechangeindriveangleandthechangeinlengthwhentheloadertravels， ensurlngSmOOthflowofpowerfromthetransmissiontotheaxles・

「「tニーt＝＝＝＝＝■＝【＝一￣ ￣■

「

。EAR

AXLE j 軋 ーー − 耳

しノ

Note：B＞ぢ＝コ70．6to77．4N−m（7．2to7．9kgf− m）［52．1to57．11bf−ft］（16points）

1．PROPELLERSHAFT（FRONT） 2．PROPELLERSHAFT（CENTER） 3．PROPELLERSHAFT（REAR）

祀＝ゝThreadedarea：LOCTITE＃262

臣＞ぢ＝コ223N−m（22．8kgf−m）［1651bf−ft］

Fig．2．43 PropellerShaftAssembly

−65−

2．POWERTRAIN

（FrontandCenter）

1．UNIVERSALJOINTASSEMBIX

5．UNIVERSALJOINTASSEMBIX

2．H−YOKE

6．SLEEVEYOKEASSEMBLY

3．GREASEFITTING

7．SHAFTYOKE 8．BOIJ

4．PILLOWBLOCK

（Rear）

1．UNIVERSALJOINTASSEMBLY 2．二H−YOKE

3．BOIJ

Fig．2．44 PropellerShaft

t66−

2．POWERTRAIN

2．6DRIVEAXLES（FRONTANDREAR） Drivlng

4−Wheeldrive

Frontaxle

Frame−nXed，Semi−floatingtype

Rear axle

Trunnion，Semi−floatlngtyPe

Reductiongearanddifferential Model

TCM648−30

「吋pe

0rdinary，2−Stagereductiontype

Differential gear box Differential limiter

One−PleCetyPe Tbrqueproportionaldifferential

Finalreductiongearassembly Model

TCM648−30

r吋pe

Planetary gear

Weight Front

642kg［14161bs］

Rear

628kg［13851bs］

2．6．1DRIVEAXLE

Thedriveaxleconsistsofthedifferential，nnalreductiongearassembly，WettyPehydraulicdiskbr unit，andaxleshafts．

Thepowerfromthedriveunitistransmittedthroughthepropellershaftstothefrontandreardriveaxle Thepoweristhentransmittedtothedifferentialwhereitisdividedintotherightandleftaxleshaftstothe finalreductiongearaSSemblyoneachshaftend，thusdrivingthewheels・

Thewettypehydraulicdiskbrakeisinstalledinfrontofthennalreductiongearassemblyandservesasa SerVicebrake．Fortheoperationoftheservicebrake，referto

3・BRAKESYSTEM・

AxleMount

Thefrontaxleisbolteddirectlytothefrontframe． TherearaXleissupportedbythetrunnionmethodinwhichaxlesupportsareinstalledacrosstherearaxle

andboltedtotherearframe・Consequently，therearaxleiscradledupanddownaroundthecenterlineoft difftrentialaccordingtothegroundconditiontheloadertravels・

Thetrunnion−mOunteddriveaxlehelpslmPrOVeOPeratOrCOmfortbecauseloaderswithatrunnion−mOu

driveaxlejoltlessthanthosewiththeconventionalcradle−SuPPOrteddriveaxle，Whentheytravelona

groundcondition．

ー67−

2．POWERTRAIN

1

Note：B＞ぢ＝コ100．9±19．6N−m（10・3±2・Okgf−m） ［74．5±14．51bト珂

紹＝ゝThreadedarea：LOCTITE＃262

匡＞ぢ＝コ890±178N−m（90・8±18・2kgfLm） 【657±1321bf一明

匡＞ぢ＝：：コ784±98N−m（80±10kgf−m） ［579±721bf一明

匡＞〆＝＝恥Innersurface：Grease （Assemblewithchamftrpointedtotheaxleside．）

DetailsofareaB

直＞Assemblewithlippointingoutward。 医＞Assemblewithgroovepointingtowardpart（7）・ 医＞r⊂＝恥Assembleafter鎖11inggrease・

1．FRONTAXLE 2．REARAXLE 3．AXLESUPPORT（FRONT）

4．AXLESUPPORT（REAR）

7．THRUSTPLArE

5．PACKING 6．BUSHING

8．THRUSTCAP 9．THRUSTWASHER

Fig．2．45 DriveAxleAssembled −68−

2．POWERTRAIN

14倒

Note：E＞ぢ＝：：コ98N−m（10kgf−m）［721bf−ft］，超＝ゝThreadedarea：LOCTITE＃262 匡＞仁＝コ225N−m（23kgf−m）［1661bf−ft］，正＝ゝThreadedarea：LOCTITE＃262 匡＞紹＝ゝThreadedarea：LOCTITE＃572 駐＞l⊂＝鞠Lip：Grease 匠＞紹＝ゝMatingsurface：LOCTITEFMD−127

匪＞ぢ＝コ29N−m（3kgf−m）［221bf−ft］，正＝ゝThreadedarea：LOCTITE＃262

1．OmSEAL

11．BREArHER

2．AXLESHAFT

6．FINALASSEMBIX 7．AXLETUBE

12．BLEEDER

3．DIFFERENTIALBODY 4．DIFFERENTIAL

8．LEVELGAUGE 9．RINGGEAR

13．COVER 14．DRAIN

5．PLUG（CHECKINGPORT）

10．PIN Fig．2．46 FrontAxle −69−

2．POWERTRAIN

Note：区＞ぢ＝コ98N−m（10kgf−m†［721bf−f［］，正＝ゝThreadedarea‥LOCTITE＃262 匪＞ぢ＝コ225N−m（23kgf−m）【1661bf−ft］，d＝ゝThreadedarea＝LOCTITE＃262 駐＞紹＝ゝThreadedarea：LOCTITE＃572 匡＞〆＝＝恥Lip：Grease 匪＞紹＝ゝMatingsurface‥LOCTITEFMD−127

匪＞ぢ＝：コ29N−m（3kgf−m）【221bf−ft］，紹＝ゝThreadedarea：LOCTITE＃262

1．OmSEAL 2．AXLESHAFT

6．AXLETUBE 7．RINGGEAR

4．DIFFERENTIAL

8．PIN 9．BREATHER

5．FINALASSEMBLY

lO．BLEEDER

3．DIFFERENTIALBODY

Fig．2．47 RearAxle −70−

11．COVER 12．LEVELGAUGE 13．PLUG（CHECKINGPORT）

14．DRAINPLUG

2．POWERTRAIN

2．6．2DIFFERENTIAL Thedifftrentialisintegralwiththereductiongear． Thepowerfromthepropellershaftistransmittedthroughthedriveplnionandtheringgeartothedifftrential

gearcase．Itisthensentthroughtherightandleftsidegearstothefinalreductiongearassembly・Thes

reductionofthepowerisaccomplishedbythedriveplnionandtheringgear． ThedifEbrentialoperatesasn）1lows：

Whiletheloadertravelsstraight，theringgear，difftrentialgearcase，andsidegearsrotatetogether，W

thepiniongearsinsidethedifferentialgearcasenotrotatlng・Thepowerofthesamespeedisthustransm

fromtherightandleftsidegearSthroughtheaxleshaftstothewheels．Whentheloadermakesatur

rightandlef［wheelsrotateatdifferentspeeds；thepiniongearsinthedifftrentialgearcaserotatearoundthe OWnaXeSaCCOrdingtothediffbrenceinspeedbetweentherightandlef［sidegears． While travelin

While makinl

Fig．2．48 DifftrentialGearOperation

Torque proportional differential Whee1loadersoftenneedtoworkonabadgroundconditionsuchasonsandorinaswampyplace．On

SuChabadgroundcondition，aloaderwiththeconventionaldifftrentialcanskid，thusmakingitdifncu

deliveritsperfbrmance．Inaddition，thetireswi11alsowearoutprematurely．Topreventthisfromhappenlng，

SOmemOdelsmaycomeequlPPedwithatorqueproportionaldifftrentialwhichlimitsdifferentialaction・ Thetorqueproportionaldifftrentialhasalmostthesameconstructionasthestandarddifferentialassembly

exceptthatthedifftrentialpiniongearshaveanoddnumberofteethofaspecialcontour・Whenthetiresa

abouttoskidonsof［ground，theplniongearscontinuetotransmltPOWertObothsidegearswithoutidlin untilthediffbrenceinroadresistancebetweentherightandlefttiresreachesacertainpolnt，thuspreventlng thetires丘■OmSkidding．

ー71一

2．POWERTRAIN

Note：B＞ぢ＝コ98N−m（10kgf−m）【721bf−ft］，正＝ゝThreadedarea：LOCTITE＃262 匪＞ぢ＝コ147N−m（15kgf−m）［1081bf−ft］，14＝ゝThreadedarea：LOCTITE＃262 桓＞ぢ＝コ540N−m（55kgf−m）［3981bf−ft］，超＝ゝThreadedarea：LOCTITE＃262 匪＞正＝ゝOuterdiameter：LOCTITE＃262，l⊂＝恥Lip：Grease 匠＝＞Backlashbetweenringgearandpiniongear：0・25toO・36mm［0・0098toO・0142in・］ 匪＞AdjustshimsinarangeofO・55tol・55mm［0・0217toO・0610in・］atbothsides・ B＞Afterassembly，maChinespacerstoobtainatorqueofl・47to2・55N−m（0・15toO・26kgf−m） ［1．08tol．881bf−ft］（withoutoilseal）． 1．OmSEAL 2．BEARINGRETAINER 3．CASEB 4．RINGGEAR 5．CASEA 6．SHIM 7．THRUSTWASHER

8．THRUSTWASHER 9．PINIONGEAR lO．BEARINGCAGE ll．SPACER 12．FLANGE 13．COVER 14．OmSEAL Fig．2．49 Differential

−72−

15．SPACER 16．SHIM 17．SPIDER 18．PINIONGEAR 19．SIDEGEAR

2．POWERTRAIN

2．6．3 F［NALREDUCT10NGEAR

The丘nalreductiongearassemblyisaplanetarytypeandprovidesnnalspeedreductionofthepowerfrom theenglneinthepowertransmissionline・

Thepowerfromthedifftrentialgearrotatestheshaftandthethreeplanetgearsinsidetheringgear・T rotationoftheplanetgearistransmittedtotheplanetcarrierandtheaxleshaft・

8 7 6

5 4 3 2

Section A−A （Planetgearoperation）

1．DRIVEPINION 2．DIFFERENTIAL

4．PLANETSHAFT 5．PLANETGEAR

3．GEAR＆SHAFT

6．RINGGEAR（Fixed）

Fig．2．50 PowerFlow

−73−

7．PLANETCARRIER 8．AXLESHAFT

2. POWER TRAlN

Note：旺＞Stampedsurfaceshouldbepointedtothepistonside・ E＞Shimadjustmentprocedure l）Tightenthebolt（12）tothetighteningtorqueof49N−m（5kgf−m）【361bf−ft］andpushin axleshaftbearingcone，turnlngaXleshaft・

2）Measurespacingbetweenretainerplate（11）andaxleshaft・Measuredvalue＝Y 3）ChooseshimswhosethicknessisO．03toO．10mm［0・0012toO・0039in・］greaterthanthe valueY 4）Insta11shimsandinstallretainerplateandbolt・

ぢ＝コ644N−m（65．7kgf−m）［4751bf一札パ⊂ゝThreadedarea‥LOCTIiE＃262 Thebearing srotationalresistancetorqueis19・6to39・2N（2to4kgf）［4・4to8・81bf］on thetubenttingvoltpitchcircle・

1．PLANETCARRIER

7．ENDPLArE

13．GEAR＆SHAFT

2．SHAFT

8．BRAKEDISK

14．PIN

3．BALL

9．BRAKERING

15．D−RING

4．PLANETGEAR

lO．SHIM ll．RETAINERPLATE 12．BOIJ

16．PISTON

5．RINGGEAR 6．NEEDLEROLLER

Fig．2．51FinalReductionGearAssembly −74−

17．D−RING

2．POWERTRAIN

2．7WHEELASSEMBLY（TIREANDWHEEL） Tire

17．5−25−12PR，Tubeless，L−3

Wheel（rim）

13．00x25DC

Weight（PerPiece）

174kg［3841bs］

Tire

102kg［2251bs】

Ri111

72kg［1591bs］

Inflation pressure

343kPa†3．50kgf／cm2）［49．8psi］

2．7．1TIRE

Thestandardmodelisprovidedwithlock−tyPeL−3tireswhichfeaturedamageresistanceandabrasion resistance．Selectapproprlatetiressincethereareavarietyoftiresavailableaccordingtotheapplicationand PurPOSeOfwork．

Thetiresizeisexpressedininches．Thestrengthoftiresareexpressedinplyrating（PR）：forexam

10PRmeansastrengthcorrespondingtothatoflOpiecesofcottoncords．（PRdoesnotnecessarilystandf

thenumberofcordpliesintire．） 17．5

T Tirewidth（in．）

25

12PR ：

Example：

Rimdiameter（in．） Tirestrength

2．7．2 WHEEL Thewheelconsistsoftherimanddisk．Thediskisboltedtotheaxleshaft．

ThetireisinstalledontherimandbothserveasonepleCe．ItisthusverylmPOrtanttOuSeanaPPrOPrlate rimwheninstallingatireontherim．Theuseofaninapproprlaterimmayresultinashortliftofthetireand

intheworstcasemightleadtoaseriousaccident．Therimsizeisalsoexpressedininches．The丘rstnumb standsfbrtherimdiameterandthenextonetherimwidth．

−75−

2．POWERTRAIN

（Tire）

1．TIRE 2．RIM 3．VAI」VE

（TreadPattern）

（Rim）

1．RIM 2．VALVEGUARD 3．DISK

Note：ぢ＝コWheelbolt：862N−m（88kgf−m）［6371bf−ft］

Fig．2．52 TireandRim

−7（ト

3．BRAKE SYSTEM

3．BRAKESYSTEM Servicebrake

Type

Frontandrearwheelindependentbraking，Wetdiskhydraulic，

fu11−POWerbrake Numberoffluidlines

2 lines

Brakevalve

Singlebrakevalve

Diskbrake

4−Wheelwettypediskbrake

Brakepump

RearpumpofcharglngPumPl）

Oiltank

0．28L［0．074U．S．gal．］

Brakeoilpressuresettlng

2．94MPa（30kgf／cm2）［427psi］

Alarmsystem

Warninglampandbuzzer

Safety system

w／accumulator

Parking brake lサpe

Transmissionintermediate−Shaftbraking，Wetdiskmechanical （SPring）brake

Insta11ation

Inside transmission

Note：1）Forthebrakepumpspecificationsandconstruction，See

6・2PUMIl

AIfサeenginestallswhilethelo？derisrunning，thebrakemaybecomeinoperative・Donotshuto theenglneWhiletheloaderisrunnlng．

AExceptinanemergencysituation，donotapplytheparkingbrakewhiletheload占rismovin Abusingemergencybrakingfunctionmightcausemalfunctionoftheparkingbrake・

Acautiontobetakenwhenservicingaccumulatoranditspiping．

●Theaccumulatorisfi11edwithhigh・PreSSurenitrogengas．UseduecautionwhenservIClngt

accumulatoIl

●ServIClngOftheaccumulatorsuchasmlingofnitrogengas，Shouldbepern）rmedonlybyquali

PerSOnnel． ●Donottrytomachineorweldtheaccumulatordirectly． ●Theaccumulatorpipinghaspressurizedhydraulicoilinsideit．Be払reworkingontheaccumulator

PIPlng，releaseanyresidualpressurefromthepiping． ●WhenreleaslngreSidualpressurefromtheaccumulatorpIPlng，Parktheloaderonalevelsurf

Shutofftheenglneandlowertheboomsandbucketontheground．

−77−

3．BRAKESYSTEM

3．1SERVLCEBRAKE 3．1．1GENERALDESCRIPT［ON（BRAKELINE） （1）Servicebrakeline

Theservicebrakeisa4−Wheelwettypediskbrakeandusesthefu11powerbrakesystem・ Thehydraulicbrakelineafterthesplitcylinderhasanindependent2−1inesystemR）rthefrontandre wheels．Ifoneofthetwolinesisdamaged，anOtherlinewilloperateproperlytobraketheloader・

（2）Safbtysystemandalarmsystem ●Anaccumulatorisinsta11edasasafbtydevicebrtheservicebrakeline・

IfthebrakepumphasanyfailureortheenglneStOPSR）rSOmereaSOn，thediskbrakecanbeoperat uslngthepressurizedoilintheaccumulator・

Inaddition，theaccumulatorisprovidedwithapressureswitchwhichinformstheoperatorbywayofthe

buzzerandthe＝brakeoilpressure＝warnlnglamponthedashboard，Whentheaccumulatorpressuredro

●Thebrakeoiltankhasalevelswitch．Ifthebrakeoilislessthanthespecifiedamount，theoperatorwi noticeitimmediatelybywayofthe‖brakeoillevel

warnlnglamponthedashboard・

Note：Specincationsandapplicationsofswitches（Fig・3・2） Position

Name

A

Stop lamp switch

B

Pressureswitch

Application

Specification OFFwhenpushrodispushed ONwhenpushrodisreleased

Stoplamp

OFF：1．47MPa（15kgf／cm2）［213psi］， ON：1．18MPa（12kgf／cm2）【171psi］

Brakeoilpressure

Warn1nglampandbuzzer （TurnSONatatmosphericpressure） Level switch C

（Builtinoiltank）

D

Pressureswitch

＝Brakeoillevel

Warnlnglamp

Onwhenbelowstandardlevel OFF：1．18MPa（12kgf／cm2）［171psi］，

（Inchingswitch）

Forinchingoperation

−78−

ON：0．78MPa（8kgf／cm2）［l14psi］

（TurnSONatatmosphericpressure）

3．BRAKESYSTEM

㊧＝tOTRANSMISSIONSUMPTANKFILLERTUBE（DRAIN） ㊦：tOTRANSMISSIONFWD／REVCLUTCHSHAFT（LUBRICATION） ②‥tOTRANSMISSIONCONTROLVALVE Note：Forthespecificationsandapplicationsofswitches，SeePage78・

1．BRAKEPEDAL

5．BRAKEPUMP

2．BRAKEVALVE

6．TRANSMISSION INLINE FILTER

3．TRANSMISSION SUMP TANK 4．CHARGINGPUMP

7．CHECKVALVE 8．ACCUMULArOR

Fig．3．1ServiceBrakeLine

−79−

9．BRAKEOILTANK lO．SPLITCYLINDER ll．WETDISKBRAKE （builtinAXLE）

3．BRAKESYSTEM

1．TRANSMISSION 2．STRAINER 3．CHARGINGPUMP 4．BRAKEPUMP 5．TRANSMISSION INLINE FILTER 6．BRAKEPEDAL

7．BRAKEVALVE 8．ACCUMULATOR 9．CHECKVALVE lO．BRAKEOILTANK ll．SPLITCYLINDER

14．PARKINGBRAKEVAI一VE

12．DISKBRAKE（FRONT）

15．PARKINGBRAKE 16．TRANSMISSIONCONTROL VALVE 17．PRESSURESWITCH 18．PRESSURESWITCH

13．DISKBRAKE（REAR）

Fig・3・2 BrakeOilPressureCircuitDiagram −80−

3．BRAKESYSTEM

（3）Inchingmechanism

Theinchingmechanism，interlockedtothebrakesystem，StOPStranSmissionpowertemporarilybypla

thetransmissioninneutral． Whentheinchingmechanismisactivated，thedrivingpowerisconcentratedontheload−handlingsyst

・Whenthebrakeisapplied，theinchingswitchisturnedofftostopthepowersupplytotheforwar reversesolenoidsinthetransmission，thusputtlngthetransmissioninneutral・

・TheloaderisequlPPedwithamodeselectswitchintheoperator scompartment・Theinchingmechanism （Clutchcut−Off）isturnedonoroffbyoperatingtheswitch． a．LoadhandlingwithmodeseleetswitchHOFF The

clutchcut−Off

indicatorlampISOut，indicatlngthattheinchingmechanismisinactivation・When

thebrakepedalispressed，thebrakeisappliedandtheinchingswitchisturnedofftoputthetransmissionin neutral・Whenthebrakepedalisreleased，theinchingswitchisturnedontolinkthetransmissionlineagaln・ b．Startingofronaninline，Withmodeselectswitch The

clutchcut−OfT

ON

indicatorlampISOn，indicatlngthattheinchingmechanismisnotworking・T

POWerSuPPlytotheforwardandreversesolenoidsofthetransmissionissuppliedthroughthemodeselect

SWitchregardlessoftheinchingswitchoperation・Therefbre，Whenthebrakepedalispressed，thetransmissio won

tshiftintoneutral．

Note：Thisdiagramshowsacircuitwiththeservicebrakeandtheparkingbrakereleased・ Fig．3．3 ModeSelectionMechanismCircuitDiagram

−81−

3．BRAKESYSTEM

Operation （1）Brakepedalinneutral

①Whenthebrakepedal（1）isnotpressed，thebrakevalve（2）isinthereleasedstate・

Theoildischargedfromthebrakepump（5）passesthroughthebrakevalveandflowsoutfromthetank port・Theoilfromthetankportissenttothetransmissionfwd／revclutchshaft・

②Thebrakelinetothesplitcylinder（10）（Primaryline）（A）isconnectedtothetankportinthebrakevalv （2）sothattheoilintheprimarylineisdrainedfromthetankport・Thediskbrake（11）isreleasedwhen thesplitcylinderisinthereleasedstate・

③Theoildischargedfromthechargingpump（4）passesthroughthetransmissioninlinenlter（6），isdivide

intwoflowsandaccumulatedintheaccumulator（8）．Thecheckvalve（7）isusedtopreventoilfro flowlngbackward・

Theaccumulatorportinthebrakevalve（2）isclosedwiththevalve・

Fig・3・4 BrakePedalinNeutral

−82−

3．BRAKESYSTEM

（2）Brakepedalinoperation a．Brakepedalinoperation

①Whenthebrakepedal（1）ispressed，thebrakevalve（2）isoperatedtosendtheoilfromthebrakepu （5）underpressuretothesplitcylinder（10）．

Thebrakevalvetankportisclosedbythespool・ ②Thesplitcylinderisoperatedbytheoil（attheprimaryside）sentunderpressurefromthebrakevalv Sendthebrakeoil（atthesecondaryside）inthebrakeoiltank（9）tothediskbrake（11）forbrak OPeration．

Thebrakelineafterthesplitcylinder（SeCOndaryline）hasanindependent2−1inesystemfortheh■Ontand rearwheels．

Fig．3．5 BrakePedalinOperation

ー83−

3．BRAKESYSTEM

b．Brakepedalinreleasedstate

①Whenthebrakepedal（1）isreleased，thebrakevalve（2）returnstotheneutralposition・Then，theoil（ theprimaryside）operatingthesplitcylinder（10）underpressurepassesthroughthebrakevalve（2）an isdrainedintothetransmissioncase．

②Thesplitcylinderreturnstotheoriginalreleasestate，thebrakeoilpressure（atthesecondarysi operatingthediskbrake（11）isremovedandthediskbrakeisreleased・

③Theoilsentunderpressurefromthebrakepump（5）tothebrakevalve（2）passesthroughthevalvean issenttothetransmissionfwd／revclutchshaftinthesamewaywhenthebrakepedalisintheneutral・

Fig・3・6 BrakePedalinReleasedState

−84−

3．BRAKESYSTEM

（3）Accumulatorinoperation Whentheenglneisstoppedfbrsomereasonorthebrakepumphasanyfailure，brakingshouldbeperbrmed

uslngtheoilcollectedunderpressureintheaccumulator・ ①Whenthebrakepedal（1）ispressedfu11ytooperatethebrakevalve（2），theoilintheaccumulator（8）is

Sentunderpressurethroughthebrakevalvetothesplitcylinder（10）・ Allotherportsinthebrakevalveareclosed・ ②Theoperationofthelineafterthesplitcylinderisassameasthatdescribedin

（2）Brakeinoperation

andthebrakingoperationshouldbeperformedbythediskbrake（11）・

Fig．3．7 WhenBrakePedalIsPressed（Enginenotrunning）

−85−

3．BRAKESYSTEM

3．1．2 BRAKEVALVE

Thebrakevalveisactuatedbyoperatlngthebrakepedal．Itisanopencentertypewhichgeneratesoil PreSSurebygivlngthrottleresistancetotheoildischargedfromthebrakepumpwhichnorma11yflowswithout resIStanCe．

Thebrakeoilpressureissenttothesplitcylinderforbrakingoperation．

ThebrakevalveisequlPPedwiththeaccumulatorport・Ifthebrakepumpisbroken，thebrakeisoperate

uslngtheaccumulatoroil．

10−1 10−2 10−310−4

11

12

13

14

A Behreremovingthebrakevalvefromtheloader；Shutofrtheengine，OPeratethebrakeva approx．50timesinfu11stroketoremoveaccumulatoroil．

Note：B＞ぢ＝＝コ88N−m（9kgf−m）［651bfbft］ 匪＞ぢ＝コ64N−m（6．5kgf−m）［471bf−ft］Removeonlywhentheinputpistonisdisassembled． （Whentheinputpistonisdisassembled，theoilpressureneedstobeaqjusted・）

1．PLUG 2．RETURNSPRING

7．COMPRESSIONSPRING

10−3．SEAT

8．COMPRESSIONSPRING

lO−4．ROD

3．REACTIONPISTONGUIDE

9．INPUTPISTON

ll．BODY

4．REACTIONPISTON

lO．CLOSEDVALVE

12．BOOT

5．VALVESPOOL 6．INPUTPISTONGUIDE

lO−1．SPRING

13．PUSHROD 14．CLEVIS

lO−2．BALL

Fig．3．8 BrakeValve −86−

3．BRAKESYSTEM

Operation （1）Brakevalveinreleasedstate Whenthebrakevalveinreleasedstate，thevalve（a）opensandthevalve（b）isclosed・

Thebrakeoilsuppliedfromthebrakepumpreturnstotheoiltankthroughthevalvespool（1）groove・

匡垂］

Fig．3．9 BrakeValveinReleasedState （2）Operation（A） ①Whenthebrakepedalispressed，theinputpiston（3）shiftsthroughthepushrod（2），andthevalvespool （1）andreactionpiston（5）shiftbythespring（4）． Then，thevalve（C）isclosedtoshutoffthehydraulicpressurecontroIchamber（6）fromthetankport・

Afterthat，thevalve（b）openssothatthepumppartisopenedtothehydraulicpressurecontroIcha

（6）． ②Whenthevalvespool（1）ispushedinfurther，thevalve（a）isthrottledtoincreasethepumpoilpressure

andtheoilpressureinthehydrauliccontroIchamber（6）andthebrakeportisalsoincreased・ Thediskbrakeisnowreadyforoperation．

Fig．3．10 0peration（A） −87−

3．BRAKESYSTEM

（3）Operation（B）

①TheoilpressureinthehydraulicpressurecontroIchamber（6）pushesthereactionpiston（5）totheright inthefigurebelowatthestateofoperation（A），SOthattheoilpressureandthebrakepedalpressi brcebytheoperatorarebalanced・

②Whenthebrakepedalispressedfu11y，thenut（7）comesincontactwiththeplate（8）tocontrolthe hydraulicpressurecontroIchamber（6），i・e・，maXimumoilpressureinthebrakeoilpressureline・ 座I祖KEl

十

回

l

1■

Fig．3．110peration（B） （4）ReturnOperation

①Whenthebrakepedalisreleased，thepushrod（2）returnstotheoriginalposition・

Thereactionpiston（5）andvalvespool（1）aremovedtotherightinthengurebytheoilpressurefo

ofthehydraulicpressurecontroIchamber（6）andreturnspring（9）force，SOthatthevalve（C）opens， valve（b）isclosedandthevalve（a）opens・

②Thepressurizedoiloperatingthebrakeflowsthroughthevalve（C）tothetankportandthenreturnst theoiltank．

Theoildischargedfromthepumpreturns，PaSSingthroughthevalve（a），tOtheoiltank・ Thisstateisassameasthatdescribed （1）Brakevalveinreleasedstate・

Fig．3．12 ReturnOperation −88−

3．BRAKESYSTEM

（5）EmergencyBrakeinOperation

①Whenthebrakepedalispressedwiththebrakepumpstopped，boththevalvespool（1）andthereaction Piston（5）shiftasdescribedin Operation（A） butnooilpressureisgeneratedinthehydraulicpressu

controIchamber． ②Whenthebrakepedalispressedfurther，thetopendofthereactionpiston（5）comesincontactwitht Valverod（11）toclosethevalve（e）．Then，thevalverod（11）pushestheball（10）toopenthevalve（d）・

Theoilintheaccumulatorissentthroughthevalve（d）andthehydraulicpressurecontroIchamber（ tothediskbrake．

Note：Operationofthevalve（d）innormalstate Innormalbrakingoperation，thevalve（d）isoperatedbythedifferenceinoilpressurebetween hydraulicpressurecontroIchamber（6）andtheaccumulatorport・ Whentheoilpressureintheaccumulatorportishigher，thevalve（d）iskeptclosed・

lACCUMULATOR

d 6 e

Fig．3．13 EmergencyBrakeinOperation

−89−

3．BRAKESYSTEM

3．1．3 SPLITCYLINDER

Thesplitcylinderisoperatedbythepressurizedoilfromthebrakevalveandsendsthebrakeoiltothedisk brake for braking operation.

ThesplitcylinderhastwopIStOnSforfrontandrearwheelstoformtwoindependentbrakelinesafterthe splitcylinder，thusincreaslngthereliabilityofthebrakesystem・

④：OILFILLERPORT

⑧：BRAKECYLINDERPORT ◎：BRAKEVALVEPORT

Note：B＞ぢ＝コ19．6to25・5N−m‡2to2・6kgf−m） 【14．5to18．81bト珂

臣＞紹＝ゝThreadedarea：LOCTITE＃262

7 6 5 4 3 2 1

R 9．VALVE

R

3．PISTON 4．VALVEROD

Ⅷ肌mm

2．CUP

S S S S 5 ／LU 7

1．BODY

8

Fig．3．14 SplitCylinder −90−

lO．COVER ll．CONNECTOR 12．AIRBLEEDSCREW

3．BRAKESYSTEM

Operation （1）Splitcylinderinreleasedstate

Thepiston（1）ispressedtothelowersurfaceofthebody（3）byspring（2）force．Thevalve（4）opensand

theoilinthesecondarychamber（B）isreleasedthroughthetankportintotheoiltank． （2）Brakeinoperation

①Thepressurizedoilfromthebrakevalveflowsinto theprimarychamber（A）．

②Thepiston（1）overcomesthespring（2）forceto

moveupward． ③Thevalve（4）ispressedagainsttheseatsurfaceof

theendcover（6）bythevalvespring（5）andthe

COnneCtionbetweenthesecondarychamber（B）and theoiltankisshutoff． ④Whenthepiston（1）movesupwardfurther，theoil

inthesecondarychamber（B）issenttothedisk brakeandpressurized．

Thediskbrakeisapplied．

Fig．3．15 0peration

（3）Brakeinreleasedstate ①Theoilintheprimarychamber（A）isdrainedfromthebrakevalve． ②Thepiston（1）movesdownwardbyspring（2）fbrce．

③Theoilpressureinthesecondarychamber（B）decreasesandtheoilpressureappliedtothediskbrake alsoremoved． ④Whenthepiston（1）movesdownwardfurther，thevalve（4）isopenedbythevalverod（7），thesecondary Chamber（B）isopenedtotheoiltankandthebrakelinehasatmosphericpressure．

Thediskbrakeisreleased．

−91−

3．BRAKESYSTEM

3，1．4 D［SKBRAKE Thediskbrakeisawetslngleplatedisktypeandbuiltinthedifftrentialbodyofthedriveaxle．Onthe loader，fourdiskbrakeunitsareinstalledonthe4wheels，Oneforeach． Forthestructureofthediskbrake，reftrto

2．6DRIVEAXLE．

Operation

（1）Brakeinoperation ThebrakeoilpressureactsonthebackofthebrakepIStOnandlocksupthebrakediskswiththebrake rlngSandendplates． Theinnerperipheryofeachbrakediskissplined totheshaftinthepowertransmissionline．Theouter

PeripheriesofthebrakeringsandendplatesareSeCuredtothedi鮎rentialbodybyplnSSOthatthelocked− brakedisksstoprotatlngtObraketheloader． （2）Brakereleased WhenthebrakeoilpressureactlngOnthebrakepistonisreleased，thebrakepistonreturnsalittletomake

thebrakedisksfree，thusreleaslngthebrakingfbrce．

K S 川∬

随PL BRAEN︒m

2．PLANETCARRIER 3．SHAFT

4 5 ∠U

1．AXLESHAFT

E

Fig．3．16 DiskBrakeOperation

−92−

7．BRAKERING 8．BRAKEPISTON 9．D−RING

3．BRAKESYSTEM

3．l，5 0THERCOMPONENTS l．BrakeOillもnk Thebrakeoiltankisinstalledtosupplyoiltothesplitcylinder（diskbrake）．

Oiltobeused：EngineoilSAE5W−20 Capaclty：

1．OL［0．26U．S．gal・］（totalcapacity），0・28L［0・07U・S・gal・］（Brakeoiltank）

Auseamineralbrakefluidfbrthebrakesystem．

IfyouuseageneralautomobilebrakefLuid（JISautomobilenon−mineralbrakefluid），therub PartSOfthebrakesystemmightbedamagedtocausemalfunctionofthebrake・Intheworstcase，it

mightcauseaseriouslnJuryOrdeath．

Note：MAX：283cc［0．075U．S．gal．］

MIN：150cc［0．040U．S．gal．］

1．CAP 2．STRAINER 3．BRACKET 4．LEVELSWITCHASSEMBLY

Fig．3．17 BrakeOilTank

−93−

3．BRAKESYSTEM

2．Accumulator

Abladdertypeaccumulatorisinstalledinordertoaccumulatetheoilpressureforactuatlngthebrakefor

emergency・TheoildischargedfromthecharglngPumPisdividedandflows，PaSSlngthroughthec Valve，lntOtheaccumulator．

Note：Nitrogengasshouldnotbesealedintheaccumulator・

Name：．

MU70−500

Gascapacity：500cm3［30．5in・3］

1．GASPLUG 2．‖0 −RING

3．POPPET 4．BLADDER 5．HOLDER 6．SHELL 7．0ILPORT

Fig．3．18 Accumulator

3．CheckValve Thecheckvalveisinsta11edinordertopreventtheaccumulatoroilfromflowlngbackward・

④toACCUMULArOR （診fromINLINEFIIJER

⑧封④

Crackingpressure：0．135MPa（1・5kgf／cm2）［21・3psi］ Fig．3．19 CheckValve −94−

3．BRAKESYSTEM

3．2 PARKING BRAKE

Manualreleasingofparkingbrake（asanemergencymeasure）A Iftheparkingbrakecannotbereleasedwiththeparkingbrakeknobduetoadefectivepumporforany Otherreason，manual1ymovethebrakepistonbyuslngtheparkingbrakereleasebolttoreleasetheparking brake．

AManualIyreleasingtheparkingbrak。Sh。。1dn。tbeab。Sed．Itsh。。JdbeIimitedt。

loaderneedingtobemovedtoanout・OfJtrafncarea・Iftheparkingbrakeneedstobereleasedwith loaderparkedonaslope，besuretoblockthewheels． Manuallyreleasingtheparkingbrake

①Removetheparkingbrakereleasebolt（l）fromthe Parkingbrakecapofthetransmission． ②Removetheplug（2）fromthecenterofthecap．

Fig．3．20

③Inserttheremovedbolt（1）throughtheplughole intothescrewholeatthecenterofthebrakepiston （3）． ④Tightenthereleasebolt（1）towithdrawthebrake Piston（3），thusreleasingthediskbrake．

Fig．3．21

t95−

3．BRAKESYSTEM

3．2．1GENERALDESCRIPT10N（BRAKEL［NE） Theparkingbrakeismechanical（SPring），Wetmultiple−Platediskbrakeandinstalledontheintermediate shaftofthetransmission．

Theparkingbrakeisoperatedwiththeparkingbrakeswitchintheoperator

scompartment・

1

Note：Specificationsandapplicationsofswitch Position

E

Name

Application

Pressureswitch

Transmissionclutchcutoffand

（Parkingswitch）

ParkingBrake indicatorlamp

1．PARKINGBRAKESWITCH 2．WIREHARNESS 3．PARKINGBRAKEVALVE

4．TRANSMISSION CONTROLVALVE 5．SPRING

Fig・3・22 ParkingBrakeLine −96−

Specincation OFF：1．18MPa（12kgf／cm2）［171psi］ ON：0．78MPa（8kgf／cm2）［114psi］ （TurnSONatatmosphericpressure・）

6．BRAKEPISTON 7．DISKBRAKE 8．1ST／2NDSPEEDSHAFT

3．BRAKESYSTEM

0peration （1）Releasingparkingbrake

①Whentheparkingbrakeswitch（1）isturnedOFEthepressureoilfromthechargingpumpflowsth theparkingbrakevalve（3）intothefrontchamber（A）ofthebrakepiston（6）・ ②Thebrakepiston（6）movesagainstthespring（5）byoilpressuretoreleasethediskbrake（7）・

Fig．3．23 ReleaslngParkingBrake

（2）Applyingparkingbrake ①Whentheparkingbrakeswitch（1）isturnedON，theoilfromthechargingpumpisblockedinthe Parkingbrakevalve（3）．Thepressureoilinthefrontchamber（A）・Ofthebrakepiston（6）isdrained throughthebrakevalve（3）・

②Thebrakepiston（6）ismovedbythespring（5）toactuatethediskbrake（7）・

Fig．3．24 ApplyingParkingBrake −97一

3．BRAKESYSTEM

（3）Transmissionclutchcut・Ofr a．Whenparkingbrakeisapplied：

①Whentheparkingbrakeisapplied，theoilpressureactingonthebrakepistonisdrained・Thepressur switch（Parkingswitch）installedonthepistonhousingturnsontochangeoverthetransmissioncut−0ff relays． ②ThepowersupplytothefbrwardandreversesolenoidsofthetransmissioncontroIvalveiscutoffsotha thetransmissionisputinneutral．（transmissionclutchcut−0ff） ③The parkingbrake indicatorlampcircuitisclosedandthelampcomeson・

Note：Thisdiagramshowsacircuitwiththeservicebrakereleasedandtheparkingbrakeapplied・ Fig．3．25 ElectricCircuitDiagram

b．Whenparkingbrakeisreleased：

①Whentheparkingbrakeisreleased，theoilpressureisproducedtoactonthebrakepiston・Theparkin switchisturnedoffandtheparkingrelayreturnstotheorlglnalcondition・

②ThepowersupplytotheforwardandreversesolenoidsofthetransmissioncontroIvalveisrest makeitpossibletoshiftthetransmission・ The

parkingbrake

warnlnglampgoesout・

−98−

3．BRAKESYSTEM

3．2．2 PARKING BRAKEVALVE

TheparkingbrakevalvecontroIsthesupplyofpressureoiltothediskbrake・

Theparkingbrakevalveisswitchedoverwiththeparkingbrakeswitchtoactuatethediskbrake・ ParkingbrakevalvehasdetentmechanismstoholdeachspooIposition・

Leadwire：O Black

Leadwire：⑳Red

Note：B＞ぢ＝：コ9tollN−m（0．92tol．12kgf−m）［6．7to8．11bf−ft］ 匪ぢ＝コ6・9to7・8N−m（？・70toO・80kgf−m）［5・1to5・81bf−R］ 桓＞ぢ＝：：コ18to22N−m†1．84to2．24kgf−m）［13．3to16．21bf−f［］

P：fromTRANSMISSIONPIPING A：Blocked B：tOPARKINGBRAKE

T：tOOILTANK（RETURN） Fig．3．26 ParkingBrakeValve −99−

3．BRAKESYSTEM

3．2．3 DISKBRAKE

Thediskbrakeisawetmultiple−Platetypeandinstalledontheintermediateshaftofthetransmission

Thediskbrakeisactuatedbythebuilt−insprlngandreleasedbythepressureoilfromtheparkingbrakeva

Forthestructureofthediskbrake，referto

2．1DRIVEUNIT．

Operation （1）Diskbrakeinoperation

①Whenthepressureoilactingonthebrakepistonsisdrained，thebrakepistonismovedbythespr forcetolockupthebrakediskswiththebrakeplates． ②Theinnerdiametersofthebrakedisksaremeshedwiththetransmissionshaftthroughthediskhub．The

Outerdiametersofthebrakeplatesaremeshedwiththebrakehouslng．Asthebrakedisksareforced agalnStthebrakeplates，theyarelocked・Thisinturnstopstherotationofthetransmissionshaftthrough

thediskhub，thusapplyingtheparkingbrake．

3 4 5 1．BRAKEPISTON 2．SPRING 3．ENDPLArE・

4. BRAKE HOUSING 5．BRAKEPLATE 6. DISK HUB 7．BRAKEDISK 8．TRANSMISSIONSHAFT

7 8

Fig．3．27 DiskBrakeinOperation

（2）ReleasingBrake

①Whenthepressureoilissenttothebackofthebrakepiston，thebrakepistonovercomesthespringfbrce andshif［sitsposition．

②Aclearanceiscreatedbetweeneachbrakediskandbrakeplatetomakethebrakedisksfree，thus

releaslngthebrake．

−100−

4．STEERING SYSTEM

4，STEERING SYSTEM 「吋pe

Frame−articulating

Mechanism

Orbitro1

Frameactuatlngangle

400torightandleft

No．ofrotationsofsteerlngWheel

4．0

Powersteerlng Name

Orbitrol，L2HDBD

「吋pe

Dynamicslngletype

Pressure setting

17．2MPa（175kgf／cm2）［2490psi］

Steering pump

Usedalsoasmainpumpl）

SteerlngCylinder r吋pe

Double−aCtlngPIStOn

Q ty

2

Cylinderstroke

395mm［15．6in．］

Weight（perpiece）

17kg［37．51bs］

Note：1）Forthespecificationsandconstructionofthemainpump，referto

6．2PUMP．

4．1GENERALDESCRIPT10N ThesteerlngSyStemisaframe−aCtuatlngtyPeWhichsteerstheloaderbyoperatlngthetwosteerlngCylinders installedbetweenthefrontandrearframes．

Fig．4．10rbitroITypeSteerlngSystem −101−

4．STEERINGSYSTEM

Itusesanorbitrol（fu11−hydraulicpowersteering）whichdoesnotuseanylinkagemechanismbutop on hydraulic power alone.

ThesteerlngSyStemCOnSistsofthesteerlngWheelunit，Orbitrol，Pr10rltyValve，SteerlngCylindersando tubing．

AIfthepressurizedoilisnotsuppliedfromthepumpwiththeengineatrest，theorbitrolactsas

manualsteeringsystem，thusmakingitpossibletosteertheloaderlHowevelちnOtethatthestee operationisconsiderablyharderthanusual・ STEER［NGWHEEL

STEERINGWHEELUMT PR10R［TYVALVE

ORBITROL

STEERINGCYLINDER

Note：Theabovesketchdoesnotillustratetheoiltubing． Forthetubing，reftrto‖6・HYDRAULICSYSTEM・ Fig．4．2 SteerlngSystem −102−

4．STEER［NG SYSTEM

4．2 01LCIRCULAT10N ROUTES TheoilpickedupftomtheoiltankbythemainpumpISSentunderpressuretotheprlOrltyValvewhereit isdividedintotwoportions：Onefbrthemainhydrauliccircuitandoneforthesteerlnghydrauliccircuit・

ThesteerlnghydrauliccircuitusestheloadsenslngSyStemSOthattheorbitrolreceivesthenecessary

amountofoilfromtheprlOrltyValve，Withtheresidualamountofoilbeingsenttothemaincircuit・When

SteerlngWheelisturned，theoilissentintothesteerlngCylinderforsteerlngtheloader・Theoildisc fromthesteerlngCylinderreturnsintotheorbitrolfromwhichitreturnsintotheoiltank・ Note：FortheoperationoftheloadsenslngSyStem，reftrto＝4・5PRIORITYVALVE・

STEERlNG WHEEL

OIL TANK

Fig．4．3 HydraulicCircuitDiagram −103−

4．STEERINGSYSTEM

4．3 STEERINGWHEELUN］T Thesteeringwheelunitisinstalledinthecockpit・Belowitisthesteeringvalve（Orbitrol）・When

steerlngWheelisturned，therotationistransmittedthroughthesteerlngShaftwhichinturnactuatesthe orbitrol．

∵

Assembled view

Note：B＞ぢ＝コSteeringvalveinstallationbolt： 34．3to40．2N−m（3．5to4．1kgf−m） ［25．3to30．01bf一明

匡＞忙＝⊃もSplinedarea‥mOlybdenumgrease ConstructionofSteerin

B＞紹＝ゝWaterproofseal

Wheel Unit

匡＞〆＝＝恥Grease

匪＞紹＝ゝSyntheticrubberadhesive

1．STEERINGWHEEL 2．STEERINGWHEELUNIT 3．MOUNTRUBBER 4．BRACKET

5．SOUND−ABSORBINGMAr

9．BEARING

6．STEERINGVALVE 7．BUSHING 8．GROMMET

10．COLUMN ll．STEERINGSHAFT

Fig．4．4 SteerlngWheelUnit −104−

4．STEERING SYSTEM

4．4STEERINGVALVE（ORBITROL） TheorbitroIconsistsofthecontroIvalveandtherotorset． ThecontroIvalveisarotaryvalvewhichchangesthealignmentofoilpassagesbyrotatlngltSelf，thus actuatlngthesteerlngCylinders．TherotorsetislocatedunderthecontroIvalve・

UsuallyitactsontheoilmotortoperR）rmmeterlngfunction・Inanemergency，1tisusedasahandpump

andactsasamanualsteerlngunit．

R

L

」

T LS P （Cjrcuitdjagram）

L，R：CYLINDERPORT

P ：PUMPPORT T ：TANKPORT LS ：LOADSENSINGPORT

View100kingfromZ

Note：圧＞l芯＝コ28．4N−m（2．9kgf−m）［21．01bfLft］ Fig．4．5 0rbitrol −105−

4．STEERING SYSTEM

（8）

（4） 巌

Detai10fareaB 1

10 9

1

2 113141

（Gerotorstarmountingposjtion）

O 7

U

6 5

4

3

B 4 2

2

5 2

1

SectionA−A

1．ENDCAP 2．SPACER 3．SPACERPLATE 4．DRIVE 5．HOUSING 6．SPOOL 7．SLEEVE 8．PIN 9．NEEDLEBEARING

10．OmSEAL ll．SEALGLANDBUSHING 12．DUSTSEAL 13．RETAININGRING 14． 0 −RING

15．FLArSPRING 16．CENTERINGSPRING 17．BALL 18．CHECKVAIJVEBODY Fig．4．6 ConstructionofOrbitrol −106−

19．CHECKVAI」VEPOPPET

20．GUIDE 21．SPRING 22．ADAPTERSCREW 23．GEROTOR 24．DRIVE 25．GEROTOR 26．ORIFICEPLATE

4．STEERING SYSTEM

Orbitrol Operation （1）Steeringwheelinneutral

TheoilfromthePportflowsintothecavitybetween

thespool（2）anddriveshaft（3）throughthesmall OPeningsofthesleeve（1）andthespool（2）・Theoilin

thecavityflowsoutfromtheTportthroughtheupper PartOfthedriveshaftandnotchgrooveofthespooland Sleeve．TheRandLports（Cylinderports）areclosedby

thespool．

Fig．4．7 NeutralState （2）れ1rningsteeringwheelcounterclockwise

WhenthesteerlngWheelisturnedcounterclockwise， thespool（2）isrotatedwithrespecttothesleeve（1）to Closetheneutralflowpassage（Smallopenings）・The

OilformthePportpassesthroughthechangedover SleeveopenlngS，SPOOlgrooveandsleeveopenlngSand issenttotherotorsetsectionthroughtheoilpassageof thehousing（4）torotatetherotor（5）・

Theoildischargedbyrotationoftherotorissentto thecontroIvalvesectionandthenflowsfromtheLport intothesteerlngCylinderthroughthesleeveandspool・

TheoildischargedfromthesteerlngCylinderreturnS totheRportandflowsoutfromtheTportthroughthe Sleeveandspool． Note：Whentherotorrotates，thedriveshaftandthe

Sleeverotatetogether．

Fig．4．8 CounterclockwiseRotation

Namely，ifthesteerlngWheelistumedtorotate thespool，thesleeveisalsorotatedequally， therebynullifyingspooldisplacement・

Consequently，therotorisrotatedcorresponding totherotationangleofthesteerlngWheel，and theoildisplacedbytherotorissenttothe Steering cylinder．In actualsteering the followlngmOtionofrotortosteerlngWheelis executedcontinuously．

Fig．4．9 RotorSetSectioninOperation −107−

4，STEERING SYSTEM

（3）TtLrningsteeringwheelclockwise

WhenthesteerlngWheelisturnedclockwise，therotor

rotatesinadirectionoppositetowhenthesteerlngWheel isturnedcounterclockwise，therebyinvertlngOilintake anddischargebytherotor・

TheoilflowsfromtheRportintothesteering cylinders，andtheoildischargedfromthesteering CylindersreturnstotheLport・

Fig．4．10 ClockwiseRotation （4）Emergencyoperation

Whenthehydraulicoilisnotsuppliedfromthepump duetoenglneStOP，theod，itroIservesasanemergency

steerlngunit・WhenthesteerlngWheelisturned，rOtation istransmittedtothedriveshaft（3）andtherotor（5） throughthespool（2）andcrosspin（6）・Therotor，Put intorotation，drawsinoil．

Negativepressureiscreatedintheoilpassage，SO

thatthecheckvalve（7）isopenedtodrawinoilfromthe Tport・

Theoildischarged丘・Omtherotorissenttothesteerlng

cylinderthroughthecylinderporttosteertheloader・ TheoildischargedfromthesteerlngCylinderreturnsto anothercylinderportandisdrawnintotherotorthrough thecheckvalve（7） Note：Incaseofemergencyoperation，thesteerlng

wheelishardertoturnthaninnormaloperation．

−108−

Fig．4．11 EmergencyOperation （ClockwiseRotation）

4．STEERrNG SYSTEM

（5）Operationofcenteringspring

WhenthesteerlngWheelisturned，thecenterlngSPrlngisdeた）rmedcorrespondingtotheclearancebetween thecrossplnandspool．

WhenthesteerlngWheelisreleasedorlocked，thesleeveisrotatedbytensionofthecenterlngSPrlng，

restorestheneutralposition・Inthisstate，rOtationcontinuesataglVenturnlngangleuntilthesteerlngWhee isturnedagaln． Thus，thedeformationrecoveryofthecenterlngSPrlngaCtSaSfeedbackofthesteerlngmeChanism・

（6）Pportcheckvalve AcheckvalveisbuiltinthePportoftheorbitrol． Thischeckvalvefunctionsasfollows：

WhenthesteerlngWheelisturnedclockwise，andthesteerlngCylindersreachitsstrokeend，thepres attheRportsideoftheorbitrolisincreasedtothereliefsettlngPreSSure・

Ifinthisstate，thesteerlngWheelisreleased，thewholesystemrestorestheneutralstate・Buthighpressu OilmayreturnintheRport，Sincethecylinderportsideisblocked・

Afterthat，WhenthesteerlngWheelisslowlyturnedclockwise，namelyinthesamedirectiona mentionedabove，theRportoforbitrolisconnectedtothePportthroughtherotor・Therotorisimmediat rotatedbyresidualpressureinthePport，SOthatoilflowsbacktothePport・

Astherotorismechanica11yconnectedtothesteerlngWheelthroughtheinternalpartsoftheorbitrol，the steeringwheeltendstoberotatedinreversedirection（COunterClockwise），OPPOSitetosteeringdir （clockwise）．ThecheckvalveisbuiltinthePportoftheorbitroltopreventsuchareverseturn・

−109−

4．STEERING SYSTEM

4．5 PR10RITYVALVE TheprlOrltyValvecombineswiththeorbitroltoformtheloadsenslngSyStemWhichdistributestheoil

dischargedfromthemainpumptoboththesteerlngandhydraulicsystems・TheprlOrltyValveispr withareliefvalveforthesteerlnghydrauliccircuit・

13＜瑠

A斗

SectionA−A

Note：B＞ぢ＝コ20．6N−m（2．1kgf−m）［15．21bf−ft］ LS CF EF

匪＞ぢ＝コ44．1N−m（4・5kgf−m）【32・51bf−ft］

P：Pumpport（fromMAINPORT） T：Tankport（toOILTANK） LS：Loadsensingport（fromORBITROL） EF：Maincircuitport（toCONTROLVAI〃E） CF：Steeringcircuitport（toORBITROL）

1．HOUSING 2．SPOOL

5．RING

10．SPRINGGUIDE

6．VAI」VESEAT

ll．ADJUSTMENTSCREW

3．SPRING

7．BODY 8．POPPET 9．SPRING

12．PLUG 13．PLUG

4−11．RELIEFVALVE

4．SCREEN

Fig．4．12 Prioritylね1ve −110−

4．STEERING SYSTEM

LoadSensingSystemOperation

Theloadsensingsystemallowsonlytheamountofoil（OutOftheoildischargedfromthemainpum necessaryforsteerlngOPerationtoflowintotheorbitroIwhilelettlnga11theremainlngOilflowintotheload handlingsystem（COntrOIvalve）・

Forexample，WhenthesteerlngWheelisinneutral，mOStOftheoildischargedfromthemainpum

directedintothecontroIvalvefortheoperationoftheloadhandlingsystem，SOthattheoildischargedfrom

themainpumpisefncientlyusedtoachieveamoreenergy−SaVlnghydraulicsystemdesign・ （1）Steeringwheelinneutral（engineatrest）

Whileengineisatrest，thespool（1）ofthepriorityvalveiskepttotheleftinthefigureduetotheco SPring（2），WiththeCFportfu11yopenandtheEFportfu11yclosed・

Fig．4．13 SteeringWheelinNeutral（EngineatRest） −111−

4．STEERING SYSTEM

（2）Steeringwheelinneutral（enginerunning）

①ThepressurizedoilfromthemainpumpentersthepriorityvalvethroughthePport，andthendi intobranches． ②ThepressurizedoilenteringtheorbitrolthroughtheCFportwillgetblockedinsidetheorbitrol，th flowingintothechambers（A）and（B）throughtheorificesClandC2reSPeCtively・ ③Sincethepressurizedoilinthechamber（B）entersthehydraulicoiltankthroughtheLSport丘■Omt orbitrol，theorificeC2Willcausethepressureinthechamber（B）tobecomelowerthanthat Chamber（A）．

WhenthepressuredifferentialexceedsthecontroIspringpressureofthespring（2），thespool（ Shiftedtotherightinthefigure・

④Consequently，theEFportofthepriorityvalveisfu11yopened，WhiletheCFportisslightlyopened・

Mostofa11theoildischargedfromthemainpumpISrOutedtothecontroIvalvetooperatetheload handlingsystem．

Fig．4．14 SteeringWheelinNeutral（EngineRunning） −112−

4．STEERING SYSTEM

（3）Whensteeringwheelisinrotation

①Whenthesteeringwheelisturnedfromneutral，theoilpassagesintheorbitrolareswitchedo

allowtheoilinthechamberAandCFportoftheprlOrltyValvetoenterthegerotorthroughtheorifice C4．

②Withthepressurizedoilenteringthegerotor，thepressureinthechamberAdecreasesaccordinglyso

thatthespool（1）ofthepriorityvalvemovestoapositionwherethepressuredifferentialbetween PreSSureChambers（A，B）andthecontroIspring（2）strikesabalance，thusdeterminingtheratioofthe flowtoEFport，COnCernlngtheoildischargedfromthemainpump・

③TheopeningoftheorificeClinsidetheorbitrolisdetermineddependingonthespeedatwhicht

SteerlngWheelisturned．ThequickerthesteerlngWheelisturned，thewidertheorificeopens・Th

Sloweritisturned，thenarrower・Consequently，WhenthesteerlngWheelisturnedquickly，mOre

flowstotheCFporttoquickensteerlngOPeration．

GEROTOR

Fig．4．15 SteeringWheelinRotation

一113−

4．STEERING SYSTEM

（4）Whensteeringcylinderisatstrokeend

①ThepressurizedoilenteringthegerotorpassesthroughtheLSportandtheorificeC30fthepri valve，thusactinguponthechamber（B）・

②Whenthesteeringwheelisturnedtoitsstrokeendateitherofitsrotationaldirections，thepressur thechamber（B）inthepriorityvalveincreaseswithincreasingcircuitpressure・

Whenthepressureinthechamber（B）reaches17・2MPa（175kgf／cm2），thereliefvalve（3）oft priorityvalveisactuatedtoreducethepressureinthechamber（B）・

③Whenthepressureinthechamber（B）isreduced，aPreSSuredifftrentialiscreatedbetweenthepres chambers（A，B）throughtheorinceC2・

④Consequently，theEFportofthepriorityvalveisfu11yopened，WhiletheCFportisslightlyopened・ MostoftheoildischargedfromthemainpumpISrOutedtothecontroIvalve・

Fig・4・16 SteerlngCylinderatStrokeEnd −114−

4．STEERrNG SYSTEM

4，6 STEERINGCYuNDER TwosteerlngCylindersofdoubleactlngPIStOntyPeareuSed，Withthepistonrodandcylindertubeconnected tofrontandrearftames，reSPeCtively．Theloaderissteeredbythepistonrodextendingandretractlng・

「

ニ

」 ＿

臣臣り臣臣

卜．2．い．4∵い．6．

Note：

304N−m（31kgf−m）［2241bf−q，正＝ゝThreadedarea：ThreeBondチ1901 613N−m‡62．5kgf−m）［4521bf−ft］

6．9N−m（0．7kgf−m）【5．11bf−ft］（Aftertightening，Calk2parts．）

76．4±3．8N−m（7．8±0．4kgf−m）［56．4±2．91bf−ft］

17．2±0．9N−m（1．8±0．1kgf−m）［13．0±0．71bf−ft］

Pressurecheckport（PTl／8）． 1．CYLINDERHEAD 2． 0 −RING

3．BACK−UPRING 4．

0

tRING

5．WIPERRING 6．BUSHING

7．一 U −RING

8．PISTONROD 9．CYLINDERTUBE lO．SLIDERING 11．SEALRING／＝0＝−RING

12．PISTON

Fig．4．17 SteerlngCylinder −115−

13．SETSCREW 14．STEELBALL 15．SPHERICALBEARING 16．SNAPRING 17．PLUG

4B．STEERING SYSTEM

NOTE

一116−

5．FRAMEANDCOCKPIT

5．FRAMEANDCOCKP［T

5．1FRAME Theframeisasteel−Plateweldedtypeanddividedintotwoparts‥丘ontandrearframes・Thecockpita OPeratOr

sseataremountedontherearframe・

ADonottrytomodifytheROPS（Roll−OVerPrOteCtionstructure），ifmounted，withoTtP

permissionfromthemanufacturerlIftheROPSshouldgetdamagedordehrmedduetoturnlngOVer orcollision，itisadvisabletoreplaceitwithanewone，becauseadamagedordefbrmedROP lowstructuralstrength．

ー117−

5．FRAMEANDCOCKPIT

「￣￣…「 」■■」 一一一一一一一一′￣

」−一て￣

1．BALANCEWEIGHT：1080kg［23811bs］ 2．REARFRAME

Note：B＞ぢ＝コ451to676N−m（46to69kgf−m） ［333to4991bf一円

臣＞（芯＝コ225to339N−m（23to34・6kgf−m） Note：Ifthebalanceweightistobeincreased，

thebalanceweightassemblyshallbe

［166to2501bf一珂

replacedasaset．［Option］

（Increasedweight：1550kgor34171bs）

Fig．5．1BalanceWeightAssemblyDrawlng

ー118−

5．FRAMEANDCOCKPIT

5．2 CENTER HINGEPIN Theloaderisaframe−articulatedtype‥thefrontframeisJOinedtotherearframewithtwohingeplnS aroundwhichtheloaderpIVOtSforsteerlng・

Awhentheloaderissteered，theareanearthe CenterhingepinsbecomessonarrOWthatyoumight

getcaughtbetweenthefrontandrearframes・Ben）re tryingtoservicetheloadeI；makesuretosetthesafbty link． Priortomoving（traveling）theloadeIちmakesurethe Safbtylinkissetattheoriginalposition・

Fig．5．2SafetyLink

ー119−

5．FRAMEANDCOCKP［T

Upper hinge

二

9く司く司

DetailsofareaA

Lowerhinge

Note：B＞β＝＝恥Innersurface：Grease（Bebreapinisinstalled）

P＞ぢ＝コ62．6N−m‡6．4kgf−m）［46・31bfLft］ B＞ぢ＝コ549N−m（56kgf−mi［4051bf−ft］

駐＞紹＝ゝThreadedarea：LOCTITE＃262

7．SHIM

3．BUSHING 4．GREASEFITTING

8．FLANGE 9．U−NUT

5．LOWERHINGEPIN

lO．DUSTSEAL

4 1

Fig．5．3 CenterHinge −120−

AR

2．BUSHING

2 1 3 1

6．COLLAR

P肌LLBB

L 1

1．UPPERHINGEPIN

6．HYDRAUuCSYSTEM

6．HYDRAULICSYSTEM ThehydraulicsystemusesthemainpumpasitspowersourceanddirectsoilflowwiththecontroIvalve

accordingtotheworkyouwanttodo・

Thehydraulicsystemconsistsofthemainpump，COntrOIvalve，ValvecontroIs，Oiltank，andhydrau plplng・

6，10ILC］RCULAT10N ROUTES Thehydrauliccircuitoftheloaderconsistsofthemainhydrauliccircuitandsteerlnghydrauliccircuit・ Forthesteerlnghydrauliccircuit，referto

4．20ILCIRCULATIONROUTES・

MainHydrauIicCircuit

Theoilpickedup丘・OmtheoiltankbythemainpumpisdirectedintotheprlOrltyValvewhereitisdivide intotwoportions‥Oneforthemainhydrauliccircuitandtheotherforthesteerlnghydrauliccircuit・

TheoilfbrthemainhydrauliccircuitisroutedtothecontroIvalve・WhenthecontroIvalveisinneutra

theoilpassesthroughthecontroIvalvebackintotheoiltank・ Whentheloadhandlinglever（COntrOllever）isoperatedtoshiftthespoolofthecontroIvalve，theo

flowsthroughtheoilpassagechosenbythespoolintothecylinder・Theoildischargedfromthecy PaSSeSthroughthecontroIvalveandreturnsintotheoiltank・Intheoiltank，areturnfilterisinstalled・

−121−

6．HYDRAULICSYSTEM

BUCKET CYLlNDER

OILTANK Capacity：Refrenceleve180L

Fig．6．1HydraulicCircuitDiagram −122−

BOOM CYLlNDER

6．HYDRAULICSYSTEM

6．2 PUMP Mainpump Name

SB（1）21

Type

Gear type

Drive

Geartype（attachedtothesteeringpump）

Discharge（unloaded）

52L／min［13．7gpm］at2550rpm，

0．98MPa（10kgf／cm2）［142psi］ 14．9kg［32．91bs］（W／steeringpump）

Ⅵ厄ight

SteerlngPumP

（Usedincommonwithmainpump） Name

SAR（2）50

lサpe

Geartype

Drive

Gear type

Discharge（unloaded）

124L／min［32．8gpm］at2550rpm，

（0．98MPa†10kgf／cm2）［142psi］）

Chargingpump SDYIA36・16

Name

GeartyPe，tWO−WayPumP

「吋pe

Gear type

Drive

Discharge（Front）

87L／min［23gpm］at2380rpm，

2．2MPa（22kgf／cm2）［319psi］ （Rear）

38L／min［10．Ogpm］at2380rpm，

（0．2MPa（2kgf／cm2）［28psi］） 6．8kg【15．01bsl

Theloaderusestwopumps：themainpumpandcharglngPumP，Whichareattachedtotheconverter houslnganddrivenbythepumpdriveofthetorqueconverter・ TheyalwaysrotateastheenglnerunS・

Note：Fortheinstallationofthechargingpump，reftrto 2・1DRIVEUNIT・ 6．2，1MAIN PUMP

ThemainpumpISageartyPeWhichdoublesasthesteerlngPumP・

ThemainpumppicksuphydraulicoilfromtheoiltankandsendsittotheprlOrltyValvewhereitis

dividedintotwoportions：Onefbrthesteerlnghydrauliccircuitandoneforthemainhydrauliccircuit・

−123−

6．HYDRAULICSYSTEM

1．MAINPUMP

2．PUMPDRIVESLEEVE 3．TORQUECONVERTER Fig．6．2 MainPumpInstallation

6．2．2 CHARGINGPUMP（BRAKEPUMP）

Theloaderusesageartypetwo−WayCharglngPumP・TheftontpumpISuSedasadriveunitchargln PumPandtherearpumpISuSedasabrakepump・

Thistwo−WayPumP，PrOVidedwithonesuctionport，Picksupoilfromthetransmissionsumptank・Th

oilflowsunderpressurethroughthedischargeportofthefrontpumptothetransmissioninlinefilterand throughthedischargeportoftherearpumptothebrakevalve，reSPeCtively・

一124−

6．HYDRAULICSYSTEM

SECONDPUMP

Directionofrotation：CJockwise ＿・・三、

FIRST PUMP

12 3 4 5 6 7 8 91011，1213

14 15

16171819 20 212223

1．DRIVEGEAR（NO．1） 2．SNAPRING 3．OILSEAL

7．SIDEPLÅl E 8．GEARCASE 9．DRIVENGEAR（NO．1）

4．PLATE 5．BRACKET 6．DOWELPIN

10． 0 −RING ll．SEAL 12．BACK−UPRING

13．CARRIER

19．DRIVENGEAR（NO．2）

14．COUPLING 15． 0 −RING 16．BRACKET 17．DOWELPIN

20．GEARCASE

18．DRIVEGEAR（NO．2）

④SUCTIONPORT

⑧FIRSTPUMPDISCHARGEPORT ◎sECONDPUMPDISCHARGEPORT Fig．6．3 MainPump −125−

21．SEAL 22．SIDEPLArE 23．COVER

6，HYDRAULICSYSTEM

9 10

1112 13 14 15161718

lnside construction

1．DRIVEGEAR（No．1）

2．OmSEAL 3．GASKET 4．SIDEPLArE 5．BODY 6．DRIVEGEAR（No．2）

7．BUSHING 8．BODY 9．FRONTCOVER lO．BUSHING

13．ADAPTERPLArE 14．GASKET 15．STEELBALL

ll．DRIVENGEAR（No．1）

17．SIDEPLATE 18．GASKET

12．GASKET Fig．6．4 ChargingPump −126−

16．DRIVENGEAR（No．2）

6．HYDRAULICSYSTEM

6，3 CONTROLVALVE KVS−120H−2

Parallel type 2−SPOOIslidingtype（W／reliefvalve）

Mainreliefpressuresettlng

20．6MPai210kgf／cm2）［2987psi］

16．2MPa（165kgf／cm2）［2347psi］ Portreliefpressuresetting（Bucketcylinderrodside）

21kg【46．31bs］

Ⅵ厄ight

6．3．1GENERALDESCRIPT10N

ThecontroIvalveisstacked，2−SPOOIslidingtypeconsistlngOftheinletsection，tWOSPOOIsectio

Outletsection・TheoilpassagesinsidethevalvearetandemtypeandthebucketoilpassagehasprlOrltyO theboomoilpassagesothattheoilissuppliedtotheboomsectiononlywhenthebucketspoolisinneutral・ Note：ForthecontroIvalveinstallation，SeeFig．6．21． （1）Reliervalve

ThecontroIvalveisprovidedwithareliefvalvethatserveStOPrOteCttheentirehydrauliccircuitofthe loadhandlingsystemwhilecontrollingtheoperatlngPreSSure・

Thecylinderportleadingtothebucketcylinderrodsideisnttedwithaportreliefvalvewhichrelievesthe Oilpressurewhenthecylinderreceivesaloadheavyenoughtocausethepressureatthecylinderporttorise beyondthespecifiedvalue，thusprotectlngthecylinderandthepiping・

（2）Detentmechanism

①Amechanicaldetentisprovidedatthepositionwheretheboomspoblisfu11yextendedoratthebo

floatposition． ②Asolenoiddetentisprovidedatthepositionwherethebucketspoolisfu11ypushedin，Oratthebucket roll−backposition・Thedetentmechanismisoneoftheelementsconstitutlngthebucketleveler，SOthat

itdoesnotfunctionwhenthebucketiswithintherangefromhorizontaltoroll−backposition・

−127−

6．HYDRAULICSYSTEM

Parallelcircuit

Note：B＞ぢ＝：：コ（2locations）：64．7N−m（6．6kgf−m） ［47．71bト珂

臣＞ぢ＝コ101N−m（10・3kgf−m）［74・51bf−ft］ 匝＞ぢ＝：：コ78to88N−m（8to9kgf−m）［58to651bf−ft］ 1．MAINRELIEFVALVE 2．INLETSECTION 3．PORTRELIEFVALVE

4．SPOOLSECTION（BUCKET） 5．OUTLETSECTION

6．白pooLSECTION（BOOM） Fig．6．5 ControIValve −128−

＝D．C．24V

6．HYDRAULLCSYSTEM

（BUCKET卜

4．VAI」VEHOUSING

CAP

3．SEAL

／hU

2．WIPER

5

1．SPOOL

9．COILTUBEASSEMBLY 10．CHECKVALVESPRING ll．CHECKVALVEPOPPET

7

1．SPOOL 2．WIPER 3．SEAL 4．VAINEHOUSING 5．SPRING

8

（BOOM）

11．DETENTSPACER

6．DETENTPIN 7．DETENTSPRING

12．SHIM（t＝0．5mmOrO．0197in．）

8．CAP 9．DETENTSLEEVE lO．STEELBALL

13．CHECKVAIJVESPRING 14．CHECKVALVEPOPPET

Fig．6．6 ConstructionofSpooISection −129−

6．HYDRAUuCSYSTEM

6．3．2 0PERAT10N

Whenthecontrolleverisactuated，theoilpassagesareswitchedoverbythespooIssothatthepressurized Oil放■OmtheprlOrltyValveisselectivelysenttothebucketorboomcylinder．

Theboom Float positionandbucket Roll−back positionhavedetentmechanismswhichautomatically holdthatposition，keeplngthespoolfromreturnlngtOneutralwhentheoperatorremoveshishandfromthe

lever・ThecontrolleverautomaticallyreturnstoneutralfromoperatlngPOSitionsotherthanthe Float and Roll−back positions．

1．ControlValveinNeutral

①WhenthespooIsofthebucketsectionandtheboomsectionareinneutral，boththecylinderportsA（rod Side）andB（tailside）areclosedbythespooIs．

②ThepressurizedoilwhichhasreachedthecontroIvalveflowsthroughtheinletsection，PaSttheneutr OilpassagesinthebucketspooIsectionandtheboomspooIsectiontotheoutletsectionfromwhichitis

directedtothelow−PreSSureOilpassageandleavesthecontroIvalvethroughtheexhaustportoftheinlet SeCt10n．

Note：AstandardtypevalveoftheKVSseriesisusedforthengureshowlngeaChoperation・Theshap maybedifftrentfromtheactualvalve・

Fig・6・7 ControlValveinNeutral（BucketSpooISection）

−130t

6．HYDRAUuCSYSTEM

2．BucketSpoolOperation （1）Roll−back

①Whenthecontrolleverisplacedinthe

Roll−back

position，thebucketspoolispushedinasshown

Fig．6．8．

②Theneutraloilpassageisclosedbythespoolandthepressureoilpushesopentheloadcheckvalv flowtothecylinderport（Bl）fromwhichitisdirectedintothebucketcylindertail・

③Theoildischargedfromthebucketcylinderrodsideflowsthroughthecylinderport（Al）tothelow− PreSSureOilpassageandbacktotheoiltank・

Fig．6．8 BucketinRoll−back （2）Dump ①Whenthecontrolleverisplacedinthe

Dump

position，thebucketspoolispulledoutasshowninFig

6．9．

②Theneutraloilpassageisclosedbythespoolandthepressureoilpushedopentheloadcheckvalv

flowtothecylinderport（Al）fromwhichitisdirectedintothebucketcylinderrodside・ ③Theoildischargedfromthebucketcylindertailsideflowsthroughthecylinderport（Bl）tothelow− PreSSureOilpassage．

Fig．6．9 BucketinDump −131−

6．HYDRAUUCSYSTEM

3．BoomSpoolOperation （1）RaiseandDown TheoilpassageintheboomspooIsectionisidenticalwiththatofthebucketspooIsection・Therefore，

boomralSlngOPerationisidenticalwiththebucketroll−backoperationwhereasboomlowerlngOPerationis

identicalwithbucketdumpoperation・Forthedetailsofboomoperation，Seethepertinentsectionsofb OPeration・

Note：PressurizedoilisnotsuppliedtotheboomspooIsectionunlessthebucketspoolisinneutralsince theoilpassagesinthecontroIvalveformatandemcircuit・（Theboomcylinderisnotactuated・） （2）Float

①Whenthecontro11everisfurtherpusheddownfromthe

Down

positiontothe

Float

position，th

boomspoolispulleddownasshowninFig・6・10・

②Duetothismotiontheneutralpassageisopened．Thepressureoilflowsasifinneutralposition・ ③Thecylinderports（A2）and（B2）areconnectedtothelow−PreSSureOilpassage・Asaresult，thebooms floatoverthegroundsurfaceaccordingtoitsirregularities・Theoildischargedh・Omtheboomcyl

rodsideissenttothetailsideandtheoilforcedoutfromitstailsideissenttotherodsiderespectively throughthelow−PreSSureOilpassageinthecontroIvalve・

Fig．6．10 BoominFloatlng

−132−

6．HYDRAULICSYSTEM

4．DetentOperation （1）Boomside

①WhenthecontrolleverispushedR）rWardfu11yto the

Float

position，theboomspool（1）ispulled

OuttOthefull．Duetothis，thedetentpin（2） installedinthespoolendshiftsandthedetentball （3）fallsintothegrooveofthedetentsleeve（4）・ ②Sincethedetentballsarepushedbythespring（5），

theboomspoolholdsitsposition，andthedetent becomesoperative． ③Toreleasethedetent，Pullthecontrolleverto

disengagethedetentballs． Fig．6．11BoomSideDetentinOperation

（2）Bucketside

①Theelectromagneticdetentisusedonthebucketsection．Theelectricalcircuitisconnectedfromth

batterytotheproximltySWitchofthebucketlevelerthroughthecoilassemblyofthebucketspooI

section． ②Whenthebucketistiltedforward，theproximityswitchiselectricallyclosedsothatthecoilassemb （4）isexcited．

③Whenthecontrolleverispulledoutfu11ytothe

Roll−back

position，thebucketspool（1）isfu

PuShedinandthepin（2）atthespoolendisalsopushedin，SOthattheplate（3）contactsthecoil（4）・As aresultthebucketspoolholdsitsposition，andthedetentbecomesoperative・

④Tbreleasethedetent，electricallyopentheproximityswitchtode−energizethecoilassemblyorop

thecontrolleverbyhand． 1

2

3

Fig．6．12 BucketSideDetentinOperation

−133−

6．HYDRAULJCSYSTEM

6．3．3 RELIEFVALVE 1．MainReliefValve Themainreliefvalveislocatedbetweentheneutraloilpassageandthelow−PreSSureOilpassage（ret Oilpassage）intheinletsection・

Operation （1）Ininoperativestate

Thepressurizedoilintheneutraloilpassage（HP） flowsthroughthethrottlehole（2）inthemainpoppet （1）to丘11theinternalcavity（3）．Owingtothedifftrence

inareaonwhichthehydraulicpressureacts，themain POPPet（1）andthesleeve（4）aresecurelyseated・

Fig．6．13InInoperativeState

（2）Operation（A）

Whenthepressureintheneutraloilpassage（HP） risesenoughtoexceedthereliefpressuresettlng，the Pilotpoppet（5）opens・Thepressurizedoilflowsaround thepilotpoppetintothelow−PreSSureOilpassage（LP）， PaSSingbetweenthesleeve（4）andthehousing（6）・

Fig．6．14 0peration（A）

（3）Operation（B）

Asthepilotpoppet（5）opens，theoilpressureinthe internalcavity（3）lowerssothatthepressurizedoilin

theneutraloilpassageflowsdirectlylntOthelow− PreSSureOilpassage（LP）・

Fig．6．15 0peration（B）

−134−

6．HYDRAULICSYSTEM

2．PortRelierValve

Theportreliefvalveislocatedbetweentherodsidecylinderportandthelow−PreSSurePaSSage（retu PaSSage）inthebucketspooIsection．

Thecombinationvalveused丘）rtheportreliefvalvehasalsoananti−CaVitationfunctionaswe11asr Valvefunction．

Operation （1）Ininoperativestate

｛＿

Thepressurizedoilinthecylinderport（HP）flows throughtheholeofthepistonpoppet（1）andactsfrom theoppositesideofthecheckvalvepoppet（2）andthe reliefvalvepoppet（3）．Owingtothedifftrenceinarea OnWhichthehydraulicpressureacts，thepoppetis

SeCurelyseated．

Fig．6．16InInoperativeState

（2）0peration（A）

Whenthepressureintheneutraloilpassage（HP） risesenoughtoexceedthereliefpressuresettlng，the Pilotpoppet（4）opens．Thepressurizedoilflowsaround thepilotpoppetintothelow−PreSSureOilpassage（LP），

PaSSingbetweenthecheckvalvepoppet（2）andhousing （5）．

Fig．6．17 0peration（A）

（3）Operation（B）

Asthepilotpoppet（4）opens，thepressureattherear

Sideofthepistonpoppet（1）lowerstoshiftthepiston

POPPet・Theholeofthepistonpoppet（1）isclosedby thepilotpoppet（4）andthepressureattherearsideof thereliefvalvepoppet（3）lowersfurther．

Fig．6．18 0peration（B）

−135一

6．HYDRAULICSYSTEM

（4）Operation（C）

Thepressureacrossthereliefvalvepoppet（3） becomesunbalanced，andthedifftrenceofthepressure Shiftsthereliefvalvepoppet・Asares、ult，thepressurized

Oilinthecylinderport（HP）flowsdirectlyintothelow− PreSSureOilpassage（LP）．

Fig・6・19 0peration（C）

（5）Suckingoperation

Ifthepressureatthecylinderport（HP）becomeslower thanthatatthelow−PreSSureOilpassage（LP）duetothe

LP

2

developmentofcavitation，thecheckvalvepoppet（2）

movesdependinguponthedifftrenceinareaonwhich

negativepressureactsacrossthecheckvalvepoppet・ Consequently，Oilissuppliedfromthelow−PreSSureOil PaSSage（LP）tothecylinderportside（HP）toeliminate

thecavitation． Fig・6・20 SuckingOperation

ー136−

6．HYDRAUuCSYSTEM

6．4 VALVECONTROLS

ThevalvecontroIsystemisaslnglelevertype・WhenthecontrolleverismanlPulated，thecontroIval

SPOOIsareOPeratedbythecables；ShiftingtheleverbackandforthwillactuatetheboomspooIwhileshifting theleversidewayswillactuatethebucketspool・

ADSSswitchisbuiltinthecontrolleverknob．FortheDSSmechanism，referto

2．3．4TRANSMISSION

CONTROL．

AAsasabtydevicn）rthevalvecontroIsystem，aStOPPerlinkisprovided・Usethestopperlinkt lockthecontrolleverlnneutralwhentheloadhandlingsystemdoesnotneedtobeused．

−137−

6．HYDRAULICSYSTEM

Note：D＞紹＝ゝThreadedarea：LOCTITE＃262 臣＞l⊂＝：恥Applygreasewheninstalling・

1．KNOB（DSSSWITCH）

2．BOOT 3．COVER 4．CONTROLBOX 5．PLATE 6．CONTROLVALVE 7．BRACKET

8．MOUNTRUBBER 9．CONTROLLEVER lO．BUSHING

15．STOPPERLINK 16．SPRING

ll．PⅡ寸

18．BALLLINK

12．BUSHING 13．BOSS 14．BRACKET

20．CABLE（FORBOOM）

17．HANDLE（LEVERSTOPPER） 19．CABLE（FORBUCKET）

Fig．6．21ValveControISystem −138−

6．HYDRAULICSYSTEM

6．5 01LTANK Pressurized，enClosedtype

「吋pe

Tank capacity CapoperatlngPreSSure

80L（21．1U．S．gal．） Positivepressure：44to54kPa（0．45toO．55kgf／cm2）［6・4to7・8psi］ Negativepressure：4to5kPa（0．04toO．05kgf／cm2）［0・6toO・7psi］

Returnfilter

1pc，15い

Theoiltankholdshydraulicoilforthemainhydrauliccircuitandsteerlnghydrauliccircuit・Itiswe totheinsideofthefront丘・ame．

Thereturnnlterisinstalledintheoiltank．

〜 −・

Return員1ter

Crackingpressure： 98kPa（1．Okgf／cm2）［14psi］

〟J／ノ ′

／． ／

1．RETURNFILTER 2．GASKET 3．LEVELGAUGE 4．HOSE ・ト ヽ ／ ／

5．CAP 6．0ILTANK 7．FRONTFRAME 8．DRAINPLUG

／ノ灯一・一−￣￣￣

9．ELEMENT

：：ミ：：去；；ク

8

」

lO．SPRING ll．PROTECTOR

Fig．6．22 0ilTank −139−

6．HYDRAULICSYSTEM

NOTE

−140−

7．LOAD HANDLING SYSTEM

7．LOADHANDLINGSYSTEM

Theloadhandlingsystemisoperatedbyhydrauliccylindersandisusedtodig，loadandunload， transportloads・ThelinkageemployedfortheloadingsystemisaZ−Shapedtypewhichissimplerindesig

andproducesmorepowerfulbucketbreak−Outfbrcethantheduplexorothertypes・

Fig．7．1LoadHandlingSystem

−141−

7．LOADHANDLINGSYSTEM

7．1BOOM，BELLCRANKANDBUCKET Linkage

Z−Shape

Bucket shape

DEB「吋pel

Bucketcapaclty Heaped

2．Om3［2．4yd3］

Bucketleveler

Provided（non−COntaCttyPe）

Boom kickout

Not provided

Ⅵ屯ight

Boom

793kg［17491bs］

Bellcrank

126kg［2781bs】

Pushrod

47kg［1041bs］

Bucket（Withdoubleedge）

834kg［18391bs］

7．1．1GENERALDESCRIPTION Theloadhandlingsystemconsistsofbooms，be11crank，PuShrod，bucket，bucketcylinder，boomc andpins・Thebucketlevelerandboomkickouthelpsprovideefncientloadhandlingoperation・Allconne plnSOftheloadhandlingsystemhavedustsealstopreventtheentranceofwater，mudordustintothesyste ThethreeconnectlngPlnSOfthebucketareprovidedwithりOM−rings・AlltheconnectlngPlnSareSeCure withlockbolts．

（ThenamesofthepartsinFig．7．2）

1．BUCKETCYLINDER 2．BELLCRANK 3．PUSHROD 4．BOOM 5．BUCKET

6．FRONTFRAME

11．BUSHING

7．SPACER

12．DUSTSEAL

8．BOOMCYLINDER

13． 0 一RING

9．PIN

14．LOCKBOLr

lO．GREASEFITTING

一142−

7．LOAD HANDLINGSYSTEM

Detai10ftypICalpln

（Pinsonbucket）

Note：B＞〆＝＝恥Allpins，bushings，andbosses‥Grease（ApplybeR）reinstallingpins） 臣＞Dustsealmustbeinstalledwithlipfacingoutward． Fig．7．2 Boom，BellcrankandBucket（1） −143−

7．LOAD HANDLING SYSTEM

Procedurefbrmountingthebucketstopper DUMPSTOPPER

Note：Extendthebucketcylinderfu11yandretractitby3mmorO・118in・Afterthatweldthestopper・

Proceduren）rmOuntingplnSrelatedtothebucket ■．−■．

﹁．︐．■．−． ﹂

﹁一1．−一l一L

し

−．−．﹂

①Beforeassemblingthebucketandboomwithtwopins， andbucketandpushrod，Settheパ0＝一ringsasshownin Fig．7．3．

﹁．

②Afterassemblingthebucket，boomandpushrod，aPPly greasetoallperipheriesoftheareasindicatedwitha mark＊andinsert 0 −ringsinthegrooves・

Fig．7．3 Boom，BellcrankandBucket（2） −144−

7．LOAD HANDLING SYSTEM

7．1．2 BUCKET

Thegeneral−PurPOSebucketwithabolt−OnreVerSiblecuttingedge（DEB）isstandard・Thelight−materia

bucketwithweldedcuttingedge（Typel）andthegeneral−PurPOSebucketwithbolt−Onteeth（Type3） OPtlOnallyavailable・

Thebucketshouldbeselectedwithduecare，COnSideringtheconditionofjobsites，thenatureofload

behandled，andtheoperatlngCOnditions・Awrongbucketwillcauseaninemcientoperationandmaycause

themalfunctionoftheloadhandlingsystemaswell． （General・PurPOSebucketwithreversiblecuttingedge，DEB）

Note：E＞ぢ＝コ1070N−m（109kgf−m） ［7881bf一珂

（恥pe3Bucket，B3）

Note：匡＞ぢ＝コ1070N−m‡109kgf−m） ［7881bf一珂

Fig．7．4 Bucket −145−

7．LOAD HANDLING SYSTEM

7．l．3 BUCKETLEVELER

Withthecontro11everputinRoll−backafterdamplngthebucket，thebucketlevelerautomaticallyre thecontrollevertoneutralwhenthebucketisputinhorizontalposition・

Operation

①Asthebucketisrolledback，thebucketcylinderpistonrodextendsenoughtoletthelevelerbarleave thesensingsurfaceoftheproximityswitch（thusopeningtheelectriccircuit）・

②TheproximityswitchisconnectedtothesolenoiddetentcoilofthecontroIvalvebucketsection・The solenoiddetentisthusreleasedtoletthecontrolleverreturntOneutral，StOPPlngtherollingbackoperation ofthebucket．

Note：Thebucketrollbackpositionofthecontrolleverisasolenoiddetentmechanism・Whenthe isrolledbackbeyondthehorizontalline，theelectriccurrentstopsflowlngtOthesolenoiddetentcoil sothatthecontrolleverdetentmechanismwon

twork．

1．BUCKETCYLINDER 2．LEVELERBAR 3．BRACKET 4．PROXIMITYSWITCH 5．CONTROLVALVE 6．WIRING 7．BRACKET

Fig．7．5 BucketLeveler

−146−

7．LOAD HANDLING SYSTEM

7．1．4BOOMKICKOUT（OPT10N）

Theboomkickoutdevicestopstheboomsatapresetheightduringtheliftingphase・Withthecon leverintheRAISEposition，theboomkickoutdeviceautomaticallyreturnsthecontrolleverintoneutral Whentheboomsareraisedtoapresetheight，thusstopplngtheliftingoperationofthebooms・

Operation

（∋Whentheboomsareraisedtoapresetboomkickoutheight，thelevelplateontheboomleavest SenSingsurfaceoftheproximityswitch（thusopeningtheelectriccircuit）・

②TheproximityswitchisconnectedtothesolenoiddetentcoilofthecontroIvalvebucketsection・The SOlenoiddetentisthusreleasedtoletthecontrolleverreturntoneutral，StOPPlngtherollingbackoperati dfthebucket．

Note：ThecontroIvalveoftheloaderequlPPedwiththeboomkickoutisdifftrentfromthatofthestandard loader．

1．PROXIMITYSWITCH

4．LEVELPLATE

2．BRACKET 3．TAPPEDPLArE

5．WIRNG 6．CONTROLVALVE

Fig．7．6 BoomKickout −147−

7．BOOM 8：FRONTFRAME

7．LOADHANDLINGSYSTEM

7．2 CYLINDER BoomCylinder

Type

Double−aCtlngPIStOn

Q ty

2

Cylinderbore

120mm［4．72in．］

Cylinderrodouterdiameter

65mm［2．56in．】

Cylinderstroke

665mm［26．18in．］

Vhight（PerCylinder）

81kg［1791bs］

BucketCylinder r丹pe

Double−aCtlngPIStOn

Q ty

l

Cylinderbore

150mm［5．91in．］

Cylinderrodouterdiameter

85mm［3．35in．］

Cylinderstroke

431mm［16．97in．］

Weight（PerCylinder）

123kg【2711bs］

7．2．1BOOMCYL］NDER

Thetwoboomcylindersareofthedouble−aCtlngPIStOntyPe・Whentheboomcylindersareexten

retracted，theboomsareraisedorloweredrespectively・Theboomcylinderconsistsofacylindertube， Cylinderhead，Pistonrod，andpackings・ 7．2．2 BUCKETCYuNDER

Thebucketcylinderisadouble−aCtlngPIStOntyPe・Asthebucketcylinderisextendedorretracted，

bucketisdumpedorro11edbackthroughthebellcrankandpushrodmechanism・Thebucketcylinderconsist Ofthecylindertube，Cylinderhead，Pistonrod，Pistonandpackings・

−148−

7．LOAD HANDL［NGSYSTEM

5 6 7 Detailofinside L

18

りり臣臣臣

∵∵3．二十二Lい．

e t O N

1060N−m（108kgf−m）［7811bf−ft］，疋⊃ゝThreadedarea：ThreeBond＃1901 2390N−m（244kgf−m）［17651bf−ft］ 56．9N−m（5．8kgf−m）［42・01bf−ft］（Aftertightening，Calk2parts・） 128N−m（13．1kgf−m）［94．81bf−ft］ 17．2N−m（1．75kgf−m）［12．71bf−ft］

1．CYLINDERHEAD

7． U −RING

2．り0 −RING

8．PISTONROD

3．BACK−UPRING 4． 0 −RING

9．CYLINDERTUBE lO．SLIDERING

5．WIPERRING

ll．SEALRING／

6．BUSHING

12．PISTON

13．NUT

14．SETSCREW 0

−RING

Fig．7．7 BoomCylinder

ー149−

15．STEELBALL 16．PINBUSHING 17．WIPERRING 18．PIPE

7．LOAD HANDuNGSYSTEM

‖「

ト

■．

Detail of inside

Note：B＞ぢ＝：：コ442N−m（45．1kgf−m）【3261bf−ft］

匡＞ぢ＝コ4460N−m（455kgf⊥m）［32911bf−ft］ B＞ぢ＝：コ56．9N−m（5．8kgf−m）【42．01bf−ft］（Aftertightening，Calk2parts．） R＞ぢ＝コ118N−m（12・8kgf−m）［92・61bf−ft］ 匪＞Pressurecheckport（PTl／8）

B＞ぢ＝コ39．8±7．5N−m（4．06±0．76kgf−m）［29．4±5．531bf−ft］ 1．CYLINDERHEAD

7．PISTONROD

13．SETSCREW

2．BACK−UPRING 3． 0 −RING

8．CYLINDERTUBE 9．SLIDERING

14．STEELBALL 15．PINBUSHING

4．WIPERRING

10．SEALRING／

5．BUSHING

11．PISTON 12．NUT

6． U −RING

0

−RING

16．WIPERRING 17．PIPE

Fig．7．8 BucketCylinder

ー150−

7．LOAD HANDLING SYSTEM

7．3ANTl−PITCHINGSYSTEM（APS）［OPT10N］ Whentravelingathighspeedonbadroads，Pitchingorbounclngmightoccurandusuallythereisneedto slowdown．

TheAPSsuppressespitchingandbounclngOftheloaderbodytomakeitpossibletotravelinasafeand stablemanner．

Fig．7．9 Anti−PitchingSystem（APS） −151−

7．LOAD HANDLING SYSTEM

1．Generaldescription TheAPSconsistsbasicallyofanaccumulatorwhichisconnectedtothetailsideoftheboomcylinders withhydraulicpIPlng，andasolenoidvalvewhichislocatedatthepIPlngtOCOntrOltheoilpassage・

TheAPSisactivatedbyturnlngtheAPSswitchONanddeactivatedbyturnlngtheAPSswitchO WhentheAPSisactivated，thegasnlledintheaccumulatorworksasasprlngtOallowtheloadhandling

SyStemandtheloaderbodytomoveindependently・Thisrelativemotionoftheloaderbodyandthel handlingsystemdissipatesvibrationenergytosuppresspitchingorbounclngOftheloaderbody，makinglt POSSibletotravelinastablemanneronbadroads・

TheelectricandhydrauliccircuitsofthismechanismconsistprlnCIPallyoftheboomcylinders，aCCumulator travelingdampervalve，APSswitch，COntrOller（ATCunit），andtravelingspeedsensor・

2．Operation ①WhentheAPSswitchisturnedON，thetravelingspeedsensorandcontrollerfuncti？nandthemonitor lamp comes on.

②Whenthetravelingspeedexceeds7km／h［4・3mph］，thesolenoidvalveinsidethetravelingdamper valveisswitchedbythesignalfromthecontroller，tOCOmPletethecircuitbetweenthetailsideofthe boomcylinderandtheaccumulator，thusactivatlngtheAPS・

③Ifthetravelingspeeddropsbelow5knJh［3・1mph］whiletheAPSisinoperation，APSwillbedeactivated・ ④WhiletheAPSswitchisinOFF，theAPSisindeactivatedstate・

APS SW

Fig．7．10 APSElectricCircuit

ー152−

7．LOADHANDLINGSYSTEM

ACCUMULATOR

Fig・7・11APSHydraulicCircuitandElectricUnit 3．Accumulator

Gascapacity：41iters［244in・3］ Gaschargepressure：2．0±0．1MPa（20±1・Okgf／cm2）［290・1±14・5psi］at20±50C［68±90F］・ Fig．7．12 Accumulator

Acautiontobetakenwhenservicingaccumulatorandpiping

●Usecautionwhenhandlingtheaccumulatorandpipingbecausetheaccumulatorhashigh・PreSS nitrogen gas charged.

●Fillingnitrogengasintotheaccumulatorshouldbeperfbrmedonlybyqualifiedpersonnel・

●Donotmodi抒OrWeldtheaccumulatoIl

●Ben）retryingtoservicethepiping†makesuretoremovethepressurefrominsidetheaccumul usingtravelingdampervalve，becausehydraulicoilremainsinthepiping・（Fortheprocedure，Se ㍑4．Travelingdampervalve ・）

●Whenremovingthepressurefrominsidetheaccumulator；Parktheloaderonalevelsurface，S

downtheenglne）andlowertheboomsandbucketontheground・ ●Checkthegaspressureevery2000hoursofoperationoroneyearwhichevercomesfirst・ −153一

7．LOAD HANDLING SYSTEM

4．Travelingdampervalve

D −ヒ Circ山tdiagram

SectionC−C Note：ぢ＝＝コD‥29±1・ON−m（3・0±0・1kgf−m）［21・7±0・71bf−ft］

E：13±0．6N−m（1．3±0．06kgf−m）［9．4±0．41bf−ft］ F：6．9±0．6N−rn（0．70±0．06kgf−m）［5．1±0．41bf−ft］

Fig．7．13 TravelingDamperValve（1） ［Removingpressure］

Loosenthelocknut（E）andthenloosenthepoppet（F）toreleasethepressure． Donotplug（D）asmuchaspossibletopreventdamagetothe replacethe 0 −ringwithanewone．

0

−ring・Iftheplug（D）wasloosened

［Installing］

①Tightentheplug（D）tothespecinedtorque． ②Tightenthepoppet（F）tothespecinedtorquetoseatittothevalvehousingsecurely． ③Tightenthelocknut（E）tosecurethepoppet（F）． −154−

7．LOADHANDLING SYSTEM

23 22 20 21 Section B−B

SectionA−A

1．HOUSING

10．PLUG

19．SPACER

2．SPOOL

ll．ADJUSTER

20． 0 一別NG

3．SPRING

12． 0 −RING

21．BACK−UPRING

4．PLUG

13．PLUNGER

22．SPRING

14．SPRING

23．POPPET

6． 0 −RING

15．SPOOLSEAT

24．PLUG

7．CAP

16．SPOOL

25．SPOOL

8．SOCKETHEADBOLr

17．PLUG

26．SPRING

9．SOLENOIDVALVE

18．VALVE

27．PLUG

5．＝0

−RING

Fig．7．14 TravelingDamperValve（2）

−155一

7．LOAD HANDuNGSYSTEM

NOTE

−156−

8．ELECTRICSYSTEM

8．ELECTR］CSYSTEM 8．1LIGHTLNG EQU］PMENT Name

Specincation

Headlights

24V75／70W

Widthlamps

24V5W

Turnsignals（front）

24V25W

Brakelamps Taillamps

Remarks

Q ty

2

Halogen

2

Front combination lamp

2

Rearcombinationlamp

24V25／10W

Back−uPlamps

24V12W

Turnsignals（rear）

24 V 25W

Licencenumberplate 1amp

24V12W

Rear work lights

24V40W

2

−157一

8．ELECTRICSYSTEM

8．2 METERSANDSWLTCHES 8．2．1MONITORLAMPS（CLUSTERGAUGEUNIT）

TheoperatlngStatuSmOnitorsystemmonitorstheloaderoperatlngStatuSbymeansofthesensorsand switchesinstalledontheloaderanddisplaystheinformationontheclustergaugeunitintheoperator

compartmenttoinformtheoperatorofthecurrentoperatlngStatuSOftheloader・

Theclustergaugeunitconsistsofmetersincludingthespeedometer，mOnitorlamps（warninglamps） whichindicatewhetherornoteachsystemisoperatlngPrOPerly，andindicatorlamps・

q ⊂コ［＞

FM ：FUELMETER WTM ：ENGINEWERTEMPERArUREGAUGE OTM ：TRANSMISSIONOILTEMPERATUREGAUGE EHM ：ENGINEHOURMETER SM

：SPEEDOMETER

Ll−L13：MONITORLAMPS L14−L18：INSTRUMENTLAMPS Fig．8．1ClusterGaugeUnit（1） −158−

8．ELECTRICSYSTEM

Connectedto

CONN． No．

15 Charge

口 Turnsignal（R）

2 Highbeam

CNl

Connectedto

CONN． No．

CNl

16 （Aircleaner）

3 Turnsignal（L）

17 Parkingbrake

4 Watertemperaturesensor

18 Worklight

5 EnglneOilpressure

19 Instrumentlamp

6 Powersource

20 Powersource

7 Brakeoilpressure

21 （Emergencysteering）

CN2

8 Fuelsensor

22 Oiltemperaturesensor 23 OPT−1

10 （Notconnected）

24 CNト3

四 （Notconnected）

25 Transmissioncut−0ff

12 （Notconnected）

26 Brakeoillevel

13 Ground

CN3

哲

9 Speedsensor

27 HourmeterGND

28 Hourmeterpowersource

14 CNl−3

Fig．8．2 ClusterGaugeUnit（2）

1．Meters

EnglneWater

Meter

Transmissionoil temperaturegauge

temperaturegauge

Fuelmeter E

若

Scale

Standardresistancevalue

Fuellevel Senderunit

670C［1530F】ノ 1020C［2160F］／オ 500C［1220F］ノ 1200C［2480F】ノ

49．8日

Fuelmeter

ThermOSenSOr Enginewatertemperaturegauge Thermosensor Transmissionoiltemperaturegauge

10．4n

91．7n

16．8日

Application

Sensor

団

融

Q息

Measurementpolnt

F

苫隼 主亘§夢

E〆／

F〆／

80n

10 SZ

Location

Spec泊cation

Float

E

ResistanceE2 80 32

1／2

F Ihsidefueltank

10

Upperfrontofenglne

Tbmperature OC【OF】

50［122］ 80［176］ 120［248］

Resistancef2 80 30

−159一

（COOlingfanside）

10 Tbrqueconverter

8．ELECTRICSYSTEM

2．MonitorLamps（Warninglamps）

Theloaderisprovidedwithatotalof7monitorlamps：4warninglamps（Nos・1，2，3and7）an indicatorlamps（Nos・4，5and6）・

The3warnlnglampscomeonwhenthestarterswitchisturnedtotheONposition・Ifanywarnlngla doesn

tcomeon，itissuspectedthatthebulbisblownout・

No．

口 ▲

Name

Description（Whenitcomeson）

Engine oil pressure

Oilpressurebelowspecifiedvalueoroilfilterclogged

2

Q餅 Brakeoilpressure

3

EヨBatteryvoltage

4

《誹parkingbrake

5

Oilpressurebelowspecifiedvalue

Batteryundercharged

Parking brake applied

，a Worklight

6 O

Travel mode check

Light is on

TravelmodeisON

7 ト⑳Brakeoillev？1

Levelisbelowspecined

8 APS APS（OPtion）

APS in operation

Name

Specifications

Application

OperatlngPreSSure：

Oil pressure switch

29kPa（0．3kgf／cm2）【4．3psi］

EnglneOilpressure Cloggedfilterswitch

Location

Rightsideofenglne

Turnsonwhendifferentialpressureis Rightsideofenglne 137kPa（1．4kgf／cm2）［19・9psi］

Oilfilter

OFF：1．47MPa（15kgf／cm2）［213psi］ ON：1

Pressureswitch

Pressure switch （parkingbrakeswitch）

Levelswitch

Brakeoilpressure

．18MPa（12kgf／cm2）［171psi］ （TurnSONatatmosphericpressure）

Parkingbrake

ON：0．78MPa（8kgf／cm2）［114psi］

Brake oil level

TurnSOnbelowoperatlnglevel

OFF：1．18MPa（12kgf／cm2）［171psi］ Transmission disk brake

（TurnSONatatmosphericpressure）

−160−

Incorporatedinbrakeoil tank

8．ELECTRICSYSTEM

8．2．2 LIGHTINGSWITCH R LR L

LB RW LW

L LR R LW RW LB ONl

○

OFF ON2

○

Fig．8．3 LightingSwitch

8．2．3TURNSIGNALSWITCH

（TurnsignaIswitchconnectiontabIe） Connected FLasher to 1七rminalNo．

L

Unit

Left

6

5

TFO

Right

OTL

N R

OTL

TF

Automatically returns

（Dimmerswitchconnectiontable） Connected to Te「minalNo．

DIMMER MAIN

Fig．8．4 TurnSignalSwitch −161−

MAIN DIMMER BATT 7

3

2

○

○

8．ELECTRICSYSTEM

8．3 RELÅYMOUNTING LOCAT10N

RELAY BOX

Rl：NEUTRALRELAY

R4：PARKINGRELAY2

﹇且﹇且

﹇且﹇且

h︑■Ⅶ

一郎−Re一

一⁚⁚⁝い⁚■■

R2：ENGINESTOPRELAY R3：PARKINGRELAYI

R5：TRANSMISSIONCUTしOFFRELAY R6：DSSRELAYI R7：DSSRELAY2 R8：HORNRELAY

R9：BACK−UPLAMPRELAY Wl：FRONTWORKINGLAMPRELAY

RELAYARRANGEMENT

Fig．8．5 RelayMountlngLocation

−162−

8．ELECTRICSYSTEM

8．4 ELECTRICCIRCUITDIAGRAM Note：Wirecolors：

Thewiresareclassifiedbycolor・ThefirstsymboIshowstheinsulationcolorandthe2ndthema color．

（Wirediameter） 40mm2［0．0620in．2］ 5．Omm2［0．0077in．2］ 1．25mm2［0．0019in．2］

B ／′・￣

20 Gh′

（25日×2）

A：indicatesthewirenumberandcolor B：indicatestheconsumptionpower（electriccurrent）

ABen）retryingtoworkontheelectricsystem，besuretodisconnectthebatteTyCOnneCtOrS・Wヤ

disconnectingthebatteryconnectors，firstdisconnectthenegativeside（−）termlnalbefbreremov theotherterminal． −163−

8．ELECTR［CSYSTEM

（Emptypage）

−164−

8．ELECTRICSYSTEM

Fig．8．6 ElectricCircuitDiagram −165−

8．ELECTRIC・SYSTEM

Fig・8・7 ElectricCircuitDiagram（ArMspecincation）［Option］ −166−

9．AIRCONDIT10NER

9．A［RCONDmONER（OPT［ON） Model

F40AC

Heater Heatdissipation

5．9kW（5100kcal／h）

Blastvolume

PowerconsumptlOn Cooler Coolingcapaclty

450m3／h［15879が／h］ 215WW

4．7kW（4000kcal／h）

Circulation air volume

Power consumption Compressor

550m3／h［19423が／h】 255W

Model

lOPA15Cwithmagnetclutch

Discharge

155．3cm3／rev［10．2in．3／rev］

1．AIRCONDITIONERUNIT ASSEMBLY 2．DEFROSTE 3．DEFROSTERHOSE 4．GRmLE

Fig．9．1AirConditionerAssembly（installedinsidethecockpit）

−167−

9．AIRCOND［TIONER

9．1GENERALDESCRIPT10N 9．1．10PERAT［NG PRINCIPLE

ENGlNE COOLlNG WATER REFRLGERANT（GAS）

／／／／／／／ REFRIGERANT（LIQUID）

Fig．9．2 0peratlngPrinciple

l．Functionalcomponents （1）Compressor

Thecompressorre−Circulatestherefrigerantinthecoolingcycleforrepeateduseandcompressesthe refrigerant to facilitate liquefaction. （2）Condenser

Thecondenserconvertsthehigh−temPerature，high−PreSSuregaSeOuSrefrigerantwhichhasbeencompresse bythecompressor，intoliquidrefrigerantthroughheatexchangewiththeopenair，uSlngthecoolingfan・ （3）Receivertank Thereceivertanktemporarilystorestherefrigerantliquefiedbythecondenserinit・

一168−

9．AIRCONDIT10NER

（4）Expansionplug

TheexpansionpluglIt）eCtSthehigh−temPerature，high−PreSSureliquidrefrigerantsentfromthereceiv tank，throughsmallholestoexpanditrapidlyandmakeintolow−temPerature，low−PreSSure，mistyre血・igerant・

Inaddition，theexpansionplugalsoa叫uststhequantltyOftherefrigeranttobesuppliedtotheevapora

accordingtothecoolingload． （5）Evaporator Theevaporatorexchangesheatbetweenthemistyrefrigerantandtheairinsidetheoperator Themistyre放・igerantthusvaporizestocooltheairintheoperator

scompartment・

scompartment・

（6）Heatercore

TheheatercoreexchangesheatbetweenheatedenglneCOOlingwaterandtheairinsidetheoperat COmPartmenttOheattheairinsidetheoperator

scompartment・

2．Heatingcycle

TheheatingcycleisachievedbyuslngtheenglneCOOlingwater・ High−temPeratureCOOlingwaterispassedintotheheatercoreandhotairisblownoutbythefan・ 3．Coolingcycle Thecoolingcycleisachievedasfbllows：Therefrigerant（CFC）isrecirculatedinthecycletotransferthe heatfromthelow−heatsource（theairinsidetheoperator

scompartment）tothehigh−heatsource（openair）・

ThismethodiscalledthevaporrefrigeratlngSyStem．

Flowoftherefrigerant

①Therefrigerant（gas）evaporatedbytheevaporatorissuckedintothecompressorwhereitiscompres intoahigh−temPerature，high−PreSSuregaS．

②Thegaseousrefrigerantdischargedfromthecompressorflowsintothecondenserwhereitiscoo brcefu11yandliquenedbythecondenser・

③Theliquidrefrigerantthenentersthereceivertankwhereitisclearedofwatercontentanddustbefor beingsenttotheexpansionplug．

④Thehigh−PreSSureliquidrefrigerantisirtjectedthroughthesmallholesoftheexpansionplugsoth

expandsrapidlytobecomelow−temPerature，low−PreSSure，mistyrefrigerantbeforeflowlngln evaporator・

⑤Themistyrefrigerantdeprivesthesurfaceoftheevaporatorpipeofheattoevaporate・Atthistime，aSthe

airissuppliedbythefan，theairisdeprivedofheatandblownoutascoolair・Sincetheairiscooled rapidly，thewatercontentintheairiscondensedtodehumidifytheairinsidetheoperator scompartment・

⑥Thereh・igerantleavingtheevaporatorchangesintothegasandsuckedintothecompre占sor・

−169−

9．AIRCONDIT10NER

9．l．2AIRCONDIT10NERUNIT

Theairconditionerunitconsistsoftheevaporator，heatcore，eXPanSionplug，blowermotor，andfan・

1．HEATERCORE 2．EVAPORATOR 3．EXPANSIONPLUG 4．WERVAIJVE

A．fromRECEIVERTANK B．toCOMPRESSOR C．ENGINECOOLINGWERINLET D．ENGINECOOLINGWEROUTLET

5．BLOWERMOTOR，FAN Fig．9．3 AirConditionerUnit

−170−

9．AIRCONDITJONER

9，l．3 COMPRESSOR

1．MAGNETCLUTCH ASSEMBLY 2．COMPRESSOR ASSEMBLY 3．MAGNETCLUTCH LEAD WTRE

Fig．9．4 Compressor

Note：D＞ぢ＝コ7・8toll・8N−m（0・8tol・2kgf−m）［5・8to8・71bf−ft］ B＞ぢ：：：：：コ20・6to30・4N−m（2・1to3・1kgf−m）［15・2to22・41bf−ft］ Fig．9．5 CompressorInstallation

−171−

9．AIRCONDIT10NER

9．1．4 RECEIVERTANK

Thereceivertankhasastraineranddesiccantinside it，tOremOVedustandwatercontentfromtherefrigerant duringcoolingcycle・

Thefuseboltconsistsofaboltwithaholeatitscenter andaspecialtypeofsolderfilledinthehole，andactsas afusefortheelectriccircuit．Ifthecondenserfailsto disperseheatforanyreason，thesolderwillmeltinthe fusebolttodischargetherefrigerantintotheatmosphere・

Thesightglassisusedtocheckthestatusofthe

refrigerant． Fig．9．6 SightGlassandPressureSwitch

1

2

View100kingfromA

1．REFRIGERANTINLET 2．REFRIGERANTOUTLET

Fig．9．7 ReceiverTank −172−

9．A［RCONDIT10NER

9．1．5 CONDENSER

A．fromCOMPRESSOR B．toRECEIVERTANK

Fig．9．8 Condenser

−173−

9．AIRCOND［T［ONER

地点d式huuOつ竃uO︺h苛

﹃訊．恩﹄

−丘当bJ︒︶苫u︒急叫↑﹇‖‖＝ぜ

⁚れ．1火空言

．∞︷○︶れ．寸こ︵苧ち芸．NO；．N︶∈・Nれ．寸NO︺や巴⁚¶−爽NN∑

冨⊥q−m．れNO︶卜．︷巴︵苧苛芸．CO；．〇∈・Nm．寸M〇一寸．系⁚れ．−火寸N∑ 冨⊥q

slコ≡S︒

冨⊥q−∞・≡○︶卜・巴︵∈・も適¶−01N．こ∈・N卜．寸−○︶∞．

lu空ひぞー①U▲ ⁝ ・

しむldきぎニ00U2る u 山 l

出N＜↑出凹AI山︺山錮．寸

鉱山SN山口NOU．m

出OSS山出d﹈言○︺．N

↑−Nn出国NOiトⅠ凸NOU出Ⅰ＜．1

・℃︶か・巴盲⊥叫だ・〇︒毒○︸宇Z芸︒︶票∩‖ぜ∧△⁚琶Z

﹇王q−卜・害︶∞・竺宇も弐・−︒−∞・〇︸宇N≡︻︒︶∞・卜﹇＝ぜ∧益

︻宣q

嬰≡d︼d∝山N01ヒ凸NOU⊆く甲L．の

ー174−

No．SEW−648CE

lssued： June，2000 Revised： March，2003 Revised：July，2004

丁伽。。。。。。Å， lNTERNAT］ONALMARKETINGD［VIS10N： 1−15−5，Nishi・＄himbashi，Minato・ku，lbkyo lO5−0003，Japan FAX：JAPAN＋81・3・35918152，3−35918153 A rightsreserved

JB−0407010（OS）PrintedinJapan

7，伽c。R，。RAT．。