TCM L3-2 L4-2 L5-2 L6-2 Wheel Loader Shop Manual MEW-600A - PDF DOWNLOAD

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lntroduction ThisshopmanuaIdescribesthestructureandtheserviceproceduresofthemachineforits SerViceuses．Usethismanualwhenserv）Clng． Please note that vaIues or other features might be change to enhance the machine s Performance・

▲cAUT10N ・RefertoOPERÅTION＆MA［NTENANCEMANUALforthe＄afetyoperation＄Of themachineanditsequlPmentandfortheinspectionprocedures． ・Mi＄understandingandfau［tyoperationofthemachinemayresultinanlnJury

Ordeathofyouorthepersonaroundthemachine・TheymayaI＄Odamagethe machine，

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GENERALCONTENTS 1．GENERALINSTRUCTIONS 2．CONSTRUCT10NAND FUNCT10N 3．OVERHAUL 4．TROUBLESHOOT］NG

JDIAGNOSIS

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1．GENERALINSTRUCT10NS

）

1−1．Common［tems

……………

1−1−1

l−2．Specifications

……………・

1−2−1

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1・1．COMMON［TEMS 1−1−1 ScopeofDescriptionandUsageofThisManual・・・＝…・

PrecautionsinlnspectionandService

……………・

1−1−4

GeneralPrecautionsforInspectionandService………・ 1−1−6

Genera］PrecautionsforSafetyOperation・ …………1−1−7 Disassembly and Assembly

〕

…・・・…・・・・・ 1−1−14

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ScopeofDescriptionandUsageofThisManua［ ） TbReadersofThisManuaI

Thismanua］providesservicesta庁whohavecompLetedbasictrainingwithtechnica＝nformationnecessar forserviceactivity・Forobtainingsatisfactionandtrustfromcustomers，yOuareeXPeCtedtoreadthrou thismanualandacqulreCOrreCtPrOductknowtedgeandservicetechnique・ Reference Materialal

Thismanualdoesnot，inprincip］e，describebasicitemsandoverlappedareaswithothermaterials（bet toeliminateredundancy． ● Forhandlingandinspectionprocedures，refertoT．Operation＆MaintenanceManual：l ・Forstructureandcomponentparts，referto‖PartsManual・ ● Forhandting，maintenanceprocedureandpartsoftheenglne，refertomaterialsissuedbytheeng）ne manufacturer．

（Organization Thismanualisorganizedintofourparts‥1・GeneralInstructions2・ConstructionandFunction3・Oveahau1

4．Troubleshooting l．General）nstructions

Safetyduringmaintenanceworkandgeneralcautionaryinstructionsarecomp‖ed・ 2，ConstructionandFunction

An expIanation of the construction and function and an exptanation of operation（function）by iILustrations，Circuitdiagramsandsystemdiagramsarecompiled・ 3．0veahau】

MethodsofremovinghydraulicequlPmentfromavehic［e，it＄disassembIyandreassembly，itsadjus method，Standardva［uesusedforserviceworkandserviceIimitsarecompiled・ 4．Troubleshooting Probablecausesandcorrectionsfortroublesarecompiled．

1−1−1

1−1．Commonlterns

ScopeofDescriptionandUsageofThisManual ■ltemsListedinThisManual ● Pagenumber（3digitindication）

Equipment 0

2−0−1 2

Note）Lfa page number has a2digitindication，the

SeCOnddigitshowsthepagejneachchapter． Equipmentcode：RefertotherighttabIe．

Equipmentname Engine E［ectricsystem PowertrainI （HSTreductiongear）

3

Powertrainn（Axle）

4

Brake

5

Steerlng

6

Frame

7

Hydrauljcsyst9m

8

WorkingequlPment

● Po＄itionanddirectionofvehicle

Respectivepositionsanddirectionsofa Vehicte areindicatedin the traveling djrection ofthe vehicLe（i［lustration on theright）．

● Symbo［＄andnotation ：）temsthatrequIreSPeCia暮cautionsareindicatedinaboxtopreventpersonaIinjuriesor

damagestotheequlPment． DANGER：indicatesimmediatehazardsthatWILLresuttindeathorsevereJrVuryLna

▲

box． VVARNING：indicate＄POtentialhazardsorunsafepracticesthatCOULDresultindeath OrSeVereFnJury［nabox．

CAUT10N：indicatespotentiaJhazardsorunsafepracticesthatMAYresu［tinhlinoror medium明urylnabox． lMPORmNTindicate＄importantitemsforoperationandmaintenanceinabox． NOTE： indicatesinfbrmativeitemssuchastechnicalinformationandknow−howin abox．

鹿 ：indicate＄amaSSOfpartsthatrequFreCaUtionwhenheldormoved． 亀 ：indicatesaspeci罰caIlysetvalue（torque）whenboltsaretightened． ⊥ ：indicatesavoIumeofdischargedwateroroilこ 誓

：indicatesavoIumeof而‖edwateroroiL

1−1−2

ScopeofDescriptionandU＄ageOfThisManua］ ●lndicationofUnit

tnthis manual，unitindication ofquantityand unitis mainly based on Sl（）nternational System）unitsystem（righttable），

Examp［eofmainunitconversion （Conventiona［unit） Slunit （10．197kg眈m2） Pressure 1MPa 1N （0．10197k9f） Fo「ce （0．10197kgf・m） 1b「que 1Nm （1．360PS） Powe「 1kW

1−1t3

PrecautionsinlnspectionandServjce This section provides theinformation whichis heIpfu［fordisassembling and assemb［ing the machine PrOPerIyandcoversthesafetyprecautionsandgenera［instructions．

■ Precaution for Hydrau］ic and Pneumatic

r DustPrevention

Systems Themostimportantprecautionformaintaininigthe longerservicelifeofamachineistopreventdirt and dustfrom adhering totheimportant movlng

Whenimpurities such as dirt and dustenterthe

PreVentdirtanddustfromgettingintoeachmovLng

SyStem are damaged excessiveJyto resuItin the

hydrau［icandpneumaticsystems，theoperationis PartS．Onourprodusts，SPeCiaIattentionispaidto a作ected adverseIy and，further，the partsin the

Part．Inaword，animportantpartsisenc10Sedand， fai】uresofthemachine． further，PrOVidedwithasealorRlterand，thereby， Accordingly，When the partsinthe hydrau［ic and

CIean air，fule andlubricant are always sent to Pneumaticsystemshavebeenremoved，COVerthe eachpart． When disconnecting hydraulic，fuel，lubricating or air pIPeS and hosesfordisassembFy，Clean each

OPenlngS．Further，When pleCeS Of broken metal

and rubber have been fbund Lin the hydraulic

SyStem，flush the whoIe ofthe＄yStem．Remove COnneCtionandaroundtheconnectionthorough［y． andinsta the parts re暮ated tothe hydrauIic and After disconnectiong the pIPeS and hoses， Pneumatic systemsin a cIean p［ace．Wash a［［ immediate）ycovereachopenIngWithacap，PIug meta［LicpartsinuninfIammabLesafetysoJventand OrtaPetOPreVententryOfforelgnmateriaLWhen COatthemwith［ubricatingoilfbreasierinst ation．

removInganinspectioncoverorplatealsodothe ■ DangerPrevention W畠ShandcheckaH partsremoved．Checktosee thataItoilpassagesandoilho］esarenotclogged． Before serv［Clng the hydrauLic ＄yStem fbr the Cover all parts to prevent dirt and dust from WOrkingequlPmentS，PerformthefbIIowlngStePS： adheringtoeachpartand，WhenreinstaI［ingeach Part，ChecktoseethatitiscIean．Onanewpart， （1）Lowerallworkingequipments（bucket，etC．）on donotunpackthepartuntiIitisinsta＝ed． the ground．1fa working equlPment muSt be removedwhileho［dingitinacertainposition， Engine Overhaul Timingng refertoILDisassembtyandAssembly ． （2）Stop the engine and move each working Fordetails，refertothedocumentssuppliedbythe equlPmentCOntrOIIevertoallpositionstomake SameWay．

Sure that no pressureis appIied to the hydraulicsystem．

engtnemanufactureT．

（3）Seta controllever＄tOneutra）andlockthem．

■ HydraulicandPneumaticVilve＄ CheckalIvalves，VaIve hotesandvahle＄eatSfor SCratChes and folds．Remove them with a督ne oil

StOneOrSandpaper．A‖thevaLve＄Should move SmOOthlyintheirrespectiveholes．Make＄urethat aL［passage＄arefreefrom fbregIn materials and Clean．

1−1−4

Precautionsin［nspectionandService ■ Hydraulic and Pneumatic Pipes and

NEUTRALposition．hydrauricoilw＝f10WOutOfthe tank．

Hoses

When connectiong a metaIIic p［Pe，first■ BleedingAirfromHydrauIicSystem finger−tighten a［lbolts and then tighten each end

and attaching bracket bo［ts．A微erconnecting the Whenahosehasbeenreplaced，thehydrauticoil has beenchanged，aCylinderhasbeen removed PIPe，COnneCtthehose．Atthistime．finger−tighten the bo［ts at both of the hose as a temporary and othersimilarwork has been performed，Start measure．¶∋kecarenottoa［Iowthehosetocome the englne，mOVethe controHevers to movethe

incontactwiththepartsandotherhoses，reduce WOrkingequ［PmentStOallposition＄andbIeedairin the bend and twistand then tighten thecoupling the hydraulic system．After making surethatthe hydraulicsystem operates properly，Checktheoil

bolts．

A hydraulic hoses has its own bending pattern levelinthetank． NOTE：Run the englneat］owidlespeed and，in dependingonthemanufacturingmethod． that condition，eXtend and retract each Accordingly，When bending a hydraulic hose for COnneCting，bendaccordingtothebendingpattern． Furhter，When rep［acIng a hose provided with ang［edstem，aSSembleandconnectwiththehose

Cylinderaboutten times．Atthistime，do

A代erconnectingthehoses，PrOCeedasfo＝ows：

not move the cylinder to the stroke end． Whentheenglneisrunathighidlespeed and each cytinderis moved tothestroke endfromthefirst，airin the cylindermay

Run the engine and move each control lever to

damagethe＄ea［s．

bendingpatternfuIlytakenintoconsideration．

movetheworkingequipmentstoposition，（Referto Bleeding Air from Hydraulic System to be ■ CIeanngtheHydraulicBrakeSystem mentionedLater．） Usethespec摘edbrakef［uid．1fotherbrakefluidis Duringthattime，Observeeachhosecarefu［［y． Lowertheworkingequ）PmentSOntheground，StOP used，a rUbber part may be deteriorated and

the engIne and then recondition the twist，

SWOl】en．

interference or excessively hanglng．etC．Of theWhen adjusting the hydrau［ic brake system，take Care nOttO alIowfore］gn materialto getinto the hosebytumingthestem． brakefluid．1bwashthe mastercylinder，WaShin

■ HydraulicCyIinder

general part washing agent and then wipe the

Theterm＄forthecyIinderhave beendecided as

trace of solvent with denatured alcohol or brake fIuid．A代erthat，drythecyIinderandtakecarenot

bl10WS：

toaI10WdirtanddusttoadheretothecyIinderuntiL itis assemb［ed．Wash rubber partsin denatured alcohoIor brake fluid．Do not use sorvent of PetrOleum series，SuCh as gaso）ine，kerosene， acetone，Paintthinner，Whichwi［tso代enandsweIla rubberpa丘

■ Remova［ofCylinder WhenremovFngeaChcytinder，itisnotrequiredto drainthehydrau［icsystem．On［yasmatlamountof

hydraulic oilin the oilpa＄Sage between the Cylinder and controIvalve flow＄Out．However，

When the controlleveris not pLacedin the l−1−5

GeneralPrecautionsforInspectionandService General Precautions for Checking and Serv［Cmgthemachine l．When checking and seⅣIClng the machine， decidethe［eaderandworkingprocedures．

2．WhencheckingandservIClngthemachine，hang a

CAUT10NmG

onthestarterswitch，COntrO［

leversandsteenngwheeltopreventtheenglne from being staned and the contro［fevers打om being moved care［essJy．Disconnect the cabIe

from the negative terminal of each battery for Safety． 3．Whencheckingandservrclngthe machine，Pay a恍entiontothefb owlngPOints．

（1）Placethemachineonthe［eveIground，］owera WOrkingequ［PmentSOntheground，aPPlyparking brake and p［ace the shiftleverin the neutra［

POSition．Stoptheenglneandremovethestarter SWitchkey． （2）Move the working equipments controIIever to

relievethepressureinthehydraulicsystem． （3）Engage the stee血g framelock and bIockthe ti「e＄．

4．When disassembling and assemb］ing the machine，doitinorderandsecureIy． A允erassembling，aqjust andlublicate proper］y．

相er that，be sure to check for proper aqjustment．

Beforeuslngthemachine，OPerateittocheck forproperadjustmentagain． When the machineis checked，aqjusted and

measured，the performances should be as SPeCified．Check，adjust and measurein the foI［owFngCOnditions：

（1）VVarmuptheenginesu怖cientLyandtheneedleof

thewatertemperaturegaugeshouldstayinthe 9reenZOne・

（2）The hydraulic oiltemperature shouLd be the temperatureatoperatjon（40−600C）．

（3）HSToiltemperaturegaueshouldstayinthe greenzone．IfthegaugelSnOtequlPPed，raise

the oiJtemperature to the normaIoperating temperature，

1−1−6

GeneraIPrecautionsforSafetyOperation ■ GeneralPrecautionsforSafetyWork l．Wearahelmetandsafetys．hoes． Wearsafetyg）assesandadust−PrOOfingmask

ifnecessarybythejobconditions． WearneatsothatyourcLothing［S nOtCaught by the prqections of the machine and the COntrOllevers．Empty your pockets to avoid dropp［ng anythingin the equlPment When WOrkingwithyourbodyfacingdownward．1bke O仔rings，WatChesandjewelry．

2．When uslng a grinder，Crane Or WeLding machine，etC．，fot10W theinstructions fbr handlinganduseitcarefu y． Prepare safety equ［Pment SuCh as 伽e

extinguishers．Rememberwhereitis stored andknowhowtouseit．

3．Do notleavetooIsand partsscatteredon the f100rPlatesand stepswhicharethefoothotds forworkingbecauseseriousaccidentsmaybe CauSed．

AIso，ifmudandoiladherestof100rPlatesand StePS，itis sLippery and might cause sudden accident．Therefore，WIPeito斤compIetely When ge仕ing on and ge輔ng o仔the machine，

usethesteps．Graspbothhandrailsandgeton OrO斤themachinewithyourbodyfacingtoward

themachinestraightly．

4．C）eananymud，greaSeandoilo汗themachine． When usJng COmPreSSed air for cleanlng the rnachine，a［ways wear safety gIasses and

PrOteCtiveclothingagainsttheairpressure．

1−1−7

GeneralPrecautionsforSafetyOperation 5．During operation orimmediateIy after the machine stops，the temperature of each SeCtion on the machineis hot with heated oi（ and water．DO NOTtouch such sections untiI

the temperature goes down because it might CauSeburnoranunexpectedaccident． Ln particuLar，take care of the englne， turbo−Charger，mu冊erandexhaustpipes．

6．1mmediately∈椚erthemachinestops，DONOT drain the oiIand water because scald or

unexpectedaccidentsmaybecausedbyhotoiI andwater．Draintheoi［andwateraftermaking

Surethattheternperaturehasgonedown． WhenremovingtheradiatorcapandhydrauIic Oi（tank cap，be sure to re］ieve theinternaL

PreSSurebeforehand．

PerSOnSandmakesureofsaf畠ty．

DO NOT［eaveanytooIsandparts，arOunda turnig／mov）ngPartSuCha＄thecoo［ingfan．

8．When jackin9 uP OnIy front or rear of the machine，doiton theleve［，hard ground．Be

Sure tO b10Ck the wheels and support the machinewithastand．

1−1−8

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7．Movingparts（especiaJIyrotatingparts）−areVery dangerous，Before servICIng the machine，be Sure tO StOP the eng［ne and remove starter SWitchkey． Beforecrankingorstartingtheeng［neforcheck and aqjusting，always slgnaIto the other

GeneraIPrecautionsforSafetyOperation 9．When the workis done with two or more

PerSOnS，doitwhiIemarkingsureofthesafety Ofeachperson． Catch hand signa］s from one designated PerSOn，NOTfrompIuralpersons・

肇∴ト・野‥植 10．When checking and serv］C）ng the hydraulic SyStem，Puta theworking equipmentstothe ground． However，When the hydrau）icsystem must be Checked and serviced with the working equrpmentsraised，insta＝thefa ingprevention devicestothel帆Cy［inders．OrsecurelyhoIdthe

WOrking equIPmentS With wood blocks to PreVentfalIing．DONOTuseacraneforhoIding becauseserialaccidentsmaybecaused． 11．BeforeseⅣ暮C［ngtheenglne，thee暮ectricsystem OrWelding，always disconnectthe cab‡e from thenegativetermina10feachbattery．

12．Fue［anda

oilsarefIammable．DONOTsmoke

intheptacewherethebatteryischargingand flammabtes are stored．DO NOT a［［ow any fIame nearit．Abattery generates f）ammable

gas，DONOTaIlowanynamenearitwhenthe batteryis handled．Oiled cloths or other flammabtethingswhichareeasytoburnshouId begottenintoacontainerandthen pIacedin Safetyplace．

DONOTputanycontainerincludingfIammab［e liquidsuchasfueloroil，Onthevehic［e． When anyIiquid ofhigh volati［ityis handled， PaySPeCia暮attentiontoignition・

1−1−9

GeneralPrecautionsforSafetyOperation 13．Forwashingapart，uSenOn−fIammablesafety

SOIvent．DO NOT use gasoIine orlightoilfor WaShing．Whenapartcannotbec［eanedonly bywashing，bstsmoothitwithfinesand−PaPer beforewashingit．

Check each］uburicating oilpassage for Cloggingbndwashwithnon−qammabLesafety SOIventorcompressedair． A托er washing，dryit with compressed aiL

When drying a beanng with compressed air， takecarenottorotatethebearing．

Wash a rubberpartwith denatureda］coholor ﹁ノ

OnlywJPeamatteradheringtothepa托Off・

14．When seMC［ng the fuelsystem，be sure to

Checktoseethatnofuelleaks． When fuet and oiIp［PeS and hose＄ are

loosened or damaged，fueland oiJleak to resuItina而re．

15．DONOTruntheenglnefora10ngtimeoraF］ow

painting in an indoor workshop with bad Ventilation．

16．When connecting a ptpe or hose，uSe tWO SPannerS（tooIs）topreventtwistanddamage・ Connectahosesothatitdoesnottwist．

Because a twisting high−PreSSUre hose may burst．

Be sure to tighten a pJPe Or hose to the SPeCifiedtorque．

1−1−10

GeneralPrecautionsforSafetyOperation 17．DONOTcheckanoilleakagewithyourhand， lfoilgetsintoyourbody，itisverydangerous・

EspeciaLly，DONOTapproachoilleakagefrom Pin−hole．

18．Before disconnecting a pIPe Or a hose for hydrauIic and pneumatic systemsis to be removed，re［ievetheinternalpressure．

Before disconnecting an air pIPtng，discharge theairinthetank．

Beforedisconnectingahydrau［icp［Plng，mOVe

theworkingequlPmentCOntrO［leverstorelieve 、theinterna（pressure，andthenremovethetank CaP・

If high pressure oil blows out it is very dangerous．

19．AIwayscheckthetoo［stobeused・DONOT

useanyspannerwhosecornersarechipped，a hammer whose edges are folded，a broken SCreWdriver，etC．

1fanimpropertoolisused，thepartisdamaged and，further．youmaybeinjured・

usepropertooIsandworkcarefulty．

20．ForworkwhereaspeciaItooLisrecommended， a）ways use the specified specialtooJ・lfany unspec摘ed too［is used，it might cause damageor明ury・

1−1−11

GeneraIPrecautionsforSafetyOperation 21．Whenaplnisremovedorinsta＝edbytapplng，

broken pleCeSmayflyabout．Besuretowear Safetyg［asses．

When removing the pLn，DO NOT aItow a PerSOntOaPPrOaChinthedirectionofremoval・

22．DONOTchecktheaIignmentofthepinholes by inserting a finger.

Wheninsertingap［n，aPPIyasma蔓Iamountof greasetothepinandmatingpart・FurthenaRer assembly，［ubricate each pin with grease・

Whenadustsealisprovided，aPPlyacoatof grease to the sea＝p and take care not to damagethesea［lip．

23．DONOTusekinkedorwornwirerope．

When handJing a wire rope，Wear reather g10VeS．

SeLect a wire rope refering to Disassemb［y andAssembly inwhichtheweightofeachpart i＄Shown．

1ftheweightofapartisnotjudgedcorrectly， thepartmaybedroppedand scratched and， further，a PerSOn maybeinjuredseriously・［f necessary，uSeI昭ingtootsbywhichapartcan beliftedproperlyandFif（Safely，

24．DO NOTIeave a heavy partin an unstabIe PIaceordonotkeepithungdownfromacrane・

Place a heavy part on blocks or on a stand PrOPerly・

1−1−12

GeneralPrecautionsforSafetyOperation 25．WhenremovlngaCOVerWhichispushedwith thespr．ngs，remOVetheboltsornutswiththe COVer PreSSed down with hand・However，if the sprlng forceis strong，fo ow the instructionsin DisassemblyandAssembly

・

When removlng aSide coverofthemachine， leavethetwoupperboltsornutsinstalLed・ Then，While holding the cover with hand， remove the two bolts or nuts and remove the COVertakingcarenottodrop．

26．Close the englne Side covers except when CheckingandservicingtheenglnerOOm・

27．Handleabatterycarefu11y． Batteryliquidisdi［utedsuIfuricacid・DONOT a）10Witadheretoyoureyes，Skin，CtOthorother metalsurface．1f electroFyte has adhered， immediateFywashawaythorou9hly・

Whenhandlinga battery．wearsafetygIasses andtakecareofafire．

28．Wheninflatingatire，Standonthetreadsideof thetireanduseaselfattachingchuck．

29．Whenwelding a part neara tire，be carefut especia ybecausethetiremayburst・

1−1−13

Disassemb］yandAssembly ■ Disassembly and AssembIy ofGeneral Parb

HeeJI喝｝be

OilSeaI Mostsealsareuseda＄anOiIseatwiththetoeor thelip，in which the garter spnnglSinstaFled，

facingtowardalubricatingoiforpressurerizedoil

tobesealed・Howeve「whensealingalubricant SuChasgrease，aSea［isgenerallyinstalledwith

thetoeorlipfacingtowardtheoppsiteside． Aliptypesealconsistsofthecase，Sealingpa止

andgarterspnng・Therightupperfigureshows

Bond Area

Case

theroughconstructionofaliptypeseafand，in

．

the rightsectiona［view，the sealisdividedinto theheelandtoe． H由ト￣向島

．Heel Tbe

Heel 1もe

HeeI ■10e

H色由 一be

Wheninsta inganoiIseal，PaySPeCiafattention tothefoJ［owIngPOints：

WhenJnstallingtoHous．ng： （a）Checktheseal［ipforscratchesandalIowthe

liptofaceinthecorrectdirection． （b）ApplyasmaI［amountofliquidpack・jngtothe

externa［surfdce of the seal（COminginto COntaCtWiththehousing）andtheninsta‖the Seal． （C）AppryacoatofIubricatingoi［totheljp．Use

thesameIubricatingoifastheoiItobesealed． DONOTappFyacoatofgreasetoanyother Seal＄thanagreaseseaI． （d）

rbinsta

theseal．guidethesea川p，uSea

SealdrivingtooIwhichcomesincontactwith theexternalsuHaceofthesealanddrivein thesea［in beeIineas shown atright．DO

NOT tap the seaIdirectly with a hammer becauseitmaybedamagedto resuItinoiJ leak． Whenjnsta ingtoShaft： （a）ApplyacoatoflubricatingoiJtotheseal［ip． （b）Wheninsta［Iing the oi［seaJthrou9h the StePPed part7threaded part or keygroove，

thelipmayeasilybedamaged・Useaguide Shownatrightorwindatapeonsuchapan toa［10WtheseartosIideeasily・

1−1−14

日由ト・職e

1＿1、Commonltems DisassembIyandAssembIy 0−ring Wheninsta＝ing an O−ring through the stepped Pan，SPlinedpart，threadedpartorkeygroove，it maybedamaged． Use a guide shown at rightorwind a tape on SuChaparttoatlowtheO−ringtos（ideeasiIy・ DONOTinsta anO−ringbyro［lingit． WhentheO−ringistwisted，Oilmayleak・

Packing WheninstalIing a packing，Cheokifthe holesin the packing a［ign with the oi［passagesin the

PaCking because a serious damage may be CaUSed．

一−−い1．︑へぃ一・⁚h︸

mating part．When a packing must be made， Se［ecta propermateriaIand checkifholes are madein place．DO NOT forget toinstaI）a

Lock Alockwasher，afLatmeta［［ockoracotterpinis usedforIockinganutoraboIt．

Benda10CkplatesecureIy． Therightfigureshowstheproperandimproper bendingmannersofthetypicaHockp［ate・

e

m

P

tocks．

WheninstaLLing a Lockwasherto an aIuminum housIng，insert a fIatwasher between thelock WaSherandhousIng． SplitPinandSpringPin Asarule，rePLaceasplitpinwithanewone，

BendthesplitpinsecureJy． DriveinasprlngPLnSeCurely． lmp「oper

1−1−15

r

Proper

r

Proper

▲U

越鼎

P

OnaflatmetaHock，VerticalIy bendoneend of the rock againstthe perphery ofthe edge ofa PartandverticalIybendtheotherenda10ngOne Side of a bolt or nut．1n a compartmentin WhichthemovIngPartSareinstalled，installnew

Disassemb．yandAssembly Bearln9 DirtanddustLocksthebea「1ng

Wash a usable beanngs with nonflammab］e

SafetysoIventanddryitnatura11y． The bearing may be dried with compressed airbutDONOTturnthebearingatthattime． 1f dirt and dust getinto the bearing，the bearinglSIocked，thereby，thesha代isturned intheinnerraceortheouterraceisturnedin

thecage． DO NOT unpack a new beanng untilitis instalied．

Theshaftisturnedintheinnerrace． Actionsofdirtanddustinbearing

（1）lnstaIlationofBearjng

When installing a new bearing or used beanng，aPPly su情cient coat of oi［to the bearing．1fpre−Ioadingabearing，aSu冊cient

Oitfilmshoutdbemadeonthebearin9． Whenpressfittingabeanngintoaretaineror abore，aPPlyapressureontotheouterrace （Outer Wheet）． When press fitting the

bearingintoashaft，aPPlyapressureontothe inner race（innerwheeI）．Wheninsta［Iing a

beaTing，uSeadrivingtooIcomln9intocontact Witheachraceshownatright．Useapressfbr instal［ing a bearjng，ifpossible，and appIy a

PreSSuretOeaChraceforthesecurework． （2）DoubJe−rOWTaperR011erBearing The combination of cup，COm，SPaCer and roIIersofeachdoubIe−rOWtaPerrO暮Ierbearing is already decided and，aCCOrdingIy，One

duble−rOW taPer rOller bearln9is not interchangeabLe with other one．Those COmPOnentS are genera y stamped with the

Same Part and manifacturing number but， When the components are no numbers，Put themtogetherwithawire．Wheninsta［finga

reusable part，be sure toinstallitin the PreViousposition＄． （3）PLairtBearing（StidingBearing）

WheninstaFIingap［ainbearing，DONOTuse ahammer．Useapress，ifpossible，andapply a unifbrm pressure to■the bore．When a

bearing must be drivenin，uSe a bearing drjverorabarwithsmooth，f］atend．When

a pJain bearinglS PrOVidedwith anoiL hoIe， alignitwiththeoi［hoJeinthematingpart．

1−1−16

Disassemb［yandAssembly （4）Wheninsta inga bearing，SPaCerOrWaSher to the shouLder ofa sha軋insta＝it with the

Chamferedsidefacingtowardtheshoufderof thesha軋 （5）Pre10ad

Thepreloadisathrust10adtobeapp］iedtoa bearing beforehandin ordertoincrease the rigidityofthebearingorremoveac［earance・

＝＝＝ Correct

The pre［oad to be app］ied to a taper ro［ler

bearingisdecidedaccordingtotherigidityof thehouslng andshaft，andthesweI］ing and turnIng SPeedofthe bearing，etC・ Tb know

thatapreloadmustbeapp＝edtothebearing OrthatanendcLearancemustbegiventothe bearing，referto Disas＄emblyandAssembIy ．

When a beanng，tOWhichan end clearance must be glVen．is preloaded care［essly，the

bearingmaybedamaged．WhenpreIoaslng abearing，becarefulthoroughly． （6）ShrinkFit

When a bearing mustbeshrunkon，itmust beheatedinoilwhosetemperatureis120℃ Or beIow．VVhen the diameter of the hole （the bearing bore）is sma er than the sha微

diameter，thebearingisheatedforexpanding andthenthesha代is細edintothe bearing．

Afterthat，theinnerraceofthebearinghoIds theshaftfirmlyatnormaltemperature． Press Fit Whenpressfittingapart・intootherpart，aPP［ya

COat Ofproperlubricant to the contact surface． Howeve「when that partis tapered，PreSS fitit Without coating with［ubricant．When press

fittingatapersplinedpart，Checktoseethatno dirt and dust adhere to the splines and the SPlinesaredryandnotfblded．A敢erthat，first

PuShinthepartbyhandtoalignthespIinesand the mating part and then press fit．［n pres fitting with taper sp［ines，the connection must aIways befirm．Ifnot，Checkthetapersp［ines and，ifitisworn，rePIace．

1−1−17

lncorrect

DisassemblyandAssembIy LinesandWires Whenany［ines（tubes，hoses．etc．）orwiresare removed，PutatagOnitforcorrectconnection．

＄him（Spacer） A托erremovlngShims，bundlethemand markso

thattheinsta［lationpositioncaneasilybecaught． Keepshimsinsuchamannerthattheyareclean andnotbentuntiltheyarereinsta＝ed．

Sealing Parts When disassembling the hydrau［ic and Pneumatjc systems and then assembling them， be sure to repIace the sealing parts，SuCh as O−rings，gaSketsandoi暮SeaIswithnewoneasa rule，AIways use genuine parts．Similar seals

CannOtaIwaysbeused．

Spring Checkif the tensions of aIIsprlngS are aS SPeCified．Check with the freelengthsin MaintenanceStandard ．

RLJStPreventive Wheninsta［1ing a new part，thoroughly remove

therustproofsoIventfromthemachinedsurface Ofthepart．

Ba仕ery

Wipe a battery with diluted sodium bicarbonate SOIventanddryitweM．Then，aPP［yacoatofrust

PrOOf soLvent or grease to the terminals and COnneCtions． When a machineis stored oritis notused fora Jongpeirodoftime，remOVethebatteries．Place the removed batteries on a wooden she）fin a

Warm and dry pLace． DO NOT pIace the batteries on the concrete floor．Charge the ba仕eriesperiodica

ysothatthespecificgravity

OftheelectroIyteisaIwaysbroper．

1−1−18

Disassemb［yandAssembIy BoltandNutTighteningTorque Thebo［tlengthmustbeproper．1ftheboltistoo

10ng，itcomesincontactwiththebottomofapart

7bbleofReti

to be secured beforethe head comesin contact

With the upper surface of the part．Further， When a［ong boltis removed，take care notto damagethethread．Onthecontrary，lftheboltis too short，the threads for secu「lng a Part are insu惰cient．

When secunng two or more parts，tighten the bolts or nuts to the specified torque．For each tightening torque，refer to Maintenance Standard of Disassemb［yandAssembly ．

Tightening ln most cases，tighteningin uMaintenance Standard isdoneinthefo owlngPrOCedures：

（1）Cleanthethreadsofboltandnut． （2）Applyacoatofoiltothethreadsandseatof boltornut．

（3）Tightenaboltornuttothespecifiedtorque・ Retightening （1）Putanalignmentmarkontheboltornutand

（a）

theparttobesecuredinthatposition．

（b）

（2）Furthertightenthebo［tornutbythespecified ang［e from the above−mentioned mark．

When no alignment marks can be put，the head ofthe bo［tornutcan be positionedas SPeCi軒edatrjght．

LockingofDoubIeNut A doub［e nutis a means of preventing the threaded partfromloosenlng anditmustbe

（a）

ti9htenedproperly．Iftighteningadoublenut isinsu惰cient，the e怖ect of preventing IoosenessisIost．Tighten a doub暮e nutin thefo ow［ngPrOCedures：

Asshownin（a）oftherightfigure，firsttighten

thelower nut①to80％of the specified torque．Then，aS Shownin（b），tighten the uppernut②．Fina）1y，aSShownin（C），uSea SPannertOPreVentthe10WernutfromturnIng

and tighten the upper nut to the specified torquefbrIocking．

1−1−19

（b）

（C）

DisassemblyandAssembly Torque Wrench Extension Whenanextensionisusedforatorquewrench，

the graduation of the torque wrench indicates SrnatlervaluethananactualtorquevaIue． （1）Put a mark on the handle・Measure the dimension（W）between the mark on the hand［e and the centerofthetorquewrench

Mark

lbrqueTl

d「ive．

（2）Measure the dimension（E）between the

torque wrench drive and the center ofthe torquewrenchextensiondrive・ （3）Whenthecorrecttorque（RT）isknown，find

the graduation corresponding to the correct torquebythefo owingequation：

さ／

−TbrqueRT

E：Dimension between center of the torque WrenChdriveandcenteroftheextensiondrive． W：Dimension between mark on the hand暮e and

CenterOfthetorquewrenchdrive

RTxW Tt＝1〃＋E

Example：W ＝304．8mm（12in） E＝65．Omm（2．55in） RT＝17．3kgf−m（1251b一代） （MaintenanceStandards） 17．3x304．8 Tl＝ 3掴．8＋65．0 ＝14・2kgトm

（4）Grip the torque wrench handIe so thatthe

middle fingeris placed on the mark and Obtain the correct torque（RT）from the graduation（Tr）ofthetorquewrench， App暮yingAdhesives（ThreadLock）

An adhesive may be used to prevent the threadedpartfrom］00S［ng．Whencoatingapart With adhesiveis spec摘ed，Pay attention to the fb ow暮ngPOints：

（1）CIeanthecomponent（De−Oiling）

（2）Dry the＄urface where adhesiveis to be

applied．BIowcIeanairordrythecomponent naturar［y．

（3）App［y a smallamount of adhesive to the

internaIly threaded part one ortwo threads away from the end．After applying．finish assemb［ingbeforetheadhesiveisdried・

Whenapartcoatedwithadhesivehasbeen leR，remOVe the adhesive and perform the abovestepsagaln．

1−1−20

DisassembLyandAssemb）y TighteningTbrqueforMetricBoltsandNuts

Thefollow】ngarethemetricboltandnuttightenlngtOrqueSinservicLngaCOnStruCtionmachine，eXCePtt torquesstatedspecial］yintheshopmanuaL・Thefo＝owlngtablecoversthehexagona［coarseand threads（Strength8・8，10・9）・ForthetighteningtorqueofJleXagOnaTsocketheadbolts，fo［（owthegrade lO．90fthistabIe． （Nm）

8．8

DiameterXPitch M4xO．7 M5xO．8 M6xl．0 M8xl．25 M8×1．0

MlOxl．5 MlOxl．25 M12xl．75 M12xl．25 M14x2．0 M14xl．5 M16x2．0 M16xl．5 M18x2．5 M18xl．5 M20x2．5 M20xl．5 M22x2．5 M22xl．5 M24x3．0 M24x2÷0 M27x3．0 M27x2．0 M30x3．5 M30）企．0

10．9

Standard

Range

Standard

Range

3．24 6．27 10．9

2．94〜3．53 5．68−6．86 9．80−12．0

4．22 8．24 14．3

3．82〜4．61

25．4

22．8−27．9

33．2

29．8−36．5

49．1

44．2−54．0

64．3

57．8−70．7

85．8

77．2−94．4

112

101−123

136

122−149

177

159〜194

209

188〜229

273

245〜300

288

259■−316

376

338−413

418

375−460

545

490−・600

549

494−604

718

646−789

699

629−768

910

820−1000

861

774−948

1132

1019・−1245

1186

1068〜1303

1539

1382−1695

1−1−21

7．45−9．02 12．8−15．7

Disassemb）yandAssembly TighteningTorqueforUnified（UN）BoItsandNuts Thefol［owingaretheuniRed（UN）typeb01tandnuttighteningtorquesinservicingaconstructionmachine，

exceptthetorquesstatedspecialJyintheshopmanual． （N

㊤

㊦ Standard

Range

Standard

Range

11．9

10．7〜13．0

13．7

12．3−15．0

5′16

23．9

21．5〜26．2

27．3

24．5〜30．0

3′8

41．7

37．5−45．9

47．7

42．由一52．5

7′16

66．6

60．0〜73．1

76．1

68．4〜83．7

1佗

100

90．0−110

115

103−126

9′16

144

129−159

165

148−181

5侶

198

178−218

227

204−249

3川

339

305−372

388

349〜426

DiameterxPitch 1／4

20UNC 28UNF

1−1−22

1q2．SPEC］FICÅTIONS

〕

OutLineDrawtngs／Specifications

……………・

Fue［，WaterandOitSetectionandCapacities

・………・1−2−5

WeightofMainComponents

……・・・・…・・・ 1−2−9

CheckandServiceList

…………‥

1−2−1

1−2−10

ー

●

﹁ノ

OutlineDrawIngSISpecifications

■

lL OutlineDrawIngS／Specifications ● L3−2

﹁ノ

BucketCapacity（WithBOC）

OperatingWeight Maker／Model q） ⊂

0．3m3 1915kg KUBOln／DllO5−K2A 16．2kl〟（22PS） 2500叩m

RatedOutput

■弓〉 ⊂

1．123L

l⊥J

FueLl盲nkCapacity

33L（LightOiI）

Operatin！ILoad

500k9

Max．DrawbarPulI

17200N（1750kg） 6．2km／h

q〉 0

⊂ q

2ndGear

巨

15km／h 300

卓 q〉

a TurningRadius

（CenterofOutsideWhee［）

Articu［ationAngle

2545mm 420

1−2−1

OutIineDrawJngS／Specifications

■

● L4−2

ヽノ

BucketCapacity（WithBOC）

OperatingWei9ht

0．4m3 2645kg KUBOTA

M∂ker

Model

D1503−D［−K2A

q〉

⊂

21．3kW（26PS）

ぎ l．∪ pRatedSpeed

2400rpm

lbtalPistonDisp］acement

1．499L

Fuel￣bnkCapaciり

50L（LightOil）

OperatingLoad

650k9

Max．DrawbarPuIr

27000N（2750k9） 7．5km／h

q〉 U

⊂ （∇

∈ 日

2ndGear

卓 ￠ m

（CenterofOutsideWheel）

ArticuIationAngIe

15km／h 300 3040mm 410

1−2−2

OutlineDrawlngSISpecifications

■

● L5−2

﹁−ノ

﹁ノ

BucketCapacity（With・BOC）

OperatingWeight

0．5m3 3265kg KUBOl■A D1503−Dl一丁K2A

Maker

Model

0 l＝

27．2柏〃（37PS） RatedOutput

lコ〉

⊂ RatedSpeed l．∪ 「btalPistonDisplacement

2500「Pm

FueIlbnkCapacity OperatingLoad

50L（LightOiL）

Max，DrawbarPuI［

33350N（3400k9）

1，499L

850k9 8km／h

q〉 く）

⊂ H

巨

2ndGea「

15km／h 300

卓 0

m

（CenterofOutsideWhee［）

Articu［ationAngle

3220mm 4lO

1−2−3

OutIineDrawlngS／Specifications

■

● L6−2

t260 BucketCapacity（WithBOC）

OperatingWeight

0．6m3 3565kg KUBOTA D1503−DトTK2A

Make「

Model q〉 ⊂

P lbtaLPistonDisp］acement 11J RatedSpeed Fue11盲nkCapaci吋 Opera伽9Load

27．2抽〃（37PS） 2500叩m 1．499L 50L（LightOiI）

960kg 3400k9

Max．DrawbarPulF

8km／h

8

⊂ ￠ ∈ 日

2ndGear

卓 ① L

（CenterofOutsideWheel）

ArticulationAngle

15km／h 300 3220mm 4lO

1−2−4

FueI，WaterandOilSeLectionandCapacities t Fuel Useonlyc［ean，high−qua［ityfue］・ UseGradeNo．2−DfueIabove40C UseGradeNo．1−DfueLbe10W40C

Donotusefuelthatcontainsgasolineora［coholoranysubstitute SuCh as kerosene．Use of these fue］s causes performance deteriorationorotherdefects．

●HandJingofFue］ Boththeinjectionpumpandtheinjectionnozz］e，Whicharevery PreCisecomponents，arelubricatedbythefue［．thatis．thefue］oiL itse［f．Use of a fueIthat contains water or dirt causes machine

trouble．Ac）ean fuelmust therefore be used．Storage ofthe fuelrequlreSStrictobservationofthefo owlngPreCautions． 1．FiI［the fueltank at the end of each day s operation．This PreVentSCOndensationofanyairwithinthetankand，hence，

entryoftheresultingmoistureintothefuel，andgjvestimefor anyinternaIdirtand moisturetoseparatefromthefueIand Se柑einsidethetank．

2．F‖afueLstoragetankandleaveitforatIeast24hours，and useonlythesupernatanta債era owlnganydirtandmoisture tose他e．

3．WhiIefi

ingthefueltank，becarefulnottoaIIowanysediment

in thefueIstorage tank to be pumped uptogetherwith the SuPernatant・

4．Openthedrainplugsonthebo仕OmSOfbothstoragetankand

fueL tank periodicaLly to drain any entrapped water and Sediment．

5．ReplacethefueIfiTterandelementperiodically・ l■Grease UsegreaseofNLGINo，2forairtemperaturesofOOCormore，Or usegreaseofNLG［No．1forairtemperaturesbelowOOC．

1−2−5

FueI，WaterandOilSelectionandCapacities ■LubricationOi暮 ・A］ways use engLne Oi10fGrade CD based on APIService Classifications．Use highly wear−reSistant hydraulic oil（lSO No．46）．

・The viscosity ofoi［s changes asthe temperature changes： Whenairtemperatureishigh，theoilisthinned，andwhenair temperatureislow，the oilis thickened・Use oiis of the Viscosityappropriatefortheparticularairtemperature・ ・The characteristics of oils vary from manufacturer to

manufacturer，anduseofoiLsofdifFbrentbrandsinmixedform maylmPa［rPerformance．AFwaysuseoi［ofthesamebrandto refill．

fIushingoil． t C00lant Thecoo［antshou［dbesoftwater．suchascitywater，thatcontains theminimumofimpurities．Wel［waterorriverwatermustnotbe used．

Whenantifreezeisnotused，addarust−PreVentiveagenttothe coolant to prevent rustin te cooling system．（FoIIow the instructionsofrustpreventivemanufacturersformixingratio）． Whenantifreezeisused，aruSt−PreVentiveagentisnotneeded． When renl［ing of coo．antis required，uSe a COOJant with an

antifreezeorarust−PreVentiveagentandsoftwateratthesame mtxlngratioasthatoftheinitiaIwatermixture・ ■Antifreeze ・Antifreeze prevents freezlng and rustingin the cooling SyStem．

・Useantifreezewhentheairtemperatureis［owerthanOOC． ● Use antifreeze which can be used throughout a year． Changeantifreezeevery2years（autumn）・ ・Ifothertypesoftheantifreezethanlong−1ifecoo7ant（LLC）is USed，ChangeittwiceayearinSpringandAutumn． ・WhencooLant（antifreeze）ischanged，besuretocLeaninside

thecoolingsystem． ・ThefreezlngtemPeratureOfthecooIantchangesaccordingto

theparticutarrnlXlngratiorelativetotheantifreeze．Tbseta mlXlngratio，aSSumethatthecooIantfreezesattemperatures fromabout5−100C暮owerthantheminimumIeve［e＄timated．

（Fo［Iowtheinstructionsoftheantifreezemanufacturers）．

1−2−6

﹁ノ

・lbreplacetheenglneOil，firstcompIete［ydraintheo［doiIand fiL］theenglneWith newenglneOila什erhavingcleanedwith

FueI，WaterandOiISelectionandCapacities ）AntifreezeMixingRatioTab e MinimumAirl七mperature （OC） RatioReLativetoWater L3−2

（％）

−15 30 3．8

5．5（L）

L4−2 3．9

5．7（L） L5−2／

L6−2

Amo叩tOfWater（L）

6．1（L）

4．2

−20 35 2．0 3．5 2．0 3，7 2．2

−25 40 2．2 3．3 2，3 3．4 2．5

−30 45 2．5 3．0 2．6 3．1 2．8

−35 50 2．7 2．8 2．9 2．8 3．1

−45 55 3．0 2．5 3．2 2．5 3．4

−55 60 3．3 2．2 3．5 2．2 3．7

3．9

3．6

3．3

3．0

2．7

2．4

● Antifreezemusta］waysbeusedatamix［ngratiooffrom30％to60％，Onethatisappropriateforthe particu［arairtemperature・Mixingratioslessthan30％noton［yfreezethecoolantandcausedamage

totheradiatorbuta［spg［Veinsignificantcorrosionpreventionresults・Mixingratiosexceeding60％not On［yglVeins■gniRcantantifreezeresults，butalsoincreasetheriskofoverheating・

●Iftheantifreezecomesintocontactwithyourskin，immediatelywashawaytheagentuslngrunnlng Water．

Note）lnanewmachinethecooLantwithLong−［ifecoolant（LLC）wi

havebeenused，SOnOCOOlant

changeisrequireduntilthetemperaturegoesdownto−200Corbe10W・Whenthetemperature goesdownto−200Corbe10W，adjusttheconcentrationofthecoolantaccordingtotheabove AntifreezeMixingRatiol盲bIe．

LApplicabIeOilLi＄t

1，ThecharacteristicsofoiI＄difFeraccordingtothemanufacturersISObesuretousethe＄ame Oil．

2．Whenthetypeofoilistobechangedtoanotherafteroverhaul，COmPlete］yremovetheotdoiI・ Comp）ete［ybIeedaira＄WelI・When＄uPPLyingoilforrepLeni＄hment，be＄uretOSuPPLythe SameOila＄befor0．

3．When＄uPPIyingoi10fanotherbrandname，Carefu］［ycheckitsspecificationsr 4．Theoil＄W肘Ia＊markhavebeenusedirLthemachinewheniti＄deIiveredfromthefactory．

EngineOil Radiator（EngineCoolingWater）

HydraulicOil BrakeOil ReductionGear

ApoloilMotiVeCD−MlOW−30 SanshinChemicalCoaranLongLifeCooJant NissekiMitsubishiHP46 ［demitsuDaphnelbrqueOi＝∋

NissekiMitsubishiFirmGearB（OldNamei？NissekiMitsubishi AntoilSuperB）★

Di馳rential（AxIe）

CosmoGearSAE90＊

Grease

CosmoDynamacSuperNo．2

1−2−7

Fuel，WaterandOilSetectionandCapacities ■AppIicableFue］，Water，OilTab［e

≧、

6

SpecifiedCapacity（L） u超

購

LS2／L62

②

③

33

5．5 5．7 6．1

Refi［］ed

50 50

Type

Sectiontobe

⑤

Engine Oil

CDGradeDiesel

Forl盲mperatureRange

SAE5W

250hou「s

Everyday

（Li9htOiI）

So代VVater

③■ Radiator

（ite）

AddingLongLi

（CityWater） 肌瞳ar−Resistant

HydrauIic ④

BrakeOil Tnk

1000hours

lSOVG46

HydraullCOll

1盲nk

⑤

（12month＄）

1000 hours 12 th

1b和Ue

（SAE5WMinera10il）

Reduction ⑥

ReplacementPeriod

（3months）

Diesel Oil ② Fuell盲nk

⑦

1．8 3．5／Each 1．8 4．5ノEach 1．8 4．5／Each

SAE30

EngineOir

OilPan

⑥

18（1bb125） 0．1（1bta10．3） 28（1bbI42） 0．1（1bta＝）．3） 28（1bta142） 0．1（¶ぬ10．3）

ApplicabIeStandard＼血Iue −30 −20 −10 0 10 20300C

Engine ①

④

①

3．6 5．6 5．6

Gea「

⑦ Axle

PinBearing

Fi汀nGea「B

Specia10

AElOW

0rSAElOW Nisseki Mitsubishi FimGearB

（12months） NLGINo．2

NLGINo．1

1−2−8

（12months）

1000hour＄

Specね10

LithiumType

1000 hours

100／250hours

（1／3mon肋s） Multi−PurposeGrease

WeightofMainComponents JWeightofMainComponents Unit：kg ltem

L3−2

L4−2

L5−2

L6，2

115

170

173

←

1．1

←

←

←

6．5 22．5 25 17．3

7．0

←

←

Engine AirC］eaner

Eng［neRelated EqulPment FuelT5nk B；州ery

←

←

←

←

38．9

HSTMotor

21 57 1．1

37

←

←

←

←

←

←

←

←

9．7 3．1 108 108 10．1

10．5

40．6 19．6

SuspensionBracket WheelAssemb［y Rim Ste今ringWhee［

PowerSteer［ng SteeringCylinder CenterPin Front Frame Cover OperatorFrame（F） FloorPlate HoodSupport Hood FrontCover

．3

←

← 4−

←

131 126

←

←

←

←

←

←

←

47．8 19

73．5

←

29．6

←

2

←

←

←

7

7．1

←

←

8．3 6．1 1．9

←

10

←

←

6．9

6．9

←

←

←

27．8

32．3

←

←

4．9

4．7

←

←

8．8

4．1

←

←

7

←

←

←

←

←

←

←

←

351

635

940

←

嶋−

←

←

ControLVa［ve

8．3 4．5 10．0 151．2 7．9

Oil職nk

24．2

31．6

←

←

ReturnFilter

1．0 86．8 13．8 33．1

←

←

←

156．8 23．5

215．8 26．0

53．5

62．3

12．5

17．5

24．0

226 31．5 63．5 25．3

5．6 99．3 24．6

10

12．6

←

149 29．6

169．8 31．6

185．2

OperatorSeat Weight

Liff Arm Assembly L椚Cylinder

Device

←

37

FrontAxle RearAxIe

Operating

◆−−

←

PropeIIerShaft（Rear）

Hydraulic System

←

←

2．1

PowerTrain

Exterio「

26

CouplingAssembly HSTPump（MainPumpwith aChargingPump） ReductionGear HST Oil Filter

Steerlng

22 32．1

Bell Crank Assembly TiJtCyIinder LinkAssembly Bucket（Standard）

Ed9e

1−2−9

←

CheckandServiceList ■CheckandServiceList CheckandServiceItems

■PeriodicMaintenance／Daily Walk−AroundInspection CheckEngineOilLeveJ CheckCooIantLevel

CheckHydraulicOilLeve［ CheckFue［Level

DrainWaterandSedimentfrom FueIT白nk DrainWaterandSedimentfromVVaterSeparator CheckBrakeOi＝＿eVeI

CheckBatteryElectrolyteLeve］ CheckandAqjustment■指nsionofFanBert

CheckSteeringWheelFreePlay CheckBrakePeda［Stroke Check Tire CheckVVheelHubBoJtforLooseness Othe「S

■PeriodicMaintenance／100日oursorlMonth（1stMaintenanceofNewMachine ChangeEngineOifandReplaceEngrneOi［Filter RepJaceHydraulicReturnFilterEIement RepIaceHSTOilFiIterELement L PeriodicMaintenance1100Hour＄OrlMonth

GreaseO＄CillatingRearAxle CleanFue［FilterEtement

lL PeriodicMaintenance／250Hoursor3Month＄（1stMaintenanceofnewMachine ChangeAxLeOir ChangeReductionGearOiI

1−2−10

CheckandServiceList CheckandService［tems

■PeriodicMaintenanceI250Hoursor3Months ChangeEngineOilandRepLaceEngineOiIFiIterE）ement CheckandCleanAirCIeanerE［ement CheckBattery「晦rminaIs GreaseCenterPin

GreaseWorkingEquipment GreaseSteerlngPins LIPeriodicMaintenance／500Hoursor6Months

RepLaceFue［FilterElement C［eanWaterSeparatorFilterScreen LubricatePrope erShaft CheckLnjectionNozzle

■P虐riodicMaintenanceIlOOOHoursor12Months ChangeHydrauLicOilandCIeanSuctionStrainer RepIaceHydraulicReturnFilter ReplaceHSTOilFi［terE［ement

ChangeAxleOil ChangeReductionGearOil ChangeBrakeOil BleedAirofBrakeSystem RepIaceAirCIeanerElement

MaintenanceMlhen Requireded CheckAxIeOilLevel CleanandCheckRadiatorFin

ChangeCooIantandC［eanCoo［ingSystem CleanFuellbnk

CIeanEngineBreatherE［ement CheckandAqiustEngineV白IveClearance

Rep［aceFuse ReplaceSlowBlowFuses Rep［aceCuttingEdge（Bucketl七eth）

1→2−11

﹁ノ ﹁ノ

2．CONSTRUCT10NANDFUNCT10N

〕

2−0．Engine

・・・・・…＝…・・

2−1．EtectronicSystem

…・‥＝……・

2−2，PowerTrain1

・・＝＝…・……

2−3．PowerTrainJJ

……………・

2−4．BrakeSystem

……………・

2−5・SteenngSystem

……………・

2−6．Frame

・・・・＝・・・t……

2−7・Hydrau［icSystem

………・＝・・・

2−8・WorkingEquipment

……………・

2−0−1

2−1−1

2−2−1

2−3−1

2−4−1

2−5−1

2−6−1

2−7−1

2−8−1

︺ ﹁ノ

2・0．ENGINE

〕

Engine

・・・・・……＝‥・ 2−0−1

EngineAssembly，EngineMount

■t…・………・

2−0−5

AirCIeaner

……‥t・・…‥

2−0−6

Mu用er

t・・t……‥‥＝

Radiatorrr

・・・………・・ 2−0−10

EngineControI

…………‥

FuelSystem

…・…・・・・・・・ 2−0−13

2−0−7

2−0−12

﹁ノ ヽノ

■ Englne T Engine The type of eng，ne for this machineis the water−COOLed4−CyCle dieseleng［ne・Aturbo−Chargeris equlPPedtotheenginesmountedonL5−2andL6−2・

TheenglneCOmPOnentSCanberoughlydividedintothefollowIng： 1．Engine−EngineassembIyandmount 2．Aircleaner 3．Mu用er

4．Radiator（Oilcoo［er）

5．EnginecontroL 6・Fuelsystem−Fueltank，fue［pump．waterseparatorandfuelfilter

Theabovei

2−0−1

ustrationisforL4，2

● EngineSpecifications ● L3−2

ltem

De＄Cription

Remark＄

EngineModeI KUBOTADllO5−K2A 旬Pe 4−Cyc［eDiese［，WaterCOOled NumberofCy］inders−BorexStroke

3−78mmx78．4mm

lbta［Displacement 1．123L

TypeofCombustionChamber E−TVCS（PrecombustionChamber） 16．2kW（22ps）±2．5％／2450−2550

RatedOutput／RatedSpeed

「Pm

Output／Tbrque（Gross）

17・OkW（23・1ps）／70．6Nm（7，2kgfm）

HighIdleSpeed 2665−2735rpm LowldIeSpeed

1100−1200「Pm

Max．1brque／EngineSpeed

68．6Nm（7．okgfm）／1500−1700rpm

RotatingDirection Counterclockwise（ViewfromFlywhee［） lnjectionNozzleType

DN−OPDMinトNozzre

JnjectionPumpType BOSHMDTypeMini−Pump JnjectionPressure 13．7MPa（140k9／cm2）

lnjectionTiming BTDC17−190 CompressionRatio、

23

FueIRequired Diese10il Fue［Consumption 258g／kW・h（1909／ps・h）

PressurizedRadiatorType

CoolingSystem

（WithCoolantPump，ForcedCircuIation）

LubricatingSystern ForcedLubricationwithTrochoidPump LubricantRequired

GradeCCorhigher，10W−30

LubricantCapacity 3．8L CoolantCapacity 1・7L（On［yEngine） AirCleaner

CyclonelYpe，Paper，Fi［ter

ReguLator ICType（WithBui［t−inAIternator） DimensionsofEngine（LxWxH）

532．8mmx398．8mmx580mm

DryWeight 113．5k9 StartingSystern

StarterMotorType（WithgIowp［ugs）

StarterMotor

12V−1．4kW

Alternator

12V−0．48kW

12V−52Ah（WarmLocation） Battery

12V64Ah（CoJdLocation）

2−0−2

75D26L X 1 pce 95D31LX 1 pce

● L4−2

EngineModeI

De＄Cription KUBO7AD1503−Dl−T−K2A

Type

4−CyCIeDiesel，WaterCOOled

ltem

NumberofCylinders−BorexStroke

Remarks

3−83mmx92．4mm

lbtalDisplacement 1．499L TypeofCombustionChamber

lbroidalType（DirectInjection）

RatedOutput／RatedSpeed

21．3kW（29ps）±2．5％／2350−2450rpm

output／lbrque（Gross） 21．9kW（29．8ps）／95．4Nm（9．73kgfm） HighldleSpeed 2550−2650rpm LowldleSpeed 950−1050rpm Max． Tbrque／EnglneSpeed 93．3±5％Nm（9．52±5％kgfm）／1600「2000 lnjectionOrder 1−2−3

RotatingDirection CountercLockwise（ⅥewedfromF［ywheeL） lnjectionNozzleType PNozzle PFR3KlサPePump lnjection Pump Type ）njectionPressure

（Bosh3KTypeMiniPump） 18．6MPa（190k9〝cm2）

22．6MPa（230kgucm2） lnjectionllming BTDClO−120 CompressionRatio 20 FueLRequired DieseIOil FuelConsumption

CooIingSystem

First

Second

238−261g／kWh（175−192g／psh）

PressurizedRadiatorlYpe

Lubricating System Forced Lubrication with Trochoid Pump LubricantRequired

GradeCCorh？gher，10W−30

LubricantCapacity 5J6L CooIantCapacity 1．7L（OnlyEngine）

AirCleaner Cyc10neType，PaperFilter ReguIator lCType（WithBuiIt−inAlternator） DimensionsofEngine（LxWxH）

599．2x514．4x643．5

DryWeight 165．5kg StartingSystem StarterMotorType（Withglowp［ugs） StarterMotor Altemator

12V」．4kW 12V−0．48kW

12V−52Ah（WarmLocation） Battery

12V巧4Ah（ColdLocation）

2−0−3

75D26L X 1 pce 95D31LX 1 pce

● L5−2／L6−2

De＄Cription

ltem EngineModeJ

Remarks

KUBOTAD1503−D［−K2A 4−CyCIeDiesel，WaterCOOled

Type

WithTurbocharger

NumberofCylinders−BorexStroke ，rbtalDispIacement

3−83mmx92．4mm

1．499L

TypeofCombustionChamber lbroidaLType（Directlnjeption） RatedOutput／RatedSpeed Output／lbrque（Gross）

27．2kW（37ps）±2．5％／2450−2550 rPm 28・OkW（38ps）／117・6Nm（12kgfm）

Highld［eSpeed 2650−2750「Pm LowldleSpeed 950−1050「pm Max．1brque／EngineSpeed 114二7±5％Nm（11．7±5％k9fm）／1600−2000 lnjectionOrder 1−2−3 RotatingDirection Counterc10Ckwise（View＄dfromFlywhee［）

lnjectionNozzleType PNozzle PFR3KIYpePump InjectionPump■丹Pe

lnjectionPressure

（Bosh3KTypeMiniPump） 18．6MPa（190kg〝cm2）

Fi「St

22．6MPa（230kg仇m2）

Second

］njectionllming

BTDClO−120

CompressionRatio 20 Fue［Required Diese10iI FuelConsumption 238−261g／kWh（175−1929／psh） PressurizedRadiatorlYpe

CooIingSystem

（WithCoolantPump，ForcedCirculation）

Lubricating System Forced Lubrication with Trochoid Pump LubricantRequired GradeCCorhighe「10W−30 LubricantCapacity 5．6L Coo］antCapacity 1．7L（OnIyEngine） Air Regulator lCIYpe（WithBuilt−inAlternator） DimensionsofEngine（しXWxH）

599．2mmx514．4mmx643．5mm

DryWeight 170kg StartingSystem StarterMotorType（Withg［owplug＄） StarterMotor 12VJl．4kW Alternator

12V・0．48kW

12VL52Ah（WarmLocation） BatteⅣ

12V64Ah（CoIdLocation）

2−0−4

75D26L X ?pcee 95D31LXIpce

■■■■■■■ Eng］neAssembIy，Eng］neMount ■EngineAssembIy，EngineMount TheenglneaSSemblyismountedtotherearframeviafourcushionrubbers・

TheenglnemOUntSarethevibration−PrOOfstructure，WhichabsorbsthevibrationoftheenglneaSSembIy・ Theengineassemblyismountedontherearframeusingtherubbermounts（4Iocations）・

TheengineoildrainpIugisLocatedattherightsideofthemachinetoenhancetheserviceability（itcanbe accessedwithoutgoingunderthemachine）・

ThisillustrationisforL3−2．

0010．Engineassembly

0130．＼棚娼her

OO20．Enginemountbracket（RearLH） 0030．Enginemountbracket（RearRH）

O140 Bolt O180 Joint O190 Packing O200． Drainhose O230． Connector O260．Drainplu9 0270． Gasket

0040 Bolt OO60 BoIt

OO80．Enginemountbracket（FrontRH） 0090．Enginemountbracket（FrontLH） 0101． Bolt O120． Cushionrubber

2−0−5

AirC［eaner ■ AirCIeaner ln theairintake systemofthe eng［ne，theairis passedthrough the aircIeanerand enterstheinlet

manifo［d・Theaircleanerhasapaperfirtertypes［ngIeelement．

・lJ

﹁ノ

0010．Airc［eanerassembly lOlO・Body lO20．Element lO30．Cover

lO40．AjrcJeanerdustindicator OO20．Hose OO30．Hose

OO40．Hoseclamp ①．TheIightturns on when theaircleaneris

CIo9ged．

①

Monitor［ightinmeterpane［

2−0−6

2−0．Engine Mu什Ier ■ Mu什Ier In the exhaust system ofthe eng［ne，the exhaust gasis passed to the mu斤［erthrough the exhaust manifo［d：Iow−PreSSUre and tow temperature gasis discharged・This mufneris the expansion and

resonancetype． ● L3−2

0011．Exhaustpipe OO20．Packing OO50． B「acket OO91． Mu冊er

0131．Clamp O140．Glasstape O150．Hoseclamp

2−0−7

● L4−2

0010・ExhaustPipe OO20． Ga＄ket

0130．ExhaustPipe

OO50． MufFler

O180．Clamp

OO61．B「acket，「i9ht

O190．Bracket，le微

O140，Mu用erClamp

2−0−8

Mu什Ier ● Turbo−Charger ● L5−2，L6−2

Theturbo−Chargerisequ（PPedtotheintakesystemofaD1503Ttypeenglne．

Highoutputcanbeobtainedintheintakestrokeoftheeng］nebecausetheamountofairisincreasedby PreSSinghighdensityairintothecylinderandthefue［injectionisincreased・ Theturbinewhee］oftheturbo−Chargerisconnectedtotheexhaustmanifo］dandtheexhaustgasesturn

theturbinewheelathighspeed． Thecompressorwhee＝nstaIIedtotheothersideoftheturbinewheelonthesameshaftisalsoturnedata highspeed，WhichcompressestheairfromtheaircleanerandsendsittotheintakemanifoJd・

0010．Exhaustpipe OO20．Gasket OO51．Mu用er O140．MufFIerc）amp O200．B「acket

2−0−9

Radiator ■ Radiator

CooIingSystem： CooIingFan： WaterPump： Thermostat： Radiator：

VVater−COOIed Pushertype，PPmade

Coolantしevel：

L3−2：5．5し

Centrifuga［type，Beltdriving Waxpe＝ettype，＼ね1veopentemperature820C／Fullopentemperature920C

TubeandpJatefintype L4−2：5．7L し5−2：6．1L

L6−2：6．1L

ThecooIingsystemoftheenglneiswatercooJedforcedcircuIationtypeuslngWaterPumP． Thecoolantissuckedfromtheradiatorbythewaterpumpandcoo］seachsectionoftheenglne．

Whenthecoo［anttemperatureisIowandthethermostatisc］osed，thecooJantiscirculatedintheeng［ne Withoutpasstn9throughtheradiator． Whenthecoolanttemperaturerisesandthethermostatisopened，the・COOlantissenttotheradiatorand SuCkedbythewaterpumpa代eritiscooled． Radiator line

2−0−10

Radiator 0060 0090

0010．Radiatorassembly OO20．Oitcooler OO30．Duct OO60．Cap OO70 日ose

OO80．Draincock OO90 Clamp OlOO．Fanguard OllO．Drainhose

1．010．Upperhose

lO20．Lowerhose lO30．Hoseclamp lO40．Hoseclamp lO50．Cushionrubber lO60．Cushionrubber lO70．Bott lO90．Nut llOO．Resen／etankr l180．肌bsher

2−0−11

EngIneContro［

■

Engine Controlol Theeng■neSPeediscontroHedbytheoperationoftheacceleratorpeda［． Whentheacceleratorpeda［ispressed・theeng■negOVernOrIeverismovedthroughtheIinkandpu［）cabJe．

TheenglneSPeedappropriatefortheworkconditioncanthusbeobtained．

0150

0240 0010． AcceJeratorpeda1

0190．Splitpin

OO60． Bracket

0120． Link O130． Bush O150． Splitpin

O200．CabIeas＄embJy O210． Rodend

OlOO． Stopperbo托

O160． Pぬte

O240．Sprin9

0110． Nut

O170．Ybkepin

0020． P暮ate

2−0−12

Fue［System ■FueISystem Thefueltankislocatedattheleftsideoftherearframeandthefuelhoses（feedandreturn）areconnected to the engine.

AIso，thefuelsenderunitisinstalIedonthefueltankandthefueltanklevelisindicatedonthefuelgauge Onthemeterpanel． lnjection pump

0010．Fueltank OO20．Strainer OO30．Cap OO40．Fuelsenderunit OO50．Gasket OO60．Bolt OO80． Cover OO90．0−Hn9 0130．Drainp［ug lOlO． Bolt

2−0−13

Fuel System ● Fue［Piping FueloiIissuckedupfromthefueLtank①bythefueJpump③and throughthewaterseparator②．

Thefuerisdischargedfromthefue［pump③ismteredbythefue用ter④andsendtothe呵ectionpump ⑤．

Theinjectionpump⑤increasesthefuelpressureanddistributesthefueItotheinjectionnozzIe⑥of eachcy］inderthroughwhichthefue［isinjectedintothecy［inder Thesurplusfuelininjectionnozzle⑥ returnstothefue＝ankthroughreturnhose⑦． 1ftheairentersinthefuelpIPlng・thestarterswitchisturnedon，theaircanbeb−edthroughthereturn

Circuit・（AutomaticairbIeedingsystem）． 6

−トFeedCi，C。it M＞ReturnCircuit ① Fue］tank

④Fue］fiLter

②waterseparator ③Fuelpump

O lnjection pump ⑥呵ectionnozz暮e

2−0−14

Fuel System ● WaterSeparatorFilter Thewaterseparatorfi［terseparateswaterinthefueL However，ifitis used for a［ong time，forelgn Substances，etC may CauSe CLogglng．Cleanit Periodica］ly．

lMPORTANT DONOTclean＄CreenWithgasoIine．

● FueLFiIter The fueL filter removes any foreIgn Substances and Waterdepositedinthefuel．However，ifitisusedfora Iongtime，forergnsubstances，etCmayCauSeCIogg［ng・ Cleanitperiodically．

2−0−15

﹁ノ ﹁ノ

2Ll．ELECTRICSYSTEM MeterPanel

‥………＝‥・

2−1−1

E［ectricalComponents

……………・

2−1−2

Main Circuit

‥‥‥………・

2−1−5

MonitorLampCircuit

……………・

2−1−6

GaugeCircuit

………・t…＝

2−1−8

ChargIngCircuit

…………‥

Pre−heatingCircuit

……・t……・ 2−1−11

Sta止andStopCircuit

…………‥

2−1−13

TraveLingSystemCircuit

＝………・＝

2−1−15

LightCircujt

…………‥

2−1−21

HornCircuit

・・……‥＝‥ 2−1−23

Auto−leveIerCircuit

・‥………‥

ElectricalCircuit

〕

2−1−10

2−1−24

﹁ノ

︺

MeterPane［ Meter Panelel

﹁−ノ

● Meters

・Monitor［ights（WarmingIights）

l．FueHeve］gauge 2．Eng［neWatertemPeraturegauge

8．EngineoilpressurewamlngLight

ヽ．ノ

3．Hourmeter

9．AircIeanerwarn］nglight lO．Alternator（Charging）warningIight ll．BrakeoiIleveLwarnlngLight

● Pilotlights（Operationindicator［ights）

4．Enginepre−heatpiIotlight

5．Parkingbrakepilotlight 6．DrivemodeindicatorIight 7．Turnslgnalindicatorpi10tlight

2−1−1

Electrical Components ｝ElectricaIComponents ● Around FrontFrameandMeterPanel

ノノ⑨ ⑩ ⑪ ＼ ＼

′巨ノ

Ⅴ睾トト

か＼．

．／

ヽ ヽ ．1−1・

︑︑・

．r﹁

O Meter panel

⑪Horn

②parkingbrakeswitch

O Glow timer

③Travermodeselector＄Witch ④sh的Iever

⑱Re［ayl（MonitorJightcheck） ⑭Re［ay2（MonitorIightcheck） ⑮Relay3（Parkingbrake） ⑱ReIay4（Parkingbrake）

⑤combinationLightswitch ⑥starter＄Witch （∋Fusebox ⑧FueIlevelgaugesendingunit ⑨Head［ight ⑩Turnsignallight／CJearancelight

O Flasher unit

2−1−2

Electrical Components ・ BodyRear

﹁ノ ⑳

①Brakelampswitch

（診Backbuzzer

O StaFter relay

⑨Backlamp

O Glow relay

⑱Airc［eanerindicator

④Slowblowfuse

O Battery relay

⑪Solenoidva［ve（forward） ⑫Sotenoidva［ve（back）

⑥Ba恍ery

⑱1st−SPeed触ngso）enoid

⑦Combinationlamp

⑭ParkingbrakesoIenoid

2−1−3

EIectrica［Components

⑥

⑤

②

①v他tertemperaturegaugesendingunit ②Alternator

O Starter motor ④．Engineoi［pressureswitch ⑤EnginestopsoIenoid ⑥Glowがugs

2−1−4

①

③

E［ectrica［Components

Starter．S血itch

RearHarness

408

ヽ−＿＿＿＿＿．＿．．．＿ ⊥

40B

￣■■−

RearHamess

2−1−5

EIectricarCircuit／MonitorLampCircuit Meter Panel

2−1−6

ElectricalCircuitIMonitorLampCircuit

AItemator

Air Cleaner Switch

EIectricalCircuit／GaugeCircuit 卜

￣＋−−→−−

Meter Panel一−−＋−−＋●− −−∵−−

Fuse Box ￣￣

1 1l

FueILeveI

HourMete

●

芦 ・．＿乳．

Fuel Level Gauge SendingU雨

2−1−8

Electrica［CircuitlGaugeCircuit MeterPane［

MeteF Panel

Main Harness

Fue］LevelGau9eSendingUnit

2−1−9

ElectricalCircuit／CharglngCircuit

■

2−1−10

ElectricalCircuitlPre−heatingCircuit Glow Lamp StarteF Switch

Meter Panel

Glow Relay

Timer

l￣■￣盲這JGi有一￣「

轡

！

i

」＿．＿＿＿

＿＿＿．●」 墓

琶

Sh胎Lever

−￣￣￣

B

8R

「甘 A）ternator G10WPk唱

」

＿＿＿．＿＿I＿＿」

Engine

（1）Whenthekeyswitchissetto HEAT ，thegLowrelayisactivatedandthecurrentgoestothegIow Plu9S． （2）1ntheotherline，thecurrentturnsontheglowlamponthemeterpaneIthroughthegIow［amptimer・ （3）Theg］owlampisturnedo仔5seconds［aterbytheglowLamptimerandindicatesthecompIetion Pre−heating．

（4）Whenthekeyswitchissetto S17LRT ，thecurrent90eSfromkeyswitchterminal C totheg10Wlamp timerthroughtheshiftlevertoactivatethegIowre［ay・ThecurrentthengoestothegLowplugs・ （5）lntheother［ine，thecurrentpassestotheg10WLamponthemeterpane［throughthegLowIamptimer andturnsontheglowIamp． （6）・Aftertheenginewasstarted，thekeyswitchisreturnedto ON一 ・ Atthesametime，theactivatedcircuitoftheglowre暮ayISOPened，thenthegIowplugstumo庁．

2−1−11

E［ectricalCircuitIPre・heatingCircuit Meter Panel

GJowRelay

■■ ・こ∴二桁唱 ■こ￣￣餅⊥＝ ∵∴・

、ヒ＝＝−こよ．・！

2−1−12

・也

E［ectricalCircuitlStartandStopCircuit Sta止erRe［ay slowBIowFuse

Starter Switch

﹁ノ

StopSoIenoid

1．−．t

Ter Alternator

州

﹂

Engine

＿＿

1．StartCircuit （1） StarterSwitch： ON→START

operation．

TheeIectriccurrentfromCofstarterswitchissenttocoi10fstarterreLaythroughneutralswitchof

theshiftIeve「SOthestarterre［ayISC10Sed．Atthe＄ametime，thepositivecurrentfrom batter

relayrunsthroughthestarterrelaytothestartermotortostartthestartermotor

（2） StarterSwitch ON→SIART operationwhiIetheengineisrunning Whentheengineisrunning，aStheterminaLLonthealternatorisnotgrounded（a［ternatormonitor Iightturnedo鱒）thecurrentdoesnotgotothecoiIofthestarterrelay，SOthesta托errelayisinope COndition．Therefore，thestartermotorisnotactivated．

2．StopCircuit （1） StarterSwitch ON

Thepo＄itivecurrentfromthefuseboxissenttothecoi［ofeng［neStOPSOIenoid，andtheeng［neis rUnnln9・

（2） StarterSwitchL OFF

ThecurrentfromfuseboxtotheengLneStOPSOlenoidiscutofF，andenglneisstopped．

2−1−13

E］ectricalCircuitIStartandStopCircuit

﹁ノ

Batte「yRelay．

StaterMotor

2−1−14

ElectricaICircuitlTraveIingSystemCircuit Fuse Box

−一十十十十−−・−「−⊥−

2−1−15

Electrica］Circuit／TravelingSystemCircuit

﹁ノ

2−1−16

ElectricalCircuit／TravelingSystemCircuit 1．Shiftlever：【N］i）［F］

WhentheparkingbrakeisreLeased，theeLectriccurrentissentfromfusetotheparkingbrakesolenoid andthesift［everthroughthere［ay（4）．

WhentheshiftLeverischangedfrom［N］to【F］，thecurrentgoestothe［F］solenoidontheHSTpump． 2．Shif＝ever：【N］う【R］

Whentheparkingbrakeisreleased，thee［ectriccurrentissentfromfusetotheparkingbrakesolenoid andthes脈Ieverthroughtherelay（4）・

Whentheshif‖everischangedfrom［N］to【R］，thecurrentgoestothe［R］solenoidontheHSTpump． 3．TravelmodeseLectorswitch：［AUTOI

Theelectriccurrentfrom thefuse maintainstheautomaticspeed circuitwithout making thecurrent PaSStOthefirst−gearfixingsoIenoidontheHSTmotor・Ontheotherhand，thecurrentpassIngtOthe meterpanelturnsonthe Rabbit monitor］ight・ 4．TraveLmodeseLectorswitch：【LOWI

Thee［ectriccurrentfromthefusegoestotheRrst−gearfixingsoIenoidontheHSTmotorandactivates it．0ntheotherhand，thecurrentpass［ngtOthemeterpaneL，turnSOnthe lbrtoise monitorIight． 5．Parkingbrakecircuit ■Parkingbrake＄Witch Automaticreturn

「ヽ

Parkingbrake＄WitchconnectiontabIe NEUTRAL

2 3 4 5 6

5

2

6

3

ON NEUTRAL OFF （Automaticreturn）

﹁ノ 2−1−17

○

○

EIectricalCircuit／Trave暮ingSystemCircuit （1）Beforeenginestart（Starterswitchisin

ON

position）

Currentfromthefuse③goesto： Termina］bofreIay［1］−＞terminalcうcoilうterminaIg⇒terminaILofaLternator・｝ground，thenrelay［1］

isswitchedfromb−etOb−a．

Atthesametimecurrentfromthefuse①goesto： −TbrminaIbofre［ay【4］⇒terminale・＞Parkingmonitorlightうground，Parkin9mOnitorlightturnson．

（2）Afterengineisstarted． ①parkingbrakeswitchisin ON （Applied）position． Thecircuitbetween9rOundandterminalLofalternatorisopened，Whenthea■ternatorischarging． Currentfromthefuse③goesto： TerminalbofreJay［1］うterminaleiterminaJlofparkingbrakeswitch．

Atthesametimecurrentfromthefuse①goesto：

Trbrminalbofrelay［4］⇒terminalei）p野kingmonitorrigQ！ラground，theparkingmonitorIighti＄On． Relay【3】 《勤 BrakeSwitch

Parkin9 MonitorLight

ParkingBrake Solenoid

l

GR

Sh脈Lever Forward／Reverse S01enoid

2−1−18

Electrica］Circuit／TraveTingSystemCircuit ②Parkingbrakeswitchisin Neutral position・

Currentfromthefuse③goesto： 1盲rminalbofrelay［1］⇒termina）e⇒termina110fparkingbrakeswitch・

Atthesametimecurrentfromthefuse①goesto： TerminaIbofre［ay［4］うterminaLe⇒parkingmonitor［ight⇒ground，Parkingmonitor［ightstayson

andparkingbrakeisapp［ied．（Travelinginhibitorcircuit）

③Parkingbrakeswitchisoperatedip OFF position・

Currentfromfuse③goesto： 鴨rminalbofreIay［1］⇒terminale⇒termina110fparkingbrakeswitchうterminat2うterminaI5・

CurrentfromterminaI50fparkingbrakeswitchgoestorelay［3］andt4］separateIy・ Onegoesto：鴨rminalbofreIay［3］T｝terminaIe⇒parkingbrakesoFenoid⇒ground，thenparking

breakisreleased・ Anotheron台goesto：鴨rminalcofrelay［4］T＞coiLうterminalg⇒9rOund・

Arternator

2−1−19

ETectricalCircuit／Trave［ingSystemCircujt （3）A什errese輔ngtheparkingbrakeswitchto

OFF

①Oncetheparkingbrakeswitchis＄ettO

（automaticreturn）．

OFF

，there‡ay［4］staysonbythecurrentfromfuse①．

②Parkingbrakeswitchisswitchedin ON position．

Currentfrom terminalc ofrelay【4］goesto‥ Tbrmina150fparking brake switch⇒terminaI6 L）terminalcofre［ay［3］うcoi［−｝ground，thenrelay［3］isswitchedfromb−etOb−a．andparkingbrake isapplied・

Atthesametime，Currentfromterminafcofre［ay［4］goesto：Tbrmina］bofrelay［3］

⇒termina［a⇒parkingmonitorlightturnson．

③ParkingBrakeSwitchisswitchedfrom ON toL■NEUTRAL ． Currentforthecoi［ofreIay【3］iscut0年，thenparkingmonitorlightturnsofF． Atthesametime，CUrrentfromtermina［cgoesto：−Fbrminalbofre［ay［3）⇒terminaleT｝parkingbrake

SOfenoid・｝ground，thenparkingbrakeisreLeased．

Altemator 2−1−20

ElectricaICircuitlLightCircuit

︺ 2−1−21

E［ectricaLCircuit／LightCircuit

Shiff Lever

2−1−22

Electrica［CircuitIHornCircuit

CombinationLampSwitqh

GroundingattheSteering CoIumnFixingSection

2−1−23

E］ectricalCircuit／Pre−heatingCircuit ＿＿＿上蹟e＿塾遡」＿−

三言二：き：

2−1−24

2・2．POVVERTRAIN］

〕

PowerTrain

……………・

HST

＝‥…・・・・・・・・・ 2−2−4

HSTPump

＝‥…………

HSTMotor

……・・・・・・・・ 2−2−18

HSTPiping

…………‥

ChargLngPump

……・「……2−2−25

HSTOiIFi］ter

…………・・

2−2−25

ReIief＼ねIve

…………‥

2−2−26

HSTControI

…＝………

2−2−27

HST Hydraulic Circuit

…………＝

2−2−28

ReductionGearBox

…………‥

2−2−30

2−2−1

2−2−5

2−2−24

↓ノ

﹁ノ

Power Train

■ PowerTrain ThepowertrainconsistsofaHSTpump，HSTmotor，reductiongearbox，PrOPeI［ershaft，frontaxle，rear axIeandwhee］s．

The powerfrom theenglneistransmitted tofrontand rearaxlesthrough the HSTpump，HSTmotor． reductiongearandprope ersha托． ThepowertransmittedtothefrontandrearaxleturnsthewheeIsanddrivesthemachine・ ①Engine ②Coupling

O HST pump ④HSTmotor ⑤Reductiongearbox ↓ノ

⑥Prope［Iershaft（Front）

⑦propeIlershaft（Rear）

⑧FrontaxLe ⑨Rearaxle ⑩Wheels

（Two whee［seachattheFrontandRear）

㈲

●DrivingForceTransmissionChart

③HSTpump ◆（Hydrau■ichoses）

④HSTmobr

⑧Frontaxle

⑥PropelLer Sha債（Front）

⑤Reduction

gearbox

⑦Prope川er Shaft（Rear）

⑨RearaxIe

⑤Wheels

⑤Wheels

（F「ont）

（Rear）

2−2−1

Power Train ●HSTPump，HSTMotor

0100

0010．CoupIingassembly OO20．BoIt OO30．Bracket OO40．Pin OO50．Bolt

0070・HSTpumpassembIy OO80．Bolt OlOO・HSTmotorassembIy OllO．Bolt

2−2−2

Power Train ●Coup）ing ・ EngineandHSTpumpconnectingsection

OOlO．CoupIingassembIy lOlO．Rubber lO20． Hub

lO30．BoIt lO40．Springp［n

EnginefJywhee］

● HSTmotorandreductiongearbox HSTmotorandreductiongearconnectingsection．

Reduction gear box,,

L3−2： SeaIwithscrew10Ck

（Loctite242，ThreeBond324，etC．） L4，L5．L6−2： SealwithO−ring

2−2−3

t HST（Hydro−StaticTransmission） HSTisahydrauJicdrivingunitwheretheeng−neIspoweristransmittedtothewheelsbythehydrau］ic PreSSure・The machine．s HSTis equlPPed with a combination of variabJe−displacement pump and

Variable−disp［acementmotor．

Theeng［ne−smechanicalpowerisconvertedtohydraulicpowerus−ngthepump・Thishydraulicpoweris re−COnVerted to mechanicalpower bythe motorand transmitted tothewheeIs．HSTfunctions both as CIutchandtransmissionandthenon−StageCOnVerSionisavai［ableusIngthehydrauliccontrol．

Basically，HSThasasystemwhereIow−SPeedandhigh−PreSSureOilisusedandtheoiliscircu［atedinthe C10Sedcircuitconsistingofpumpandmotor． TheHSTiscontro［ledbythefoL10Wrngthreefactors：

OilDischarge

−Machinespeed

Directionofoi［fIow 0iLPressure

−Machinemovlngforwardandreverse． −DrivingForce

Bycontro ingtheabovethreefactorsproperty，themachinecantravelsmoothIy・

ThedirectionofthepumplnPutShaftrotationisalway＄ thesame．ThedirectionoffIowofoi［dischargedfぬm

the pump changes according toti（ting ofthe swash P［ateand，thereby，thedirectionofmotoroutputsha＃

rotationchanges． In other words，the machine moves forward or backward according to the direction ofswash p［ate tiltingt Further，gearShifting（OrSPbedchanging）is

donebychanglngthemotorcylinderblocktiltingangle．

2−2−4

CyJinderbIocktj）tangle，large

HST Pump t HSTPump L4−2

L3−2 ModeI

PVK25FRAU1230SlOO8 PVK25FRAU1235SlOO5

Variable−displac9ment

L5−2／L6−2

PVK25FRAU1239SlOO7

PVK25FRAU1239SlOO6

←

←

←

←

0−25cc／「ev

0−27．5cc／rev

←

MaxPressuretobeused

42MPa

42MPa

←

（ReliefvaIvepressure）

29．4MPa

ControIsystem

AUcontroI

34．3MPa ←

38．2MPa ←

36．4kg

38．9kg

39．1k9／39．3k9

Gearpump

←

←

Type Drivingsystem

Discharge

Weight

HST Charging Pump

axiatpistonpump

Enginecrankshaft directconnection

包卜∵司l

︑誓・﹂／

・・言

′ ＋

︶打吊パ・ ／ン

ヽ．ノ

① Mainpump ② Chargingpump ③ Inchingva［veassembIy

④−1，So［enoidva［ve［Y］（forFoTWard） ④ゼ．Solenoidvalve（Z］（forReverse） ⑤

High−PreSSurereliefvalve

⑥ Low−PreSSurereliefvaIve

2−2−5

HST Pump HST pumpmp TheHSTpumpistheswashplatetypeaxjaIpistonpumpwithautomotivecontroLThecyIinderb暮ock⑤，

Withninepistonsintotar，isconnectedtotheshaft⑭usingaspline；andthemainpump②andcharging

PumP①areconnectedtoitthroughthecoupling③． 恥theHSTpump，theAUcontrolter⑧whichisthecenteroftheautomotivecontrol，andtheneutra）ho）d mechanism．andtheinchingvalve⑮，WhichcontroIsthepjlotpressurefortheautomotivecontroJ，areaH

integratedintotheHSTpump．

ViewA

1． Chargingpump

7・9radle（Swashp［ate）

2． Mainpump 8．AUcontroIsection NeutralhoJdSection 3・ Coupling 4・ PortpIate（Valveptate） 9．Spacer 5・ Cy［inderBIock lO．Pin（B） 6・ Piston

12．Pin（A）

13．Needlebearing 14． Sha徴

15．lnchingvalve 16．High−PreSSUrereliefvalve

17 Low−PreSSurereIiefvalve

ll Pin（C）

2「2−6

HST Pump HST Pumpmp

2−2−7

HST Pump ●AUcontrol［er l．・TheelectromagneticselectorvaJve①forforwardandreverseisequipedtotheAUcontroLIer WhenelectriccurrentissenttosoIenoid②，thespoo10ftheselectorvalveisoperatedandthepi10t

PreSSuregeneratedintheinchingva［vesendspressurizedoiItotherightorIeftpressurechamberof thepiston③．

2．ThepiIotpressurecontroIsthestrokeofthepiston③againstforceofthespring⑦whichisinstaIled inthepiston③． 3．Whenthepiston③ismoved，thecradLeistiJtedthroughthespacer④andthepin⑤．whenthe Cradteistilted，thepumpdischargesoi］． 4．Theamountofoiidischargingbythepumpisdecidedbythestrokeofthepiston③．

Theaqjustingscrew⑧limitsthestrokeofthepiston③anddecidesthemaximumamountofoi［ discharge by the pump.

●Whenthee［ectriccurrentissenttothesolenoidYthepumpdischargeso‖fromtheportP Andwhen theeIectriccurrentissenttotheso［enoidZ，thepumpdjschargesoilfromtheportS，

●Neutralholder l．Holdingtheneutralpositionisdonebyforceofspring⑦whichisinstaIledinthepiston③． 2，Theadjustingscrew⑨isequippedtoaqjustthepiston③totheneutrarposition，

Note：DONOTre−adjustneutralpositioninthefie［d．Becauseitmustbeadjustedontestbench． TheAUcontro［）erandtheneutra＝101derarenotindependentofeachother，buttheyarecombinedsystem．

2−2−8

HST Pump ●AUContro

er，NeutralHo［der

8

9

﹁ノ

1．ELectromagneticselectorva［ve

6．CradIe（Swashp］ate）

2．So】enoid

7．Sp「ing

3．Piston 4．Spacer 5．Pin

8．Aqju＄tingscrew（F［owrateadjustment） 9．Adjustingscrew（Neutra［adju＄tment）

2−2−9

HST Pump ●Horsepowercontro［mechanism ThisHSTpumpusesthehorsepowercontrolmechanismusLngthehydraulicpowerworkingontherotary

COmPOnentS． ThefolIowingdescribesthehorsepowercontro［mechanism． 1，Whenthepump］SrOtatinginthedirectionofthearrowthecradlereceivesthereactionforcefromthe

high−PreSSurePistonside・Theninepistonsarerotatingand40r5pistonsareatthehigh−PreSSure Side・Thereactionforcefromthosepistonsworksonthecrad［e・Whenthepistonsarerotating，the resu［tantreactionforceofeachpistonworksasifdrawingafigureofejght（8）asshowninthefigure，

ThemeanpositionoftheresultantforceisshownasG． 2．ThedeviatedpositionofGfromtheshaftcenterisshownas8．

TheresuttantforceonGisincreasedwiththedischargingoilpressureandreducesthetiltangIeofthe Cradle・Theforcethatis reducing ti［t angle ofcradleis decided bytheformu［a（resu［tant force x eccentrjcamount（8））．

The decrease ofthe cradle tiJt angleindicates a decreasein the pump■s discharge・［t mean the

horsepowercontrolisstarting，

ViewVV−W

2−2−10

tion…

HST Pump

3．Theeccentricquantity（8）canbeadjustedbychangingtheportpLatephaseangle．Thephaseang［eis Changed byturnlngtheeccentricbolttowardsAorBwithinthe rangeof±90degrees．When the eccentricboItisturned±90degrees，thephaseangleofportp［ateischangedabout±2degrees． When the eccentric boItis turned towardsA，the eccentricamount（8）isincreased and when the eccentricboltisturnedtowardsBtheamount（8）isdecreased，Withinthisrange．itcanbeadjusted．

Dischargequantity．

Pressure

4．ThecradIe−sreactiontotheresu］tantforcexeccentricamount（8）isdecided bythepistonarea，t SPrlngforceinthepiston，andthepi10tPreSSureOnthepiston．1bmatchtheengIneOutPUtandH PUmP［nPutthe piIotpressureisadjusted becausetheareaand spr］ngforceofthe pistonare both 而xed．

WhenthepilotpressureisFow，thepressurepointstartingthehorsepowercontro＝smovedtoth

Iow−PreSSureSideandwhenthepi［otpressureishigh，itismovedtothehigh−PreS＄ureSide．

Pilot pressure Low

←・→

Dischar9e quantity

Pressu帽

2−2−11

High

HST Pump ●InchingvaJveassembly 1・TheoiJfromthechargingpumpentersfromport④anddividesintotwo，gOingtotheorince④ofthe PreSSureCOntrOIvalvespool①andtheoriRceofthevalvebody②．

2・WhentheoiIsenttothepressurecontro［vaIvespool①passesthroughtheorifice④adi庁erent PreSSureiscreatedbefbreandaftertheorificebecausethed悔rentpressuremovesthespool①to thespring③sideagainstthespringforce．

3，Thevalvebody②functionsasthevariab］eorjfice． Whenthevariable．oriRce⑩isc［osed，a＝theoi［goesfromthechargingpumptothepressurecontroI

Va［vespool①・WhenthevariableoriRce⑩isfullyopened，aHtheoiFgoesfromchargingpumpto

PO托㊥throTghtheva−veBody②，lnthiscase・P‖otpressureisntcreated・ Thisfunction［SCOnneCtedwithbrakepedalofthemachine，andisuslngaStheinchingcontroI．

4・

〕 ，

5・Thepi10tPreSSure（APc）is）edtopo代⑥tocontroLthe．pumpdischargequantity．ThepiJotpressure

from pon⑥goes tothe piston chamberwhich contro［s the pumpdischarge，thr。。ghthe eIectromagneticse［ectorvalve． 6・Thepumpspeedchangestheproportionatlycharg暮ngPumP．Sdischargesothattheeng．nespeedis SenSeda托erithasbeenconvertedtothechargingpump．sdischarge・

1．PressurecontroJvaIve SPOO1 2．＼ねlvebody

3．SpHng 4．Orifice 5．Or涌ce 6．Or涌ce

7．Adjustingscrew 8．Low−PreSSurere［iefva［ve

9．Shim lO．＼ねriabJeorifice

2−2−12

HST Pump ●PiLotpressurecreatingmechanism l．Therelationshipbetweenpumpspeedandpi］otpressure（△Pc）isasfo［［ows・

Pi］otpressure

A P c Enginespeed 2．Thisshowsthespoo（positionwhentheeng［neisstopped・

Thespoo−ispushedtothe■e代becauseofthespringforceandthepon⑥whichcreatespi10t PreSSureisc10Sed．

FromPo托④

3．ThespoolbeginstomovewhentheenglneSPeedhasgonebeyondlowidIespeed・Theopemngo

thecontroIsectionisthenincreasedandpi10tPreSSureiscreated（POintX）．ThepointXisdecidedby setting］oadofthespring③−1．Thespringloadsettingi＄adjustedbytheshims・

2−2−13

HST Pump speedisincreased，adifFerentiarpressurebeforeandaftertheoriRce④，thespoot 4．WhentheengIne ①ismovedtotherightandtheopeningofthecontroIsectionisincreased，SOthatthepi10tPreSSureis increased，aSShowninthefigure．Thespring③−2determinesthepi［otpressuregradient・Adjusting thesmatlerspringsetIoadcreatesthepitotpressurecharacteristicstogainhorsepowerandyieid OPtimumcharacteristics・

2−2−14

HST Pump ●HSTpumpmeasurementport Unit：MPa

SymboL

L3−2

L4−2

L5−2

L6−2

29．4

34．3

38．2

←

29．4

34．3

38．2

←

Refertothe Characteristic

←

←

←

Po「t

High−PreSSurePOrt（Forward）★

Pl． （PIugsize：Gl／4，0−Ring） High−PreSSurePOrt（Reverse）

Sl． （Plugsize：Gl／4，0−Ring） Q2．

AUcontroIpressureport（Pilotpressure） （￠6BitetypetuPefitting，1／4）

Cun／e．

★Re］iefPressure

PI

sl

﹁ノ

Viewinqfromthetopofthemachine

2−2−15

HST Pump ●HSTpumpcharacteristiccurve L3−2 Eng．rpm−HSTcontroIpressure

0

500

1000

1500 Eng．rpm

2−2−16

2000

2500

3000

HST Pump ●HSTpumpcharacteristiccurve

L5−2，L6−2

Eng．rpm−HSTcontroIpressure

0

500

1000

1500 Eng．rpm

2−2−17

2000

2500

3000

HST Motor HST Motoror

ThisHSTmotorisabentaxistypeaxia［pistonmotorandthevariabLe−displacementtypeinwhichthe displacementcanbechangedintwosteps・ThebentaxistypefeaturesthatthecylinderbIocktiItswith

respecttotheshaR・Bysendingthepressurizedoilfromcharg−ngPumPtOthechamberAorBofthe

Piston⑥，themaximum，middLeorminimum（maximumorminimumfortheL3−2）cy［inderb］ock⑩tilting anglecanbeobtained． Thefo［10WjngfigureshowstheconditionwherethemotordispIacementismaximum（Low−SPeed）． ● L3−2

1．Ndt 2．Shaf1 3．Pushrod

7．Pin 8．Setscrew 9．Bush

4・Pistonassemb［y

lO．Cy［inderblock ll．SystempressurecontroIva［ve

5・Po止plate（∨白1vepIate）

6．Piston

2−2−18

HST Motor ・ L4−2，L5−2，L6−2

﹁ノ

1．ELectromagneticse［ectorvalve

2．SystempressurecontroIvalve 3．Body 4．Piston（formiddle−SPeedcontroI） 5．Piston

2−2−19

HST Motor ●Systempressurecontro［vatve l．Twokindsofpressurizedoi［aresupp［iedfromtheHSTpumptothesystempressurecontroIvalve．

①pi）otPressuretochangethemotordispLacement −ConnecttoPort G ． 1tisconnectedfromport V ontheHSTpump． ②pi［otPressure（APc）tocontrolthesystempressure−ConnecttoPort H ． Itisconnectedfromport

Q

ontheHSTpump．

2．WhentheenglneSPeedis10W；

AsprIngforceisg］VentOtherightsideofthespool，andthepi10tPreSSUre，Whichisusedfbrthepump dischargeratecontroJ．isgNentOtheJeftsideofthespooLWhentheeng）neSPeedislow，thepi10t PreSSUreisaLsoIow・ThespnngforceisstrongerthanthepiIotpressure．sothatthespootismoved tothe］e軋 WhenthespoolisinthispositiontheHSTmotorcapacitybecomes（arge．Therefore，When

theenglneSPeedjsIowthemotorcapacityislarge． From HST From HST PumP

Aqjustingscrew

chamberA↓乍hambe，B＋Drain 3．WhentheEngineSpeedisHigh； AstheenglneSPeedincreases，thepi10tPreSSurerisesgraduarly．Whenthepi10tPreSSurerises，the fbrcepresslngthespooltothesprIngSjdea［sorises．Asthefbrceofthepi10tPreSSureincreases，the

SPOOlmovestorightside・AndthencircuitofthechamberAisconnectedtodrainportthroughthe SPOOlandportGisconnectedtochamberBtochangeHSTmotorcapacityto＄malL A微erthe＄POOI POSitionhasbeenchangedtotherightside，thesmal＝1STmotorcapacityi＄maintainedeventhough

theenglneSPeedisfurtherincreased． Po托H PortG ￠

す

chamb。，A†bhamberB已；ain 2−2−20

HST Motor 4．Systempressurecontrol（Automaticspeedchangecontrol）

Thecheckva］vese［ectsthehigherpressurefromthetwosidesinthemaincircuitpressure，andis］ed totheendofthepinbui［tinthespooLWhenhighpressureactsonthep［n，thespooIismovedtoth

left．WhentheHSTmotorcapacitypositionissma［lerpositionandthemaincircuitpressureishigher， thespoolmovestothe［e代Sidebyacting high pressuretothepin．Thenthecapacityofthe HS motorbecomes］arge．

Adjusting screw

5．Whenthemotorcapacitychangesfromsma‖toIargethemaincircuitpressureisa飴ctedbythepiI PreSSUre（△Pc）whichitself changes with the engine speed．The higher the engine speed（Pi［ot PreSSure），thehigherthemaincircuitpressuretochangethecapacityoftheHSTmotor．

6．1nordertoadjusttheenginespeedwhentheenginecapacityischangedfromIargetosmaII，the tensionofthesprInglSSetbyus［ngtheadjustingscrew．

Speedchange PreSSure （MPa）

Pilot pressure

2−2t21

HST Motor ・HSTmotorlargecapacity（First−Speed）fixing（L3−2）

lthasafunctionofthefirst−SPeedfixingbyconstructingacircuitwherethepilotpressureconnection

fromtheHSTpumpport Q toHSTmotorport H can beshutdownbyusLngtheelectromagnetic se］ectorvalve①． Thefo＝owjngfigureshowsthehydrauliccircuit・ WhentheeIectromagneticselectorvaIve①isturnedOFF，itfunctionsasageneraFsystempressure COntrOLandwhenitistumedON，the］argecapacity（first−SPeed）isfixed．

● HSTmotorfirst・SPeedcontrof（L4−2，L5−2，L6−2）

TheetectromagneticseIedtorvalvecontroIsthedirectionofpi10tPreSSureWhichisintoportt．G Chooseautomaticshiftmodeormiddlespeedfixingmode．

to

Thefol10WrngShowsthehydrauliccircuit・

L

WhentheeIectromagneticvalveisturnedOFF，theHSTmotorisfunctionedasautomaticshiftmode・ WhenitisturnedON，thepi10tPreSSuregOeStOthemiddIespeedcontroIpiston，andthentheHST motorchangestomiddlespeedfixingmode．

Pilotpressurefrompumppo丘仏V 2−2「22

HST Motor ・ SolenoidOFFCondition（Automaticsh択mode）

・SoIenoidONCondition（Middle speedfixingmode）

2−2−23

HST Piping HST Pipingng

TheHSTpipingisdividedroughlyas：SuCtioncircuit（A），Chargingpumpcircuit（B），HSThigh−PreSSure Circuit（C）．pi10tPreSSureCircuit（D）andlubrication／C001ing／returncircuit（E）．

ThecasingoftheHSTpump①andHSTmotor④are刷Iedwithoildischargedfromthechargingpump ②・Theoi［cooIseachpartandfLowstotheoilcooler⑥．Theoiliscoo［edbytheoifcoo（er⑥and returnstotheoi［tank⑤． 1nthemainbody，theRrstspeedfixingsoIenoidva［ve⑦isconnectedtotheinchingvalve⑧usingthe

hydrau［ichoseinthesystempressurecontroIpiIotcircuit．

2−2−24

CharglngPumpIHSTOilFilter

■

■Charg［ngPump

ThetandemgearpumpwhichconsistsofthemainpumpandthecharglngPumP・ltis・insta［］edtothe PumPandturnstogetherwiththeeng）ne・

ThecharglngPumPSuPPliesoi］totheHSThigh−PreSSureC10SedcircuitandautomotivecontroLcircuit，a itsendsoi］totheparkingbrakeforreIeas［ng．TheoildischargedfromthechargingpumpISSenttOthe inchingvalveassemb［ythroughtheHSToilfi［ter・

CharglngPumPCaPaCity

CC／「ev

8．0 8．1 8．1

L3−2 L4−2 L5−2／L6−2

t HSTOilFiIter TheoiLfromthechargingpumpfIow＄intothecase④

throughtheinletportanditisfiLteredbythee］ement ①．Thentheoi［flowingoutoftheoutletportgoesto theinchingva［veassembly． WhentheeIement①isc10gged，thepressureatthe inletrisesandthed桁erencein pressurebetweenthe

in［etandoutletbecomesO．34MPaorover，theby−PaSS Valve（1）opensandtheoiIf）owsfromtheinlettothe outletwithoutflowingthroughtheelement①．

OUT ∵ ＞

tn

2 3

蜘謁CaSe

1

﹁ノ

4 −

5 2

2

2 ●

Re］iefValve ■ Re［iefValve

●Low−PreSSurereliefvaIve

TheoiIsentfromtheinchingvalveassemblyactsonthe POrt（A），PuShesoutthevalvestem（1）atapressureof

l・57MPaoroverandfIowsintothecaslngthrou9hthe POrt（B）toholdthepressureinthelow−PreSSureCircuit．

﹁ノ

●High−PreSSurereliefvalve くRelieving＞

1・TheoiIfrom the high−PreSSure POrt（A）actson the

difFerenceinareabetweenthetwopartshavingthe diametersDandd．（D＞d）． 2・Whentheoilpressureinthehigh−PreSSure POrt（A） reaches the high−PreSSureSetting＊MPa，thevaIve

body（1）opensandtheoilinthehigh−PreSSurePOrtB （A）fIowstotheIow−PreSSUrePOrt（B）． 史MPa

L3−2 L412 L5−2 L6−2

29．4 34．3 38．2 38．2

くSucking＞ Whenthepressureinthehigh−PreSSurePOrt（A）is［ower

thanthepressureinthe10W−PreSSurePOrt（B），thevaIve body（2）opensandtheoilinthe［ow−PreSSurePOrt（B）

f（owstothehigh−Pre＄SurePOrt（A）topreventcavitation．

2−2−26

HST Control

■ HSTControI TheHSTequipmentisoperatedbythesh椚Iever（1）（forward・andreverse［ever）insta［1edtothesteering CO）umnandthedrivingmodeselectorswitch（2）inthemeterpaneJ． Operationofthesh汎Iever（1）actuatesthedirectionswitchingvalve（SO】enoid）oftheHSTpump，Changing thedischargedirectionoftheHSTpump．Thus，thedrivingdirection（forwardorreverse）ofthevehicIe Changed． OperationofthedrivingmodeseLectorswitch（2）actuatesthevalve（SOIenoid）thatsetsanincIinatio theHSTmotorcyLinderblock，Changingtheinclination．Thus，thespeedgears（automaticandRxedlst gear）arechanged． Thevehic］espeed can be continuously controLled from starttoacceleration，deceleration and stop by OPeratingtheacceleratorpedal（3）（enginespeed）． （1）

（2）

2−2−27

HSTHydraulicCircuit 1HSTHydrauIicCircuit TheHSTpumpandmotorcomposesthefo

ow■ngOilcircuitforthesystempressurecontroJ．

● L3−2

﹁ノ ︺

①High−PreSSurereliefva［ve ②Low−PreSSUrereliefva）ve ③Mainpump ④Chargihgpump

L3−2 29．4MPa 1．57MPa 9．5∝／rev 8．Occ／「ev

● 2

8 2

2

■

HSTHydraulicCircuit ● L4−2，L5−2，L6−2

﹁ノ

︺

L4−2

L5−2

L6−2

①High−PreSSurereliefvalve ②Low−PreSSurereliefvalve

34．3MPa

38．2MPa

←

1．57MPa

←

←

③Mainpump ④Chargingpump

14．3cc／rev

16，8cc／rev

19．2cd「ev

8．1cdrev

←

←

2−2−29

ReductionGearBox Reduction Gear Boxox ThereductiongearboxdecreasethespeedofthepowertransmittedfromtheHSTmotortoincreasethe torqueandthentransmitsthetorquetotheax］eassembIies． The mounthasavibration−PrOOfstructurethatabsorbsthevibration ofthe reduction gearbox．The reductiongearboxismountedontherearframeusingtherubbermounts（3［ocations），

●Operation（Powertransmission） ThereductiongearboxconsistsofinputshaR，OUtPutShaft7tWOPiecesofgears，diskbrakeassembFyand CaSeetC． ThetorquefromtheHSTmotoristransmittedtotheinputshaft7inputgeanoutputgearandoutputshaft anditisincreased・ThenthetorqueistransmittedtotheaxleassembliesthroughthepropeIIershafts．

0030

0011

0060

0010．Reductiongearbox OO20．Bracket．L．H． 0030．Bracket，R．H．

0040．Bolt OO60，Rubber OO80．BoIt

2−2−30

Reduction GearBox ●Reductiongearboxassembly Airbleeder（ForbrakeairbIeeding）

﹁ノ I・

HSTMotorside

1． Case

6． Plug

2． Bolt（Forparkingbrakefbrcedcance［Iatjon） 7． FIange 3． Cove「

8． OilIevelpJug

4． Flange 5． Airbleeder

9． DrainpIL喝 10．Oj［創Ierplug

2−2−31

﹁ノ ヽノ

2・3．POWERTRAIN

〕

Prope［［erShaft

……………・

2−3−1

Axle

…・・……＝…

2−3−2

Di＃erential

・＝＝・………・ 2−3−5

FinaIGear

……・＝……・

2−3イ

WheeI

……………・

2−3−8

﹁ノ ︺

Propeller Shaft Propeller Shaftft

Theprope一一ersha触transmitthepowerfromthereductiongearboxtothefrontaxleandtherearaxle・

MovementinthedirectionoftheLengthcausedbytheturningofthemachineframesanduneventrave［

（rearax］eosci［［ation）isabsorbedbythesp［ine・Thechangeofangleisabsorbedbytheuniversa［joint， sotheprope■IershafttransmitsthepowersmoothIyfromthereductiongearboxtothefrontax［ean rearax］e．

0050

0010．PropelIershaftassembIy OO20．Bolt OO40．Prope［Iersha代assembly

OO50．Bolt

2−3−1

■ Axle Theaxleconsistsoftheax［etube，di庁erentia［unit，fina［reductionandax−eshaft，andwheelsareinstalIed

totheaxleshafts． ThepowerfromthereductiongearboxistransmittedtothefrontandrearaxresthroughthepropeIIer

Sha触・WithintheaxJeassemb［y・thepoweristransmittedtothed肺erentiaLunitandbranchestorightand leftandthentotheaxlesha触todrivethewheelsthroughthefinaIreductionassemb−y・Referto Power T「ainl ．

Thefrontaxleisfixedtothefrontframebybolts・Fortherearaxle，aCrad．epinsupportsystemisequ．pped， WheretherearaxIeissupportedbytherearframeus，ngtheaxlesupportsatthefrontandrearsections．

Therearaxlethereforeoscillatesthemotionofthemachineinaccordancewiththeunevennessofthe roadsurface，uSlngthecrad［eplnatthefrontandrearasanaxis．

0020

0030・・−・−−−、，、．＿

0010・FrontaxIeassembly

OO20．Bolt OO30．Ⅵねsher

OO40．Nut

1010・Rearax［eassembly 2010．Axletube 2020．Diqerentialunit 2030・FinalreductionassembIy

2−3−2

Front axlele

0010 Axletube OO20 AxIe

tube

0030 Axle shaff 0040 Beari咽

0050 0il＄ea1 0060 Retainer plate OO70 BoIt OO80−0120 Shim

0130 BoIt O150 Pin O160 Ring9ea「 0170 Pin

O180 LeveIgauge O190 PLanetarycarrierassemb暮y lOlO D桁erentialassembly

2−3−3

Rear axlele

﹁ノ ﹁ノ

0010 Axletube 0020 Axle tube

0130 Bolt O150 Pin

OO30 AxIe＄ha代 0040 Beari咽

0160 Ring gear

0050 Oil seal 0060 Retainer plate OO70 BoIt OO80−0120 Shim

O180 Levelgauge O190 PJanetarycarrierassembly

O170 Pin

lOlO D桁erentja［assembly

2−3−4

Differentia］ ■ Differential

ThedifFerentialturnsthepowerfromthereductiongearboxintherectangulardirectionanddecreasesthe

SPeedofthepowertoincreasethetorque・Further7Whenthemachinesw■ngSOrittravelsontheroug road surface，thedi＃erentialchangestheIeftand rightwheelspeeds sothatthe machinecan move SmOO州y．

●Operationprincipleofdifferential WhenthemachinetraveIsinabeeLineundertheconditionthattheroadsurfaceonwhichthe）eftandright Wheelsmoveareequa［orwhenthe10adtobeappliedtothele代andri9htwheelsareequal，thesame torqueactsontheleftandrightsidegears（2）withinthedi伴erentialcase（4），thepinion（1）turntogether

Withthed肺erentialcase（4）andtheleftandrightwheeIsturnatthesamespeed・ Ontheotherhand，WhentheLoadstobeapp］iedtothe［e代andrightwhee［sared桁erent，forexample，in SWinging，thetorqueactingontheleftandrightsidegears（2）ared侮rentandtherebyeachpinion（1）

revoIvesroundthesidegear（2）ofwhichtheresistanceisgreaterwhileitturnsonthespider（5）tod（i theothersidegear（2）forperformingthedifferentia（action・

ヽノ

Tumhq

5．Spider

1． Pinion 2．Sidegear 3．Sungear

6．Drivep［nlOn

7．Ringgear

4． Di鞄rentialcase

2−3−5

DifferentiaT ●DifferentialassembIy ∧U

3

︵U

O

3

O

︵U

3

∩︶

03

5

l−

▲U

3

0

O

O 6

▲U

3

O

4 3 2

す−0170 曾−0180

0130 0200 0㌫苧虐 0240−→診0210

0120 0130 0140 0150 0160

0010 Ringgear 0020 Pinion gear OO30 Diqerentialbody OO40 Cover OO50 Bolt OO70 Gearandsha微

0080 Plug 0090 Bearing retainer OlOO Bolt O120−0160 Shim O170 Breather

ooso Od70

0180 Bushin9

0290 Nut

0190 Bolt

O300 Ⅵねsher O310 0ィi咽 0320−0360 Shim

0200 Bearing O210 Di庁erentiaIsidegear O220 Di庁erentia［pIn10ngear 0230 Thrust washer 0240 Thrust washer O250 DifFerentialcase（A） 0260 Di飴rentialcase（B）

0270 Pinion gear O280 0ィing

2−3−6

O370 Bolt 0390 Bearing cage O400 Bearing O410 Bea「ing

O420 Spacer 0430 Oil seal 0440 Fね咽e

Final Gear

■ FinatGear Thetorquefromd桁erentialistransmittedtothefina］gearthroughthesungear（3）・Thespeedisreduce

toincreasethetorqueandthenthetorqueistransmittedtothewheet・

Thesungear（3）mesheswiththethreepIanetarygears（5）andtheplanetarygears（5）meshwith internatgear（6）．Thethreep［anetarygears（5）areinsta

edtothegearcase（7）bytheshafts（4）andthe

internalgear（6）isheIdtothehousingthroughthepins・ Whenthetorquefromthed侮rentiaTrotatesthesungear（3），thep［anetarygears（5）rotateon・theinternal

gear（6）whiletheyrotateontheshafts（4）・TherotationofthepLanetarygears（5）ontheinternaFgear（6） drivestheshaft（4）togetherwiththegearcase（7）torotatethewheel・

Rotation

SectionA−A Ptanetarygearfunction

7

1．Drivepln［On 2． Di飴rentia1

3．Sun9ear 4．Sha粍

5．Planetarygear

6．］nternalgear 7．Gearcase（Planetarycarrier）

8．Axleshaft 9．Bat1 10．Needlebearing

2−3−7

■ Wheel

L3−2

（kg）

re

L5−2

10−16．5司PR 15．5／70−16−6PR 15．5／60−18−8PR

TireSize

Tube［ess

TubeIess

40．6

47．8

73．5

21

28．8

43．9

19．6

19．0

29．6

278−306

375−412

196−215

←

Tireandwheelass y

Weight

L4−2

Rim

Tighteninglbrqueofhubbolt

L6−2 ←

Tubeless ←

←

←

215−235

←

（Nm）

AirPressure（kPa）

0010−−

Rearaxle −0020

0010・WheelAssemblyR．H．

1010． Rim lO20． ¶帽R．H． 0020・Whee［Assemb［yL．H．

2010． Rim 2020． TireLH．

0030． HubboIt

2−3−8

2・4．BRAKESYSTEM Brake System

……………t

HowtolbwaVehic）e（inanEmergency）・・・・ ……・・・・

WetBrakeAssembIyin

……………・

2−4−1

2−4−7

2−4−8

Reduction Gear Box Master Cylinder

〕

……………■

2−4−9

︺ ﹁ノ

Brake System ）BrakeSystem

Service brakeke Theservicebrakeuseswetdiskbrakeequ［PPedtotheinputshaftinthereductiongearbox，Thishydraulic brakesystemconsistsofthebrakepeda［（1），brakefIuidreservoir（2），maSterCy［inder（3）andpiping． Thismastercytinder（3）isasingletypeandthebrakehydraulicIineissing［ecircuitsystem．

●］nchingmechanism

Thebrakepeda［（1）is［inkedwiththeHSTpump（inchingvalve）bytheinchinglink．Wheneitherrighto ］eftpedaL（1）isdepressed，themachineisstopped，uSingthewetdiskbrakea托ertheinchingfunction （HSTbrakefunction）ispeげormedbytheoperationoftheinchingIever．

も

・ デ

▲．．、 ′：・

＼、モ、、＼

′「■■ l

￣

て、

＼ ＿′・′ヽ． ヽ

① Brakepedal ② Brakeoil陀SeⅣOir

⑤ Brakelight（ttisfunctionedbythebrakelightswitch（4））

③ MastercyIinder ④ Brakelightswitch

⑦ BrakeoiIlevelwarningIamp （Whenoi［［evelis［oweredin（2）itcomeson）． ⑧ B［eeder（ForAirBleeding）

⑥ Brakeoillevelswitch

2−4−1

Brake System ●Servicebrakeisoperated l・Whenthebrakepedal（1）（eitherrightor［e微）isdepressed，theinchingva）ve（2）operatestostopthe HSTpumpfromsendingoiF・Consequentlythedrivingforceiscutandthebrakingforceiscreated．

（HSTBrakingFunction） 2・Whenthebrakepeda）（1）isfurtherdepressed．thepushrod（3）operatestopushthepistonofthe

mastercylinder（4）・Theoilpressurecreatedbythepistonissenttothechamber（5）andpushesthe Piston（6）ofbrakea早Semblyinthereductiongearbox． 3・Theservicebrakepiston（6）isthereforemoved，andthewetdiskbrakes（7）arepressedtocreatethe

brakingforce． 4・ThestopIampswitch（8）isalsoturnedONandsothestoptampisturnedON．

Parkingbrakepi＄tOn

2−4−2

Brake System ●Servicebrakeisreleased l．Whenthebrake pedal（1）isre］eased（eitherrightorleR），thepushrod（3）is returnedtoitsoriginal POSitionandapistoninthemastercy］inder（4）isalsoreturnedtoupward・Consequent］ythebrakeoil PreSSureinthechamber（5）isreLeased． 2，Theservicebrakepiston（6）becomesfreeandthebrakedisks（7）arereleased． 3．Atthesametime，the HSTpumpinching vaIve（2）［everis returned toits ori9inalposition andthe inching（HSTbrake）functionisreleased． 4，Thestoplampswitch（8）isturnedOFFandsothestoplampisturnedOFF． 1

Parkingbrakepiston

2−4−3

Brake System Parking brakeke

Theparkingbrakeandtheservicebrakeusethesamewetdiskbrake・［tconsistsofHSTcharging hydrauIiccircuit（hydrau［icpressuresource）ande［ectricalcircuitsincludingtheparkingbrakeswitch① andparkingbrakesolenoidvaIve②． Theparkingbrakeswitch①ontherighthandsideofthemeterpaneIoperatestheparkjngbrake， Meter panel

（2）

①parkingbrakeswitch ②parkingbrakesoIenoidvalve

2−4−4

Brake System ●Parkingbrakeoperation Parkingbrakei＄aPPlied

l．Whentheparkingbrakeswitch（9）ispushedtoturniton，thehydraulicoilintheparkingbrakecyLinde Chamber（11）isdrainedbytheparkingbrakeso（enoidvalve（10）． 2．Theparkingbrakepiston（12）ismovedtotheleftduetoforceofthespring（13）andthewetdiskbrake isapp［iedthroughtheservicebrakepiston（6）．

Thefo‖owingcircuitdiagramshowstheconditionwhentheparkingbrakeisapp［ied（ON）．

7

6

11

2−4−5

12 13

】0

Brake System Parking brake operationon ParkingbrakeisreIeased 1・Whentheparkingbrakeswitch（9）ispushedtoturnito庁，PreSSurisedoilissentfromHSTinching

VaIvetotheparkingbrakecylinderchamber（11）bytheparkingbrakesoLenoidvalve．

2・Theforceofpressureraisedoirinthechamber（11）overcomesthefbrceofthespring（13）andmoves theparkin9brakepiston（12）totheright・ConsequentIytheservicebrakepistonbecomesfreeand releasesthewetdiskbrake（7）．

2−4−6

HowtolbwaVbhicle（inanEmergency） ■HowtoTowaVehicle（inanEmergency） ●ManuaIparkingbrakerelease Theparkingbrakeisre］easedbypressureraisedoir． Therefore，Whentheeng［neisnotrunnLngtheparking

brake cannot be reIeased，because oilpressure to releaseparkingbrakeisnotcreated． When the englne CannOt be operated and the machineis to be towed，the parking brake can be releasedmanua

y．

Reductiongearbox

▲cAUT10N Do not tow a vehicle by compu］sory（manual）

re（ease of the parking brake exceptin an emergenCy・

1．Removethebolt①（MlOxL55）． 2．Removethep］ug②． 3．1nsta［landtightenthebolt①totheportBwhere theaboveplug②hasbeenremoved．

The parking brake pistonis pulled andit becomes re暮easedpositionsothevehiclecanbemoved．

●ShortcircuitofHSTpumphydrautic cir￠uit

1，Loosen reIiefvaIves（2Locations）threetimesto CauSe Short circuit between the high and暮ow PreSSureSides．

▲云AUT10N DonotIoosenmorethanthreetimestoavoidoi1 leaks．

Reliefva［ve

2・4−7

WetBrakeAssemb］yinReductionGearBox 十WetBrakeAssemblyinReductionGearBox Inthereductiongearbox，thewetbrakeassembJy■Sequ■PPedtotheinputsha軋Itisusedinboththe

SerVicebrakeandparkingbrakeoperations．

●WetbrakenaturaIlubricationmechani＄m Inthismechanism，Oi［inthereductiongearboxsp［ashesthroughthesealretainer⑦oilhoIe（SeCtionB）

andlubricatesthebrakesection．

Airbleeder（forbrakeairbIeeding）

1．Cap 2. Piston housing 3．Wavesprlng

8．Endplate

4． B「akedisk

5．Brakep［ate

ll．Spring 12．lnputshaft

6. Brake housing

13・Parkingbrakepiston

9・Servicebrakepiston lO．Diskhub

7．Sealretainer

2−4−8

MasterCy［inder T MasterCy］inder

Themastercylinderisoperatedby・thebrakepedalandpressurizedbrakeoi［issenttothewetdiskbrake inthereductiongearbox， Thismastercy［inderhasabrakeoilreservoir・

AwARNING U＄ethespecifiedmineraIbrakeoilinthere＄erVOirofthemastercylinder・ DONOTu＄eautOmOtivetypebrakeoil（Vegetableoit）・ Tbbrakeinreductiongearbox

＼ノ

①Cylinder

O Piston assembly ④Scup ⑥Pcup ⑨Snap「ing ⑫．Bleederscrew

⑭pushrod

2−4−9

﹁ノ

﹁ノ

2・5．STEERINGSYSTEM

〕

Steenng

……………・

SteenngHydrau［icCircuit

…………‥t・

Power Steering Assembly

…・＝…＝…‥

SteenngCylinder

……■・……‥

2−5−1

2−5−2

2−5−3

2−5−4

﹁ノ ﹁ノ

Steer［ng

■

■Steerlng ThesteerIng SyStem mainJyconsistsofthesteenngwheeI，POWerSteenng aSS

y，Steenng Cylinderand

hydraulicoi［pIP［ng．

Whenthesteeringwhee＝sturned（byhand）thepowersteeringass ydirect［yinsta［［edtothesteeringshaft

inthesteenngco［umnassemblyisturnedandpressurizedhydrauIicoilissenttothesteenngcyIinderto turnthemachine．

Power steeringng Theuseofthesteeringwhee［（turningitbyhand）changestheoilpassageusingthepowersteeringass

andthepressurizedhydraulicoilcausedbyabovemakesthesteer］ngOPerationeasy．

Rodside：frontframe

O Steering wheel ②Steeringcolumnassemb［y

③PowerSteeringassembly ④SteeringcyIinder

2−5−1

y

SteerJngHydrau［icCircuit

■

T SteerlngHydrau）icCircuit

ThehydrauLicoiIisdrawnupfromtheoiltankbythemainpump・Thenthehydrau］icoilissenttothe POWerSteenngaSSemblyanditisdistributedtothesteer．ngcircuitandmaincircuit．

ThesteernghydrauIiccircuitusesa［oadsenslngSyStem，SOWhenthesteenngwheelistumed，the amountofoiLcorrespondingtotheamountofsteenngwhee［turn■ngISSenttOthepowersteenngassemb．y

andremainlngOilissenttothemaincircuit．

Theoi［senttothepowersteer［ngaSSemblyisthenfedtothesteenngcylindertosteerthemachinein accordancewiththesteenngwheeJoperation． Thehydraulicoilf10WSOutfromthesteer■ngCylinderreturnsthroughthepowersteerJngaSSembly，用trated

bythereturnfiJterandfinaILytotheoiItank．

Model P型些工j！野里迫月琴ン

Powerstee「lng

flowrate

■一−L■．．

96cc／rev

L4T2

120cc／rev

L−2

120cc／rev

L62

120cc／rev

−

L3一軍

■− −

e

d e

L

n∵

ートl・トトト

ト

ー

q

g

S

n

1−・・−1トー

n

ヽ＿＿＿＿−＿，＿＿

Pressurepo「t 17．2MPa＿＿＿∴＿＿∵

Main pump

0．15MPa●￣￣

lbcontro［valvePport

10〟

Return filter

HydrauIicOi】1盲nk 2−5−2

PowerSteerlngAssembly

■

■PowerSteerlngAssemb］y

Thepowersteer．ngassemblyconsistsofthecontroIva［vesectionandrotorsection・Whenthesteenng wheelisturned，thespoo＝nthepowersteer−ngisturnedtochangetheoilpassage；thisdirectstheoilto thesteer．ngcy］inder・TherotorsectionisequLPPedunderthecontroIvalve・rnanemergenCy，itcanbe usedasahandpumptosteerthemachinemanua y・

Emergency steeringng Thepowersteenngass，yalsoactsasanemergencysteenngmechanismbywhichthesteerlngOPeration isperformedevenwhennopressurizedoilsuppIiedduetothedefectivepumportheenglneStOP・ ■VP（Priority）valve TheVPvalveisapr■Orityva［vebuiltinthepowersteer．ngass，y・Thisvalvedistributestheoildischarged

fromthemainpumptothesteerlngSyStemandtheshovelequlPment・ A）so，theVPvaIvehasareliefvalveforthesteeringhydrauticcircuit・

●Load＄enSingvaLve When the steerLngWheelisin neutralposition orthe steer−ng reliefvaIveoperates7mOStOfthe oil

dischargedfromthemainpumpLSSenttOtheshovelunit・Whenthesteer．ngwheelisturned，theamO ofoilcorrespondingtothesteerLngWheelturn．ng．ssenttothesteenngsystemandrema．∩一ngOi［issentto

theshovelequLPment．

●Dynamicsigna［system Thedynamics■gnalsystemisemp10yed，WheretheLSlinecheckvatveandtheCFIinecheckvaIveare builtin．ThereforekickbacktothesteerlngWheelcanbeprevented．

（D ControIvalvesection O Rotor section

2−5−3

SteerlngCyIinder

■

Steering Cylinderer Asing（esteenngcylinderisequIPPed． Therodsideofthesteenngcy［inderisinsta［ledtothefrbntframeandthebottomsideisinsta11edtothe rearframe・Therefore，themachinecanbesteeredtotheleftandtherightaroundthecenterpinby

StrOkingsteerlngCylinder．

Oq30

1020．SteeringCy＝nder OOlO． LockPin OO20． LockPIate

0040 0

OO50．Spacer OO60．Greasefitting OO70．Plug

ノ￣ r

Rea「什ame ′／

｝ ．

、・−−−−−−−−−〜．＿．

0060

0010 0050 ＼−・凄壷堅≡≡

0050

・−一

l

ざ し

，＝＝ヽ一ヽ ／ 1020

＼

．

﹁

0050 Frontframe Tube

﹁ノ

Bottomside ① wiperring

② Head ③ 0−rin9 ④ Back一叩ring

⑨ piston

⑤ 0ィin9 ⑥ Back−uPrin9 ⑦ ∪ィing

⑩ slideri咽 ⑪ sealring

⑧ Bush

⑫ Setscrew ⑱ Stee［baIl

SteeringCy［inder mm （Bore−RodO．D．−Stroke）

L3−2

L4−2

L5「2

L6−2

￠50−￠25−233

←

￠55−￠25−228

←

2−5−4

2・6．FRAME

1〕

Frame

‥……‥‥‥‥

CenterPin

……………・

2−6−2

Suspension

……………・

2−6−3

2−6−1

﹁ノ ヽノノ

Frame ■ Frame

Thevehiclebroadlyconsistsofthefrontandrearframes7Whichareconnectedwiththecenterpln・I

frontframeareinsta［）edthefrontax［e，frontfenders，COntrOJvalve71ampbracketsandshovelequ［Pment・ln therearframeareinsta［ledtheeng）ne，reductiongeanfueltank，hydraulicf［uidtank，OPeratOrframe，rear

fenders，rearaXleandweight．

ヽノ 1

5

9

6

﹁ノ

3

7、8（ri9htside）

①②③④

⑤ Frontfender iamp bracketket

⑨ operatorframe

（∋ Fueltank

⑪ Rearax［e

⑧ Hydraulicoi［tank

⑫ Ⅵ厄ight

2−6−1

Rear fenderder

Center Pin Center Pinin

0010．1盲PerrO＝erbearing OO20． Oilsea1 0030． CoIlar OO40．Shim（Thickness：1．Omm） 0050・Shim（Thickness：0．5mm）

0060・Centerpln OO70．Plate OllO．Ⅵ由sher

O120・Grea＄e剛血g

2−6t2

Suspension lSuspension

0040 0010．B「acket

0080．Dustsea1

OO20．Bush OO30．Snapnng OO40．Dustsea1

0090．Thrustplate O120．Thrustcap O150．Greasefitting

0050．Bu＄h OO60．Snap「lng

O160．BoIt

OO70．Thrustwasher

O190．Greasefitting

O180．Nut

2−6−3

﹁ノ ﹁ノ

2r7，HYDRAULICSYSTEM

〕

MainPiping

・・…………‥

2−7−2

ControIValve

……‥t……・

2−7−3

MainPump

…………‥

2−7−10

Oi11七nk

……………

2−7−11

Return Filter

…………‥

2イー12

Li肘Ti［tCylinder

…………＝

2−7−13

﹁ノ E

Main Piping 1MainPiping

ThemainhydrauIicsystemmain］yconsistsofthemainpump，COntrOIvalve，hydrau］icoiItank，returnfiIter， Iiftcy＝nder，tiltcy［inderandthehydraulicpIPlng・Byoperatingtheworkcontrollever，thehydraulicoilfLow frommainpumpISCOntrOlledviathecontroIvalvetooperatetheworkasdesired・

The hydrauIiccircuitforthe machineconsists ofthe main hydrauliccircuit，HSThydrau］iccircuit Steeringhydrauliccircuit・Referto

2−2Pow戸rTrainl

forthedetailsoftheHSThydrauliccircuitandrefer

to 2−5SteeringSystem forthedetailsofthesteeringhydrau［iccircuit・ HST pump

00iltankkk ②ControLvaIv畠

O Main pump

2−7−1

Main Piping ●Majnhydrauliccircuit Theoildischargedfromthemainp，mPisdividedtothemain・hydrauliccircuitandthesteer．ngcircuitbythe

VP−Va［veisinthepowerstee「lngaSSembly．

Theoildischargedfromthemain pumpissenttothemaincontroIvaIveanditreturnstotheo＝tank throughthereturnfiIterwhenthetittpIungerandliftprungerareintheneutra］positjon．

WhentheshoveIcontrolleverismoved，theti［tplungerand／or［iftp［ungerofthemaincontroLva［veis

OPeratedtosendtheoiJdischargedfromthemainpumptothetiItcylinderand／Or［iftcyIindersforoperating theshoveJequIPment．

DC12V

監

Oiltank

2−7−2

Control Valve ■ControIVa］ve

ThecontroIva［veconsistsoftheinletsection（7），liftplungersection（2），tiltprungersection（3）andou

SeCtion（1），ltis a2−PtungerValvewhich contro］sthedirection ofthefLowand the pressure oftheoil dischargedfromthemainpumptooperatethebucketandl椚arm・

●Re［iefvalve ThiscontroIvalveequipsmainreLiefvaLve（4），Whichisinsta［［edininletsection・ThemainreLiefvaLve（4） COntrOIsthepressureintheshovelcircuitto20．6MPamaximum・

Theover10adreliefvalvesareinsta＝edtothecylinderportwhichconnectswiththerodandthebottomside

Ofthetiltcylinder．VVhenagreatexterna）forceisappliedtothebucketandanexcessivelyhighpressure Createdinthetirtcylinderthroughthelink，theoverloadreliefvalves（5）operateatapressureof22・

topreventeachdevicefrombeingdamaged・EachoverLoadreLiefvalvealsoactsasacheckvalve： Detent mechanismsm As a detent mechanism forthis vaIve，an electromagnetic detent（auto−Ieve［er）is equipped to the tilt PLungersection．

P B2 Bl

1．Outletsection

ヽlノ

2．Liftp［ungersection 3．Ti］tp［ungersection 4．Main re［iefvalve （20．6±0．5MPa） 5．Over［oadreIiefvalve （22．6±0．5MPa） 6．Anti−VOidvalve

7．tnletsection

P： Frompump T ¶）Oiltank（toreturnfilter）

Al：lbrodsideofti［tcylinder（Bucketdump） Bl：lbbottomsideoftiltcylinder（Buckettiltback） A2：lbrodsideof一統cylinder（L汎arm10Wering） B2：lbbottomsideofliftcylinder（Liftarmraising）

2−7−3

ControIVa暮ve ●Operation Thecontrolreverchangesthepassageoftheoi［byslidingeachspoolandsendsthepressurizedoilfrom theVPvalvetotheseIectedtiltcy［inderor［iftcylinder．

Thedetentmechanismisequ［PPedtothel椚spool．Sowhenthecontrol［everismovedtothe山FLOAJ POSition，thecontro［leverisautomatica yheIdandthespoolnotreturnedto NEUTRAL evenwhenthe handisre（easedfromthe［eve［．

TheeIectromagneticdetentmechanismisequlPPedtothetiltspool，Sowhenthecontro［［everismovedto theTIT［LTBACK

positionfromtheconditioninwhichthebucketisdumped，thecontro‖everiselectrica［Jy

heldandthespoolnotreturnedto thehandisreleasedfromthelever．

NEUTRAL

untiLthebucketautomaticleve［erisactuatedevenwhen

When the controlreveris moved to other positions，the control［ever returns automaticarly to the NEUTRAL position．

●NEUTRALpositionoftheTILTanduFTsection畠 1・AsthespooIsofthetheti［tand［if（SeCtionsareinthe

NEUTRAL

，thecylinderportsatbothA（Rod

Side）andB（Bottomside）areclosedbythespooIs．

2・TheoilissenttothecontroIvalvethatpassesfromtheinletsectionthroughtheneutra暮passage（3）of thetiltsectionand［iftsection，thenitgoesoutfromthedrainpassage（4）totheoi［tank．

1．LoadcheckvaLve

2・OiJdi＄Chargedfromthepump 3．Neutra［passagetotheI択SeCtion 4．Drainpassagetotheoi＝ank

NeutralPosition（TiltDIunqersectionl

2−7−4

Control Valve ●O‖f］owinT［LTp］ungersectioh ● TILJBACKposition l．WhenthecontroL［everismovedto

TILTBACK

position，thet‖tspoolismovedasshowninthefigure．

2．Becauseofthis

loadcheckvaIve（1）．Thenthepressurizedoi［issenttothebo仕OmSideofthetiItcy［inderthroughthe PO止Bl．

3．Further，theoiIfromtherodsideofthetiLtcylinderissenttotheoiltankthroughtheportAlandthe drainpassage（4）．

ヽノ

BucketT［LTBACKDOSition

● DUMPpo＄掴on l．Whenthecontrotleverismovedto DUMP position，thetirtspooLismovedasshowninthe罰gure・ 2．Becauseofthismovement，thespooIc［osestheneutra暮Circu旺（3），andthepressurizedoi［openst loadcheckvahIe（1）．ThenthepressurizedoirissenttotherodsideofthetirtcyIinderthroughthepor Al．

3．Funher，theoilfromtheねdsideofthetirtcytinderissenttotheoiltankthroughportBlandthedrain PaSSage（4）．

寧ucketDUMPDOS帽On

2−7−5

Control Valve ●Oilf［owinuFTplungersection ● RAISEandLOWERpo＄itions TheoiLpassageintheliftspooIsectionisexactlythesameasthatinthetiltspooIsection．Thereforewhen

thecontro‖everismovedto RA［SE‖positionisthesameactionaswhenthebucketisinthe■■T［LJBACK‖ POSition・AIso，thecontro［［everismovedto LOWER positionisthesameactionaswhenthebucketisin DUMP position，

● FLOÅTposition l・WhenthecontroIIeverispresseddownfromthe

LOWER

to

FLOAT

position，theliftspoo−ismoved

asshowninthefigure．

2・BecauseofthismovementtheneutraJcircuit（3）isopenedandthepressurizedoilfLowsasinthe neutra［condition・AIsoboththecy［inderportsA2andB2areconnectedtothelow−PreSSureOilpassage・ Thereforethetiftarmisfreelymovedupanddownaccordingwithanyunevensurfaceoftheroad．At ■ t

thebottomsideofthe［if（Cylinderissenttotherodside．

2

3

1

2

1．Loadcheckvaルe

2・Oildischargedfromthepump 3・NeutraIpassagetothe硝section 4・Drainpassagetotheoi［tank FLOAi position

2−7−6

〕

ControIVaIve Detent operationon ● Liftplungersection l．Whenthecontrol］everispushedforwardtosetitinthe

FLOAT

position，the［肌spool（1）isfuLIypu‖ed．

Atthesametimethedetentpin（2）insta edtothespoo［endismovedand4−Piecesofthedetentballs （3）aredroppedintothegrooveonthedetents［eeve（4）． 2．Asthedetentba s（3）arepushedbythedetentspring（5），theI肌spool（1）isheldin FLOAT position andthedetentmechanismisactivated．

3．Whenthedetentoperationiscance［］ed，Pu］［thecontroILever．Thedetentba［［（3）exitsthegrooveand thedetentoperationiscanceTIed．

く■ F10at

DetentoDerationontheL肌sDOOIsection

● TiLtplunger＄eCtion l．ForthedetentmechanismonthetiItspooIsection，aneIectromagneticdetentmechanism hasb equipped．Fortheelectriccircuhthecurrentgoesfromthebatterytotheproxim吋SWitchontheauto一 IeverthroughthecoiIassembly（4）inthe川tsection・ 2．WhenthebucketistiTtedforwardfromtheIevelpos田on，theproxim吋SWitchisc10Sedandactsthecoi［ assembly（4）．

3，Whenthecontro［［everismovedfuIlytothe TILJBACK direction，theti［tspoolispressedintotheend． Atthe＄ametimethepin（2）a仕achedtothespoolendispressedin，SOthattheplate（3）touchesthe COi［（4）．ThereforethetiItspoo［（1）positionisheklandthedetentmechanismisactivated． 4．Whenthedetentoperationiscancel［ed，OPeratethecontroIIevermanua11ytocanceL

◆ ¶托back

DetentoDerationontheti（tspooIsection

2−7−7

Contro［Va】ve ●Re暮iefvalve

ThiscontroIvalvehasonemainandtwoportre＝efvaJves・Themainreliefvalveisequ−PPedbetweenthe neutralpassageinthein［etsectionandthelow−PreSSurePaSSage・The2−POrtreliefvalvesareequ■PPed， Oneisbetweentherodsideoftheti［tcylinderportandthe10W−PreSSurePaSSage，anOtheroneisbetween

thebottomsideoftiltcylinderportandthe［ow−PreSSurePaSSage．

●Operation Stop Condition l・TheoiJfr（）mthecylinderportHPissentintothe re［iefvalve through the hole（2）in the main POPPet（1）and酬sthejnside（3）． 2・Themainpoppet（1）andsIeeve（4）aresecured

Seated bythedifFerenceintheareawherethe PreSSureOilworks．

Operation（A） 1・When the pressurein the cylinder port HP

increasesandexceedsthespecified pressure thepi10tPOPPet（5）isopened． 2・Thepressirizedoirissentfromthepi10tPOPPet

（5）to theIow−PreSSure PaSSage LP．passing betweens［eeve（4）andhousing（6）．

Operation（B） When the piIotpoppet（5）is opened，theinterna暮 hydraulic pressure（3）i＄［owered．Then the main POPPet（1）ismovedandoiIfromthecylinderport

HP冊owsdirectIytothe［ow−Pre＄SurePaSSageLP

2−7−8

Contro［Valve

●Anti−VOidva［ve Whenanegativepressureiscreatedontherod・Sideoftheliftcy［inder，theanti−VOidvalverefi＝sthe Sidedirectlywiththeoilinthetankport．

●Operation l．TheoilfromthecylinderportHPissentintotheanti− VOid valve through the holein the poPpet（1）． The poppet（1）is positioned as shown due to the d昭erenceinareabetween（A）and（B）．

2．When the pressurein thecyIinder portHPislower thaninthetankportLRthepoppet（1）move＄tOthe rightduetothedi鞄renceinareabetween（A）and（B）． Atthistime，SU用cientoi＝10WStOthecyIinderportHP

from thetank port LP to preventa cavitationin the CyIinder． 〕

Main Pump Main Pumpmp ThemainpumpisadoublegearpumpwiththemainpumpcoupJedwiththechargIn9・PumP・Thispump， insta

edtotheHSTpumpvjathecoupling−rOtateSWiththeengJne・Themainpumpdoub［esasasteer．ng

PumP・Themainpumpsucksuphydraulicfluidfromthehydraulicf［uidtankandsuppliesittotheorbit−rO （VPvatve）・HydraulicfIuidissplitintothemainhydrauliccircuitandsteeringhydrauliccircuitbytheorbit− ro（l（VPvalve）・Withthemainchargingpumpoperated，thehydrau［icf］uidinthehydraulicfIuidtankfiIIsthe

SPaCemadeofthegearbottomandinsidewa11sofhousings（9）and（17）bysuctionpowergenerated Whenthedrivegear（1）engagedwiththedrivengear（8）anddrivegear（15）engagedwithdrivengear （18）rotate・Thehydrau［icfIuidispushedouttothedischargesidewhenengagementofgearsstartsagain． Themainpump，tOPreVentOi［leaksfromthecIearancebetweengearsand・Sidep［atesbyhighpressure，

uses bushings（7）and（16）toachievepressure baIanceand makethec［earancesma＝erbyIeading discharge pressureto surfaces ofthebushings（7）and（16）．resuItinginincreased pump （VOIumeefFiciency）． 20 19 18 17

12

11

10 8

7 6

5

4

1

HST pump

Main巨umpcapacity

L3−2 L4−2 L5−2 L6−2

CC／rev 9．5 14．3 16．8 19．2

2−7−10

0‖1盲nk OilTanknkk

TheoiLtankstoresthehydrauIicoi［usedinthemainhydrauliccircuit，HSThydrauliccircuitandsteenng hydrauliccircuit・Theoi［tankisinstaILedtotherighthandsideoftherearframewithbolts・ 0120

／ 一一／− ／ ◎ノ

一・／・′

・−・

一・・・・一一一・0・030

＿．＿・・・〆

0110

0070 忘⊥一・′′ ⑬￣￣−−−−−・−−−

0060

、、、0050

0010．Oiltank OO20．Suctionstrainer

0090．0‖刷Ie「plu9 0100．0−ring

OO30．Cove「 0040．0ィing OO80．Oi［levelgauge

OllO．Drainplug

O120．PIugwithhexagonsockethead

2−7−11

Return Fi［ter ■ ReturnFiJter The return fi］terisinstal］edin the return circuitto the oil

tanktoremove触edustincIudingintheoiL，Whichcou［d notberemovedbythesuctionstrainer・Theoi］returnIng

from the steering circuit and shovel circuit enters the lN CartridgethroughtheinIetport，PaSSeSthrou9hthefi］ter， →

andissenttotheoiLtankthroughtheoutletport． 1fthepressureintheinletportincreasesandthepressure

di恥rencefrom the out［et portbecomes O．14Mpa when

thefiltercloggedortheoiltemperatureis10W，thebypass ValveisopenedandtheoiLissentdirectlyfromtheinJet POrttOtheoutletportwithoutpassLngthroughthefi［ter． Asthisreturnfi］teristhecartridgetype．

2−7−12

HeadassembIy

Lift／Ti・［tCy）inder ■LiftCy［inder Twodouble−aCtingcylindersareusedasI的cy＝nders・ByextendingorretractingthecyLinders，thel汎arm raisesorlowerswitharticu］atingmovementwiththebottomconnectingplnaSaPivot．

Tilt Cylinderer

Onedouble−aCtingcylinderisusedastiItcyIinder・TheextendingorretractingmotionofthecyIinderis transmittedtothebucketviabe［lcrankandbucket）inkfortiItordampoperation，

Bottom（Distonlside

Head（rodlsic（e

① wiperring

⑧ Bushing

O I‑tead

⑨ piston

③ 0ィing ④ Back−uPring ⑤ 0イin9

⑩ s】idering ⑪ sealring

⑥ Back−uPring

⑱ SteelbaIl

⑫ Setscrew

﹁ノ

⑦ uイin9

L3−2 TiItcylinder

mm

（Bore−Rod0．D．−Stroke） L胎Cylinder

（Bore−RodO．D．−Stroke）

mm

L4−2

L5−2

L6−2

￠60−￠35，262 ￠63−￠40−364 ￠70−￠45−431 ￠70−￠45■50 ￠5む￠30−385 ￠65−￠40ヰ50 ￠65−￠40−539 ￠70−￠45−531

2−7−13

︑ノ

｛

︺

2−8．WORKINGEQU］PMENT

〕

ShoveLLinkage

……………・

Auto−［eveler

……………・

2−8−6

Shovel Control

……………・

2−8−7

2−8−1

ヽノ

︺

Shove［Linkage Lt Shove［Linkage Theshove［1inkageemp［oystheZ−barlink亭getyPe．SOthemechanismissimp［erthanthepara＝e［linkage type，andthebreakoutforceis）arger．

Theshove川nkageconsistsoftheIiftarm（1），be［［crank（2），bucket（ink（3），bucketwithcuttingedge（7）， andpinsforinsta＝ngthem．

Dustsealsareinsta edtoallthecouplingplnSfortheshove川nkagetopreventmoisture，dirtordustfrom entering・Moreover，a of the bushings have self−］ubrication mechanism so that the durabiIity and SerViceabiIityishigher．

A‖thecoup］ingplnSareSeCurelylockedbybo［ts． Thebucketauto−1evelerisequ［PPedforsmooth10ading． 5

﹁ノ

（むLiftarm

OBellcrankkk OBucket linkk ④L肌cylinder

O Tilt cylinder ⑥Auto−Ieve［er

⑦Bucket ⑧Cu輔ngedge

﹁ノ

A：Dumpangle（0）

B：TiItangle（○）

WhenL汎armisin WhenJ肌armisin L3−2 L4−2 L5−2 L6−2

uppermostposition 10WermOStPOSition 47 40 49 43 49 45 49 45

2−8†1

Shove］Linkage ●Shovel［inkage OOlO． Pin

OO90． Bolt

OlOO．Springwasher OllO． Ⅵねsher

O120．Grease触ng O130．Spacer（Notel）

1010．HNBushing Notel：Atpinconnectionswith SPaCer，adjusttheclearance betweenbossestoO．4−2 mm．

SectionB−B（2locations）

SectbnM（2locations）

0120

0010

SectionC−C

0090

1010

Note30130 0010 SectjonD−D

Section E−E

SectionF＿F

Note3 1010 0130

SectionG−G

0120

1010

Sedぬー＝十日（210Cations）

Note2：L3−2andL4r2 Note3：ExceptL3−2 2−8−2

Sed加JrJ（210Cations）

Shove［Linkage ●Shove［linkage G：6、15 A：1，10

B：3、12

F：8、17

Bushing

Pin L

L

・Ⅰ。A

（mm）

（mm）

￠AxL OAxL No．

L3−2 L肌armandfront

口

2

frame

Liftarmandbel）

Crank

￠BxL

L4−2，L5−2，

L3−2

L6−2

￠BxL L4−2，L5−2，

35x133

45x170

10

L汎a「m

45x35 55x40

50x178

60x244

皿

BeIIcrank（2pcs．）

60x35 75x65

L6−2

3

L帆armandbucket

35 x 98 45 x 123 12 Liftam7

45 x 35 55 x 40

4

L択cy［inderandfront frame

30x134 40x163 13 Liftcylinder

40x30 50x40

L肌cyIinderandlift

30xlOO 40xl15 14 L肌arm

40x35 50x40

35x98 40xl15 15 Tiltcylinder

45x35 50x40

35x98 40xl15 16 TittcyIinder

45x35 50x40

35x98 40x123 17 Bucketlink

45x35 55x40

35x98 45x123 18 Bucketlink

45 x 35 55 x 40

5

6

arm

Tiltcylinderandfront f「ame

7 8

9

TiLtcylinderandbe［l

Crank

BucketIinkandbe暮L

Crank

Butketlinkand

bucket

2−8−3

Shovel Linkage HN Bushingng Thegenera（bushingsare［ubricatedbygreas，ng・OntheHNbushing，theoiIcontainedintheHNbushing isoozedbetweenthebushingandpinbythepinmovement（frictiona［heat）forself−Jubrication．

Thisfunctjonprovides［onginterva［ofthegreas［ngandthedurabiIityofthewearfbrthebushingsandpins・

Circu［atingoilf［ow

HN Bushing

OilcomesoozlngOutinthegap

Bush（Sinteredparticle）

CAUT10N WhentheHNbu＄hing．sin＄ta‖ed，DONOThammerthebu＄hingdirectlywithametaJ

hammer；bLJthammeritwithapla＄tichammerorwoodblock．

2−8−4

Shovel Linkage Cutting edgege

Bucket

0010

0010．Edge OO20． Bo】t OO30． 肌bshe「

0040． Nut

2−8−5

Auto−1eve［er ■Auto・leve）er

Afterdumplngbucketcontents，SetWOrkingdevicecontro［leverto TILLBACK ．Whenbucketistiltedto PreSetangle，WOrkingdevicecontrol［everreturnsto NEUTRAL automaticalIyand T［しトBACK stops． Then，Whenl椚armisputonground，bucketishorizonta［ifsetangIeishorizontal．

●Operation l．Whenthebucketisti］tingback，therodofthetiItcy［inderisextendedandthenthelevelerrodmoves

awayfromtheproximityswitchsensIngSurface． 2．Astheproximityswitchisconnectedtothee［ectromagneticdetentcoilinthecontroLvatveti［tsection， theelectromagneticdetentiscance edbytheproximityswitchandtheshovelcontroHeverreturnedto neutralposition，SOthatthebuckettiltbackisstopped．

TiJtcy］inder

A 0010．Suppo止

OlOO．Harness

0050．Proximityswitch

OllO．Diode

OO60．Rod

2−8−6

Shovel Control Shovel Controlol

Whenoperatingtheworkingequ［Pment，thespoolinthecontro［valves（idesthroughthecabIewiththe motionofthecontrollever：thefIowofthepressurizedoilischangedandoperatestheeachcylinder． ThecontroIIeveristhemono−Ievertype．WhenmovedtofrontorreartheIitspooLoperates，andw movedrightorle魚thetiltspoo10PerateS．

View C 0010．Suppo止

0080．Rodend

0050．LeverassembLy OO60．Hexagonsocketheadcapscrew

OO90．Nut OlOO．Knob

OO70．Cable

2−8−7

﹁ノ ヽlノ

3．OVERHAUL

）

3−0．Engine

……………

3−0−1

3−2．Powe止rainI

……………・

3−2−1

3−3．PowertrainlI

……………・

3−3−1

3−4．BrakeSystem

……………・

3−4−1

3−5．SteerlngSystem

……………・

3−5−1

3−7．HydrauticSystem

……………・

3−7−1

↓ノ ヽノ

3・0．ENG】NE RemovaIofEngineL3−2

・…・t……・…

】nsta

ationofEngLneL3−2

……………・

RemovalofEngineL4，L5，L6−2

■……・t…‥

lnsta‖ationofEngineL4，L5，L6−2

・・・・・‥‥…・・ 3−0−26

LevelCheckandAdditionofOiIin

・・■・………・ 3−0−34

3−0−1

3−0−9

3−0−18

EngineOilPan Adjustment of Engine Control

…………‥

RemovatofRadiatorL3−2

…………‥

lnstallationofRadiatorL3−2

＝………・

Remova］ofRadiatorL4，L5，L6−2

……‥t・…・

lnstallationofRadiatorL4，L5，L6−2

‥…‥‥…‥

Leve［CheckandAdditionofCoo［ant

・・・・・………

3−0−50

RemovalofFuellbnk

…………・t

lnsta［IationofFueIlbnk

…………‥

Leve）CheckandAdditionofFue］

…‥＝‥・・・・・ 3−0−55

3−0−35

3−0−36

3−0−39

3−0−43

3−0−46

3−0−51

3−0−53

ノ ﹁ノ

RemovaIofEnglne

】■

■Remova）ofEngine

Fig12−51：

● L3−2

1．Fig12−51：Disconnectthebatterynegativecable （0030）．

2．Fig63−00：Remove the boLts（0020），then removetheseatassembly（0010）．

Fi963−00：

盆seatassemb．，（。。．。）‥．。kg

3．Fig62−11：Remove the boLts（0320），then removethehood（0300）．

Fig62−11：

0300

盆H。。。（。。。。）：9k。

4．Fig62−11：Disconnectthewiring（A）oftheright andle代rear combinationIamp，remOVe the boLts（0431），thenremovethegril［e（0410）．

3−0−1

Fig62−11：

RemovaIofEnglne

■

5．FigO4−00：Remove the bo［t（1050）and nuts （1070），thenremovethecushionrubber（1040）．

FigO4こ00：

6・Fig62−11：Remove the bolts（0250），then

Fig62−11：

removethegrif［esupport（0240）．

7・Fig62−12：Afterremovingthef］00rmat（0050），

Fi962−12：

removethebolts（0020），thenremovethefJoor PIate（0011）．

8・Fig84−112：Remove the bo暮ts（0110），then

Fi9糾−112：

disconnect the two shove［contro［cables （0070）．

、＼ミ∴■＝享ミ 3−0−2

暮 RemovalofEnglne 9．Fig12−52：RemovethegLowplug relay（0010），

Fig12−52：

Starter relay（0020）and battery relay（0070），

thendisconnectthebatterypositivecabte．

10．Fig12−51：RemovethethreeclampboLts（0180）， then remove the rear harness（0010）on the OPeratOrframe（R）（from the rjghtside ofthe machine）．

11．FigO2−00：DisconnectthewlnngOftheindicator （0040），Ioosen the hose cIamp（1060），then

FigO2−00：

0010

disconnectthehose（1040）fromtheaircleaner．

12．FigO6−21：Remove the boLts（0030），then remove the water separator（0010）and fuel fiIter（0020）（fromtheleftsideofthemachine）．

3−0−3

Fi906−21：

0020

0010

Remova10fEng［ne

■

14・Fig61−13：Remove the boLts（0060），then removetheoperatorframe（R）（0020）using a hoistorcrane．

盆。pera．。，frame（R）．h。。ds。PP。n． aircIeaner＋ShovelcontroHever：70kg

15．Remove the radiator．Refer to ‖RemovaL of RadiatoL‖

16．FigO3−11：LoosenthecJamp（0131），remOVethe four boIts（0060），then remove the mufRer （0091）togetherwiththebracket（0050）．

盆M。me，（。。9．）．b，aCke．（。。5。）＝．．kg 17．Fig12−51（1）：Remove the bo［t（0070），then removetheenginegroundcabLe（0050）（from therightsideofthemachine）．

3tO−4

Fi912−51（1）：

RemovalofEnglne

■

18．Fig12−51（2）：Disconnect the wiring of the COOlant temperature gauge sender unit（B）， alternator（C），Oilpressure switch（D）and

B

Fig12−51（2）：

Starter mOtOr（E）（from the right side of the machine）．

19．Fig12−51（3）：Disconnectthewiringoftheglow Plug（F），engine stop solenoid（G）and fueI PumP（H）（from thele代Sideofthe machine）， then the wiring of the backup tamp（l）and backup buzzer（））（from the rear of the

Fig12−51（3）：Viewed from above machine

machine），

Fig12−51（3）：Rear ofvehicle

Weight

20．Fig12−51（4）：Remove the c［amp（0160）

（fastened tothe topofthefLywheelcover by OneOfitsbo．ts），thenmovethepartoftherear harness（0010）locatedonthe［eft＄ideofthe machinetotherightsideofthemachine・

3−0−5

Remova］ofEnglne

■

21・Fig12−51（5）：Cutthecableclamp（0230），then

Fig12−51（5）：Viewed from above machine

remove the wiring（K）of the front and rear

SOlenoidvalvesfromthetopoftheHSTpump．

23・FigO6−21：LoosenthehosecIamps（0130），then disconnect the fuelhoses（0110）and（0100） fromtheengne．

24・Fig43−11：Remove the nut（0181 s fastener）， thenremovetherod（0181）．

3−0−6

FigO6−21：Viewed from above rnachine O130

RemovaIofEnglne

■

25．Remove the main pump and disconnectits PLPIng．Referto RemovalofMainPump・ ■

26．DisconnectthepIP［ngOftheHSTpump．Refer to Remova10fHSTPump．一

27．Fig27−00：Removetheclamp（0210）（fastened to▲the Lowerleft partofthe nywheelcover by

Fig27−00：

OneOfitsbo［ts）．

28．FigOl−00（1）：Remove the nut（0190），thenFigOl−00（1）：Leftsideofmount，Viewed from above removethedrainhose（0150）．

29．FigOl−00（2）：Remove the nut（0140），then removethe bolt（0100），＄Pringwasher（0110）， WaSher（0120）andcushionrubber（0080）（the One above the bracket）．Do this for the four locations．

FigOl−00（2）：Detai10fmount 0100

Braeket

Rear frame

3−0−7

RemovaIofEnglne

■

30・Remove the engIne from the machine by hoistingitus［ngaWirerope．

盆

Engine＋HSTpump：180kg

31・FigOl−00：Remove the cushion rubber（0080） （theoneunderthebracket）．Dothisforthefour

FigOl−00：

locations．

⊆r㌻

3−0−8

arf耶

lnsta ationofEnglne

■

FigOl−00（1）：Left side ofmachine

Jln＄taILationofEngine ● L3−2

1，FigOl−00（1）：lnsta［Ithebrackets（0020），（0030） andthebrackets（0040），（0050）in positionon

the engine by securing them with the boits （0060）（16places）．

亀B。．t．（。。6。）‥．9．。＿53．9Nm．App．ya．hrea。 lockingadhesive．

2．］nsta［］theHSTpumpLnPOSitionqntheenglne． Referto lnsta［lationofHSTPump．

3．FigOl−00（2）：1nsta thecushion rubber（0080） （theoneunderthebracket）．Dothisforthefour

FigOl−00（2）：

壷竿a，f，ame

locations．

4．HoisttheenglneuS］ngaWireropeandp［aceit inpositiononthemachine．

FigOl−00（3）：Detailofmount 0100

5．FigOl−00（3）：lnstallthecushion rubber（0080） Onthebracket，theninsta＝thebolt（0100）and nut（0140）aftercoatingtheboLt−sthreadwitha

Bracket

threadlocking adhesive．Do this fbr the four 10Cations．

亀N。．（。．．。）：8，．．＿93．2Nm

Rearframe

3−0−9

］nsta ationofEng）ne

■

6・FigOl−00（4）：Fit the drain hose（0150）in FigOl−00（4）：Left sideofmount，Viewed from above POSition，theninsta thenut（0190）．

7．Fig27−00：lnsta］［the hose（0190）in position， theninstarltheclamp（0210）ontheIowerle微

PartOfthefLywheelcover．

8．InstalIthe p［P［ng Ofthe HST pump．Referto LnstalrationofHSTPump：

9・）nstaI）themain pumpandits pIPlng．Referto lnstaIIationofMainPump．

3−0−10

lnsta ationofEngIne

l■

10．Fig43−11：Connecttherod（0181）totheinching Valve［ever，and secureitwith the nut（0181 s fastener）．Refer to．TAdjustment of Engine

Fig43−11：

lnching valve lever

Cont「ol．‖

FigO6−21：Viewed from above machine O130

亀H。SeC．amP（。．，。）：3．．Nm

13．Fig12−51（1）：Connectthewiring（K）ofthefront

andrearsoIenoidvalvesonthetopoftheHST PumP，theninstaⅢthecab［ecIamp（0230）whi暮e adjustingthelengthofthewiring（K）．

3−0−11

1 8

11．FigO6−21：lnstallthefueLhoses（0110），（0100）， andtightenthehoseclamps（0130）．

01

1置≡ヨ申

Fig12−51（1）：Viewed from above machine

lnsta ationofEnglne

■

15・Fig12−51（3）：Lnstallthe wiring ofthe backup

Fig12￣51（3）＝

buzzer（））andbackupLamp（［）（fromtherearof

ぅ

themachine）． Ⅵ始i9ht

l

16・Fig12−51（4）：Connect the wiring of the fue［ PumP（H），enginestopsolenoid（G）and glow P［ug（F）（fromthe［eftsideofthemachine）．

17・Fig12−51（5）：Connectthewiringofthestarter motor（E），Oilpressureswitch（D），aLternator（C） andcoolanttemperaturegaugesenderunit（B） （fromtheright＄ideofthemachine）．

3−0−12

Fig12−51（4）：Ⅵewed from above machine

1nstaI［ationofEnglne

■

18．．Fig12−51（6）：lnsta［Ithe engine ground cab［e （0050），theninsta［lthe bolt（0070）（from the rightsideofthemachine）．

Fig12−51（6）：

／∵t

19．FigO3−11：1盲mporari［yinsta‖thebracket（0050）

Fi903−11

andmu仔Ierclamp（0131）onthemu用er（0091），

theninstalItheassemblyontheenglnemOunt bracket．Make sure that the center of the

exhaustpipe（0011）isa［ignedwith thatofthe mu冊er（lN）（0091），then tighten the boIts （0060）．

0060

20．InstaIt the radiator．Refer to．．lnstallation of Radiator．

21．Fig61−13：Using a hoist or crane，Place the OPeratOrframe（R）（0020）fittedwiththe hood SuPPOrt，rairc］eanerand＄hoveIcontroHeverin POSitionontherearframe，theninsta thebolts （0060）．

3−0−13

Fig61−13：

InstallationofEnglne

」

22・Fig12−51：lnsta therearharness（0010）onthe le代side ofthe machine，theninstaJ［the three

Cab［eclamps（0230）．

23・FigO6−21：Set thewaterseparator（0010）and fueL fiIter（0020）in position，then secure them Withthebolts（0030）．

FigO6−21：

0020

0010

24・FigO2−00：Connectthe hose（1040）to the air CIeaner（0010）and fastentheconnectionwith

FigO2−00：

0010

the hose cIamp（1060）・Connectthewiring of theindicator（0040）．

25・Fig12−52：lnsta］仁the g10W Pfug relay（0010）， Starterrelay（0020）andbatteryre［ay（0070）in POSition．ConnectthebatterypositivecabIe．

3−0−14

Fig12−52：

Instal［ationofEngIne

■

27．Fig84−112：Installthetwoshove［contro］cables （0070）andsecurethemwiththebolts（0110）．

28．Fig62−12：Placethefloorplate（0011）inposition andinstaLlthe bolts（0020）．Lay thefloormat （0050）．

29．Fig62−11（1）：PIacethegri］lesuppo「t（0240）in POSitionandinsta‖theboLts（0250），

3−0−15

Fig84−112：

［nsta ationofEng［ne

30．1nsta

■

the radiator．Refer to ‖lnstalIation of

Fig62−11（2）：

Radiator．．．

0410

31・Fig62−11（2）：InstarIthe gri［Ie（0410），then COnneCtthewiring（A）ofthe rearcombination lamp．

RearcombinationFarnp

32・Fig12−51：Connectthebatterynegativecab［e．

33・Fig62−11：lnsta thehood（0300）inpositionand temporariryfastenitwiththebolts（0320）．

Fig12−51：

Fig62−11：

0300

34・Fig62−11：Adjustthe key hole position ofthe hood（O300），thentightenthebolts（0320）．

Fig63−00

35・Fig63−00：）nsta［［theseat assembly（0010）in

POSition．andfastenitwiththebolts（0020）．

3−0−16

lnsta［IationofEnglne

■

36．Starttheeng］neandrunitatid］etocheckforoi［ 1eakage．

37．Stop the engLne，Wait for5−10minutes，then ChecktheenglneOiI］evel．Referto‖Levelcheck andAdditionofOilinEngineOi］Pan．．f

3−0−17

RemovalofEnglne

■

Removal of Enginene

L4，L5，L6−2 Fig12−51：

● L4，L5，L6−2

1，Fig12−51：Disconnectthebatterynegativecab］e （0030）．

2・Fjg63−00：Remove the bolts（1060），then removetheseatassembfy（0010）togetherwith theseatsupport（1050）．

Fi963−00：

盆sea．assemb．，（。。．。）．sea．s。，P。n（1。5。）‥ 15 kg

3・Fig63−00：Remove the boLts（1060），then removetheseatsupport（1010）．

鹿sea．s。PP。n（．。．。）‥．，kg

4・Fig62−12：A什errepovingthefloormat（0050）， removethebo［ts（0020），thenremovethe刑00r Plate（0010）．

3−0−18

Fi962−12：

■ Remova［ofEngIne

L4，L5，L6・2

5・FigQ2−11：Removethesnappins（0060），then

removethehood（R）（0150）．

Fig62−11：

0150

盆H。。d（R）（。．5。）‥．2kg

6．Fig62−11：Removethebo［ts（0280）and（0320）， thenremovethehood（F）（0220）．

Fig62−11：

0220

盆H。。d（F）（。2，。）：．2kg

7． Remove the radiator．Refer to

RemovaL of

Radiator．‖

8．［L4⊥2】FigO3−00：Loosen the clamp（0140）， remove the bo［ts（0070），then remove th畠

mu冊er（0050）togetherwiththebrackets（0060） and（0190）．

盆M。＃，e，（。。5。）．b椅Cke．s（。。6。）and（。．9。）‥ 11 kg

3−0−19

Fi903−00：

RemovaIofEng［ne

L4，L5，L6−2

■

8．（L5．L6−2］FigO3−00：Loosen the mu用erclamp （0140），remOVe the bolts（0070），then remove the mufFler（0050）together with the brackets

Fi903−00：

（0200）．

鹿M。H．er（。。5。）．bracke．（。2。。）‥．．kg 0140 0050

9・（L5，L6−2］FigO3−00：Removethebolts（0030）， then remove the exhaust pipe（0010）and

FigO3−00：

0020

gasket（0020）．

10．FigO2−00：DisconnectthewlnngOftheindicator （0040），Loosen the hose clamp（1050），then removethehose（1040）．

11・Fig12−52：RemovetheglowpJug relay（0010）， Stanerrelay（0020）andba性eryrelay（0070）．

3−0−20

FigO2−00：

1040

Fig12−52：

3．Overhaul ■ Remova10fEnglne

L4，L5，L6・2

12．Fig84−11：Remove the bolts（0020），then removethesupport（0010）．Donotremovethe ShoveIcontroIcable．

Fig84−11：

13．Fig62−11：Remove the bolts（0120），then re−

Fi962−11：

movethe support（0110）togetherwith the air Cleaner．

盆s。PP。n（。．．。）．ai，。．ea。e，‥．7kg

14．Fig61−13：Remove the bolts（0020），then

Fig61−13：

removethebracket（0010）．

15．Fig12−51（1）：Remove the boIt（0090），then

Fig12−51：（1）

removetheenginegroundcable（0050）（from therightsideofthemachine）・

0050 3−0−21

RemovaJofEnglne

L4，L5，L6・2

■

16・Fig12−51（2）：Disconnect the wiring of the alternator（A），StartermOtOr（B）andoilpressure SWitch（C）（fromtherightsideofthemachjne）．

17・Fig12「51（3）：Disconnectthewiringoftheg10W Plug（D），COOIant temperature gauge sender unit（E），enginestopso］enoid（F）andfue［pump （G）（fromthe［e代Sideofthemachine）．

18・Fig12−51（4）：Disconnect・thewiringoftheright

Fig12−51（2）：

Fig12−51（3）： E

D F

Fig12−51（4）：Ⅵewed from above machine

andJeft rear combinationIamps（H），backup

lamp（l）and backup buzzer（））（from theleft

Sideattherearofthemachine）

19・Fig12−51：RemovetheboIts（0201）andcIamps

Fig12−51：Le代Sideofmachine

（0240）・Cutthecableclamp（0260）（frominside the暮eftrearfender）．Removetheclamp（0191） （fastened byoneoftheflywhee［coverboJts）， thenmovethepa止oftherearharness（0010）

located on theleft side ofthe machine to the

rightsideofthemachine．

0260

3−0−22

■ RemovaIofEnglne 20．■Fig12−51：Cut the cabte clamp（0260），then disconnectthewiring（K）ofthef「ontand rear

L4，L5，L6・2

Fig12−51：Viewed from above machine

SOlenoidvalvesonthetopoftheHSTpump．

21．FigO5−11：Cut the cabIe clamp（0250），then disconnectthecabIeassembly（0200）fromthe engIne・

22．FigO6−21：LoosenthehosecLamps（0130），then disconnect the fuelhoses（0110）and（0101） fromtheeng［ne．

23．Fig43−11：Remove the nut（0181 s fastener）， thenremovetherod（0181）．

3−0−23

FigO6−21：

RemovalofEngIne

■

L4，L5，L6・2

24・Remove the main pump and disconnectits P．P［ng・Referto，．Remova10fMainPump・■■

25・Disconnectthep■P−ngOftheHSTpump．Refer to 一RemovalofHSTPump，■一

26・Fig27−00：Removethec］amp（0281）（fastened

Fig27−00：

tothe［owerleftpartofthef］ywheelcoverby OneOfitsboIts）．

27・FigOl−00：Removethenut（0250）．thenremove

FigOl−00：

thedrainhose（0200）．

28・FigOl−00：Removing the nut（0170），then

removetheboIt（0140），SPringwasher（0150）， WaSher（0130）andcushionrubbers（0120）（the

One above the bracket）．Do this for the four locations．

3−0，24

FigOl−00：Detai［ofmount

】■ RemovaIofEnglne

L4，L5，L6・2

29．Remove the eng［ne from the machine by hoistingituslngaWirerope

盆

Engine＋HSTpump： L4−2−235k9 L5，L6−2−245kg．

30．FigOl−00：Remove the cushion rubber（0120）

FigOl−00：

（theoneunderthebracket）．

3−0−25

1nstal［ationofEnglne

L4，L5，L6−2

■

■lnsb＝ationofEngine

Fi901−00：（1）

● L4，L5，L6−2 1・FigOl−00（1）：lnstaJ［thebrackets（0020），（0030）

andthebrackets（0080），（0090）in position on

the englne by secunng them wjth the bolts （0040），（0060）（forone Locationintheleftrear bracket）and（0100）．

亀B。．t（。。4。）＝49．。＿53．9Nm Bolt（0060）：83．4−93，2Nm

0020 0030

Bo旺（0100）：122−149Nm

ApplyathreadIockingadhesive．

Bracket（0020），leftrear

OO40

2・［nsta＝theHSTpumplnPOSitionontheenglne． Referto■■lnstallationofHSTPump．

3・FigOl−00（2）：lnsta＝thecushion rubber（0120）

Fi901−00（2）：

（theoneunderthebracket）．

4・HoisttheenglneuS［ngaWireropeandplaceit inpositiononthemachine．

5・FigOl−00（3）：lnsta＝thecushionrubbers（0120） Onthebracket，theninsta thebo［t（0140）rand nut（0170）aftercoatingthebo［tlsthreadwitha

threadIocking adhesive．Do this for the four 10Cations．

亀N。．（。．7。）＝8，．．＿93．2Nm

3−0−26

壷「㌻，f，ame

FigOl−00（3）：Detai10f mount 0140

Insta［］ationofEngIne

t

6．FigOl−00（4）：Fit the drain rhose（0200）in

L4，L5，L6・2 Fi901−00（4）：

POSition，theninsta［lthenut（0250）・

7．Fig27−00：lnsta）lthe hose（0240）in position， theninsta theclamp（0281）onthe］owerleft PartOfthef［ywheeJcover．

8．1nstallthe，PIPIng Ofthe HST pump．Refer to ．lnsta＝ationofHSTPump：．

9．1nsta the main pump andits pIPIng．Referto ■一Insta［IationofMainPump．‖

10．Fig43−11：Connecttherod（0181）totheinching VaIvelever，and secureitwiththenut（0181 s fastener）．Refer to Aqjustment of Engine Control．‖

3−0−27

Fig27−00：

Insta ationofEngLne

■

11・FigO6−21：lnsta‖thefueIhoses（0110），（0101），

L4，L5，L6・2

FigO6t21：

andtightenthehoseclamps（0130）．

亀H。SeC．amP（。．3。）：3．．Nm

12・FigO5−11：lnsta［1the cabIe assemb［y（0200），

Fi905−11：

theninsta thecableclamp（0250）．

13・Fig12−51（1）：Connectthewiring（K）ofthefront

Fig12−51（1）：Viewed from above machine

andrearsolenojdva］vesonthetopoftheHST PumP，theninstaI［thecab）eclamp（0230）whiJe adjustingthe‡engtr［Ofthewiring（K）．

14・Fig12−51（2）：Movetherearharness（0010）that

WaS mOVed to the right side of the machine back to thele代Side7theninsta［［the cIamp

（0191）using one ofthe fIywhee［cover borts． ［nsta11the cIamps（0240）and cabfe cIamps

（0260）（frominsidetheleftrearfender）．

3−0−28

Fig12−51（2）：Le托Side ofmachine

Insta ationofEng］ne

L4，L5，L6−2

■

15．Fig12−51（3）：Connect thewirings ofthe right andIeft backup buzzers（L），backup］amps（J） and rear combinationlamp（H）（from the Left

Fig12−51（3）：

Sideattherearofthemachine）．

16．Fig12−51（4）：Connect the wiring of the fue］

Fig12−51（4）：

PumP（G），engine stop solenoid（F），COOlant temperature gauge sender unit（E）and glow

E

D F

P山g（D）（fromtheIe代Sideofthemachine）．

17．Fig12−51（5）：Connect the wiring of the oil

Fig12−51（5）：

PreSSure SWitch（C），Sta止er motor（B）and

alternator（A）（from the right side of the machine）．

18．Fig12−51（6）：［nsta the engine ground cab］e

Fi912−51（6）：

（0050），theninsta）Ithe boIt（0090）1from the rightsideofthemachine）

0050 3−0−29

lnsta［JationofEngIne

L4，L5，L6・2

■

19・Fig61−13：lnstallthe bracket（0010），then

Fig61−13：

SeCureitwiththeborts（0020）．

20・Fig62−11：Insta＝thesupport（0110）fittedwith

Fi962−11：

the air cleaner，then secureit with the bolts （0120）．

21・FigO2−00：Connectthe hose（1040）totheair

Cleaner（0010）and fasten theconnectionwith

FigO2−00：

1040

thehoseclamp（1050）・Connectthewjringof theindicator（0040）．

22・Fig84−11：Instal＝hesupport（0010），bysecuring

Fig84−11：

0020

itwiththebolts（0020）．

3−0−30

LnstallationofEng［ne

■

L4，L5，L6・2

23．Fig12−52：lnsta＝thebatteryrelay（0070），Starter relay（0020）andg10WPlugreLay（0010）．

Fig12−52：

24．［L4−2］FigO3−00：TemporarilyinstaIrthebrackets

FigO3−00：

（0061），（0190）andmu汗Ierclamp（0140）onthe mufFIer（0050），theninstalItheassembLyonthe

englne mOunt bracket．Make sure that the CenterOftheexhaustpipe（0010）isaIignedwith thatofthemu用er（）N）（0050），thentightenthe bolts（0070）．

24．［L5，L6−2］FigO3−00：Put the exhaust pipe （0010）and gasket（0020）together．then

FigO3−00：

COnneCtthepipeusingthebolts（0030）．

25．［L5，L6−2］FigO3−00：，remporari（yinstaJ［the bracket（0200）andmu冊erclamp（0140）onthe mufFler（0050），thenin＄ta theassemb［yonthe englne mOunt bracket．Make sure that the CenterOftheexhaustpipe（0010）isatignedwith thatofthemu用er（［N）（0050），thentightenthe bolts（0070）．

3−0−31

FigP3−00：

lnstal］ationofEng］ne

L4，L5，L6・2

」

26．lnsta‖ the radiator．Refer to．，Jnstallation of

Fig62−11（1）：

Radiator．‖

27・Fig62−11（1）：P［ace the hood（F）（0220）in

POSition，thensecureitwiththeboIts（0280）and （0320）．

28・Fig12−51：Connect the battery negative cabFe

Fig12−51：

（0030）．

0030

29・Fig62−11（2）：】nsta＝the hood（R）（0150），then

Fig62−11：（2）

insta＝thesnappin（0060）．

0150

30・Fig62−12：PLa？e the fIoor p［ate（0011）in

POSition，theninstalItheboIts（0020）．Laythe 月00rmat（0050）．

3−0−32

Fig62−12：

Insta ationofEnglne

■

31．Fig63−00：Instatlthe seat support（1010）and SeCureitwiththebolts（1060）．

32．Fig63−00：Insta the seat（0010）and seat SuPPOrt（1050），thensecurethemwiththebolts （1060）．

33．Starttheeng［neandrunitatidletocheckforoiJ leaka9e．

34．Stop the engLne，Wait for5−10minutes，then Check the engrne oillevel．Refer to LeveI CheckandAdditionofOilinEngineOi［Pan．

3−0−33

L4，L5，L6・2 Fi⊆I63−00：

3−OI Leve］CheckandAdditionofOi＝nEngineOi［Pan L3，L4，L5，L6−2 ■LeveJCheckandAdditionofOilinEngineOi） Pan

● L3，L4，L5，L6−2

▲wARNtNG Wipe o斤oi［compJetelyifspilled when addingit． SpiL［edoiJcou［dsta止fire．

fMPORTANT

・Before adding oil，Carefully c］ean the area aroundthefi erporttopreventdirtfromgetting insidetheengIne． ・Checktheoi11eveIonlyfiveorsixminutesafter Oilhas been added．1fitis checkedimmedi−

atelyafteraddition，theindicatedleve［wil＝）e

［owerthantheactuaIIevel，misleadingyouto OVeげ‖ing．

・UseanengIneOi10fproperviscpsityaccording totheambienttemperature．

1．Opentheenginehood． 2・FigOl−00（1）：Removetheoi［Ieve19auge①，

FigOl−00（1）：

Wipeitwithcleanc［oth，thenreinsertthegauge a‖thewaydown．PuI＝touts10Wlyandcheck thelevelonthegauge．（Checktheoilalsofor COntaminationandviscosity．）

3・FigOl−00（2）：The engine oilLeveIshould be betweentheupperand10WerLimitmarks．

FigOl−00（2）：Oi＝eve［gauge

4．FigOl−00（1）：IftheoilleveIisbeIowthelower

［imit，add englneOiIthroughthefuelfi［Ierport ②．

3−0−34

AdjustmentofEnglneControI

L3，L4，L5，L6・2

■Adju＄tmentOfEngineContr01 ● L3，L4，L5andL6−2 1．Withtheacceleratorpedal（0010）released，adjustthepositionofthelocknutonthecableassembly （0020）sothatthegovernorlevercomesincontactwiththe［ow−idIestopper・ 2．VViththeacceleratorpedaI（0010）depressed．aqjusttheIocknutsothatthegovernor］evercomesin COntaCtWiththefull−idlestopper．

AIsomakesurethattheclearancebetweenthestopperbolt（0100）andacceleratorpedal（0010）isLess thanl．5mmwhenthegovernorIeverisincontactwiththefulトidlestopper． 3．Makesurethatthe playoftheacce［eratorpedal（0010）（therangeofmovementoftheaccelerat Peda［（0010）in which no risein the engine speedis caused）islO mm orless atthe tip ofthe acceleratorpedaL NOTE：Whentheacce［eratorpedal（0010）isatthe10W−id［ingposition，thegovernorlevermustbeincontact Withthestopper． Machinemodel

Full−idlespeed（rpm）

Low−idJespeed（rpm）

①

L3＿2

2650±50

1100±50

②

L4＿2

2550±50

950±50

③

L5＿2

2650±50

950±50

④

L6＿2

2650±50

950±50

3−0−35

Remova［ofRadiator L Remova10fRadiator

Fig12−51：

● L3・2

1．Fig12−51：Disconnectthebatterynegativecab［e （0030）．

2・Fig62−11：Disconnectthewiring（A）oftherpar

Fig62−11：

COmbination ramp，then remove the griIle

0410

（0410）．

RearcombinationIamp

3．FigO4−12（1）：LoosenthecIamp（1090），remOVe thehose（1070），then removethereservetank

Fi904−12（1）：

（0090）．

4．FigO4−12（2）：Loosenthecap（0060），thenopen the drain cock（0080）to a owthe coolant to drain．A粍erthe coolant has been drained out， Closethedraincock（0080）．

⊥

Coolant containing capacity of radiator and englne：5．5L

3−0−36

Fi904−12く2）：

Remova］ofRadiator 5．Fig78−21：Removetheplug（0110）todrainthe

Fig78−21：Bo仕Om Ofoir tank

hydrau［ic f［uid out of the hydrau［ic fluid tank

（0010）．After the f］uid has been drained out， instaIlthep］ug（0110）．

⊥

HydrauIicftuid（maximumcapacity）：25L

▲wARNING Place a recIPlentunderthe radiatortocatch the hydraulicfluidinthepipingthatwi［lcomeoutwhen hoses are disconnected．Wipe o仔spilLed fluid COmPleteIytopreventfire， 6．FigO4−12：Remove the bo［ts（0120），then removethefan guard（0100）and duct（0030）． Tbkeawaythefanguard（0100），andmoveand attachtheduct（0030）totheenginefan．

FigO4−12：

0120

7．FigO4−00：Loosenthehoseclamps（1030），then removetheupperhose（1010）andlowerhose

Fi904−00：

（1020）．

8．Fig27−00：LoosenthehosecIamps（0201），then removethehoses（0180）and（0190）．

3−0−37

Fig27−00：

Remova［ofRadiator 9・FigO4−00（1）：Loosen the clamp（1140），then

FigO4−00（1）：

removethedrainhose（0110）．

10・Attachawire ropetothe upperfittingsofthe

radiatorandsupporttheweightoftheradiator Withahoist．

盆

Radiator：22．5kg

1140

11・FigO4−00（2）：Removethebolt（1050）andnuts

Fi904−00（2）：

（1070）．then remove the cushion rubbers （1040）・Dothisforboththerightand［eftsides．

12・FigO4−00（3）：Hoisttheradiator（0010）todetach itfromthemachine．Removethewasher（1170） and cushion rubber（1080）from under the radiato「Dothisforboththerightandleftsides．

FigO4−00（3）：

13．Detach the duct which was attached to the enginefan．

1080

3−0−38

lnsta［lationofRadiator ■lnsta ationofRadiator

FigO4−12（1）：

● L3−2

1．FigO4−12（1）：Removefromtheradiator（0010） thebolts（0120）toremovethefanguard（0100） and duct（0030）．Fit the duct（0030）in the englnefan．

2．FigO4−00（1）：Installthecushion rubber（1080） andwasher（1170）ontherearframe・Dothis

FigO4−00（1）：

fortherightandle代Sides．

3．FigO4−00（1）：Hoist the radiator（0010），then

loweritfrom abovethemachineto placeitin POSition．Makesurethateachpin（indicatedby thearrow）onthebo仕OmOftheradiatorisfitted

into the ho［e of the corresponding cushion rubber（1080）．

4．FigO4−12（2）：l盲mporari］yinsta［ltheduct（0030）

FigO4−12（2）：

to adjust the vertica［position of the radiator （0010）．After adjustment，remOVe the duct （0030）．Refer to lAqjustment of Radiator Position．−−

5．FigO4−00（2）：lnstallthedrainhose（0110），then

FigO4−00（2）：

insta［Itheclamp（1140）．

1140 3−0−39

Jnsta［lationofRadiator 6・Fig27−00：Connectthehose（0190）andtighten thehoseclamp（0200）．

7・FigO4−00（3）：lnstallthe10Werhose（1020），then tightenthehosecLamps（1030）．

Fig27−00：

FigO4−00（3）：

8・FigO4−12（3）：lnstaIL the duct（0030）and fan guard（0100）byfasteningwiththebolts（0120）．

9・FjgO4−00（4）：Fitthecushionrubbers（1040）on theradiator（0010），theninsta暮Itheradiatoron the （1070）・Aqjust thein−and−Out POSition of the radiator（0010）．Refer to 一．Aqjustment of RadiatorPosition：l

亀N。．（．。7。）：．7．7＿2．．5Nm Locknut（1070）：14．7−16．6Nm

3−0−40

FigO4−12（3）：

FigO4−00（4）：

lnsta ationofRadiator 10．Fig27−00：lnstallthe hose（0180），thentighten thehoseclamp（0201）．

Fi927−00：

11，FigO4−00：lnsta‖the upper hose（1010），then

FigO4−00：

tightenthehosec［amps（1030）・

12．Fig78−21：FiILthehydraulicfluidtank（0010）with

Fig78−21：

thespecifiedamountofhydrauJicfluid．Referto LeveLCheckandAdditionofF［uidinHydrauIic Fluidl盲nk，‖

〕省H，dra。ticF．。id（maxim。m）‥25L

13．FigO4−12：FiIlthe radiator（0010）with the SPeCified amount of cooIant．Refer to LeveI CheckandAdditionofCoolant．

Coolantintheradiatorandenglne：5．5L

3−0−41

FigO4−12：

Insta ationofRadiator 14・Fig12−51：Connect the battery negative cabIe

Fig12−51：

（0030）．

15・Fig42r12：lnsta＝the reservetank（1090），then

Fig42−12：

COnneCtthehose（0070）．

16．Fig62−11：Connect the connector of the rear

Fig62−11：

COmbinationIamp，theninsta11thegriIle（0410）．

0410

Rearcombinationllamp

17・Start and run the engJne atidIe to check for COOLantandoiIIeaks．

18．Stop the englne，Wait for5−10minutes，then

Check the coolant and hydrauIic fluidIevels． Referto LevelCheckandAdditionofCoo暮ant and rLevelCheck and Addition of Hydrau［jc FIuidノ■

3−0−42

Remova10fRadiator

L4，L5，L6・2 Fi962−11：

■ Remova［ofRadiator 0150

● L4，L5，L6t2 1．Fig62−11：Removethe snap pins（0060），then removethehood（R）（0150）．

2．Fig12−51：Disconnectthebatterynegativecable

Fig12−51：

（0030）．

0030

3．FigO4−12（1）：Loosentheclamp（0090），remOVe

figO4−12（1）：

thehose（0070），thenremovethereservetank （1100）．

4．FigO4−12（2）：Loosenthecap（0060），thenopen the drain cock（0080）to allowthe coo［？nttO drain．A代erthe coolant has been drained out，

CIosethedraincock（0080）．

⊥

CooIant containing capacity of the radiator andeng［ne：

L4−2−5．7L

L5，L6−2−6．1L

3−0−43

FigO4−12：（2）

Remova］ofRadiator 5・Fig78−21：Removetheplug（0110）todrainthe hydrau［icf［uidoutofthefIuidtank（0010）．After thef）uidhasbeendrainedout，insta＝thepJug

L4，L5，L6・2 Fig78−21：Bottom ofoiltank

（0110）．

⊥

HydraulicfJuid（totaIcapacity）：L4，L5，L6−2− 42 L

6・FigO4−12：Remove the bolts（0120），then removethefanguard（0100）andduct（0030）． 1盲keawaythefanguard（0100）andmoveand attachtheduct（0030）totheenginefan．

FigO4−12：

0120

7・FigO4−00：LoosenthehosecIamps（1040），then

FigO4−00：

removetheupperhose（1010）andlowerhose （1020）．

8・Fig27−00：LoosenthehosecFamps（0270），then removethehoses（0230）and（0240）．

3−0−44

Fig27−00：

Remova10fRadiator

L4，L5，L6−2

9．FigO4−00（1）：Loosen the clamp（1150），then

Fi904−00（1）：

removethedrainhose（0110）．

10．Attach awire ropetothe upperfittingsofthe radiatorand supporttheweightoftheradiator

0110／

Withahoist．

盆

Radiator： 1150

L4−2−22kg L5，L6−2−26k9

11．FigO4−00（2）：RemovetheboIt（1070）andnuts （1090），then remove the cushion rubbers （1060）．Dothisforboththerightand［eftsides．

12．FigO4−00（3）：Hoisttheradiator（0010）todetach

FigO4−00：（2）

1090

FigO4−00（3）：

itfromthemachine．BothrightandIeftwashers （1180）and cushion rubbers（1050）come attachedtothebottomoftheradiator．

13．Detach the duct which was a恍ached to the

enginefan．

3−0−45

］nsta ationofRadiator ■InstallationofRadiator

L4，L5，L6・2 FigO4−12く1）：

● L4，L5，L6−2

1．FigO4−12（1）：Removefromtheradiator（0010） thebo［ts（1120）toremovethefanguard（1100） and duct（1030）．Fit the duct（1030）in the engIneねn．

2．FigO4−00（1）：lnstaltthecushionrubber（1050）

FigO4−00（1）：

andwasher（1180）ontherearframe．

3．FigO4−00（1）：Hoist the radiator（0010），then

Ioweritfrom abovethe machine to p］aceitin POSition．Makesurethateachpin（indicatedby

thearrow）onthebottomoftheradiatorisfitted into the hole of the corresponding cushion mbbe「（1050）．

1050

4．FigO4−12（2）：l盲mporarilyinstaIltheduct（0030）

Fi904−12（2）：

to aqjust the verticaIposition of the radiator （0010）．After a叫ustment，remOVe the duct （0030）．Refer to Aqjustment of Radiator Position．‖

5．FigO4−00（2）：lnstallthedrainhose（qllO），then

Fi904−00（2）：

insta［ltheclamp（1150）．

1150

3−046

Insta ationofRadiator

L4，L5，L6−2

6．Fig27−00：Connectthehose（0240）andtighten

Fi927−00：

thehoseclamp（0270）．

7．FigO4−00（3）：lnsta［ltheIowerhqse（1020），then

FigO4−00（3）：

tightenthehosecIamps（1040）・

8．FigO4−12（3）：lnstal］the duct（0030）and fan

FigO4−12（3）：

guard（0100）byfasteningwiththebolts（0120）・

9．FigO4−00（4）：Fitthecushionrubbers（1060）on theradiator（0010），theninstaLItheradiatoron the fenders with the boIts（1070）and nuts （1090）．Adjust thein−and−Out POSition of the radiator（0010）．Refer tol Aqustment of RadiatorPosition．一■

鞄Nut（1。9。）‥17．7t。21．5Nm Locknut（1090）：14．7to16．6Nm

3−0−47

FigO4−00（4）：

1090

Insta ationofRadiator 10・Fig27−00：lnsta‖the hose（0230），thentighten thehosec］amp（0270）．

L4，L5，L6・2 Fig27−00：

11．FigO4−00：lnstaJlthe upper hose（1010），then

Fi904−00：

tightenthehoseclamp（1040），

12．Fig78−21：Fi

hydraulic ftuid tank with the

Fig78−21：

SPeCified amount of hydrauIic flujd．Refer to ．．LeveICheckandAdditionofF）uidinHydrau［ic FLuidT畠nk．一■

省Hyd，a。．icn。id（t。ta．CaPaCi．，）：L．，L5，L6＿2＿ 42 L

13．FigO4−12：Fi［lthe radiator（0010）with the SPeCified amount of cooLant．Refer to‖Level CheckandAdditionofCoolant．M Coolantintheradiatorandeng［ne： L4−2−5．7L

L5，L6−2−6．1L

3−0−48

FigO4−12：

lnsta］IationofRadiator

L4，L5，L6・2

14．Fig12−51：Connect−the battery negative cable

Fig12−51：

（0030）．

15．Fig42−12：lnsta［lthe reservetank（1100），then

Fig42−12：

COnneCtthehose（0070），

16．Fig62−11：）nsta［［the hood（R）（0150），then installthesnappin（0060）．

Fi962−11：

0150

17．StartandruntheengLneatidletocheckforoil leakage．

18．Stop the eng［ne，Wait for5−10minutes，then Check the coo［ant and hydraulic f［uidlevels． Referto LeveICheckandAdditionofCoolanfT and LeveICheck and Addition of FIuidin Hydrau［icFIuidl盲nk：一 3−0−49

Leve［CheckandAdditionofCoo［ant L3，L4，L5，L6−2 ■ LeveICheckandAdditionofCoolant ● L3，L4，L5，L6・2

▲wARNING ・ Do notremovetheradiatorcapexceptwhen absolute［ynecessaryandunlesstheeng［neis

COld．1fthe radiatorcapIS remOVedwhenthe englneis at an operating temperature，eX−

tremelyhotsteamandcoolantmayblowoutof theradiatorandcouldscaLdyouseriousIy． ・ Checkthecoolant［eveIonlyonthe reservoir

tankandwhentheengIneiscold．

tMPORTANT ● The coolant used for addition must contain anti−freezeorrustinhibitoratthesameconcen−

trationasthatofthecoolantintheradiator． ● Donotaddwaterfromawerlorariver．Besure

tousesoftwatersuchastapwater．

1．Fig42−12：Check the coolantIeveIin the

Fig42−12：

reservoir tank① when the engineis not runnmngandthecoolanttemperatureis暮ow． 2．Fig42−12：Thecoolantlevelshouldbebetween the FULL and LOVV marks．If theleveIis at

LOWf10rbelow，OPenthecap③atthetopof thereservoirtank①，andaddcooIantuptothe ‖FULL．1mark．If thereis no coolantin the

re＄erVOirtank①，remOVethe radiatorcap② andaddcoolantuptothetopoftheradiator s 罰‖e「neck．

Fig42−12：Reservoirtank① ③

3．1f the coo］ant reduces too quickIy，Check the

radiatorandradiatorhosesforleakage．

3−0−50

Remova10fFuelThnk ■ RemovalofFue［Tank

L3，L4，L5，L6・2 Fig12−51：

● L3，L4，L5，L6−2 1．Fig12−51：Disconnectthebatterynegativecab［e （0030）．

2．Fig62−12：Remove the f］00r mat（0050），then removetheboJts（0020）todetachthenoorplate

Fig62−12：

（0011）．

3．FigO6−21（1）：Turnthe［eversofboththewater

FigO6−21（1）：Le托side of machine

SeParatOr（0010）and fuelfi［ter（0020）to the ■

CLOSE ■positions．

4．FigO6−21（2）：Removetheplug（0130）toallow thefuelinthefueItank（0101）todrain．A微erthe fue［has been drained out，instaI暮 the pLug （0130）．

⊥

Fueltankcapacity（maximum） L3−2−33L

L4，L5，L6−2−50L

3−0−51

FigO6−21（2）：Bo仕Om OffueItank

RemovalofFue［「hnk 5．Figll−51：Disconnectthewiring（A）ofthefue】

L3，L4，L5，L6・2 Figll−51：

Sendingunit．

6，FigO6−21（3）：Loosenthe hoseclamps（0130）， then disconnect the fueIhoses（0090）and （0101）fromthefueltank．

7・FigO6−21（4）：With the fueltank（1010）

FigO6−21（4）：

SuPPOrted uslng a jack，remOVe the bolts （1020），thenremovethefue［tank（1010）．

盆Fue．．ank（．。．。）‥ L3−2−26kg 1020

L4，L5，L6−2−33kg

3−0−52

InstaIlationofFuelねnk 1）nsta ationofFueITank

L3，L4，L5，L6−2 Fi906−21（1）：

● L3，L4，L5，L6・2 1．FigO6−21（1）：With the fue］tank（1010）

SuPPOrted uslng ajack，Placeitin position on the rearframe andinsta＝the bolts（1020）at fourLocations．

1。

亀B。．t（．。2。）‥77．．．。，．．。Nm 2．FigO6−21（2）：Connect the fuelhoses（0090） and（0101）tothefue［tank（101b），thentighten thehosec［amps（0130）．

3．Figll−51：Connect the wiring（A）of the fue［ Sendingunit．

4．FigO6−21（3）：Turn theIever＄Of the water SeParatOr（0010）and fuel用ter（0020）to the open ．positions．

3−0−53

Figll−51：

lnsta［IationofFueIlbnk 5・FigO6−11：Openthecap（0030）andfiHthetank With the specified amount of fuel．Refer to

L3，L4，L5，L6・2 Fi906−11：

LevelCheckandAdditionofFuel．

雀F。e．tankcap叫（maxim。m） 一 L3−2−33L L4，L5，L6−2−50L

6．・Fig62−12：Placethef100rPlate（0011）inposition andsecurethemwjththeboIts（0020）．Laythe

Fig62−12：

floormat（0050）．

7・Fig12−51：Connectthe battery negative cable

Fig12−51：

（0030）．

8・BIeedairoutofthefue［systemandcheckfor fueHeakage．

●Airb［eedingofthefue［＄yStem TurningthestarterswitchtotheONpositionstarts theelectricfueIpump，Whichautomatica］）ybleedsair

OUtOfthefuelsystem．ThereisnoneedtopIacethe StarterSWitchtotheS rART（enginestarting）posi− tion．

1MPORTANT ［fthe englne runS OUtOffue10rthe eIectricfue［ PumPSuCksaれthepumpbecomeshighanddry， generating10udpumplngnOise．［fthisoccurs，tum OFFthestarterswitchtopreventthepumpfrom

becominghighanddry． 3−0−54

LevelCheckandAdditionofFuel

L3，L4，L5，L6−2 FigO6−00（1）：Left side ofmachine

J LevelCheckandAdditionofFue］

▲wARNING ・The■fueI（LightoiL）isfIammable．Whenrefueト

LngOrdrainlngWaterOraSedimentoutofthe fueltank，neVerSmOkenorholdanopenf［ame

nearby． ・ Fue［spi edduringrefueringmustbewipedup

COmPletelytopreventriskoffire．

1．FigO6−00（2）：TurnthestarterswitchtotheON

FigO6−00（2）：Fuelgauge（meterpaneI）

POSitionandcheckthefuelgaugeforsufFicient fue］［evel．Afterchecking，turnthestarterswitch totheOFFposition．

2・FigO6−00（3）：When refue．［iりg，PreVent Water

andd帆fromge輔ngintothefue［tank．Besure toattachastrainer（D tothefueltank．

3．FigO6−00（3）：After refueling，10Ckthe cap②

FigO6−00（3）：

uslngthekey，Makeitaruletofi［lupthetank

aftereverydayLsoperation．

誓F。e．ta。kcapaci．，（maxim。m）‥ L3−2−33L L4，L5，L6−2−50L

● Draining water and sediment out of fue轟 tank l，FigO6−21（4）：Removethedrainplug③（Width acrossfIats：19mm）todischargewateranda Sediment that co ectin the bo仕Om Of the fuet tank．

3−0−55

FigO6−21（4）：Bottom offueltank

↓ノ ︶・

3−2POWERTRAINl Remova［ofHSTPumpL3−2

＝＝……・・・…

InstaI）ationofHSTPumpL3−2

…………‥‥

Remova10fHSTPumpL4，L5，L6−2

……………・

Insta［［ationofHSTPumpL4，L5，L6−2

…………＝

DisassemblyofHSTPump

………‥・…

Remova10fHSTMotorL3−2

…………‥

Insta［LationofHSTMotorL3−2

・…・・…・・…

3−2−17

Remova）ofHSTMotorL4，L5，L6−2

‥‥………・

Insta［［ationofHSTMotorL4，L5，L6−2

・…・………

DisassembIyofHSTMotorL3−2

…………‥

3−2−1

3−2−4

3−2−7

3−2−10

3−2−13

3−2−15

3−2−19

3−2−21

3−2−23

DisassemblyofHSTMotorL4，L5，L6−2…………‥

3−2−24

Remova］ofReductionGear

…………＝

3−2−25

JnstaJJationofReductionGear

…………‥

OiJChangeofReductionGear

…………‥

LevefCheckandAdditionofF（uidin

・・・・・………

3−2−32

3−2−28

3−2−31

BrakeF［uid−Tbnk

BIeedingBrakeFluid，rbnk

・………・…

DisassembJyofReductionGear

＝………・＝

AssembJyofReductionGear

…………‥

ServiceStandardsofReductibnGear

…………‥

3−2−33

3−2−34

3−2−40

3−2−48

ヽノ

︺

Remova［ofHSTPump ■ RemovalofHSTPump

Fig12−51：

● L3−2

1．Fig12−51：Disconnectthebatterynegativecable （0030）．

2，Fig62−12：Remove the f［00r mat（0050），then

Fig62−12：

removethebo］ts（0020）todetachandremove thef100rPlate（0010）．

3．Fig12−51：Cut the cable clamp（0230），then disconnectthewiring（K）ofthefrontand rear SO［enoidvalvesfromthetopoftheHSTpump．

Fig12−51：Ⅵewed from above machine

4．Fig43−11：Remove the nut（01811s fastener）， thenremovetherod（0181）．

0181

3−2−1

Remova10fHSTPump 5．Fig78−21：Remove the p］ug（0110）to drain

Fig78−21：Bottom of hydraulicfIuid tank

hydrau［ic fluid out of therhydrauIic fluid tank （0010）．A債erdraining，insta＝theplug（0110）．

⊥

Hydrauliclfruid（totafcapacity）：25L

▲wARNtNG PlacearecIPlentundertheHSTpumptocatchthe hydrauLicfIuidinthe・PipingthatwilLcomeoutwhen hoses are disconnected．Wipe o仔spilled fLuid

COmPletelytopreventfire． Fi978−00：

6．Fig78−00：Disconnect the main pump hoses （0030）and（0080）．

7．Fig27−00：Disconnectthechargingpump（OUT） hose（0100）andHSTdraintube（0030）．

8．Fig27−00：Disconnecttheinching va］ve hoses （0090），（0111）and（0120）．

9，Fig27−00：Disconnectthehoses（0040），（0180） and（0251）fromthetopoftheHSTpump．

10．Fig27−00：Disconnectthehose（0030）fromthe bottomoftheHSTpump．

3−2−2

RemovalofHSTPump 11．Suppo止the weight ofthe HST pump（0070） uslngahoistandny［onsling．

鹿weigh．。fHSTp。。P（。。7。）‥39kg 12．Fig25−00：Remove the bolts（0080）to detach theHSTpump（0070）．

／ ／

machine．

3−2−3

／

0080 ∫ご

13．L椚theHSTpump（0070）toremoveitfromthe

lnsta＝ationofHSTPump ■ln＄ta ationofHSTPump

Fi925−00：

● L3−2

1．Fig25−00：Using a hoistand nyIon s［ing，bring the HST pump（0070）into position so thatit alignswiththeengine（COuP．ing）．Applygrease

tothesplinedsectionoftheHSTpump．

亀B。．t（。。8。）＝188，3＿229．5Nm

2．Fig27−OO：Connect the hose（0030）to the

bottomoftheHSTpump．

3，Fig27−00：Connect the hoses（0040），（0180） and（0251）tothetopoftheHSTpump．

4・Fig27−00：Connectthehoses（0090），（0111）and （0120）tothejnchingvalve．

5．Fig27−00：Connect the hose（0100）to the Charging pump（OUT），then connect the tube （0030）totheHSTdrainport．

6・Fig27−00：Connectthehose＄（0030）and（0080） tothemainpump．

3−2・4

Fig78−00：

1nstalIationofHSTPump 7．Fig12−51：Connect the wiring（K）ofthe front andrearsolenoidvalvestothetopoftheHST PumP，theninsta＝thecabIeclamp（0230）whi［e

J Fig12−51：

adjustinglengthofthewiring（K）．

8．Fig43−11：Connecttherod（0181）totheinching Valve Lever，theninsta the ′nut（0181−s fastener）．Refer to． Adjustment of Engine Control．−■

9，Fig78−21：Fi the hydraulic fluid tankwith the

Fig78−21：

SPeCified amount of hydrauIic fluid．Refer to T．Leve［CheckandAdditionofFluidinHydrau［ic 円uid￣bnk．−■

誓H，d，a。［ic。。id（．。．a．CaPaCi．，）：25L

10．Fig62−12：Place the fIoor plate（0011）in POSition，theninstaIlthe bo暮ts（0020）．Laythe 刊00「mat（0050）．

3−2−5

Fig62−12

Lnsta ationofHSTPump 11．Fig12−51：Connect the battery negative cab）e （0030）．

12．Starttheengrneand runitatidIetocheckfor fLuidleakage．

13，Stop the englne，Wait for5−10minutes．then Checkthefluidlevel．Referto‖LevelCheckand

AdditionofFluidinHydraulicFluid■ねnk，

3−2−6

Fig12−51：

RemovalofHSTPump ）RemovalofHSTPump

L4，L5，L6−2 Fig12−51：

● L4，L5，L6・2

1．Fig12−51：Disconnectthebatterynegativecable （0030）．

2．Fig63−00：Remove the bo［ts（1060），then

Fig63−00：

removetheseatassembly（0010）togetherwith theseatsupport（1050）．

盆sea．assemb．，（。。．。）．sea．s。PP。n（．。5。）＝ 15 kg

3．Fig63−00：Remove the bolts（1060），then removetheseatsupport（1010）．

鹿seats。PP。n（．。．。）＝．，kg

4．Fig62−12：Removethef［∞r mat（0050），then removethebolts（0020）todetachandremove thef）00rPlate（0010）．

3−2−7

Fig（∋2−12：

RemovaIofHSTPump

L4，L5，L6−2

5・Fig12−51：Cut the cable clamp（0230），then disconnectthewiring（K）ofthefrontand rear SO［enoidva［vesfromthetopoftheHSTpump．

F短12−51：

6・Fig43−11：Remove the nut（0181−s fastener），

Fi；I43−11：

thenremovetherod（0181）．

InchingvaJvelever

1匠≡ヨ0

0181

7・Fig78−21：Remove the plug（0110）to drain hydrau［ic刊uid out of the hydrau［ic fIuid tank （0010）・A代erdraining，installthepJug（0110）．

⊥

Fig78−21：Botbm ofhydrauJicf［uid tank

HydrauIicf（uid（totalcapacity）：

L4，L5，L6−2−42L

▲wÅRNING P［acearecipientundertheHSTpumptocatchthe hydrau［icfluidinthepipingthatwi

comeoutwhen

hoses are disconnected．Wipe o仔SPiI［ed fIujd COmPletelytopreventRre．

Fig78−00：

8・Fig78−00：Disconnect the main pump hoses （0030）and（0080）．

3−2−8

Remova］ofHSTPump

L4，L5，L6・2

9．Fig27−00：Disconnectthechargingpump（OUT）

Fig27−00：

hose（0120）．

10・Fig27−00＝Disconnecttheinchingvalvehoses oo50 （0130）and（0140，tWOPieces）．

11．Fig27−00：Disconnect the hoses（0060）and （0190）fromthetopoftheHSTpump・

0140

12．Fid27−00：Disconnectthehose（0050）fromthe bo仕Om Ofthe HSTpump，thendisconnectthe hose（0320）a托er）00Sening then hose c［amp （0360）．

13．Support the weight ofthe HST pump（0070）

Fi925−00：

uslngahoistandnylons］ing・

盆

WeightofHSTpump：L4，L5，L6−2−42kg

14．Fig25−00：Remove the bo［ts（0080）to detach theHSTpump（0070）．

15．Lift the HST pump to removeit from the

0080

machine．

3−2−9

Insta［IationofHSTPump

L4，L5，L6・2

JlnstaLlationofHSTPump

Fi925−00：

● L4，L5，L6・2 1．Fig25−00：Using a hoistand nylon sllng，bring the HST pump（0070）into position so thatit a［ignswiththeengine（COuP［ing）．AppIygrease

tothesplinedsectionoftheHSTpump．

亀B。．t（。。8。）‥188ふ229．5N。 0080

2．Fig27−00：Connect the hose（0050）to the bottomoftheHSTpump．A］soconnectthehose （0320），thentightenthehosec［amp（0360）．

Fi927−00：

0190

3．Fig27−00：Connectthehoses（0060）and（0190） tothetopoftheHSTpump．

4．Fig27−00：Connectthehoses（0130）and（0140， twopieces）totheinchingvalve．

0140

5．Fig27−00：Connect the hose（0120）to the Chargingpump（OUT）

6．Fig78−00：Connectthe tube（0030）and hose （0080）tothemainpump．

3−2−10

Fi978−00：

lnsta ationofHSTPump 7，Fig12−51：Connect the wiring（K）ofthe front and rearsolenoidva［vestothetopoftheHST PumP，theninsta thecablec［amp（0230）while

L4，L5，L6・2 Fig12−51：

adjustingthelengthofthewiring（K）・

8．Fig43−11：Connecttherod（0181）totheinching Valvelever，theninsta the nut（0181−s fastener）．Refer to ■ Adjustment of Engine Cont「ol．■−

9．Fig78−21：Fi＝the hydrau［ic fruid tankwith the SPeCified amount of hydrauIic f［uid．Refer to 一一LevelCheckandAdditionofFluidinHydrau暮ic

Fig78−21：

Fluidl盲nk． 一

雀H，dm。，．c。。id（．。ta，capaciり）‥25L

10．Fig62−12：P［ace the f［00r P［ate（0011）in POSition，theninstallthe bo［ts（0020）．Lay the 刊00「mat（0050）．

3−2−11

Fig62−12

lnsta ationofHSTPump

L4，L5，L6t2

11・Fig63−00：Place the seat support（1010）in POSition，theninstaJItheboIts（1060）．

Fig63−00：

12・Fig63−00：hlSta the seat（0010）and seat SuPPOrt（1050），theninstallthebolts（1060）．

13・Fig12−51：Connectthe ba壮ery negative cable

Fig12−51：

（0030）．

0030

14．Starttheeng（neandrunjtatjdletocheckfbr fIuidleakage．

15・Stqp the englne，Wait fbr5−10minutes，then CheckthefIuidleveI．Referto

LevelCheckand

AdditionofF［uidinHydraulicFIuidl盲nk．，．

3−2−12

DisassemblyofHSTPump

L3，L4，L5，L6・2

J DisassemblyofHSTPump ● L3，L4，L5，L6・2

a cnuTlorJ AstheHSTpumpcannotbeadjustedcorrect］y［n the罰e］d，donotpe血rmanyworkbeyondtheex− tent described in the following disassembly and assembLyprocedures．

Fig25−11（2）：Viewedin direction ofarrowA

● Pumpgroup l．Fig25−11（2）：Remove the bolts（0010），then removetheoilsealcover（0020）．Nowyoucan rep［acetheoilsea［（0030）andO−ring（0040）・

● Contro］group（1）

Fig25−11（3）：Ⅵewedin direction ofarrowA

1．Fig25−11（3）：Remove the bolts（0140），then remove the gear pump（0120）．Now you can remove the coupIing（0090）and replace the Oィing（0110）．

2．Fi925−11（4）：Ybucan removeandrepIacethe high−PreSSure relief vaIve （0150） and

Fi925−11（4）：

10W−PreSSurere［iefvalve（0160）．

0150 0160 3−2−13

DisassemblyofHSTPump

L3，L4，L5，L6・2 Fig25−11（5）：

3． Fig25−11（6）：Remove the bo［ts（0420）．Now

Fig25−11（6）：ViewedindirectionofarrowB

youcan removeand rep［acetheinchingvaLve assemb］y．

▲cAUT10N Donotdisassembletheinchingvalve．

0420 ● Contro］group（2）

Fig25−11（7）：Viewedin direction ofarrowC

1．Fig25−11（7）：Remove the bolts（0040），then

OO40

removethesolenoidvalveassembly（0020）and Orifices（0010）．NowyoucanreplacetheO−hng （0030）．

Pump piping groupup

Fig25−11（8）：

l．Fig25−11（8）：Ⅵ）UCanremOVeandrepIacethe Pipe（0030），tee（0010）and pin（0020），nippIe （0040），tee（0050），nipple（0060）and orifice （0070）．

3−2−14

Remova10fHSTMotor ＋ Remova［ofHSTMotor

Fig12−51：

● L3・2

1，Fig12−51：Disconnectthebatterynegativecable （0030）．

2．Fig62−12：Remove the fIoor mat（0050），．then removethebolts（0020）todetachandremove

Fig62−12：

thef100rPlate（0010）．

3．Figll−51：Cut the cab］e clamp（0080），then

Figll−51：Viewedfromabovemachine

disconnectthesolenoidvalvewrrLngOftheHST moto「（0010）．

4．Fig78−21：Remove the pIug（0110）to drain hydraulic刊uid out of the hydrau［ic fluid tank （0010）．Afterdraining，installthep［ug（0110）・

⊥

Hydraulic罰uid（totalcapaci吋）：25L

▲wARNING PFacearecipientundertheHSTpumptocatchthe hydraulicfIuidinthepipingthatwiI［comeoutwhen hoses are disconnected．Wipe o汗spiI［ed fIuid COmPleteIytopreventfire， 3−2−15

Fig78−21：Bottom ofhydrauLic刊Uid tank

Remova［ofHSTMotor 5．Fig27−00：Disconnect the hoses（0030）and

Fig27−00：

（0040）oftheHSTmotor．

6．Fig27−00：Disconnect the pi［ot pressure hose （0111）and hose（upper）（0120）from the HST moto「

7・Fig27−00：Disconnect the drain hose（upper） （0251）oftheHSTmotor．

8・Support the weight ofthe HST motor（0100）

0100

uslngahoistandny［onsling．

盆

WeightofHSTmotor：23kg

9・Fig25−00：Remove the bolts（0110），then removetheHSTmotor（0100）．

10・Hoist away the HSTmotorto removeitfrom underthemachine．

3−2−16

Fi925−00：

Insta ationofHSTMotor tIn＄ta

ationofHSTMotor

● L3・2

1，Fig25−00：Using a hoistand nylon sIing．bring

theHSTmotor（0100）fromunderthemachine into position so thatit engages with the reduction gear．AppJy grease to the splined SeCtionoftheHSTmotor（0100）．

亀B。．t（。．．。）‥．．．．＿5，．9Nm 2．Fig27−00：Connect the drain hose（upper）

Fig27−00：

（0251）oftheHSTmotor．

3．Fig27−00：Connect the pilot pressure hose （0111）and hose（upper）（0120）of the HST motor．

4．Fig27−00：Connectthehoses（0030）and（0040） OftheHSTmotor，

5．Figll−51：lnstallthe cablec［amp（0080），then COnneCt the solenoid valve wiring（A）of the HSTmotor（0010）．

3−2−17

Figll−51：

lnsta］IationofHSTMotor 6．Fig78−21：F＝the hydrau［ic fluid tank with the SPeCified amount of hydrauLic f］uid．Refer to ■■LevelCheckandAdditionofF］uidinHydrauIic

Fig78−21：

Fluid￣ねnk．

省Hyd，a。．ic。。i。（．。ta．CaPaCit，）‥25L

7・Fig62−12：P［ace the f］00r Plate（0011）in POSition，theninstaIlthe bolts（0020）．Laythe

Fi962−12：

floormat（0050）．

8・Fig12−51：Connectthe battery negative cable

Fig12−51：

（0030）．

9．Starttheenglneand runitatidleto checkfor fluidleaka9e．

10，Stop the en9Lne，Wait fbr5−10minutes，then CheckthehydrauLicfIuidleve［．Referto Leve［

Check and Addition of Fluid in Hydraulic Fluid l盲nk．‖

3−2−18

Remova［ofHSTMotor ■ Remova］ofHSTMotor

L4，L5，L6−2 Fig12−51：

● L4，L5，L6−2 1．Fig12−51：Disconnectthebatterynegativecable （0030）．

2．Fig62−12：Remove the fIoor mat（0050），then removethebolts（0020）todetachandremove

Fig62−12：

thefIoorpIate（0010），

3．Figll−51：Cut the cab］e clamp（0080），then disconnecttheso［enoidvalvewiring（A）ofthe

Figll−51：Viewedfromabovemachine

HSTmotor（0010）．

4．Fig78−21：Remove the p暮ug（0110）to drain

hydraulic fIuid out of the hydrauLic f［uid tank （0010）．A代erdraining，in＄ta‖thepIug（0110）．

⊥

HydraulicfIuid（tota［capacity）： L4，L5，L6−2−42L

▲wARNING P［acearecipientundertheHSTpumptocatchthe hydraulic刊uidinthepipingthatwilJcomeoutwhen hoses are disconnected．Wipe o仔spi COmPlete）ytopreventfire．

ed fluid

3−2−19

Fig78−21：Bottom of hydrauIic fIuid tank

RemovaIofHSTMotor

L4，L5，L6・2

5．Fig27−00：Disconnect the HST motor hoses

Fi927−00：

（0050）and（0060）．

6．

Fig27−00：Disconnect the HST motor pi10t PreSSurehoses（0140，tWOPieces）．

7．Fig27−00：DisconnecttheHSTmotordrainhose （0190）（upper）andhose（0230）（Iower）．

8・Supporttheweightofthe HSTmotor（0100） usIngahoistandnylonsJing・

L＆weigh．。fHSTm。．。r（。．。。）‥39kg 9・Fig25−00：Removethebolts（0120）todetach

Fi925−00：

theHSTmotor（0100）．

10・RemovetheOィing（0110）fromtheHSTmotor （0100）．

0100

11・LowertheHSTmotor（0100）toremoveitfrom underthevehic［e．

3−2−20

0120

［nstallationofHSTMotor

L4，L5，L6−2 Fig25−00：

■lnstallationofHSTMotor ● L4，L5，L6・2 1．Fig25−00：lnsta［ltheO−ring（0110）ontheHST motor（0100）．

2．Fig25−00：Using a hoistand ny10n S）ing，bring the HST motor（0100）into position so thatit

engageswiththereductiongear．Applygrease tothesp）inedsectionoftheHSTmotor（0100）．

盆B。岬2。）＝44．1＿53．9Nm

3．Fig27−00：Connectthe HST motordrain hose

Fig27−00：

0190

（0190）（upper）andhose（0230）（10Wer）．

4．Fig27−00：Connect the HST motor pi10t PreSSurehoses（0140，tWOPieces）．

5．Fig27−00：ConnecttheHSTmotorhoses（0050） and（0060）．

3−2−21

lnstal［ationofHSTMotor

L4，L5，L6・2

6．Figll−51：1nstallthe cabIe cIamp（0080），then

Figll−51：

COnneCt the so［enoid varve−Wiring（A）of the HSTmotor（0010）．

7．Fig78−21：FiLlthe hydrauIic．fIuid tank with the SPeCi而ed amount of hydraulic fluid．Refer to ■■Leve［CheckandAdditionofFluidjnHydrau］ic

Fig78−21：

F仙dl盲nk．‖

省H，。ra。．ic仙id（．。ta，capaci〜）：．2L

8．Fig62−12：P［ace the fIoor p［ate（0011）in POSition，theninsta the borts（0020）．Laythe

Fi962−12：

fIoormat（0050）．

9・Fig12−51：Connect the battery negative cab［e （0030）．

Fig12−51：

10．Starttheeng［neand runitatidJetocheckfor ¶uidleakage．

11．Stop the eng［ne，Wait fbr5−10minutes，then Checkthefluidlever，Referto一一LevelCheckand AdditionofFIuidinHydrau）icFluidl盲nk．一一 3−2−22

0030

DisassembLyofHSTMotor ■DisassembtyofHSTN10tOr ● L3−2

▲cAUT10N AstheHSTmotorcannotbeadjustedcorrectlyln thefield，donotperfbrmanyworkbeyondtheex−

tent described in the following disassembly and assemblyprocedures．

● Motorgroup

Fig25−21（2）：

l．Fig25−21（2）：Remove the boIts（0010），then removetheoilsealcover（0020）．Nowyoucan repLacetheoilseal（0030）andO−ring（0040）・

2．Fig25−21（3）：Ybu can remove the soIenoid Valve（0480）andreplaceit．

3−2−23

Fig25−21（3）：

DisassemblyofHSTMotor t Disas＄emblyofHSTMotor

・L4，L5，L6−2 Fi925−21（1）：

● L4，L5，L6−2

′A ▲wARNING AstheHSTmotorcannotbeadjustedcorrectlyin thefield，donotperformanyworkbeyondtheex−

tent described in the following disassembiy and assemblyprocedures．

● Motorgroup

Fig25−21（2）：

l．Fig25−21（2）：Remove the bolts（0010），then removetheoiLsea［cover（0020）．Nowyoucan rep［畠cetheoi［sea）（0030）andO−ring（0040）．

2．Fig25−21（3）：Ybu can remove the soFenoid Valve（0640）andrepIaceit．

3−2−24

Fi925−21（3）：

Remova10fReductionGear

L3，L4，L5，L6−2

■ RemovalofReductionGear

Fig12−51：

● L3，L4，L5，L6，2 1．Fig12−51：Disconnectthebatterynegativecable （0030）．

2．Fig62−12：Remove the floor mat（0050），then removethebo［ts（0020）todetachand remove

Fi962−12：

thefIoorplate（0010）．

3．Figll−51：Cut the cable c［amp（0080），then disconnectthesoIenoidvalvewiring（A）ofthe

Figll−51：Viewedfromabovemachine

HSTmotor（0010）．

4．Fig34−00：Remove the botts（0030），then disconnectthepropeIlersha微assembIy（0010）

Fig34−00：

（atthefrontax［eend）．

5，Fig34−00：Remove the bolt（0050），then disconnecttheprope ershaftassembty（0020） （attherearaxleend）．

00・10

3−2−25

RemovaIofReductionGear

L3，L4，L5，L6・2 Fig78−21：Bottom of hydraulicfluid tank

6．Fig78−21：Remove the plug（0110）to drain

hydraulic fluid out of the hydrauIic fTuid tank （0010）．Afterdraining，installtheplug（0110）．

⊥

Hydraulic刊uid（tota［capacity）： L3−2−25L

L4，L5，L6−2−42L

Remova10f

﹁ノ

7． Remove the HST motor．Referto HSTMotor．

▲wARNING Placearecipientunderthereductiongeartocatch the fluidin the p）Plng that wi come out when hoses are disconnected，Wipe o汗spi ed 刊uid COmPJetelypreven用re．

8・Fig46−00：Disconnect the hose（0040），then removetheelbow（0060）（atthereductiongear

Fi！I46−00：

end）．

ParkingbrakesoIenoidvalveassemb［y 9・Fig42−00：Disconnect the hose（0110），then remOVetheelbow（0040）（atthereductiongear end）．

3−2−26

Fig42−00：

RemovalofReductionGear

L3，L4，L5，L6−2

10・Fig26−00：Using ajack，SuPPOrtthe reduction

Fig26−00：

0010

gear（0010）fromunderthemachine．

盆Red。Cti。ngear（。。．。）‥App，。Xima．e．，58kg 11・Fig26−00：Removethe boIts（0040）to detach thereductiongear（0010）．

12・Lowerthejack to removethe reduction gear （0010）fromunderthemachine．

3−2−27

析愕茶托続卍確記鬱顎

］nsta ationofReductionGearL3，L4，L5，L6・2 J］nsta［IationofReductionGear

Fig26−00：

● L3，L4，L5，L6・2 1・Fig26−00：Usingajack，bringthereductiongear （0010）into position from under the machine， theninstaIIthebo［ts（0040）．

亀。。叩。。。）‥83．4＿93．2Nm Applyathread10Ckingadhesive．

2・Fig42−00：lnsta theelbow（0040），thenconnect

Fig42−00：

thehose（0110）．

3・Fjg46−00：tnSta thee暮bow（0060），thenconnect

Fi946−00：

thehose（0040）．

ParkingbrakesoLenoidva［veassembIy 3−2−28

Instal］ationofReductionGear 4、Installthe HST motor．Refer to

1nsta＝ation of

L3，L4，L5，L6・2

Figll−51：Viewed from above machine

HSTMotor：，

5．Figll−51：ConnectthesolenoidvaIvewiring（A）

OftheHSTmotor（0010），theninstalLthecable

Clamp（0090）whiIeadjustingtheIengthofthe Wi「in9（A）．

6．Fig34−00：lnsta＝thebolts（0050）toconnectthe PrOPeller shaft assembty（0020）（at the front

Fig34−00：

ax】eend）．

亀B。叩。5。）：3。＿36Nm AppLyathreadIockingadhesive． 7．Fig34−00：Insta thebo］ts（0030）toconnectthe PrOPe［ler shaft assembIy（0010）（at the axLeend）．

亀B。岬。3。）：113＿123Nm

0010

App［yathread］ockingadhesive． Fi942−00：

8．Fig42−00：FilIthe brakefIuid tank（0010）with

the specified amount of brake fluid．Refer to 一

LevelCheck and Addition of Fluidin Brake

FIuidT畠nk．t−

雀■Brak州。（舶1。a。a。嘲ル3L 9．Bleedthebrakesystemandcheckitforbrake fLuidleakage．Refer to B）eeding Brake・Fluid l盲nk．‖

3−2−29

lnstalIationofReductionGear

L3，L4，L5，L6・2

10・Fig78−21：Fi the hydrauFic f）uid tankwith the

Fi978−21：

SPeCified amount of hydraulic fTuid．Refer to Leve）CheckandAdditionofFFuidinHydraulic F山id7云nk．‖

省H，dra。．icn。id（．。ta．CaPaCit，）：，5L L3−2−25L L4，L5，L6−2−42L

11・Fig62−12：P［ace the fIoor pIate（0011）in POSition，theninsta［1the bo［ts（0020）．Laythe

Fig62−12：

刊00rmat（0050）．

12・Fig12−51：Openthehood（R）andconnectthe batterynegativecable（0030）．

Fig12−51：

13・FillthereductiongearwiththespeciRedamount OfgearoiL Referto OilChangeofReduction Gear．−− 0030

Reductiongearoil：1．8L 14・Sta止theengJneandrunitatidletocheckforoil

leakage・一指Stdrivethemachine slowJyinthe

forward or reverse direction for atleast 30 SeCOnds．

3−2−30

OilChangeofReductionGear J OilChangeofReductionGear

L3，L4，L5，L6A2 Fi926−00（1）：

▲wARN暮NG ・ Do not change oiIimmediate［y after engrne Shutdownastheoilishot．ChangeoilonFyaf− teritgetscoLd． ・WipeofFspi edoilcomp［ete［ytopreventfire．

1．P［acearecipientunderthedrainplug．

Fig26−00（1）：

2．Fig26−00（1）：RemovetheleveL plug①，then removethedrainplug②todrainouta［［gear Oil．

3．Fig26−00（1）：Afterdraining，C［eanthedrainpLug ②，WraP SeaItape arounditand reinsta［lthe

Plug． 4．

Fig26−00（2）：Removetheplug③fromtheoil fi［ler port，then pour the specified amount of gearoiI．Addoi［untiIpartofitemergesfromthe leveLcheckhole．

Reductiongearoil： L3，L4，L5，L6−2−1．8L 5．

Fig26−00（1）：CleantheleveIpIug①andfiIter POrtPIug③，WraPSea［tapearoundthemand reinsta）］thepIugs．

6．A性er refi ing the reduction gearwith the gear

Oil，Start the englne and drive the machine S［owlytocirculategearoil．

7．Stop the englne，Wait for5−10minutes．then CheckthereductiongearoiIIevel．IftheoiI）evel is be［ow the Lowerlimit，refi the specified oiL

untilthecorrectleve［isreached．（Seestep4．） 3−2−31

Fi926−00（2）：

LevelCheckandAdditionofFIuidinBrakeFhid■bnkL3，L4，L5，L6・2 ■ Leve］Check and Addjtion of Fluidin Brake

Fiuid Tank

▲wARNING UseonlythespecifiedbrakefIuid．Neverusea Vegetable−Oi［basebrakefIuidforcarbrakes．

1f the brake fLuid Levelreduces too quickly， Checkthemastercylinderand pipingfor［eak− a9e・

IMPORTANT

When adding brakefluid，be carefuJnotto aIIow forelgnmattertOenterthetank． 1．Fig42−00（1）：CheckthefIuidleve＝nthebrake fluidtank（訪

2．Fig42−00（1）：Checkthebrakef）uidtank①and itsvicinityforleakage．

3．Fig42−00（2）：［fbrake fluidlevelisIowerthan

Fig42−00（2）：

SPeCified，remOVethecap②ofthebrakefluid tank①，andre何＝hetankwithbrakenuidtothe

PrOPerlevel． NOTE

Usea）ugWhenaddingbrakefIuid．

4．Fig42−00（2）：ThebrakefLuidIeve［inthebrake

Fig42−00（2）：BrakefLuid tank（D

fIuidtank①shouldbeintherange（A）shown

inthedrawJng． 5．Fig42−00（2）：AReraddingfIuid，SeCure［ytighten

Max 39 mm く85cc）

thecap②．

3−2−32

BleedingBrakeFluidTank ■BleedingBrakeF山idねnk

L3，L4，L5，L672 Fig42−00（1）：

▲wARNING UseonIythespecifiedtypeofbrakef（uid．Useof WrOng brakef］uid causes faulty brake operation． （RefertothetabIeofrecommended oilsand f［u− ids．）

IMPORTANT

T血opersonsareneededforbrakefIuidchangeas the operationinvoIves air bleeding．During air

bleeding，One PerSOn depresses the brake pedal ①，Whiletheotheropensandc［osestheb［eeder

Fig42−00（1）：

SCreW②．

1．Fig42−00（1）：Connectatransparentviny［tube

tothebleederscrew①，andputtheotherend Ofthetubeinac［eanJartOCO＝ectbrakeoil． 2．Fig42−00（1）：After depressing the bake pedal

②afewtimes，keepthepedaldepressedand Ioosenthebleederscrew①byl／2tolturnto

Fig42−00（2）：

a owbrakefluidtof10WOut．

3．Fig42−00（1）：CIosetheb［eederscrew①，then releasethebrakepedaI②． 4．Repeat the steps 2 and 3 unti］brake fluid

fIowing through the vlny］tube becomes c［ean andcontainsnoairbubb］es．

5．Fig42−00（2）：After making sure that no ajr

Fig42−00（2）：BrakefIuid tank③

bubbtes are visib［ein the tube，tighten the b［eeder screw① with the brake pedaI② depressed． Max 39 mm く85cc）

6．Fig42−00（2）：Afterairb暮eeding，refiIFthebrake fIuid tank③with the specified brake nuid to thecorrectIevel．

3−2−33

DisassemblyofReductionGear ■DisassemblyofReductionGear ● L3，L4，L5，L6−2

L3，L4，L5，L6・2 Fig25−00：

1．Fig25−00：Remove the bolts（0120），then

remove the HST motor（0100）and O−ring （0110）from the reduction gear（0010）．（L3−2 hasnoO−ring（0110）．） NOTE The＝front．．ofthe reduction gear（0010）refers to theendtowhichtheHSTmotorisconnected．

● Remova［ofoutputshaft l．Fig26−11（1）：Removethedrain p［ug（0060）to

a［［owgearoi暮todrainout．Afterdraining，instaH thedrainplug（0060）．

⊥

Gearoi［：1．8L

2．Fig26−11（1）：Remove the bo［ts（0040），then removethecover（0020）andgasket（0030）．

Fig26−11（2）：

3．Fig26−11（2）：Remove the nut（0520），then removethewasher（0510）andO−ring（0500）．

4．Fig26−11（2）：Remove the f［ange（0470）and SPaCer（0480）．

5．Fig26−11（2）：Removetheoi］seal（0490）from thecase（0010）．

3−2−34

0520

Disassemb［yofReductionGear 6．Fig26−11（3）：Removetheflan9e（0450）andoil

Fig26−11：（3）

Seal（0490）．

7．Fig26−11（3）：Removethesnapring（0440）from thecase（0010）．

8．Fig26−11（3）：．1bp the front end ofthe output Sha代（0400）with a soft−faced hammer to

removeit toward the rear together with the bea「ings（0420）．

9．Fig26−11（3）：Remove the snap ring（0430）， thenremovethebearing（0420）fromtheoutput Sha代（0400）．

10．Fig26−11（3）：Remove the output gear（0410） andbearing（0420）frominsidethecase（0010）． thenremovethesnapring（0440）．

3−2−35

L3，L4，L5，L6・2

0420 ＼ 0440

DisassemblyofReductionGear ● DisassemblyofBrakeAssembly

L3，L4，L5，L6・2 Fi926−11（1）：

l．Fig26−11（1）：Before disassembly，make an alignmentmark（B）onthebrakeassemb［ywith

anoiIinkfeltpen．

2．Fig26−11（1）：Loosen the bolts（0350，four Places）． NOTE

Donotloosenthetwobolts（0340）atthetopand bottom．

3．Fig26−11（2）：Remove the piston housing （Parking brakeassembly）（0230）fromthecase （brakehousihg）（0010）．

ViewedindirectionofarrowA

Fi926−11（2）：

4・Fig26−11（2）：Removethepiston（SerVicebrake） （0240）．

NOTE

This piston（0240）may have been removed to− getherwiththeparkingbrakeassembly（0230）．

5．Fig26−11（3）：Removethewavespring（0270）， Plate（0280），brakepLates（0180），brakedisks （0170）andendplate（0190）（L3，L4−2）fromthe CaSe（brakehousing）（0010）． BrakepIate

Brakedisk

（0180）

（0170）

L3−2

4

3

L4−2

5

4

L5，L6−2

6

5

3−2−36

Fi926−11（3）：

0270

DisassemblyofReductionGear 6．Fig26−11（4）：Remove the snap ring（0200）， thenremovethediskhub（0220）．

7．Fig26−11（4）：Remove the brake housing （0160）．

NOTE

lfthehousIngishardtoremove，taPitIightlywitha SO微hammer．

8．Fig26−11（5）：Screwtwooftheremoved boIts （0340）inthejackingboltholes（twoplaces）in the seaL retainer（0140）to separate the seal retainer（0140）fromthecase（0010）．

3−2−37

L3，L4，L5，L6・2 Fi926−11（4）

Disassemb］yofReductionGear

L3，L4，L5，L6−2

● Disassemb［yofparkingbrake

Fi926−11：

l．Fig26−11：Remove the boLts（for reLeasing the b「ake）（0370）．

2■

（

▲

CAUT10N

Thecap［SSPrlng−loaded．Loosentheboltsevenly and［itt［ebylitt［e．

3．Fig26−11：Removethecap（0330），thenremove thesprings（0330，10piece＄）．

4．Fig26−11：1盲keoutthepiston（forparkingbrake） （0290）fromthepistonhousing（0230）．

5・ Fig26−11：Remove the O−ring＄（0310）and （0300，tWOPieces）．

3−2−38

0330

0350

Disassemb［yofReductionGear ● Removalofinputshaft

L3，L4，L5，L6・2 Fig26−11（1）：

l．Fig26−11（1）：Taptheinputshaft（0090）fromthe front in the direction of the arrow to remove it

from the case（brake housing）（0010）as an lnPutShaftassemb暮y．

2．Fig26−11（1）：Removethesnapring（0130）from thecase（0010）（brakehousing）・

3．Fig26−11（2）：Removethesnapring（0110）from theinput shaft（0090），then remove the bearings（0100，tWOPieces）andgear（0120）・

3−2−39

Fi926−11（2）：

AssembIyofReductionGear

L3，L4，L5，L6・2

IIAs＄embIyofReductionGear

Fi926−11（1）：

● L3，L4，L5，L6−2

● AssembIyofparkingbrake l．Fig26−11（1）：Fitthesprings（0320，10pieces） intothehoLesjnthep［ate（0330）．

033

凋診

▲ CAUTtON Thecenterholeisnotforasprlng．

2．Fig26−11（2）：lnsta［lthe O−rings（0310）and

Fig26−11（2）：

（0300）onthepiston（forparkingbrake）（0290）．

AppIygreasetotheO−rings（0310）and（0300）．

3．Fig26−11（2）：Lnsta the piston（for parking brake）（0290），aIigningitsspringholeswiththe SPrings（0320）onthecap（0330）．

Fig26−11（3）：Viewed from piston（0290）side

▲cAUTtON lnsta（lthe piston（for parking brake）withits pin

holes（two places）inlinewith the groovein the CaP（0330）．（Fig26−11（3））

4．Fig26−11（4）：Drive the pins（0260）into the Pistonhousing（0230）．

5．Fig26−11（4）：1nsta the piston housing（0230）

Onthecap（0330）andpiston（0290）assembly WhiIea［igningthepositionsofthepins（0260，2 P［aces）andoftheboItholes．

3−2−40

Fig26−11（4）：

AssembIyofReductionGear 6．Fig26−11（5）：Turninsideoutthepistonhousing andcap（0330）assembledinstep5andinsta［l

L3，L4，L5，L6・2 Fig26−11（5）：Viewed from piston side O340

thebolts（0340）．

喚B。．t（。3．。）‥5。Nm （‥」■l（−卜いLい‥一トト■）ち・■−）

0

4 3 0

●AssembIyofinputshaft

Fi926−11（1）：

l．Fig26−11（1）：Fitthe gear（0120）on theinput Shaft（0090）facingthesidewithoutbosstoward theexternaJlysp［inedendoftheinputsha軋

2．Fig26−11（1）：Pressfitthe bearing＄（0100）on theinputshaft（0090）onbothsidesofthegear （0120），theninstallthesnaprings（0110）onthe Shaft．

3．Fig26−11（2）：Insta thesnapring（0130）inthe CaSe（0010）（brakehousing），thenpressfitthe inputsha代a＄Semb［yinthecase（0010）（brake housing）from the rear（in the direction ofthe ar「OW）．

3−2−41

Fig26−11（2）：

Assemb［yofReductionGear Assembly of brakeke

L3，L4，L5，L6・2

Fig26−11（1）：Ⅵewed from piston side

l・Fig26−11（1）：Jnsta the O−rings（0150）and （0210）ontheseafretainer（0140）．Applygrease totheO−rings（0150）and（0210）．

。21。」｛D ﹁︐ノ

2・Fig26−11（2）：Pressfitthesealretainer（0140）

intothecase（0010）（brakehousing）sothatthe jackingboltholes（A）areonahorizontalIin？

（asviewedinthedirectionofthearrowA）

Fig26−11（2）：Viewedin Fig26−11（2）：Ⅵewedin

3・Fig26−11（2）：］nsta＝thebrake housing（0160）

Onthesealretainer（0140）withthesidehaving themarkB（driJ［hoJe）facingrean〃ardandthe

markatthebottom（asviewedinthedirection OfthearrowB）．

3−2−42

direction ofarrowA

direction of arrow B

AssemblyofReductionGear 4．Fig26−11（3）：InstaIlon theinput sha性（0090）

L3，L4，L5，L6−2 Fi926−11（3）：

thesnapring（A）（0200），diskhub（0220）and SnaPring（B）（0200）inthatorder・

a CPIUTlON lnsta＝thediskhub（0220）withitsinterna［Iysp［ined end（A）outward．

5．Fig26−11（4）：lnstalIthe end plate（0190）（L3， L4−2）inthecase（brakehousing）（0010），then insta thebrakeplates（0180）andbrakedisks （0170）aIternate［y・］nstalltheplate（0280）and

WaVe SPring（0270）on the outermost brake disk．

▲cAUT10N Soakthebrakedisks（0170）in brakefluidbefore insta ingthem．

BrakepLate

Brakedisk

（0180）

（0170）

L3−2

4

3

L4−2

5

4

L5，L6−2

6

5

3−2−43

Fig26−11（4）：

0270

AssemblyofReductionGear

L3，L4，L5，L6・2

6・Fig26−11（5）：［nstaIlthe O−ring（0250）on the Piston（SerVice brake）（0240），theninsert the

Fig26−11（5）：

Pistoninthecase（brakehousing）（0010）．Apply greasetotheO−ring（0250）．

7・Fig26−11（5）：lnsta the O−ring（0210）on the Parkingbrakeassembly（0230）．Applygreaseto theO−ring（0210）．

8・Fig26−11（5）：InstalltheparkingbrakeassembIy （0230）inthecase（brakehousing）（0010）with

groovefacingdown．

9・Fig26−11（6）：Makesurethatthepiston（SerVice brake）isinp）ace，thentightentheboIts（0350） （atfburlocatjons）．

亀B。岬35。）＝5。Nm

3−2−44

Fig26−11（6）：Viewedin direction of arrowA

O230

AssemblyofReductionGear

L3，L4，L5，L672

● Assemblyofoutputshaft

Fig26−11（1）：

l．Fig26−11（1）：PLace the case（0010）with the HSTmotormatingendfacingdown．

⑳一／0420

2．Fig26−11（1）二1nstalt the snap ring（0440）into

the10WerSeCtionofthecase（0010），thenpress ¶tthefrontbearing（0420）intothecase（0010）・

down

3，Fig26−11（2）：PLacetheoutputgear（0410）on thebearing（0420）fittedinthecase（0010）with

Fig26−11（2）：

0410

0010

thetongerbossfacingdown・

（HSTmotormatingend）

4．Fig26−11（3）：Fit the bearing（0420）on the OutPutShaft（0400），theninsta thesnap ring （0110）．（Thelargerdiameterendoftheoutput Shaft（0400）shouIdbefacedtowardtherear・）

5．Fig26−11（3）：Press the output sha微（0400） assembIyinto the case（OOlO）through the OutPutgear（0410）and bearing（0420）in the CaSe．Forcethe outputsha代assemblywith a

PreSSintothecaseuntilthesnapnnggroovein thecase（0010）appears，theninstaIlthesnap ring（0130）．

3−2−45

Fig26−11（3）：

AssemblyofReductionGear 6．Fig26−11（4）：App［ygreasetothe［ipoftheoiI

L3，L4，L5，L6−2 Fi926−11（4）：

Sea［（0490）．theninstal＝twithapressintothe

CaSe（0010）sothatitsendis4mmdeepfrom thecaseedge．

▲cAUT10N Useajigtoensureadepthof4mm．

7．Turnthecase upsidedown，theninsta＝theoi（ Sea10n the oppositeendin the samemanner asinstep6．

8．Fig26−11（5）：App霊ygreaseto thesealcontact Surfaceoftheflange（0470）・暮nsta‖theflange （0470）withthespacer（0480）pJacedinfrontof

it，Remove defbrmation of the seaIlip by movlngitbackandforthafewtimes．

9・Fi926−11（5）：Insta）lthe O−ring（0500）and WaSher（0510），theninsta＝the10Cknut（0520）．

亀L。Ckn。．（。52。）＝2．5Nm Applyathread［ockingadhesive．

3−2−46

Fig26−11（5）：

AssembIyofReductionGear 10．Fig26−11（6）：［nsta［Ithecover（0020）andgasket （0030）usingthebo］ts（0040）．

亀B。．t（。。．。）‥．8．6Nm

3−2−47

L3，L4，L5，L6−2 Fi926−11（6）：

ServiceStandardsofReductionGear

L3，L4，L5，L6・2

■ ServiceStandardsofReductionGear Standarddjmension（mm） Servicelimit（mm）

ltem Gearbacklash（inputgeartooutputgear）

0．13−0．23

OutsidediameterofoiIsea］rubbingsectionon

（57．95−58．00）

COmPanionf）ange（front，rear）

（Amountofwear）

0．05

Brakediskthickness（inctudindfacing）

2．10−2．25

1．9

Brakeplatethickness

1．54−1．66

1．4

Endplatethickness

7，87−8．00（Notel） 3．87ヰ．00（Note2）

Freeheight Parkingbrakespnng

LnstaIled10ad（instaIled height＝41mm）

45．5

43．7

20．39k9f

18．3k9f

16．8kgf

13．5kgf

InstaIled10adofwavespnng

Outsidediameterofrub− bingsection（againstpis−

Servicebrakepiston

44．7−44．8

tonhousing） Lnsidediameterofrub−

bingsection（against Parkingbrakepiston）

30．00−30．03

104．7−104．8

Outsidediameterofrubbingsectionofparking brakepiston

29．7−29．8

lnsidediameterofrub−

bingsection（against Parkingbrakepiston） Pistonhoustng

105．00−105．03

lnsidediameter Ofrub− bingsection（agajn＄tSer−

45．00−45．03

Vicebrakepiston） ［nsidediameterofrub−

bingsection（against Parkingbrakepiston）

30．00−30．03

Notel：L3−2 Note2：L4−2

3−2−48

3−3．POWERTRAIN

〕

Remova10fFrontAxle

……………・

InstallationofFrontAxle

・・・・・…‥…・・・ 3−3−3

RemovalofRearAxle

・・t…………・

3−3−5

Insta［lationofRearAx】e

……………・

3−3−7

Ax［eOilChange

………・・…

3−3−10

Disassembly of Axle

………

3−3−12

Assembly of Axle

…………‥

3−3−19

ServiceStandardsofD桁erential

3−3−31 ・・・・………・

PostrAssemb）yAdjustmentofAx）e

…………‥

3−3−1

3−3−32

︑︶

ヽノ

RemovalofFrontAxle 1 Remova）ofFrontAxle

L3，L4，L5，L6−2 Fig34−00：

● L3，L4，L5，L6・2 1．Fig34−00：Removethebolts（0030）toseparate the propeller sha代assembly（0010）from the f「onta火1e．

2．Fig37−00：Loosen the boFts（0030）ofthe tire

Fig37−00：

assemblies（rightandleft）．

▲cAUT］ON Loosentheboltsbyon］yoneortwoturns．Donot removethem．

3．Usingajackorcrane，raisethemachineuntil the tire assemb［iesjust come o庁the ground，

thensupportthefrontframewithstandspIaced underit．（Keep the tire assemblies ofF the 9「Ound．）

4．Fig37−00：Using a nylon sIing，hoLd each tire

assembLy．

盆Ti，eaSSemb一，（。neWhee．）‥ L3−2−41kg L4−2−48kg L5，L6−2−74k9

5．Fig37−00：Remove the bolts（0030），then removethetireassembLies．

3−3−1

0030

Remova10fFrontAxle 6．Fig35−00：Using a hoist and nylon slings，

SUPPOrttheweightofthefrontaxLe．

盆

Weightoffrontaxle： L3−2−108kg

L4−2−131kg L5，L6−2−134kg

7．Fig35−00：Removethenuts（0040）todetachthe frontaxle（0010）．

3−3−2

L3，L4，L5，L6・2 Fig35−00：

軌小賀奴蹄敲官−

lnsta ationofFrontAx［e

L3，L4，L5，L6・2 Fig35−00

■lnsta［］ationofFrontAxle ● L3，L4，L5，L6−2 1・Fig35−00：P［ace the front axle（0010）into POSition，theninsta＝the nuts（0040）．AppLy a

threadlocking adhesive to the threads ofthe bo他（0020）．

亀N。t（。。．。）：．．846。Nm

2．Fig37−00：InstaLlthe tire assemblies with the

Fig37−00：

bo［ts（0030）temporari［ytightened．

3．Usingajackorcrane，raisethe machineunti［ thetireassemblies comeo仔theground，then removethestandsunderthefrontframe．Lower

thejackorcraneto［etthetireassemb［iesbear

0030

theweightofthemachine．

4・Fig37−00：Fina y tighten the bolts（0030）that

aretemporarilytightenedinstep2．

喚B。Its（。。3。）‥ L3−2−273−300Nm L4，L5，L6−2−375−412Nm

5・Fig34−00：ConnectthepropeIlersha微assembIy （0010）tothefrontaxIebytighteningtheboIts （0030）．

亀B。．t（。。3。）：11。＿123Nm AppIyathreadLockingadhesive．

3−3−3

Fi934−00：

lnsta ationofFrontAx］e

L3，L4，L5，L6・2 Fig34−00：

・ Lowerthebuckettotheground，StOPtheen− gine，and safety−lock theimplement control Iever． ・App［ytheparking brake，andplacethesafety barintheserv［C［ngPOSition．

6．Fig34−00：AppIy grease to the prope‖er shaft assembLy（0010）（threeIocations）．When greas［ng，Check the mounting bolts for looseness．

3−3−4

Remova10fRearAxle

Fig34−00：

■ Remova［ofRearÅxle ● L3，L4，L5，L6・2 1．Fig34−00：Removethebolts（0050）toseparate the propeIIer sha代assembIy（0020）from the 「earaxle．

2．Fig37−00：Loosen the boIts（0030）ofthe tire assembties（rightandleft）．

▲cAUT10N Loosentheboltsbyontyoneortwoturns・Donot removethem．

3，Using ajackorcrane，raisethemachine until the tire assembliesjust come o作the ground，

thensupporttherearframeandtheweightwith Stands placed under them．．（Keep the tire assembliesofFtheground．）

4．Fig35−00：Lnsert pieces ofwood between the rear axle stopper and rear frame to stop OSC‖atingmotionoftherearaxle．（LocationsA）

▲

L3，L4，L5，L6・2

CAUT10N

Whenin＄ertingapleCeOfwood，becarefulnotto haveyourhandpinched．

5．Fig37−00：Using a nylon s［ing，hold each tire

assembly．

盆¶reassemb．，（。。eWhee．）‥ L3−2−41kg L4−2−48kg L5，L6−2−74kg

3−3−5

RemovaJofRearAxle

L3，L4，L5，L6−2

6・Fig61−16（1）：Remove the bolts（0130），then removethethrustcap（0120）andthrustwasher （0070）．

7・Fig61−16（1）：Remove the bolts（0100），then remove the thrust p［ate（0090）and thrust WaSher（0070）．

8・Fig61−16（1）：Removethebolts（0160）and．nuts （0180）．

0010

9・Fig61−16（2）：Using acraneandny［onslings．

SuPPOrttheweightofrearaxFeandaxlebracket （001b）．

盆

RearaxIe＋ax［ebracket：

L3−2−119kg L4，L5，L6−2−137kg Fi961−16（2）：

10．Fig61−16（2）：Remove the rear axle and axle

bracketbymovIngthemtowardthefrontofthe machine，thenpuIlthemout．

11・Lowerthejackorcrane，Placetherearaxleand

Fi961−16（3）：

ax暮ebracketontheground，andtakethemout bypu］lingsideways．

12・Fig61−16（3）：RemovetheaxLebracket（0010）

fromtherearaxIe．

0010 3−3−6

lnsta ationofRearAxle

L3，L4，L5，L6・2 Fig61−16（1）：

■ln＄bllationofRearAxle ● L3，L4，L5，L6−2 1．Fig61−16（1）：］nsta＝theaxIebracket（0010）on therearaxle．

2．Usingajackorcrane，mOVetherearaxleand

Fi961−16（2）：

axIe bracket under the machine unti［their

Centeralignswithcenterofthemachine・

3．Fig61−16（2）：LiRtherearaxleandaxlebracket andmovethemfromthefrontofthemachineto

theplacejustbelowtherearframe・

4．Fig61−16（3）：PlacetheaxIebracket（0010）・in POSitionandsecureitwiththebo）ts（0160）and nuts（0180）．AppIyathreadlockingadhesiveto thebolt（0160）threads．

亀Nu．（。．8。）＝．88T，2。Nm lMPOR−TANT

Makesurethattherearax］esmoothtyosci ates．

3−3−7

Fi961−16（3）：

［nsta］lation ofRearAx）e

L3，L4，L5，L6−2

5．Fig61−16（4）：Instar［thethrustplate（0090）and thrustwasher（0070）usingthebo［ts（0100）．

亀B。1t（。．。。）‥．。．＿．26Nm Applyathreadlockingadhesive．

6・Fig61−16（4）：1nsta［［thethrustcap（0120）and thrustwasher（0070）usingthebo［ts（0130）．

Fig61−16（5）：

0070

亀B。．t（。13。）‥77＿9。Nm

0090

Applyathread）ockingadhesive．

▲cAUT旧N Fig61−16（5）：lnsta thethrustwashers（0070）with

grooved surfaces facing toward the thrust plate （0090）．

7．Fig37−00：】nstaH the tire assemblies，With the bo［ts（0030）temporar ytightened．

8．Using ajack orcrane，raisethemachine unti［ the tire assembliesJuStCOme O庁the ground，

then support the rear frame and weight with Stands placed under them．（Keep the tire assemblieso庁theground．） 9・Fig37−00：FinalIy tighten the boIts（0030）that aretemporari】ytightenedinstep7．

喚B。−t（。。3。）‥ L3−2−273−300Nm L4，L5，L6−2−375−412Nm

3−3−8

Fi937−00：

lnsta11ationofRearAxle 10．Fig34−00：Connecttheprope［1ershaftassemb］y （0020）totherearaxIeusingthebo［ts（0050）・

L3，L4，L5，L6・2 Fig34−00：

亀B。It（。。5。）‥。。＿36Nm Applyathread10Ckingadhesive・

Fig61−16：Viewedfromunderrearaxle

11．Fig61−16：Applygreasetothesuspension・ ①Rearaxlesupport（front） ②RearaxIesuppo止（rear）

Fig61−16：Viewedfromrearofrearaxle

Fig34−00：Viewed from under rearaxte

12・Fig34−00＝Apply grease to the propeIIer shaft

assembly（0020）（two［ocations）・When greas［ng，Check the mounting bolts for 100SeneSS．

▲wÅRNING ・ Lowerthebuckettotheground，StOPtheen− gine，and safety−10Ck theimp）ement contro1 lever．

・App）ytheparkingbrake，andplacethesafety barintheseTVIC［ngPOSition． 3−3−9

AxleOi］Change

L3，L4，L5，L6・2

Fig35−00（1）：Front axle viewed from be10W

■AxleOilChange ● L3，L4，L5，L6・2

▲wÅRNING Do notchangeoilimmediatelya債eroperationas theoi［may be hot．Changeoilonly；椚eritgets COld．

● Pointstorespectwhenchang］ngfrontax）eoil

lfrats［ngtheliftarmandbucketisindispensabJe foroilchange，Safety−10Cktheimplementcontrol

lever，PIace the safety barin the engaged POSition．stoptheeng［ne，andchockthewheels． Furthermore，SuPPOrttheimp］ementwithstands topreventtheimp［ementfrom10Wenng， ● PointstorespectwhenchanglngrearaX［eoil

When removaLofatireassembJyisnecessary tochangeoi暮，makenecessaryarrangementto

keep the axle−s rightandleft end heights the Same by supporting the axle stably uslng Stands． Fig36−00（1）：Rearax）eviewedfrombe］ow

1・Fig35−00（1）：Fig36−00（1）：Place a recipient

underthedrainpIug①tocatchdrainedoil．

2．Fig35−00（2）：Fig36−00（2）：Removetheoilfi er

PIug②，thenremovethedrainplug①toa

ow

OiItodrainout．

3・Fig35−00（1）；Fig36−00（1）：After draining oil，

Fig36−00（2）：Rear axle

CleanthedrainpIug①，WraPSealtapearound it，thentightenthep［ug．

3−3−10

AxleOilChange 4．Fig35−00（3）：Add the specified amount ofoil from the oit用］er port．Check the oi］］eve＝）y

inserting thedipstickattachedtothefi erpIug

②intothefiIlerportuntirthebottomoftheplug COmeSincontactwiththeseatandremovlngit again．The oi＝eve［is properifthe ojIonthe

dipstickreachestheinscribedmark．

省蝕e

Quanti yof ilchanged L3−2 3．5L ← L4，L5，L6−2 4．5L ← Vehiclemode［

FrontaXle Rearaxle

5．Fig35−00（3）：C［ean the fi er p（ug②，．then

instaIJandtightenit．

3−3−11

L3，L4，L5，L6−2 Fig35−00（3）：

Disassemb［yofAxle

L3，L4，L5，L6−2

■Disa＄＄emblyofAxle ● L3，L4，L5，L6−2 1．Fig35−00：Remove the drain plug（0080）to

Fi935−00：

a［Lowgearoiltodrainout．

⊥

Gea「oi巨3．5−4．5L

2・Fig35−31：Remove the bolts（0130），then

Fig35−31：

removetheaxletubes（0010）．（Dothisforthe

rightandleftsides，）

盆Ax．e．。be（。。．。）‥ L3−2：32kg

、L4，L5，L6−2：43kg

3．Fig35−31：Remove the shaft（0070）from the differential．（Dothisfortherightand［e債sides）

3−3−12

0010

DisassembIyofAxle ● Disassemblyofaxletube

L3，L4，L5，L6−2 Fi935−32（1）：

l．Fig35−32（1）：Remove the bo［t（0070）in the ax［etube（0010）．thenremovetheretainerpLate （0060）andshims（0080−0120）．

2，Fig35−32（1）：Removethefina（reduction gear assembly（Planetarycarrier）（0190）・

3．Fig35−32（2）：Removetheaxleshaft（0030）out OftheaxIetube（0010）bytappingthe end of

Fi935−32（2）：

theaxleshaftwithasofトfacedhammer．

虚血esha叩030）‥ L3−2−7kg L4，L5，L6−2−12kg

4．Fig35−32（2）：Removetheconeofthebearing （0040）．

5．Fig35−32（3）：Removetheconeofthebearing （0040）fromtheaxleshaft（0030）． NOTE

Use a press andjig（Separator）attached to the bearing（0040）toremovethebearing．

6．Fig35−32（3）：RemovetheoiJsea［（0050）・

7．When repLacing the bearings（0040，tWO Pieces），remOVethecupofthebearing（0040） fromtheaxletube（0030）．

3−3−13

Fig35−32（3）：

DisassemblyofAxle

L3，L4，L5，L6−2

8，Fig35−32（4）：Use a gear pul］er（A）when

Fig35−32（4）：

replacing the ring gear（0160）to remove the ringgear（0160）fromtheaxJetube（0010）・

Protection plate

● Disassembly of fina］reductiongear a亭・ Sembly（Planetarycarrier）

Fi935−32（1）：

1050

1・Fig35−32：RemoYethesnapring（1060）fromthe Sha性（1030）．

2．Fig35−32：Removetheshaft（1030），thenremove the planetary gear（1020）and thru＄t WaShers （1050，仙OPieces）．

▲c仙T10N Be carefulnotto10Setheball（1070）forlocking thesha代（1030）， 1010 ヽノ

3・

twopieces）inthepIanetarygear（1020）・

4．Fig35−32：Disassemble the other two ＄ha触 （1030）inthesamemethod．

3−3−14

DisassembIyofAxLe 1Disa＄SemblyofDifFerential ● Remova10fdrivepinion

L3，L4，L5，L6−2 Fig35−31（1）：

l．Fig35−31（1）：Remove the bolts（0050），then removethecover（0040）．

2．Check tooth contact and backlash ofthe ring gear Refer to■tPosトAssembly Adjustment of Axleノー

3．Fig35−31（2）：Remove the nut（0290），then

Fig35−31（2）：

removethewasher（0300）andO−ring（0310）．

4．Fig35−31（3）：Useagearpu［］er（A）to remove

Fi⊆I35−31（3）：

thef［ange（0440）．

5．Fig35−31（4）：Removethe bo［ts（0370），instal［ twooftheminthepu＝erscrewholes（B）（ Iocations），then turn downthe bolts evenlyto remove the bearing cage（0390）and drive Pinion（2）．

3−3−15

Fig35−31（4）：

Disassemb］yofAx［e

L3，L4，L5，L6−2

6・Fig35−31（5）：Pushtheendofthedrivepinion （2）withapresstoremoveitfromthebearing

Fig35−31（5）：

Cage（0390）．

＿／・／2

0390

7・Fig35−31（6）：Remove the pinion gear（0020） and spacer（0420）from the drive pinion（2）． Removetheoilsea［（0430）andtheconeofthe bearing（0400）fromthebearingcage（0390）．

8・Fig35−31（7）：Use a press and a jig when replacing the bearing（0410）to remove the CPneOfthebearing（0410）fromthepiniongear （0020）・Useapinortubetoremovethecupof the bearing（0410）from the bearing cage （0390）．

3−3−16

Fig35−31（6）：Drive pinion（2）

000430 0390

。42。

Fig35−31（7）：

DisassemblyofAxle

L3，L4，L5，L6−2

● Remova10fdifferentiaIca＄eaSSembly l．Fig35−31（1）：Removethe bolts（0100）．instaIl

Fig35−31（1）：

two of the removed boItsin the pu＝er screw holes（2）（two Locations），thenturndown them evenly to remove the bearing retainer（0090） fromthed肺erentialbody（0030）．Then，remOVe theshims（0120−0160）．

▲cAUT10N Supportthedi陶rentiaIcaseassemblybyhand，aS

itis detached from the difFerentiaL body（0030） Whenthebearingretainer（0090）isremoved．

2．Fig35−31（1）：Remove the bearing retainer （0090）andshims（0120−0160）ontheopposite Sideinthesamemethod．

▲cAUTION

0090

When repJacing the bearing（0200），remOVe the CuPOfthebearing（0200）fromthebearjngretainer （0090），then remove the cone of the bearing （0200）fromthed侮rentiafcaseassemb（y（1）us− Ing a press.

3．Fig35−31（2）：Removetherjn99ear（0010）and difFerentiaIcase assembly（1）from the

Fi935−31（2）：

di鞄rentiaIbody（0030）．

0030 3−3−17

DisassemblyofAxle ● DisassembIyofdifFerentiaIcaseassemb）y

L3，L4，L5，L6−2 Fi935−31（1）：

l・Fig35−31（1）：Make an a［ignmentmarkon the d悔rentialcaseassemb［y（1）．

2・Fig35−31（1）：Remove the bo］ts（0190），then

SeParate the ring gear（0010）and the difFerentialcaseassembly（1），

3．Fig35−31（2）：Disassemb［ethed桁erentialcase

Fi935−31（2）：L3−2

assembly（1）・IfthedifFerentiaLcase B（0260）

anddifFerentiaIcaseA（0250）a「e hardto be detachedfromeachother，［ightlytapthemwith 0250

asoft−facedhammer．

0260

Fig35−31（2）：L4，L5，L6−2

0260

3−3−18

Assemb］yofAxle ■A＄SemblyofAxIe ● L3，L4，L5，L6・2 ● A＄SemblyofdifferentialcaseassembIy

L3，L4，L5，L6−2 Fi935−31（1）：

0200

0260 ．√

l．Fig35−31（1）：When the bearings（0200）are repIaced，uSeaPreSStOinstaI［theconesofthe

bearings（0200）inthed粁erentiaIcaseB（0260） andd肺erentjaJcaseA（0250）．

2．Fig35−31（2）：lnstalItheringgear（0010）onthe d桁erentia］caseB（0260）．

3・Fig35−31（2）：lnstaIlthethrustwashers（0230） andsidegears（0210）onthed桁erentialcaseB （0260）．

4．［L3−2】Fig35−31（2）：lnstan the pinion gears

（0220，tWO Pieces）and thrustwashers（0240， two pieces）on the pinion pin（0270），then assembleitwiththesidegear（0210）．

4．［L4，L5，L6−2］Fig35−31（2）：Insta［Ithe pinion gears（0220，fburpieces）andthrustwashers （0240，fburpieces）onthe＄Pider（0270），then assembleitwiththesidegear（0210）．

3−3−19

Fig35−31（2）：L4，L5，L6−2

AssembIyofAxle

L3，L4，L5，L6−2

5・Fig35−31（2）：lnsta theothersidegear（0210）

Fi935−31（2）：L4，L5，L6−2

and thrust washer（0230），theninsta＝ the d桁erentialcaseA（0250）0Verit． IMPORTANT 0240

Light［y tap the d桁erentialcase A（0250）with a Plastichammertomakeitfitsnugly．Whenprop− erlyassembLed．thereisac［earanceequIVa［entto

◎ ∩ 20240

那㌣ 匂 0250

thethicknessofasheetofthinpaperbetweenthe di飴rentialcases．

0270

App［yathreadIockingadhesive，

へ﹁ノ

亀B。岬9。）‥54，9Nm

⑤

30

0240＋

虐て1︑．〇2

0240謹

6・Fig35−31（2）：1nstallthebo［ts（0190）．

TO21︒

勤慧 感

﹁ノ

3−3−20

AssembJyofAxle ●AssembIyofdrjvepinion

L3，L4，L5，L6−2 Fig35−31（1）：

l・Fig35−31（1）：Press fit the cups（1）of the bearings（0400）and（0410）into the bearing Ca9e（0390）．

2・Fig35−31（1）：Press fit the cones（2）of the bearing（0400）ontothepiniongear（0020），

3・Fig35−31（1）：P［acethebearingcage（0390）on thepinion gear（0020）．andinsertthespacers （0450）．

4・Fid35−31（1）：Usingapressandjig，installthe

COneS（2）ofthebearing（0410）onthepinion gear（0020）二 Make sure that thereis no

】00SeneSSinthebearingcage（0390）andthatit rotatessmooth［y．

5・Fig35−31（2）：PressfittheoiJsea．（0430）into the bearing cage（0390）untiIit bottoms，［f PrOPerIy fitted，the end of the oiI＄eaIis

recessed slight［yfrom theend ofthe bearing Ca！】e（0390）．

Peripheryofoilseal（0430）：Applyliquidsea［． BetweenIips：AppJygrease．

6・Fig35−31（2）：FitthefIange（0440）onthepinion gear

Iipbymovingthef）ange（0440）inandoutafew time＄．

7・Fig35−31（2）：lnsta theO−ringandwasher，then installthenut（0290）．

245．2Nm

3−3−21

Fig35−31（2）：

AssemblyofAx［e

L3，L4，L5，L6−2

8．Fig35−31（3）：HoJd thefLange（0440），attaCh a

Fig35t31（3）：

SPnng baLance to a bolt holein the bearlng Cage（0390），and puIlthe spring balance until

thecagestartsrotatingtomeasurethepreIoad Ofthebearing．（Thepre［oadshouIdnormalLybe approximately 2 kgf．）A［so check that the bearing cage（0390）rotates smoothly without

Sticking．

9．Fig35−31（4）：lnsta‖the O−ring（0280）on the bearingcage（0390）．ApplygreasetotheO−ring （028町

3−3−22

Fig35−31（4）：

0390

3−3．PowertrainJI AssembIyofAxIe ● Assemblyofdifferentia［ 1．Fig35−31（1）：Afterrep［acementofthebearings （0200），insta11the bearing（0200）cupsin the bearingretainers（0090）onbothsides，USinga P「eSS・

2，Fig35−31（1）：Putthed桁erentia［caseassembIy （1）inthe differentia［body（0030）．1盲mporarily

insta thebearing retainers（0090）and （3）on both sides to hold the d桁erentia［case assembIy（1）．

NOTE lnsta［［theshimsofthesamethicknessesasthose Oftheo「lgInaLlyinstaILedshims．

3．Fig35−31（1）：Adjustthethicknessoftheshims （0120−0160）so that thereis noJateral loosenessinthediqerentialcaseassemb［y（1）

anditturnssmoothly． Shimthickness： （0120）：0．1mm，（0130）：0．2mm （0140）：0．25mm，（0150）：0．5mm （0160）：1．Omm

3−3−23

L3，L4，L5，L6・2 Fi935−31（1）：

AssemblyofAxIe

L3，L4，L5，L6−2

●］nstallationofdrivepinion l．Fig35−31（2）：lnstal［the shims（0320−0360）of thebearingcage（0390）onthedi侮rentia［body （0030）．Theseshims（0320−0360）areeachspIit intoupperandIowerhalves． 0390

NOTE

lnstalltheshimsofthesamethicknessesasthose Oftheong［nally］nSta edshims．

2．lnstaIt the bearing cage（0390）on the di輝erentiaIbody（0030）withthegroovetoward

the bottom of the difFerentialbody，then temporarilyinsta thebLts（0370）．

3． Checkthetoothcontactand backIash．Referto Service Standards of Axle，Adjustment of Diqerentia［．

4．Fig35−31（2）：Afteradjustmentofstep3，finaI［y insta＝thebolts（0370）．

亀B。−t（。37。）‥1。1Nm App［yathreadLockingadhesjve．

5・Fig35−31（3）：Asinstep4，fina yinsta thebolt＄ （0100）onbothsides．

Fig35−31（3）：

亀B。．t（ム1。。）＝28．4N。 Applyathread10Ckingadhesive，

0100 靂

3−3−24

AssemblyofAxLe ● RinggearbackIashadjustment

Fi935−31（1）：

l．Fig35−31（1）：Set a dialgauge，aPPlying the

plungercontacttotheouteredgeofthetooth PrO用eoftheringgear（0010）・

2．

Fig35−31（1）：Holdthedrivepinion（1）andtum theringgear（0010）backandforthtomeasure thebacklash．

Measurementitem Back［ashbetweenringgear （0010）anddrivepinion（1）

L3，L4，L5，L6−2

Standard dimension（mm） 0．09−0．13

3−3−25

Assemb［yofAxle ● AssembIyofax）etube 1・Fig35−32（1）：When the ring gear（0160）is

L3，L4，L5，L6・2 Fig35−32（1）：

replaced，insta［1theringgear（0160）ontheaxle tube（0010）andfixitwiththe pins（0170，tWO O170 Piece＄）．

2・Fig35−32（2）：When the bearings（0200）and

Fig35−32（2）：

（0400）are repIaced，instaIIthe cups of the bearings（0200）and（0400）onthedifFer？ntial

end（B）andwheelend（A）oftheaxletube．

3・Fig35−32（3）：lnstaJlthecone（1）ofthebearing （0040）on thewhee［end（A）ofthe axIe tube （0010）・Then，PreSSfittheoilsea［（OO50）into theaxletube（0010）．

4・Fig35−32（3）：Removeth？SIeeve（2）fromthe

PreSS一別tedoi［seal（0050），theninstal＝tonthe axIesha什（0030）．

3−3−26

Fig35−32（3）：

AssemblyofAxle 5．Fig35−32（4）：PIacetheaxletube（0010）upright Withitswhee）end（A）facingup．1nstalltheaxle

L3，L4，L5，L6−2 Fig35−32（4）：

Sha什（0030）intotheaxLetube（0010）・Forcethe

bear［ngCOneinstalIedontheaxleshaf＝nstep 4intotheaxleshaft（0030）bytappingthesha債 endwithaso托−facedhammerfromthetop．

6，Fig35−32（5）：Place the axle tube（0010）and axIe shaft（0030）assembIy upright with the di触rentialend（B）facingup．Pressfitthecone

Fig35−32（5）：

0200／2

（2）ofthe bearing（0200）onto the axle sha代 （0030）．

7．Fig35−32（6）：】nstaIIthep［anetarycarrier（1010）

On theaxLesha微（0030）in ordertoadjustthe Pre10ad of the axLe sha托（0030）and bearing （0200）．

▲cAUTlON ThepLanetarycarriershouldnotbefittedwiththe gear．（Withthegearfitted，nOretainerplatecanbe insta＝ed．）

8．Fig35−32（6）：Measuretheheight（Y）ofa．step formedbetweentheaxlesha債（0030）endand P［anetary carrier（1）．SeJect shims that are thinnerthanthestepheightbyO．15−0．20mm． Note：Thestepheightshouldbeapproximate［y O．8−2．Omm． Thickne＄＄OfshimsavaiIabIe： （0080）：0．1mm，（0090）：0．2mm， （0100）：0．25mm，（0110）：0．5mm， （0120）：1．Omm

3−3−27

Fig35−32（6）：

Assemb］yofAxle 9・Fig35−32（7）：hlStaIlthe shims（0080−0120） Selectedinstep8，theninsta＝theretainerp［ate （0060）andbo托（0070）．

亀B。．t（。。7。）‥．37．3Nm

10・Fig35−32（8）：Check that the bearing rotates

smoothly and there is no looseness in the Planetarycarrier（0190）．Holdtheaxlesha微and

PUtlaspnngbalanceattachedtoa bolthoJein the axletube（0010）tomeasurethe rotational

resistanceofthebeanng．

11・TherotationaLresistanceisnorma＝fitis3．5kgf asmeasuredonthepitchcirc［eoftheaxtetube （0010）mountingbolts．Aqjusttheshimssothat

therotationaIresjstanceisinthisrange．

12．Fig35−32（7）：Afterthethickness ofshims has

been determined，remOVe the bolt（0070）to removethepIanetarycarrier（0190）．

3−3−28

L3，L4，L5，L6−2 Fig35−32（7）：

AssemblyofAxle

L3，L4，L5，L6・2

● AssemblyoffinaIreductiongearassembly

Fig35−32（1）：

（Planetarycarrier） 1．Fig35−32（1）：lnsta‖theneedlebearings（1040） inthep［anetarygear（1020）．

2．Fig35−32（1）：tnSta thrustwashers（1050）on both sides ofthe pIanetary gear（1020），then

PtaCe the assemblyinto the planetary carrier （1010）．

3．Fig35−32（1）：lnstallthe shaft（1030）and10Ck ba （1070），then retainthesha微withthesnap 「in9（1060）． 1010

4，Fig35−32（1）：lnthesamemannerastheabove， instaIlthesecond pIanetarygear（1020）inthe Planetarycarrier（1010）．

5．Fig35−32（2）：Fittheretainerplate（0060）inthe PLanetary carrier（1010），theninsta］［the tast PIanetarygear（1020）．

6．Fig35−32（2）：Insta the setected shims （0080−0120）and the finaL reduction gear assembly（0190）．

7．Fig35−32（2）：ln去ta thebo［t（0070）． Bolt（3）：137．3Nm

ApplyathreadIockingadhe＄ive．

3−3−29

Fig35−32（2）：

AssembIyofAxIe ● tnsta］］ationofaxletube l．Fig35−31（1）：Apply LOCTITE FMD−127tothe surfaceoftheax）etube（0010）thatmateswith

L3，L4，L5，L6−2 Fig35−31（1）：

thedifferentialbody．

▲cAUTION AppIyacontinuousbeadofLOCTITEtothearea inside the bo）t holes．The bead width should be 2−3mm．

2．Fig35−31（2）：lnsertthe sha代（0070）into the difFerential．

Fig35−31（2）：

3．Fig35−31（2）：lnstalttheaxtetube（0010），then installthebo］ts（0130）．

亀B。岬3。）‥1。1Nm AppJyathreadJockingadhesive・ 4．lnstaL暮theaxletubeontheoppositesideinthe SamemanneraStheabove．

0010

﹁ノ

5．Fig35−31（3）：ApptyLOCTITEFMD−127tobolt holesinthed肺erentia［body（0030），PIacethe COVer（0040）in position，theninstaIlthe bolts （0050）．

亀B。．t（。。5。）‥28．4Nm

3−3−30

Fi93§−31（3）：

ServiceStandardsofDifferential

L3，L4，L5，L6・2

■ serviceStandardsofDifFerentia［ ● L3，L4，L5，L6・2 Standard

ltem

dimension（mm）

Backlashbetweenrlnggearanddriveprn10ngear

Service［imit（mm）

0．09−0．13

Pindiameterofdi侮rentia］pinion（L3−2）

15．957−15．984

PindiameterofdifFerentialspider（L4，L5，L6−2）

15．957−15．984

lnsidediameterofdi侮rentialpiniongear

16．150−16．210

Outsidediameterofp［anetaryshaft

17．992−18．000

lnsidediameterofplanetarygear

25．007−25．020

ThicknessofpIanetarycarrierthrustwashers

1．88−2．12

1．70

Thicknessofdi侮rentialsidegearthrustwashers

1．95−2．00

1．80

Thicknessofd桁erentialpln（Ongearthrustwashers

1．195−1．225

1．10

3−3−31

Post−Assemb］yAdjustmentofAxIe L3，L4，L5，L6・2 ● Tbothcontactadjustmentofringgear

Fi935−31（1）：

l．Fi935−31（1）二Afterli9htlyapplyingredleadto3 to4teethoftheringgear（0010），tUrnthering

gear（0010）backandforthbyhandtocheck HeeL（］argerend） thetoothcontact． 2．Adjustthetoothcontact，referringtotheitems a）toe）beLow．

3．A微er adjusting the tooth contact to a normat COndition，Checktheback［ashagaln．

a）Normalcontact The tooth contactis normaIwhen approximately 80％ofthetoothlengthfromthetoetothehee［isin COntaCt．

▲cÅUT10N TheaqjustmentmethodsinthefoILowingitemsb） toe）pertaihstothe convex side（driveside）of eachtooth．Fortheconcaveside（COaStSide），the COntaCtCOndition・is reversetothedescription jn eachitem．

b）Tbecontact Move the ring9ear（0010）away from the drive Pinion（1）bytransferringaproperthickne＄SOfshims

fromthecaseやSidetothecaseBside・（Moveinthe directionX．）

Then，mOVethedrivepinion（1）towardtheringgear

（0010）byreducingthethicknessoftheshimsofthe bearingcage．（MoveinthedirectionY）

3−3−32

Tbe（Sma［lerend）

PostAssembly Adjustment of Axle C）Hee］contact

Movetheringgear（0010）towardthedrivepinion（1）

bytransfemngaproperthicknessofshimsfromthe CaSeBsidetothecaseAside．（Moveinthedirection X．）

Then，mOVethedrivepinion（1）awayfromthering gear（0010）byincreasingthethicknessoftheshims Ofthebearingcage．（MoveinthedirectionY）

d）Facecontact

Movethedrivepinion（1）towardtheringgear（0010）

byreducingthethicknessoftheshimsofthebeanng Cage．（MoveinthedirectionX・）

Then，mOVetheringgear（0010）awayfromthedrive Pinion（1）bytransferringaproperthicknessofshims fromth占caseAsidetothecaseBside．（Moveinthe directionY）

e）F［ankcontact Movethedrive pinion（1）awayfromthe ring gear （0010）byincreasing thicknessoftheshims ofthe bearingcage．（MoveinthedirectionX．） Then，mOVe the ring gear（0010）toward the drive

）pinion（1）bytransferringaproperthicknessofshims x fromthecaseBsidetothecaseAside．（Moveinthe directionY）

3−3−33

L3，L4，L5，L6−2

ヽノ ﹁ノ

3・4．BRAKESYSTEM

）

RemovalofMasterCylinder

…………＝‥3−4−1

Insta‖ationofMasterCyIinder

・…‥‥…‥…

DisassemblyofMasterCyIinder

……………・

Assemb）yofMasterCyIinder

…・‥………・

lnsta［IationStandardsofBrakeContro［

・…＝………・

3−4−3

3−4−6

3−4−7

3−4−8

↓ノ ﹁−ノ

Remova10fMasterCylinder

L3，L4，L5，L6−2

1RemovalofMasterCylinder

Fig12−51：

● L3，L4，L5，L6−2 1．Fig12−51：Disconnectthebatterynegativecable （0030）．

2．Fig62−12：Remove the fIoor mat（0050），then removethebolts（0020）todetachand remove

Fig62−12：

thef］00rPIate（0010）．

3．Fig51−00：Remove the bolts（0220），then removethecover（0210）．

Fig51−00：

0210

0220

4．Fig62−11：Removethebolts（0490）andscrews （0520），thenremovethefrontcover（0480）．

Fig6む11： 。49。 ノ亮

0480

0520 壱 3−4−1

Remova］ofMasterCylinder

L3，L4，L5，L6−2

5．Fig43−11：Remove the snap pin（0110），then

Fig43−11：

removethepin（0090）．

6．Fig43−11：Undothenut（0080），thenremovethe yoke（0070）andnut（0080）．

▲wÅRNING PlacearecIP［entunderthecenterpintocatchthe brake fIuidin the p［Plngthatwillcome outwhen hoses are disconnected．Wipe off spi ed刊uid COmPIetelytopreventfire．

7．Fig42−00：Disconnect the hose（0110），then removethee［bow（0120）andO−ring．

Fig42−00：

8・；Fig42−00：Loosenthehoseclamp（0090），then disconnectthehose（0080）．

9．Fig42−00：Remove the nut＄（1050），then removethemastercyJinder（1020）．

3−4−2

⑳＼

1020 1050

Insta ationofMasterCylinderL3，L4，L5，L6−2 TlnstaJ［ationofFue11bnk

Fig42−00（1）：

● L3，L4，L5，L6−2 1．Fig42−00（1）：l盲mporarilyinsta［lthe e［bow （0120）onthemastercy［inder（1020）・

2．Fig42−00（1）：Temporarilyinsta‖thenut（0080） andyoke（0070）onthemastercylinder（1020），

3．Fig42−00（1）：tnStaIlthemastercytinder（1020） usingthebolts（1030）andnuts（1050）．

亀N。t（．。5。）‥，．．5．。28．．Nm 4．Fig42−00（2）：Connectthe hose（0110）to the

Fig42−00（2）：

elbow（0120），thenfinallyinsta＝thee［bow．

5．Fig43−11：Thread the pin（0090）through the yoke（0070），then retainit with the washer （0100）andsnappin（0110）． Referto ■BrakeControIAdjustmentStandards：．

3−4−3

臥＼1050

1020 Fig43−11：

lnsta［IationofMasterCyfinder 6・Fig42−00（2）：RefiI［thebrakefruidtank（0010） Withthe specified amountofbrakef］uid．Refer

L3，L4，L5，L6−2 Fig42−00（2）：

to r LeveL Check and Addition of Fluidin Brake Fluid￣ねnk．‖

省Brake仙．d（t。ta．CaPaCit，）‥。．3L

7．Bleed the brake system and checkit for leakage．Referto BleedingBrakeFluidl盲nk．一■

8・Fig62−11：Insta［Jthecover（0480），thensecureit

Fi962−11：

Withthebort？（0490）． 0490

0480

9・Fig51−00：lnstaIlthecover（0210）．theninstaJ［ 仇ebolts（0220）．

3−4−4

／戎

Insta11ationofMasterCy［inder

L3，L4，L5，L6−2

10．Fig62−12：Place the floor p［ate（0011）in POSition，theninsta＝the bolts（0020）・Laythe

Fi962−12：

刊00「mat（0050），

11．Fig12−51：Connect the battery negative cable

Fig12−51：

（0030）．

0030

3−4−5

DisassemblyofMasterCyIinder

L3，L4，L5，L6・2

■Disa＄SemblyofMasterCytinder ● L3，L4，L5，L6・2

Fig42−25（1）：

1．Fig42−25（1）：Remove the rod（0080）．then removetheboot（0090）．

0020

汐・竺

轡

0

080

0030 0090

2．Fig42−25（1）：Remove the snap ring（0030）， thenremovethepistonassembly（0020）．

3．Fig42−25（2）：Loosen the c）amp（0050），then removethefiIlerunion（0040）．

Fi942−25（2）：

0040

4．Fig42−25（2）：Removetheva［ve（0060）．

3−4−6

AssemblyofMasterCylinder

L3，L4，L5，L6・2

L As＄embIyofMasterCyIinder

Fig42−25（1）：

● L3，L4，L5，L6・2 1．Fig42−25（1）：lnsertthepistonassembly（0020） into the cy＝nder，theninsta［］the snap nng （0030）．

▲wARNING BecarefuLnottodamagethePcupofthepiston assemb［y（0020）．

2．Fig42−25（2）：LnstaL］theboot（0090），theninsta therod（0080）．

Fig42−25（2）：

0090

3−4−7

［nstaIfationStandardsofBrakeControI

L3，L4，L5，L6・2

Tln＄ta‖ationStandard＄OfBrakeContro［ ● L3，L4，L5，L6−2 1・DimensionAmustbe200±5mmaRerinsta一■ation・■fnecessary・adjustitwiththestopperbo−t（0240）． 2．SetthedimensionBto5mm．

3・WhentheinchingleverisincontactwiththestoppertheclearanceEbetweentheyoke（0120）andpi （0130）mustbe3±0・5mm・Wnecessary7adjustitattheyoke（0120）whi．eensuringtherodend（0180） SCreW−inJengthofat［east8mm． 4・A＃erbleedingthebrakesystem，CheckthatthedimensionsA・YandZareat■east200±5mm，10to12

mm，and160mm，reSPeCtively・ 5．DimensionFshou）dbeasfo1lows： L3−2−229mm L4−2−495mm L5，L6−2−505mm

Pedalbottomend

0220 Rod 0230 Spring 0240Stopperbolt

0030Pin Note2：Applygrease OO40Bolt Notel：23to28Nm 0090 Pin 0120 Yoke

0250 Nut

0130 Pin

3−4−8

Instal］ationStandardsofBrakeContro［ L3，L4，L5，L6・2 6．ThebrakelampswitchmustbesetsothatthedimensionH（brakelampON positionrange）islO−15 mmandthedimensionGis42mm．LocknuttighteningtorqueshouFdbe7．9p9．8Nm．

Brakelampswitch

Sprinqhookinclho）e（L4．L5．L6−21

3−4−9

﹁ノ ﹁ノ

3・5．STEERLNGSYSTEM

）

RemovaIofOrbit−Ro11

・・t…………・

3−5−1

lnsta ationofOrbit−RoIt

……………・

3−5−3

DisassemblyofOrbit−RoII

……………・

3−5−6

Assemb］yofOrbit−Ro

……………

3−5−11

Remova10fSteenngCylinder

・・・・・・‥……

3−5−17

lnstalIationofSteer］ngCylinder

…………‥

3−5−19

﹁ノ ︺

Remova10fOrbit・Ro［l

L3，L4，L5，L6・2

t RemovaIofOrbit−Ro11

Fig12−51：

● L3，L4，L5，L6−2 1．Fig12−51：Disconnectthebatterynegativecable （0030）．

2．Fig51−00：Remove the bolts（0220）．then

Fig51−00：

removethecover（0210），

3．Fig62−11：Removetheborts（0490）andscrews

Fig62−11：

（0520），thenremovethefrontcover（0480）． 。49。 」亮

0480

0520 靂

Fig53−11（1）：

P］acearecipientunderthecenterpintocatchthe brakefluidin the pIP）ngthatw川comeoutwhen hoses are disconnected．Wipe ofF spi ed fluid COmPIete］ytopreYentfire． 4．［L3−2］Fig53−11（1）：Disconnect the hoses （0071，tWO Pieces），（0150），and the hoses （0080，tWOPieces）．

3−5−1

Removal of Orbit‑Roll

L3，L4，L5，L6・2

4，［L4，L5，L6−2］Fig53−11（2）：Disconnect the hoses（0070），（0091），（0230），and the hoses （1080），（1090）．

5．Fig51−00：Remove the bolts（0070），then

Fi951−00：

0070

removetheorbit−rO （1030）．

盆。，bi．＿r。．t（．。，。）‥Ap，r。×imab，，8k。

6．［L3−2］Fig53−11（3）：Removethee］bow（0010）

Fi953−11（3）：

and the e［bows（0020），（0040），（0050），then removetheO−rings．

0040

6，【L4，L5，L6−2）Fig53−11（4）：RemovetheeJbows （0010），（0040），（0050）and the connector （0020），thenremovetheO−rings

Fi953−11（4）：

0040

0010 3−5−2

lnsta［1ationofOrbit・Ro

L3，L4，L5，L6・2 Fig53−11（1）：

■lnsta［lationofOrbit−Rol］ ● L3，L4，L5，L6−2 1．tL3−2］Fig53−11（1）：LnstaI［the O−rings on the Orbit−rOIl（1030），theninsta］［the e．bow（0010） andelbows（0020），（0040），（0050）．

0010

〕1・

002憲

【L4，L5，L6−2］Fig53−11（2）：lnsta［Ithe Oィings On theorbit−rO （1030），theninsta theelbows （0010），（0040），（0050）andconnector（0020）・

Fig53−11（2）：

0040

「昏

2．Fig53−11（3）：Tnstal［the orbit−rO （1030）in POSition using the bo［ts（0070），While holding

0010 Fig53−11（3）：

0070

the main harness ground wire termina［under OneOfthebo［ts．

〕亀B。．t（。。7。）：39．2．。58．8Nm

3．［L3−2］Fig53−11（4）：lnsta‖thehoses（0071，tWO

Pieces），（0150）andhoses（0080，tWOPieces）．

3−5−3

Fig53−11（4）：

lnstallation of Orbit‑Roll 3．［L4，L5，L6−21Fig53−11（5）：Connectthehoses （0070），（0091），（0230）and hoses（1080），

L3，L4，L5，L6・2 Fig53−11（5）：

（1090）．

4・Fig62−11：Insta［lthe front cover（0480），then

Fig62−11：

SeCureit with the bolts（0490）and screws 。49。 一茂

（0520）．

0480

5．Fig51−00：1nsta thecover（0210）andsecureit Withthebolts（0220）．

6．Fig12−51：Connectthe battery negative cable （0030）．

3−5−4

0210

0220

Fig12−51：

lnstallation of Orbit‑Roll 7．Starttheengtneand runitatidletocheckfor ¶uidLeakage．

8．Stop the eng［ne，Wait for5−10minutes，then

Check the coolant and hydraulic fIuidlevels． Referto‖Leve［Check andAddition ofCoolant‖ and ‖LevelCheck and Addition of Fluidin Hydrau［icFluidlbnk．‖

3−5−5

L3，L4，L5，L6−2

Disassembly of Orbit‑Roll

L3，L4，L5，L6・2

l DisassemblyofOrbit−Rotl

Fig51−21（1）：

● L3，L4，L5，L6−2

● DisassembIyofgerotorend l．Fig51−21（1）：Holdthehousinginavisewiththe endcapfacingupward．

▲cAUTtON Light］y g「IP the mounting ftange portion of the

housingwiththeviseJaWSfittedwithcoppercaps・ Donotclampittoostrong］y，

ViewedfromendcaD 2．Fig51−21（2）：Remove the screws（0010，Six

Fi951−21（2）：

Pieces）andretainerscrew（0020，Onelocation）．

Endca

3．Fig51−21（3）：Removetheendcap（0030）and

Fi951−21（3）：

Oィin9（0180）． 0020

4．Fig51−21（3）：Removethespacer（0050）・

▲cAUTION The numberofthespacer（0050）may d椚erbe−

tweenzeroandtwodependingondisplacementof thegerotor（0040）．

5．Fig51−21（3）：Remove・the gerotor（0040）and Oィing（0180）．

Hou引ng

▲cAUTION BecarefuLnottodropthestaroutoftheouternng Ofthegerotor（0040）．

3−5−6

Disassembly of Orbit‑Roll

L3，L4，L5，L6・2

6．Fig51−21（4）：Removethedrive（0070）・

Fig51−21（4）：

0060

00ア0

7．Fig51−21（4）：Removetheplate（0060）・

0 8．Fig51−21（4）：RemovetheO−ring（0190）・

9．Fig51−21（4）：Turnthehousingupsidedownto removetheba

．

▲cAUT10N Becarefulnottodropor10Sethebalt・

3−5−7

S ectionA−A

Houslng

DisassembIyofOrbit−Ro

L3，L4，L5，L6・2

● Disassemb［yofcontro［end

Fig51−21（1）：

l．Fig51−21（1）：Withthefrangesideupward，raise One end of the retaining ring（0160）with a f］atbtade screwdriver to removeit from the hou引ng．

▲

CAUT10N

・ Place the hous［ng On a Clean c10th to avoid

0160

damagetothefinishedsurface． ・ Wear gogg］es，aS the retaining ring（0160）

mayJumPOutduringremovaI． 2．Fig51−21（2）：PIacethehousingonabenchwith

its axis horizontal．Turn the spooIand sleeve assembly（1010）to place the pin（0080）in a horizonta暮position，then move the spooIand S［eeve assembly（1010）a fittle outward to removethesealglandbushing（0170）．

3．Fig51−21（3）：Removetheoilseal（0140）from

Fi951−21（3）：

thesealglandbushing（0170）．

4．Fig51−21（4）：Removetheracebearings（0110，

Fi951−21（4）：

two pieces），thrust needles（0120）and O−ring （0130）．

0110 3−5−8

DisassemblyofOrbitJRo［l

L3，L4，L5，L6・2

5．Fig51−21（5）：PushtheinternaIlysplinedendof

Fig51−21（5）：

Houslng

thespooIwithathumbtoremovethespooIand S］eeveassembly（1010）．

▲

CAUTlON

・Dotheoperationabovetakingcarenottoaト

towtheoutsideofthes］eevetobecaughtby theboreofthehous［ng． ・Some spooland sleeve assemblies may not

OPeratePrOPerIyiftheiralignmentischanged 180degrees when reassembIed・Therefore， makeanalignmentmark（B）onthespoo［and

Fig51−21（6）：Spoo（andsleeveassembly（1010）

S［eeveassemb［y（1010）withanoilink｝feltpen atthetimeofdisassembly．Fig51−21（6）

6．Fig51−21（7）：Removethepin（0080）from the

Fig51−21（7）：Spoolandsleeveassembly（1010）

SPOOlandsleeveassembly（1010）．

7．Fig51−21（7）：Push the spool（2020）in the Sleeve（2010）slightly forward to remove the CenterSPring（0090）andf［atspring（0100）．

▲cAUT10N

2010

Wear goggles，aS the centerspring（0090）may jumpoutfromthespoo（（2020）． 8．Fig51−21（7）：Removethe sleeve（2010）from thespool（2020）． NOTE

Pul10utthes［eeve（2010）whilesLowIyturningit．

3−5−g

Disassembly of Orbit‑Roll ● Disassemblyofpriorityva［ve l．Fig51−21（1）：HoLdthehousinginavise・

L3，L4，L5，L6−2 Fig51−21（1）：

▲cAUT10N Light［ygripthe housfngWithviseJaWSfittedwith COPPerCaPS．Donotc［ampittoostrongly・

2．Fig51−21（2）：Remove the plug（0300）and O−ring（0290）．（Dothisonbothsides・）

3．Fig51−21（2）：Remove the spring（0280）and SPOOJassembly（0270）．

Houstn9

3−5−10

CrosssectionB−B

AssemblyofOrbit・Ro［l

L3，L4，L5，L6・2

Fig51−21（1）：Spoo‡andsleeveassembly（1010）

T A＄Semb）yofOrbit−Ro11 ● L3，L4，L5，L6・2

● Assemblyofcontr0lend l．Fig51−21（1）：lnsert the spoo［（2010）into the S］eeve（2020）while sIowly turning the spooL・

Pinch between fingers the sp［ined end ofthe SPOOl（2010）andturnthespooltocheckthatit turnssmooth［yinthesleeve（2020）．

▲cAUT10N Checkthe mating mark madeatthetimeofdis−

assembly to make sure correct alignmentofthe SPOOlandsleeveassembly（1010）・

2．Fi白51−21（2）：FitintotheSpringInsertinglbo］ （＃600057）thefiatsprings（0100，tWOPieceson eachside）andcentersprings（0090，OnePiece

On eaCh side）with the notch on both ends down．

3．Fig51−21（2）：lnstallthefIatsprings（0100．two Piecesoneachside）andcentersprings（0090，

One Piece on each side）both fitted on the SpringlnsertinglboL（＃600057）intrleSPOOland Sleeveassembly（1010）． NOTE A微erinsertion，a‖gn the spnng ends with the S［eevecircumference．

▲cÅUT10N Weargoggles，aSthecentersprings（0090）may

jumpoutfromthespool（2010）・

3−5−11

Fi951−21（2）：

Assembly of Orbit‑Roll 4・Fig51−21（3）：lnsert the pin（0080）into the

L3，L4，L5，L6−2 Fig51−21（3）：

Sleeve hole，and aIign both ends of the p［n （0080）withtheoutersu血ceofthes［eeve．

5・Fig51−21（4）：Placethehou＄ingonacleanc10th Withits axis horizontaI・Insert the spooIand

Fig51−21（4）：

Sleeveassembly（1010）intothe housing from theendoppositetothefIange．

▲cAUT10N ● Wheninsertingthespoo［andsleeveassembly （1010），becarefulnottotiltitasdoingsocould

CaUSetheassemblytogetcaught． ● Keep the pin（0080）horizonta［，andinsertit Whi］e turnIngit rightand）e微s［ightIy and re−

Peatedly・Makesuretheendsofthepin（0080） areflushwiththehousJngSurface．［fthepinis insertedtoodeep，itmaydropo拝thehous■ng・ ● Check that the spooland s［eeve assembly （1010）turnslightJyinthehousing．

6・Fig51−21（5）ニInstalIthe race bearings（0110， twopieces）andthrustneed［es（0120）．

Fi951−21（5）：

NOTE Besuretoin＄tallthethrustneedles（0120）byin− Serting them between the race bearings（0110）． （Positiona］order：raCebearing（0110）−thrustnee− dles（0120）−raCebearing（0110））

7・Fig51−21（5）：］nstalltheO−ring（0130）．

3−5−12

Assembly of Orbit‑Roll 8．Fig51−21（6）：FittheoilseaL（0140）inthesea］

L3，L4，L5，L6・2 Fi951−21（6）：

g］andbushing（0170）・

▲cAUTtON Be carefulnot to twist or deform the oilseaI （0140）．

9．Fig51−21（7）：lnsta the seaIgland bushing （0170），Whileturningandlightlytappingitwitha

Fig51−21（7）：

SO代−facedhammer．

10．Fig51−21（8）：］nstaIltheretainingring（0160）in

Fig51−21（8）：

thehous［ng．

▲cAUTION ・ Push apart the ends of the retaining nng （0160）withafIatbladescrewdriversothatits

Circumferenceissecurely fittedin the groove

0160

Ofthehouslng． ・Weargoggle，aStheretainingring（0160）may

JumPOUtfromthehouslng．

3−5−13

Assemb［yofOrbit・Ro

L3，L4，L5，L6・2

● Assemblyofgerotorend

Fig51−21（1）：

l．Fig51−21（1）：Ho［dthehousinginavisewiththe endcapsideup，

▲cAUT10N Lightly9rip the mounting f［ange of the houslng With viseJaWS fitted with copper caps．Do not ClampittoostrongLy．

ViewedfromendcaD 2．Fig51−21（2）：lnsta［IthebaJl（0210，OnePiece）．

Fig引−21（2）：

3．Fib51−21（2）：lnstallthe O−ring（0190）on the hous［ng．

4・Fig51−21（2）：Placethep［ate（0060），andarignbo［t holes．

NOTE Boltholesand oiL ho［esare di侮rentinthe pitch

CrosssectionA−A

Hous［ng

CirclediameteL

5．Fig51−21／（3）：TurnthespoolandsleeveassembIy （1010）to make the pin（0080）paraHeIwith the

POrtSu向ce（B）ofthehou＄ing．Engagetheyoke Ofthedrive（0070）withthepin（0080）．

3−5−14

Fig51−21（3）：

Assemb［yofOrbit・RoII

L3，L4，L5，L6・2

6．Fig51−21（4）：Instal］theO−ring（0180）ontherotor

Fig51−21（4）：

（0040），theninsta therotorontheplate（0060），

Endca

▲wARNING Be sure to a［ign al［necessary portions carefu y．

Misa］ignmentmaycausefaultyoperation，POSSib［y resultingFnSeriousaccidents．

Houslng ▲

Fi951−21（5）：

CAUT10N

・Wheninsta＝ng the rotor（0040）．be sure to facetheO−ringsidetowardthehouslng． ・A theIinesA，BandCmustbeinpara e［as Showninthedrawing（Fig51−21（5）），

NOTE

Tbensurecorrectalignment，drawontheend■sur− faceofthedrive（0070）alineparalle］withthepin （0080）withanoilinkfeltpen．

7．Fig51−21（6）：lnsta the spacerin theinternalIy SPLinedsectionofthestaroftherotor（0040）．

8．Fig51−21（6）：Lnsta‖theO−ring（0180）ontheend CaP（0030），PIacetheendcapontherotor（0040）， andalignthebo］tholes．

3−5−15

Fig51−21（6）：

0050

0030

Assemb］yofOrbit・Ro 9．Fig51−21（7）：Jnsta11the screws（0010，Six

L3，L4，L5，L6・2 Fig51−21（7）：

Pieces）andretainerscrew（0020，OnePiece）on

theendcap．

亀screw（。。．。）a。d，etaine，SCreW（0020）： 22．5Nm

ApplyoiItothethreads・（Refertothedrawing forthetighteningsequence・）

10．Fig51−21（8）：lnsta the steering wheel，then

Fig51−21（8）：

Check that the spoolof the orbit−rOll（0010） rotatessmooth］y．

● A＄Semblyofpriorityvalve l．Fig51−21（1）：lnsta［lthespoolassembly（0270），

Fig51−21（1）：

theninstaILthespring（0280）．

▲cAUT10N Be畠uretoinstaItthespoo］assembly（0270）and SPring（0280）withtheirendsfacingcorrectly・

2．Fig51−21（2）：lnstallthe Oイing（0290）on the

P［ug（0300），theninsta them on the housing （Dothisonbothsides・）

亀。．u9（。3。。）‥216Nm HoLISlng

3−5・16

CrDSSSeCtion B−B

RemovaIofSteerIngCy］inder

■

L3，L4，L5，L6・2

q Remova［ofSteeringCylinder ● L3，L4，L5，L6−2 1．StarttheengLne，turnthesteerIngWheeLtopoint the machiners front wheels ful［y to the right，

10Werthe buckettotheground，then stopthe englne・

2．Fig12−51：Disconnectthebatterynegativecable

Fig12−51：

（0030）．

3．Fig61−11：Remove the bolts（0030）to remove

Fi961−11：

thecover（0020）．

▲wARNING

Fig53−11（1）：

P［acearecIPlentunderthecenterpintocatchthe brakefIuidinthe pLPlng thatwiL［comeoutwhen hoses are disconnected．Wipe o仔spi1．ed fluid

COmPlete（ytopreventfire．

4．［L3−2】Fig53−11（1）：Disconnect the hoses

（0070，tWO Pieces）from the steering cylinder （IocatedintheIeftpartofthefrontframe）．

3−5−17

RemovalofSteenngCylinder

■

4．［L4，L5，L6−2）Fig53−11（2）：Disconnect the hoses（0070）and・（0110）from the steering Cy［inder（locatedin theIe穐part of the front

L3，L4，L5，L6−2 Fig53−11（2）：

frame）．

0110

5．Fig54−00（1）：Remove the bolts（0030），then remove the］ock ptate（0020）and pin（0010） （tocatedintheleftpartofthefrontframe）．

Fig54−00（1）：

6．Fig54−00（2）：Remove the bo［ts（0030），then remove the［ock plate（0020）and pin（0010） （locatedintheIef（PartOftherearframe）．

7．Fig54−00（3）：Removethesteeringcylinderfrom themachine．Removealsothespacers（0050）．

鹿

Steenngcylinder： L3，し4−2−8．3kg

L5，L6−2−10kg

3−5−18

Fi954−00（3）：

fnstaJlationofSteenngCylinder

■

11n＄ta‖ationofSteeringCy［inder ●−L3，L4，L5，L6−2 1・Fig54−00（1）：InstaLIthesteeringcylinderonthe machine・Use spacers（0050）to aqjust the C］earancebetweenthesteenngcylinderandthe

L3，L4，L5，L6−2 Fig54−00（1）：

占＼」

frontframeorrearframetoO．5−1．4mm．

〕 2・

Fig54−00（2）：Forthe frontcylinder，insertthe

Fi954−00（2）：

Pin（0010）（With a grease nipple），theninstal［ the［ockpIate（0020）withthe bo［ts（0030）（in thelef（PartOfthefrontframe）．

亀B。岬。3。）：44．1＿53．9Nm

3・Fig54−00（3）：Fortherearcylinder，insertthepin （0010）（WithoutgreasenippIe），theninsta＝the lockp］ate（0020）with the boIts（0030）（in the ）eftpartoftherearframe）．

）亀B。岬3。）‥44．1●53．9Nm

3−5−19

Fi954−00（3）：

0010

lnstaLLationofSteerlngCylinder

■

4．【L3−2］Fig53−11（1）：Connectthe hoses（0070， twopieces）tothesteering cy）inderasfoLLows： Connectthehose（0070）withthee）bow（0040）

L3，L4，L5，L6・2 Fig53−11（1）：

to the cyLinder rod side fi輔ng and the hose

（0070）with the elbow（0050）to the cylinder

bottom side fitting（in theleft partofthe front f「ame）．

4．［L4，L5，L6−2］Fig53−11（2）：Connectthehoses （0070）and（0110）to the steering cylinder（in the］eftpartofthefrontframe）．

5．Fig61−11：1nstaIlthe cover（0020）and secure Withthebo［ts（0030）．

3−5−20

Fig53−11（2）：

1nstallationofSteenngCylinder

■

6．Fig12−51：Connect the battery negative cable

L3，L4，L5，L6・2 Fig12−51：

（0030）．

7．Starttheeng］neand runitatidletocheckfor

fIuidleakage．Perform this check with the bucketin the trave［ing position and while turnlng the steerlng Wheelto point the machine s frontwheeLstothe right andlef＝n

Ordertocirculatehydraulicfluid．

8．Stoptheenglne，Wait5−10minutes，thencheck the fluid［evel．Refer tb LeveICheck and AdditionofOilinEngineOilPan．．l

9．Fordisassemblyandassemb［yofthesteerlng Cylinder，refertothe DisassemblyofCy［inder and ．Assembly of Cy［inde「T sectionsin■■3−7

HydraulicSystem．

3−5−21

﹁ノ ↓ノ

3−7．HYDRAULLCSYSTEM RemovaIofControIV白Ive

……………t

3−7−1

InstaIIationofControIV白Ive

………・t・・・・・

3イー4

Disassemb）yofControIValve

……………・

3−7−8

AssemblyofControIValve

＝…………

3−7−14

RemovalofMainCharglngPump

・・・…・…・…

3−7−22

lnstaLlationofMainCharg）ngPump

…・・1…＝…

3−7−24

RemovalofHydrauLicFluidlbnk

…………‥

3−7−26

lnsta＝ationofHydrau［icFluidlbnk

……・t……

3−7−28

LevelCheckandAdditionofFluidin

・・…・…・・・・・ 3−7−31

HydraulicFluidTbnk

〕

Disassembly of Cylinder

…………‥

3−7−32

Assembly of Cylinder

…………‥

3−7−35

ServiceStandardsofCyIinders

…………‥

3−7−39

︺ ﹁ノ

RemovaJofControIViIve q RemovalofControIVa】ve

L3，L4，L5，L6・2 Fig12−51：

● L3，L4，L5，L6・2 1．Lower the bucket to the ground．．stop the engIne，andreIeasetheresidua［pressureinthe CyIinderbyoperatingtheshove［control［ever．

2，Fig12−51：DisconnectthebatterynegativecabIe （0030）．

Fig84−11：

3．Fig84−11：Undothenut（0090），thenturntherod end（0080）to remove the cables（0070，tWO Pieces）fromthecontroIvalve（0010）．

4．Fig85−11：Remove the wiring（A）of the

Fig85−11：

automaticleveIer．

Fig82−11（1）：

▲wÅRNtNG P［acea recipientunderthecontroIvaJvetocatch

hydraulicf［uidinthepipingthatwillcomeoutwhen hosesaredisconnected．Wipeo汗spjIledhydrauIic f［uidcompLete［ytopreventRre．

5．（L3−2］Fig82−11（1）：Disconnect the hoses （0030，tWOPieces）and（0150，tWOPieces）．

3−7−1

RemovalofContro］VaIve

L3，L4，L5，L6・2

5．［L4，L5，L6−2］Fig82−11（2）：Disconnect the

Fig82−11（2）：

hoses（0040），（0050）and（0160）．

6．【L3−2）Fjg78−00（1）：Disconnect the hoses 0080

（0120）and（0080）．

6．【L4，L5，L6−2］Fig78−00（2）：Disconnect the

Fig78〃0（2）：

hoses（0090），（0140）and（0200）．

7・Fig73−00：Remove the nuts（0040）and bo］ts （0020），thenremovethecontroIva］ve（0010）．

鹿contro−va，ve（？010）： L3−2−ApproxlmateJy9．1kg L4，L5，L6−2−ApproximateIy9．3kg

3−7−2

Fi！I73−00：

0020

RemovatofControIValve

L3，L4，L5，L6−2

8．【L3−2］Fig82−11（3）：Removethee［bows（0010， two pieces）and adapters（0130，tWO Pieces），

Fig82−11（3）：

thenremovetheO−rings．

8．［L4，L5，L6−2］Fig82−11（4）：Removetheelbows （0010）and（0020）and adapters（0140，tWO Pieces），thenremovetheO−rings．

9．［L3−2）Fig78−00（3）：RemovetheeIbows（0100）

Fi982−11（4）：

0140

Fig78−00（3）：

and（0090），thenremovetheO−rings．

9．［L4．L5．L6−2］Fig78−00（4）：Remcvetheetbows

（0110）and（0120），thenremovetheO−rings．

3−7−3

Fi978−00（4）：

［nsta

ationofContro［Vilve L3，L4，L5，L6・2

■lnsta］lationofControIVaIve ● L3，L4，L5，L6−2

Fi978−00（1）：

1，［L3−2）Fig78−00（1）：lnstaIIthe O−rings on the

COntrO［valve，theninstalltheelbows（0090）and

。。9。

／風紅。二。。

（0100）．

1・［L4，L5，L6−2］Fig78−00（2）：1nsta＝theO−rings

Fig78−00（2）：

On the contro［valve，theninsta［Ithe e［bows

（0120）and（0110）．

2・【L3−2］Fig82−11（1）：lnsta the O−rings on the

Fig82−11（1）：

COntrO［valve，theninsta＝the adapters（0130， twopieces）andeIbows（0010，tWOPieces）．

2，［L4，L5，L6−2］Fig82−11（2）：Insta‖theO−rings

On the controJvaLve，theninstalIthe adapters （0140，tWOPieces）andthee［bows（0010）and （0020）．

3−7−4

Fi982−11（2）：

lnstalIation ofControIValve

L3，L4，L5，L6・2

3．Fig73−00：Lnsta11the controIvaIve（0010）in POSition，thensecureitwiththebolts（0020）and

Fig73−00：

nuts（0040）．

4．［L3−2］Fig78−00（3）：Connectthehoses（0120）

Fig78−00（3）：

0080

and（0080）．

4．【L4，L5，L6−2］Fig78−00（4）：Connectthehoses

Fig78−00（4）：

（0090），（0140）and（0200）．

5．【L3−2］Fig82−11（3）：Connecttheho＄eS（0030， twopieces）and（0150，tWOPieces）．

3−7−5

Fig82−11（3）：

lnstaJ［ationofControIValve 5・［L4，L5，L6−2］Fig82−11（4）：Connectthehoses

L3，L4，L5，L6−2 Fi982−11（4）：

（0040），（0050）and（0160）．

6・Fig85−11：Connect the wiring（A）of the automaticleveler．

7・Fig84−00（1）：［nstal［thenut（0090）androdend

Fi984−11（1）：

（0080）toconnectthecontroIcabIes（0070，tWO Pieces）．Makean adjustmentdescribedin the

foI10WlngSteP．

8・Fig84−11（2）：Aqjusttherodend（0080）sothat

Fig84−11（2）：

theLockJevercanbemovedsmoothJyandcan 10Cksecure［ytheimplementcontroIJeverwhen thecontroI）everi＄intheneutra［position・The Standarddimensionsareshowninthedraw−ng・ Fig84−11（2）：Detairs

3−7−6

Lnsta ation ofControLValve L3，L4，L5，L6・2 9．Fig12−51：Connect the battery negative cable

Fig12−51：

（0030）．

10．Starttheenglneand runitatidletocheckfor fIuidleakage．

11．Stop the englne，Wait for5−10minutes，then CheckthehydraulicfIuidlevel．Referto‖Level

CheckandAddition ofF［uidin Hydraulic Fluid l盲nk．■t

3⊥7−7

Disassemb］yofContro］VaIveL3，L4，L5，L6・2 lL DisassemblydfControtValve

Fig73−00（1）：

0060

● L3，L4，L5，L6・2

1．Fig73−00（1）：Rernovethe reliefvatves（0050） and（0060，tWO Pieces），then remove the Oィings．

▲cAUT10N Do not disassemble the relief va［ves unlessitis absolutelynecessary．

2．Fig73−00（1）：Remove the antipode va［ve （0070），thenremovetheO−ring・

3．Fig73−00（2）：Remove the nuts（1030）and

Fi973−00（2）：

（1050），thenremovetheout］etsection（1010）・

4．Fig73−31：Remove the O−ring（0210），＄Pring （0190）andpobpet（0200）fromtheIiftplunger SeCtion（0040）．

3−7−8

Fig73−31：

0190

0200 −0040

DisassemblyofContro［Valve 5．Fig73−00（3）：Remove the皿pIunger section （0040），then removethe O−ring（0210），SPring （0190）and poppet（0200）fromthetiltplunger

L3，L4，L5，L6・2 Fig73−00（3）：

SeCtion（0030）．

6．Fig73−00（4）：Remove the ti［t pIungersection

Fig73−00（4）：

（0030），thenremovetheO−ring（2020）fromthe inLetsection（0020）．

7．Fig73−00（4）：Remove the rods（1020）and （1040）．

3−7−9

DisassemblyofContro］Valve ■DisassembIyofTiltPIungerSection ● L3，L4，L5，L6−2

L3，L4，L5，L6−2 Fig73−31（1）：

1．Fig73−31（1）：Removethescrews（0220），then removethesealplate（0230），Wiperring（0050） andOィing（0040）．

2．Fig73−31（2）：Remove the bolt（0160）．then removethecap（0150），0−ring（0170），COiltube

Fig73−31（2）：

（0140）andshim（0180）．

3，Fig73−31（3）：Loosen theIocking nut（0110）， removethe bo［t（0130），then removethe p［ate （0120）andsteeve（0030）．

4，Fig73−31（3）：RemovethepIate（0070），0−ring （0060）and O−ring（0170）from the sIeeve （0030）．

3−7−10

Fig73−31（3）：

Disassemb］yofControIVilve

L3，L4，L5，L6・2

5．Fig73−31（4）：Removethewiperring（0050）and O−ring（0040）fromthehousing．

Fig73−31（4）：

6．Fig73−31（4）：RemovethepIunger（0020）from thehouslng．

0080

7．Fig73−31（4）：Remove the screw（0100）from the plunger（0020），then remove the seats （0090，tWOPieces）andspring（0080）．

⊂＞⊥∴0040

◎＼⊥＿、⊥、

3−7−11

DisassemblyofContro］Valve ■Disa＄＄embIyofLiftPlungerSection

L3，L4，L5，L6・2 Fig73−32（1）：

● L3，L4，L5，L6・2

1．Fig73−32（1）：Removethescrews（0210），then removetheseaIpIate（0030），Wiper（0050）and Oイing（0040）．

2．Fig73−32（2）：Remove the boLt（0220），then removetheprunger（0020）fromthehousing．

Fig73−32（2）：う

3．Fig73−32（2）：Remove the snap ring（0160）， thenremovethespacer（0150）．

Fig73−32（2）：

3−7−12

DisassemblyofControIViIve

L3，L4，L5，L6−2

4．Fig73−32（2）：Usethejig（A）topushintheba）l （0130），thenremovethesleeve（0080）andcap

Fi973−32（2）：

（0070）．

† 加温DrOO70−√c 5．Fig73−32（3）：Removethe ba‖s（0130），（0140）

‥

andspring（0120）fromthepin（0090）．

≒＿一三≡三…

−−−−0120 0

6．Fig73−32（4）：Remove the pin（0090），then remove the spring seats（0100，tWO Pieces）， SPring（0110）and spacer（0100）from the plunger.

7．Fig73−32（4）：Removethe O−rings（0040）and （0170）fromthe＄PaCer（0060）．

3−7−13

0130

Fi973−32（4）：

Assemb［yofContro］Valve L3，L4，L5，L6・2 ■A＄＄emblyofContr01VaIve ● L3，L4，L5，L6−2

Fig73−00（1）：

1．Fig73−00（1）：Inserttherods（1020）and（1040） intotheinIetsection（0020）．

2．Fig73−00（1）：lnsert the O−ring（2020），then insta‖thetiltplungersection（0030）．

3．Fig73−00（2）：lnsta the Opring（0210），POPPet （0200）and spring（0190）in the ti［t plunger

Fig73−00（2）：

0040

SeCtion（0030），theninsta）L the Lift plunger SeCtion（0040）．

4．Fig73−00（3）：lnsta‡lthe O−ring（0210），POPPet

Fig73−00（3）：

（0200）and spring（0190）in the］ift pIunger SeCtion（0040）．

5．Fig73−00（4）：lnsta theoutLetsection（1010）．

Fig73−00（4）：

6．PLacethemaincontroIvalveonafbtpIateor benchandinstaIlthenuts（1030）and（1050）．

亀N。．（．。5。）‥．6．．Nm Nut（1030）：18．6Nm 3−7−14

1010

AssemblyofContro］＼ねIve 7．Fig73−00（5）：tnStallthe O−rings and re［ief VaIves（0050）and（0060，tWOPieces）．

Fig73−00（5）：

0060

亀ReIiefva．ve（。。5。）：7，，5Nm ReLiefvalve（0060）：73．5Nm

0070 8，［nstalltheO−ring，theninsta＝theantipodeva）ve （0070）．

亀Antip。deva．ve（。。7。）‥7，．5Nm

3−7−15

L3，L4，L5，L6−2

AssemblyofControIVaIve

L3，L4，L5，L6・2

）A＄＄ernblyofTiftPlungerSection ● L3，L4，L5，L6−2 1．Fig73−31（1）：lnstatt the seat（0090），SPring （0080）andseat（0090）ontotheplunger（0020）

Fig73−31（1）：

inthatorder．

OO80

2．Fig73−31（1）：Insta‖thescrew（0100）intothe Plunger（0020）・

亀sc，eW（。．。。）‥2。．．Nm

3．Fig73−31（1）：1nstalltheO−ring（0040）andwiper ring（0050）inthehousing・

4．Fig73−31（2）：lnstaI＝heplun9er（002O）intothe hous］ng．

▲cAUT10N lnstal＝he ptunger（0020）in thedirection ofthe

arrowwhen the houslnglS PJaced with the side 柵edwiththeO−ringfacingasshowninthedraw・ ing．

3−7−16

Fig73−31（2）：

Assemb［yofControIValve

L3，L4，L5，L6・2

5．Fig73−31（3）：Insta theO−ring（0060）andp［ate

Fig73−31（3）：

（0070）ononesideandtheO−ring（0170）and Plate（0120）on the other side ofthe sleeve （0030）． ＋

▲cAUTtON WheninstaI［ing，makean adjustmentsothatthe Clearance（B）between theIock nut（0110）and Plate（0120）isO．5mm．

0070

⊂⊃一0060 0130

6．Fig73−31（3）：lnstallthe bolt（0130）into the SCreW（0100）．

亀B。．t（。．3。）‥2．6Nm 7．Fig73−31（4）：lnstaIlthe shim（0180）on one SideandtheO−ring（0170）andcap（0150）on the other side of the coiltube（0140），then instaI［thebolt（0160）．

）

亀Bo−t（0160）‥8・8Nm

3−7−17

Fig73−31（4）：

AssembIyofControIVilve 8．Fig73−31（5）：［nstaIltheO−ring（0040）andwiper ring（0050）onthepIunger（1）．

L3，L4，L5，L6・2 Fig73−31（5）：

攣ア

▲cAUT10N lnsta11thewiperriヮg（0050）withitslipfacingthe

⊂⊃ 0帥

Sea岬ate（0040）．

◎ ＼ 0050

9．Fig73−31（6）：LnstalltheseaLplate（0230），then installthescrew（0220）．

亀sc，eW（。22。）：2．9．Nm

3−7−18

Fi973−31（6）：

AssemblyofControIVa［ve

L3，L4，L5，L6−2

■AssemblyofLiftPIungerSection ● L3，L4，L5，L6・2 1．Fig73−32（1）：lnsta［［the O−rings（0040）and （0170）onthespacer（0060）．

2．Fig73−32（1）：Lnsta［Ithe spacer（0060），SPring Seat（0100），SPring（0110）and spring seat （0100）inthatorderinthep［unger．

3．Fig73−32（1）：［nsta［lthe pin（0090）in the

PIunger．

亀p，n（。。9。）：2。．．Nm

4・Fig73−32（2）：Applygreasetothespring（0120） andba s（0130），（0140），theninsta theminthe

Fig73−32（2）：

Pin（0090）．

0120 0 ‥−・−−0130

3−7−19

AssemblyofControIValve 5・Fig73−32（3）：lnstaHthes［eeve（0080）inthecap

L3，L4，L5，L6・2 Fig73−32（3）：

（0070）．

6・Fi973−32（4）：Usethejig（A）topushintheball （0130）・Then，PuSh the balI（0140）into the insideofthepin（0090）byhand．

Fig73−32（4）：

▲cAUTION Becarefulnottodropor10SethebaIrs（0130）and

0130

（0140）． 0070 0080 A

7・Fig73−32（4）：lnstarIthecap（0080）．

8・Fig73−32（4）：Insta the spacer（0150），then insta）lthesnapring（0160）inthecap（0070）．

Fig73−32（4）：

3−7−20

AssembIyofControIValve

L3，L4，L5，L6・2

9．Fig73−32（5）：Lnsta＝the pIunger（0020）in the housln9．

Fig73−32（5）：

▲cAUT10N FacingagainsttheO−ringfittedsideofthehous− ing，installtheplunger（0020）fromtherightside・

10．Fig73−32（5）：lnsta（lthebolt（0220）．

〕亀B。］t（0220）‥9．8Nm

11．Fig73−32（6）：lnstallthe O−ring（0040），Wiper

Fig73−32（6）：

（0050）and sealplate（0030），theninsta the SCreW（0210）．

▲cAUTION lnstalIthewiper（0050）withitslipfacingtheseaL Plate（0030）．

鞄s。reW（21）‥2．94Nm

3−7−21

昏−0210

Remova10fMainCharg［ngPump

■

L3，L4，L5，L6・2

■ RemovalofMainChargingPump

Fi912−51：

● L3，し4，L5，L6−2

1．Fig12−51：Disconnectthebatterynegativecable （0030）．

2．Fig62−12：Remove the f）00r mat（0050），then removethe bolts（0020）todetachandremove

Fig62−12：

thefloorp［ate（0010）．

▲wARNING PIacearecIPlentunderthemaincharg］ngPumPtO CatChthehydraulicfluidinthepipingthatwi

come

OutWhenhosesaredisconnected．Wipeo仔spi‖ed hydraulicfluidcompletelytopreventfire．

3・［L3−2］Fig78−00（1）：Disconnectthetube（0030） andhose（0080）fromthemainpump．

3．［L4，L5，L6−2］Fig78−00（2）：Disconnectthetube

（0030）andhose（0080）fromthemainpump．

3−7−22

0080

■ Remova［ofMainCharglngPumpL3，L4，L5，L6−2 4．［L3−2］Fig27−00（1）：Disconnectthehose（0100） fromthechargingpump．

Fig27−00（1）：

4．［L4，L5，L6−2］Fig27−00（2）：Disconnectthehose （0120）fromthechargingpump．

Fi927−00（2）：

5．Using a hoist and nyIon s［ing，SuPPOrt the

Weightofthemainchargingpump．

盆

WeightofmaincharglngPumP：6kg

6．Fig25−12：Removethebort（0140），thenremove

thehlainchargingpump（0010）andO−ringfrom theHSTpump．

3−7−23

Fi！事25−12：

InstaI［ationofMainCharg］ngPump L3，L4，L5，L6−2 ■lnstalIationofMainChargingPump

Fig25−12：

● L3，L4，L5，L6r2 1．Fig25−12：Usingahoistand ny［onsIing，Ii微the

maincharglngPumPand bringitinpositionon theHSTpump，theninsta＝theO−ringandbolts （0140）．Apply9reaSetOthesplined section of

themainchargrngpump．

亀B。，t（。．．。）‥．8Nm 2．［L3−2］Fig27−00（1）：ConnectthehQSe（0100）to thechargIngPumP．

Fig27−00（1）：

2．［L4，L5，L6−2］Fig27−00（2）：Connectthe hose （0120）tothechargingpump．

Fig27−00（2）：

3・［L3−21Fig78−00（1）：Connect the tube（0030） andhose（0080）tothemainpump．

3−7−24

］nsta ationofMainChargLngPump

■

3．【L4，L5，L6−2］Fig78−00（2）：Connectthetube

L3，L4，L5，L6・2 Fig78−00（2）：

（0030）andhose（0080）tothemainpump．

00白0

4．Fig62−12：lnsta［lthefloorplate（0011）withbolts

Fi962−12：

（0020）．Laythef100rmat（0050）・

5．Fig12−51：Connect the battery negative cab）e （0030）．

6．StarttheengIneand runitatidLetocheckfor fluid［eakage．

7．Stop the engrne，Wait fbr5−10minutes，then Checkthehydrau（icfLuidIeveL．Referto■ LeveJ

CheckandAddition ofF［uidin HydrauJic FIuid 「bnk，−− 3−7−25

Fig12−51：

Remova［ofHydrau］icFIuidTankL3，L4，L5，L6・2 ■RemovaIofHydraulicFluidTank ● L3，L4，L5，L6−2

Fi912−51：

1．Fig12−51：Disconnectthebatterynegativecab［e （0030）．

2．Fig62−12：Remove the f［00r mat（0050），then removetheboLts（0020）todetachandremove

Fi962−12：

thefloorplate（0010）．

3．Fig78−21：Remove the plug（0110）to drain hydrauIic f［uid out of the hydrauIic f［uid tank

（0010）．Afterdraining，insta theplug（0110）．

⊥

Hydraulicf［uid（tota［capacity）：25L

▲wARN暮NG PlacearecIPlentundertheHSTpumptocatchthe

hydraulicf）uidinthepipingthatwiLIcomeoutwhen ho＄eSaredisconnected．WipeofFspi］［edhydraulic 刊uidcompIetelytopreventRre． 4．［L3−2］Fig78−00（1）：Loosen the nut（0170）， removethebolt（1070），thenremovethereturn

PIPlngCOnneCtedtothehydrauIicfluidtank．

3−7−26

Fig78−21：Bottom bf hydrautic f［uid tank

RemovaIofHydrau［icFluidTank

L3，L4，L5，L6・2

4．［L4，L5，L6−2）Fig78−00（2）：Loosen the nut （0240），remOVe the bolt（1070），then remove

Fi978−00（2）：

the return pIPlng COnneCted to the hydraulic f］uidtank．

5．［L3−2］Fig78−00（3）：Loosen the hose cLamps

（0020）and（1201），then disconnectthe hoses （0010）and（1190）fromthehydrauLicf］uidtank．

0020 5．（L4，L5，L6−2］Fig78−00（4）：Loosen the hose CIamps（0020）and（1270），thendisconnectthe hoses（0010）and（1240）from the hydraulic

0010 Fi978−00（4）：

fIuidtank．

6．Fig78−21：With the hydrau）icfluid tank（1020） SuPPOrtedwithajack，remOVethebo［t（1030）to detachthehydraulicfluidtank（1020）．

盆Hydra。，icn。idtank（．。2。）‥ L3−2−24k9 L4，L5，L6−2−42kg

3−7−27

Fig78−21：

1nstalIationofHydraulicF］uid「bnkL3，L4，L5，L6−2

2．［L3−2）Fig78−00（1）：Connectthe hoses（0010）

and（1190）tothehydrauIicfluidtank，andthen thehosec［amps（0020）and（1201）．

0020

2．［L4，L5，L6−2）Fig78−00（2）：Connectthehoses （0010）and（1240）to the hydrauIic刊uid tank， theninstallthehosecIamps（0020）and（1270）．

3．【L3−2］Fig78−00（3）：Connectthereturnpipingto the hydraulic f［uid tank byinsta＝ng the bolts （1070）andtighteningthenut（0170）．

3−7−28

0010 Fig78−00（2）：

lnsta ationofHydrauIicFluidlbnkL3，L4，L5，L6−2 3．［L4，L5，L6−2］Fig78−00（4）：Connectthereturn

Fig78−00（4）：

PIPlngtOthehydraulicfIuidtankbyinstallingthe boFts（1070）andtighteningthenut（0240），

〕 4・

Fig78−21：Refi‖thehydrau［icfLuidtankwjththe SPeCified amount of hydrauIic f［uid．Refer to

Fig78−21：

‖LeVelCheckandAdditionofFluidinHydrau［ic Fluidl盲nk．■●

省H，dra。．icM（．。ta．CaPaC，〜）‥ L3−2−25L L4，L5，L6−2−42L

5．Fig62−12：Place the f［00r PIate（0011）in POSition，theninsta the bo［ts（0020）．Laythe

Fig62−12：

冊00rmat（0050）．

6．Fig12−51：Connect the ba性ery negative cable （0030）．

3⊥7−29

Fig12−51：

］nsta ationofHydraulicFluidTank L3，L4，L5，L6−2 7．Starttheenglneand runitatidLetocheckfor fluid［eakage．

8．Stop the englne，Wait for5−10minutes，then CheckthehydraulicfLuidleve［．Referto一 Leve）

CheckandAddition ofFIuidin Hydrau［ic Fluid ￣bnk．‖

3−7−30

LeveICheckandAdditionofFIuidinHydrau［icFIuidTink

L4，L5，L6・2

T LevetCheckandAdditionofFluidinHydrau− LicF［uidTink

a WPIRNlNO ・The hydrau［icfluidin thetankis under pres− Sure and hotespecia］lylmmediately afterop− eration．RemovethefIuidfi erplug onLy after

makingsurethatthetankiscool・AIsoturnthe Plugslowlytorelievethepressure・

・Useon［yawrenchthatexact［yfitstothefLuid fiIlerpIugtoremoveitwhenrefilIing．Ltisdan−

geroustouseaninappropriatetoolasitmay

Fig78−00（1）：

SIiponthep［ug．

Thehydrau［icftuidtankisIocatedattherightsideof themachine．

1．Park the machine on a）eveJground with the Wheelsin straight−ahead positions．Lower the bucketf［attotheground，thenstoptheeng−ne． 2．Fig78−00（1）：CheckthefFuid［eveLthroughthe

leveIgauge①atthesideofthetank． 3．Fig78−00（1）：Thefruidlevelshouldbebetween theupperand［owe「limits．

4．Fig78−00（1）：IfthefluidJeveIisbelowtheLower

limit．remove the filler plug②（Width across 凡ats：32mm），and addthespecified hydraulic

fIuid．（Refe「tothetableofrecommendedoils and刊uids．）

5．Fig78−00（1）：SecureIyinstaIlthe何Ierprug②．

3−7−31

＼ Fig78−00（1）：Oir［evelgauge①

DisassemblyofCylinders

L3，L4，L5，L6−2

■Disassemb［yofCyIinder＄（Steering，Tiltand LiftCyIinders）

Fig54−21（1）：

● L3，L4，L5，L6−2

1．Fig54−21（1）：Unbendthestop（A）atoneplace On the cylinderhead（0030），then removethe CyIinder head（0030）from the tube assemb［y （0010）．

▲

CAUT10N

・ Becarefulnottodamagethestop（A）thatis integra］partofthetubeassembly（0010）・

・ThefoIIowingcylindershavenostop（A）： L3，L4，L5，L6−2−SteerlngCylinder L3−2−L肌cy［inder

2．Fig54−21（1）：Pu暮10utthepiston rod assembly （0020）fromthetubeassembly（0010）・

3・Fig54−21（2）：Remove the s］ide rings（0120）

Fi954−21（2）：

fromthepiston（0100）．

0100

4・Fig54−21（2）：Removethescrew（0130），th甲1

remQVetheba （0140）．

▲cAUT10N Before removing the screw（0130），driIIout the PunChstaking（twoplaces）usingahanddri ・

3−7−32

DisassembIyofCylinders

L3，L4，L5，L6−2

5．Fig54−21（3）：Remove the piston（0100）from thepistonrodassembly（0020）．

Fig54−21（3）：

6．Fig54−21（3）：Using afratblade screwdriveror Cutter，Cutthesealring assembly（0110），then removetheseatring（1010）andO−ring（1020）．

Fig54−21（3）：

7

1020 朋 0100

。

7．Fig54−21（4）：Removethecylinderhead（0030） fromthepistonrodassembJy（0020）．

8．Fig54−21（5）：RemoYe the O−rings（0070）， （0090）andbackupring（0080）．

Fig54−21（4）：

Fig54−21（5）：

0090

0070 0080

3−7−33

Disassemb］yofCylinders

L3，L4，L5，L6・2

9．Fig54−21（6）：Use a flatb［ade screwdriver to removethewiperring（0060）．

Fi954−21（6）：

10．Fig54−21（7）：Remove the U−ring（0050）and

Fig54−21（7）：

0050

backupring（0060）． 0

▲cAUT10N

0040

・ Useasharp−tippedsticktoremovetheU−ring （0050）．TheremovedU−ringcannotbereused；

repIaceitwithanewone．

060 乍 臍

・Thereare・nO backup rings（0060）on thefol− 10W［ngCylinders：

L3，L5，L6−2−SteerIngCyIinder L3，L4−2−Ti）tcyIinder L3−2−L択Cylinder

11．Fig54−21（7）：Removethebushing（0040）．

12．Fig54−21（8）：Removethedustseal（2030，tWO P［aces）andbushing（2010）fromthepistonrod assembIy（0020）．

13．For the tube assembly，Perform the same

OPerationasinstep12．

3−7−34

Fig54−21（8）：

AssembIyofCyIinder

L3，L4，L5，L6−2

■AssemblyofCyIinder（Steering，Ti暮tand Lift

Fig54−21（1）：

Cylinders） ● L3，L4，L5，L6−2

1．Fig54−21（1）：Pressfitthebushing（2010）and dustsea）s（2030，tWOPieces）intothepistonrod assembly（0020）．

2．Performthesameoperationasinsteplforthe tubeassembly・

3．Fig54−21（2）：Pressfitthebushing（0040）into

Fig54−21（2）：

thecylinderhead（0030）．

0050

NOTE

Apply hydrauIicfluid to theinside surface ofthe CyIinderhead（0030）befbreinstalIingthebushing・

4．［nstaIlthe backup ring（0060）and U−ring （0050）．

5．Fig54−21（3）：Pressfitthewiperring（0060）into

Fig54−21（3）：

0030

thecy［inderhead（0030）． 0060

3−7−35

AssemblyofCy［inder 6．Fig54−21（4）：lnsta［ItheO−ring（0090），backup

L3，L4，L5，L6−2 Fig54−21（4）：

ring（0080）and O−ring（0070）on the cylinder head（0030）．

0070

7．Fig54−21（5）：Insta［［the O−ring（1020）on the Piston（0100）．

Fig54−21（5）：

8．Fig54−21（6）：Usejigs（B）．（C）and（D）toinsta

Fig54−21（6）：

thesealring（1010）onthepiston（0100）．

a CAUTloN Pushinjigs（B）and（C）byhandtoinsta thesea［ ring（1010）onthepiston（0100）．

9．Fig54−21（7）：Use the jig（E）to reshape the etongatedseaIring（1010）．

▲

CAUT10N

P［ace the piston（0100）inthejig（E），then push thesealringintopositionbyhand．Afterreshaping， make surethatthe sea暮ring（1010）is notdam− aged．

3−7−36

AssemblyofCylinder 10．Fig54−21（8）：［nsert the cytinder head（0030） intothepistonrodassembly（0020）・

L3，L4，L5，L6−2 Fig54−21（8）：

ニ

11．Fig54−21（9）：Insta［Ithe piston（0100）on the

Fig54−21（9）：

Pistonrodassemb［y（0020）・

亀，ist。。（。．。。）：Refer．。 ServiceStandards。f Cylinder．．l

12．Fig54−21（10）：lnsta theba［Ⅰ（0140）andscrew

Fig54−21（10）：

（0130）．

亀sc，eW（。．3。）‥Refer．。‖ServiceS．andards。f CylindeL‖

13．Fig54−21（10）：Stake（PunCh）thepiston・（0100）

attwoIocations around the mounting hole of thescrew（0130）． 0100

▲cAUT10N Stake（PunCh）atIocationsdi侮rentfromtho＄eat Whichstaking竜hadbeenmadebeforedisassem− bly．

14．Fig54−21（10）：lnstallthesliderings（012O）on thepiston（0100）．

3−7−37

AssemblyofCylinder 15・Fig54−21（11）：lnsertthe piston rod assembIy （0020）intothetubeassembIy（0010）．

L3，L4，L5，L6−2 Fig54−21（11）：

16．Fig54−21（11）：Insta＝thecylinder head（0030） OnthetubeassembIy（0010），

亀c，．i。derhead（。。3。）：Refert。 SeNiceStan＿ dardsofCylinder， NOTE

BeforeinstaIfing the cyIinder head（0030），aPPIy hydraulicfluidtoitsO−rings．

17．Fig54−21（12）：Bend the stop（A）toward the

Cylinder head（0030）to prevent the cyIinder head（0030）fromloosening．

▲cAUT10N ・ Therearethreestoplocationsonthecircum− ferenceofthecyIindeLWhenreassembIingthe

Cy［indenbendaonestopataIocationdifFerent fromthatatwhichthestophasbeenbentbe− foredisassembly． ・ Therearenostops（A）onthefoIIowingcylin− ders：

L3，L4，L5，L6−2−Steenngcy［inder L3−2qL汎Cylinder

3−7−38

Fig54「21（12）：

ServiceStandardsofCyJinders

L3，L4，L5，L6−2

b serviceStandard＄OfCyIinder＄（Steering，TiltandLiftCylinder＄） ● L3，L4，L5，L6−2 0030

0010

ltem ltem

0020

0100 0130

StandardvaIue

Cylinder

L3−2

L4−2

L5−2

Cylinder

Tilt

284Nm

284Nm

304Nm

←

head（0030ト

L洞：

265Nm

294Nm

294Nm

304Nm

Steenng

255Nm

←

265Nm

←

Piston「od

TiIt

0．5mm／m

←

←

←

assembly

L椚

0．5mm／m

←

←

←

（0020）−・bend Steenng

0．5mm／m

←

←

←

Tubeassem−

Tilt

￠60mm

￠63mm

￠70mm

←

bIy（0010）−

L汗t

￠55mm

￠65mm

￠65mm

tightening torque

inside diameter

Steerlng

￠50mm

←

￠55mm

Remarks

L6−2

Service［imit

Whenreboring ←

￠70mm

damagedtube VVidthacross 刊ats：

Titt

393Nm

496Nm

680Nm

←

L3−2：41mm L4−2：46mm L5−2：50mm L6−2：50mm Widthacm＄＄

Nut（forpis−

¶ats：

ton（0100））−

tightening brque

Lif【

279Nm

528Nm

←

680Nm

L3−2：36mm L4−2：46mm L5−2：50mm L6−2：50mm Widthacmss ¶ats：

Steenng

154Nm

←

210Nm

←

L3−2：36mm L4−2：36mm L512：36mm L6−2：36mm

←

←

←

Screw

Titt

6．8Nm

（0130）−

しift

6．8Nm

←

←

←

6．8Nm

←

←

←

tighten暮ng

torque

Steering

Stake（PunCh）at 2locationsafter

3−7−39

tightening

へ﹁ノ ヽノ

4．TROUBLESHOOTtNGIDIAGNOSIS

〕

4−0．Engine

＝………t…・

4−2．Powertrain1

・・・・・…‥……

4−2−1

4−3．PowertrainI1

……………・

4−3−1

4−4．BrakeSystem

……………・

4−4−1

4−5．SteerlngSystem

＝・……・・・…・ 4−5−1

4−7．HydraulicSystem

…＝＝…＝…・

4−0−1

4イー1

︑︶

︺

Faulty battery FauLtychargingsystem Opencircuitorpoorcontact Loosenconnectionorcorrosionoftermjnals

Faultystarterswitch Fau［tysafetyrelay Faulty battery ground Fau吋moto「 Faultymagnetswitch

］njection PumP

lnsu惰cient fuel

Sticking plunger MalfunctioningdeIiveryvarve FaultyoperationofcontroIrack LoosecontroJpln暮On

FauJtyoperationoffeedpump NofuelinfueJtank

Airinfue）system Water in fuel C［oggedfuel用ter

Loosefuelp暮PeCOnneCtion

Cloggedfuelhose CrackedorIooseirjectionpIPe CIoggedbreatherhoseoffue［tank

ar。

lmproper injection timing injection lbo］owinjection start pressure Poorsprayoffuel Settin9 Engine

−TboIowcompression PreSSure

Worntappetro erandcam Fau］tynozz暮eandnozzleholder

StickyneedIevalve

1

FauJtyenginecontro［mechanism Faultypreheating＄yStem 4−0−1

L二 W由korbrokennozzIespnng Burned valve Seizedorwornva［vestem

BrokenvaFvesprIng Impropervalveclearance Wearofcylinder，Pistonandpiston rin9 Stickyorbrokenpistonr．ng B［owbythroughcy［inderhead gasket

lrregular fuel

lnjection PumP

injection

Brokenplungerspnng Fau）tyoperationofcontrolrack Ma［functioningdeLiveryvalve Faultyoperationofgovernor Faultya噌UStmentOfidIingspring

Faultyoperationoffeedpump Othe「s

Airinfuersystem Water in fuel

LooseconnectionoffuelpIPe Cloggedbreatherhoseoffue［tank lmproper明eCtiontiming

Poorsprayoffuel

「

Stickyneed］evalve Weaknozzlespnng Carbondepositionininjectionnozzte

lrregu）arinjectionstartpressure−Fau［tynozzleandnozzleholder

Engine

lboIowcompressionpressure（RefertotheprobIemitem Enginestartshard． ）

Others

Faultyeng［neCOntrOlmechanism

lrregular injectionoffueI

InjectionTWornorseizedp］unger Faultyoperationofcontrolrack MalfunctioningdeIiveryvalve Faultyoperationofgovernor FauItyoperationoffeedpump Others

Airinfue［sy＄tem VVaterinfue［

Looseconnectionoffue［pIPe Cloggedbreatherho＄eOffue［tank lmproper

WorntappetroIIerandcam

叫ectiontiming

Poorsprayof fuel

Engine

Stickyneedle valve

￣￣巨

Weaknozzlespnng Carbondepositionin巾jectionnozzle

lbo［owcompres＄ionpressure（Refertothe PrOblemitem Enginestartshard．‖） lnsu惰cient

Clogged air cleaner

intakeair Fau［tyexhaust SyStem

Cloggedmu門er

4−0−2

lrregular or

Wornorstickyp［unger Brokenp［ungersprJng

excessive fuel

injection

FauLtyoperationofcontro［rack Faultyoperationofde［iveryvalve ）mproper injectiontimIng

「

rSPrayOf

l

Worntappetro erandcam

Loosetappetadjustingbo［t Stickyneedleva［ve Weaknozzlespnng Carbondepositionininjectionnozzle

lboLowinjectionsta正一LoosenozzLeadjustingscrew pressure setting

Engine

lboIowcompressionpressure（Refertotheproblem

Others−

lnsu用cientintakeair −CloggedaircLeaner

Cooling

item． Enginestartshard． ）

Coo［oantIeakage

SyStem

Wornwaterpumpsea［ WornorseizedpIunger BrokenhoseandpipeorloosecLamp Damagedcylinderheadgasket Fau［tyoperationofwaterpump

Faultycoo［ing SyStem COmPOnentS

Clogged radiator Faultyradiatorcap Faulty thermostat Looseordamagedfanbelt Scaleincoofantpassage

Excessiveirtiectionoffue［ ［mproperiqectiontiming Poorsprayoffuel lbolowinjectionstartpressuresetting Lubrication SyStem

PoorcircuIationofenglneOil MalfunctionlngOilcoo［er Carbondepositionincombustjonchamber CIoggedmu冊er lbomuchload 4−0−3

Knocking nOISe

lmproper injection timing lrregularinjectionoffue［ ¶）Ohighinjectionstartpressuresetting

PoorsprayoffueJ Poorlgnition

lborowcompressionpressure（Refertotheproblem item 一Enginestartshard， ） Rapplng nOISe

WorncyIinderandpiston Seizedorbrokenpistonandpistonrlng WornconnectingrodsmaIlendbushingandpistonpln Wornor♭rokencrankpinandconnectingrodbearing Wornordamagedcrankshaftjourna［andjournafbearing lbolargeaxialp［ayofcrankshaftandcamshaft Loo＄ef［ywheeIandcrankshaftpu［ley

Worntappetandcam Excessiveva［veclearance Continuous

Womordamagedalternatorandwaterpumpbearings

「at川ng

Wearorpoortooth．contactoftiminggears Looseordamagedfanbelt

4−0−4

Lubrication SyStem

Oil leakage

LooseoilfiIterand／ordefectiveO−ring

Excessive

Looseoilpanand／ordefectivegasket

engine oil COnSumPtion

LooseoilpIPeCOnneCtionorcrackedpipe Oil remains

WorncyIinderlinerandpiston

unscraped bypistonnng

Worn，brokenorstickingpistonmg C［oggedoilholeinpistonandoiIring C［oggedbreatherpIPe

ExternaLoi［ teaka9e

「二

Def岳ctiveva］vestemoilsea］

Defectivegasketandoilsea［

0旧eakage

Fuetsystem

Wornvalvestemandvalveguide

lrreguIarorexcessive injectionoffuel

Wornorseizedplunger BrokenpIungerspnng FauItyoperationofcontroJrack Ma［functionlngOfdeliveryvaIve

】mproperinjection

timing Excessive fuel COnSumPtion

「

Poorsprayoffue［

WbrntappetroIIerandcam Loosetappetadjustingbolt Stickyofneedlevalve WeaknozzIespnng Carbondepositionininjection

lbolowinjectionstart− pressure setting

nozzle

Loosenozzleadjustingscrew

−TboLowcompressionpressure（Refertothe PrObIemitem ．Enginestartshard： ） Others

「

Overheating（RefertotheprobIem item一一Engineoverheats． ） lnsu庁icientintakeair

4−0−5

Ciogged air cleaner

1．Machinecan bemoved￣neitherinforwardnorreversedirection

︺

1．Machinecanbemoved

neitherinforwardnorreversedirection

C．Deteriorated，emulsifiedorimpropertypeoff）uid

Peげormfluidcheぢk． 1．1sf］uiddeterioratedandbrowned？ 2．HasfJuid beenmixedwithwaterandemuIsified？

3．Doesfluidtrapair（fromintakesystem）andshowwhite？ 4．Isf［uidofspecifiedcharacteristics（especiaHyviscosity） used？（Refer to the Operation and Maintenance Manual．）

1．Machinecanbemovedneitherinforward，nOrreVerSedirさCtion

1−E．Fau）tyoperationorpooradjustmentofbrake（inching）pedaILinkage

Checkthattheinchingvalveleverisinthe

c10Se

position．

1．With the engine stopped and the brake（inching）peda［① released．checkthattheinchingva［velever②isincontactwith thestopper（f■c10Se1．position）．

Note：Make sure that theinchingleveris always jn the■ c［ose

POSitionwhenthepedalisnotdepressed．

Stopper

L4．L5．L6−2

L3−2

4−2−3

1．MachinecanbemovedneitherinforwardnorreYerSedirection

1−F．FaultyparkingbrakesoIenoidandparkingbrakeswitch（brakesdrag）

Measuretheterminalvoltageofparkingbrakes01enoid． 1．After starting the eng［ne，PLace the parking switchin the lRESET‖operation．

2．Checkthattheshif＝everisIockedintheneutralposition． 3．DisconnecttheparkingbrakesoLenoidconnector． 4．While turnIng the parking brake switch from ON t to OFF）．，

measure the terminalvoltage（make measurement on the machine side connect with the parking brake monitorlamp turnedo町 Standardva［ue：VoIta

elO．95−14．4

ParkingbrakesoIenoid

①parkingbrakeswitchisfauFty． ②Relay［3］isfaulty，

①Parkingbrakesolenoid isfaul吋．

③Connectorand／orground COnneCtionareinpoorcontact．

Connector（Vehicleharnessside）

Parkingbrakeswitch

Monitorlamp 《扮

Relay［3］

Alternator TraveIingsystemcircuit（ParkingbrakeswitchON→OFF） 4−2−4

1，Machinecan bemovedneitherinforwardnorreversedirection

1−CiDropinAUcontroLpressure

MeasuretheAUcontroIpressureoftheHSTpump． 1．ConnectanoilpressuregaugetotheQ2port（￠6fIareless tubefittingl川）oftheHSTpump． 2，Lnsta［latachometertotheenglne． 3・MeasuretheAUcontroIpressureatcertaineng］neSPeeds． 4．Standardva［ue

Refertothecharacteristicgraphsbelow．

1一日．Drop）nlow−PreSSure reliefvalvepressure

2−C．Measuretheoilpressurein high−PreSSureCircuit．

4−2−5

1．Machinecanbemovedneitherinforwardnorrever＄edirection

4−2−6

2．Machinecanbemovedonly◆inforwardorreversedirection 2−A．Faultyshiftleverorelectricalwiring Solenoidvalve（forward）

Measuretheterminalvo）tageoftheforwardandreverse 1．A微erstartingtheenglne，mOVetheparkingswitchtothe RESET position． 2．DisconnecttheforwardandreversesoIenoidconnector．

3．P［ace the shiftleverin the neutralposition and set the parking brake SWitch to the‖OFF position（to make measurement on the machine harnesssideconnectorwiththeparkingbrakemonitorlampturnedo町 4．P［acethesh汎Ieverinthe FoIWardr position，andmeasurethevoltage． StandardvaIue：Volta

elO．95−14．4

5．Placetheshif＝everinthe一 Reverse position，andmeasurethevoltage． Standardvalue：Vblta

elO．95−14．4

SoIenoidvalve（reverse） SOL：R

（DThesolenoidontheside Showingstandardvoltage isfaulty．

①Shif＝everisfauFty． ②Relay［3］isfaulty．

③parking brake switchis ねulty．

Alternator TraveLingsystemcircuit（ParkingbrakeswitchON→OFF） 4−2−7

2．Machinecanbemoyedonlyjnforwardorreversedirection

4−2−8

2．Machine．cahbemovedonlyinforwardorrever＄edirection 2−C．Measurementofhi9h−PreSSureCircuitpressure

Measurethehigh・PreS

PreSSureOftheHSTpump．

1．ConnectanoilpressuregaugetotheportA（ forward l）．

2．Preventthemachinefrommovingbypressingthebucketagainsta thickconcretewa orotherstrongoPject． 3．Sta止theengine，Setthetravelmodeswitchto AUTO ，andp［ace theshif‖everinthe■一forward position．

4．Warm up the hydraulic fluid to an operating temperature （approximately40to600C）．

5，S10WIyraisetheengIneSPeedtothemaximumspeedandreadthe Oilpressuregauge． 6．Whenmeasunngthe 一reverse■■sidecircuitpressure，COnneCttheoil PreSSUregaUgetOthepo止（B），PreVentthemachinefrommoving

bypresslngtheweightagainstathickconcretewalLorotherstrong OPject，Placethe shiftleverinthe■ reverse measurement． 7．StandardvaIue

position，and takea

2．Machinecanbemovedonlyinforwardorreversedirection 2−D．Fau］tyhigh・PreSSurereliefvalve

Removeandcheckthehi9h−PreSSurereliefvalve． 1．Checkthe high−PreSSure reliefvalvesfor［00SeneSS OrOtherdefectsin instaIIation．（lfavalveisLoose，thef］uidinhigh−PreSSureCircuitleaksinto 10W−PreSSure Circuit resu［tingin a dropin the high−PreSSure Circuit PreSSure．）

2．Ifnodefectisfoundintheinsta ation，remOVethe high−PreSSure relief

Valveand checkthe valvefor presence offorelgn matterOn theva］ve SeatS（D and②．

3．Lnterchangethe一■forward ■and‖reverse．．high−PreSSurereliefvaIvesand

Checkwhethertheabnormalconditionchange． 4．Repface the high−PreSSure re［ief valves with new ones，and check WhethertheabnormaFcondition recurs．

4−2−10

3．DropInmOV［ngSPeed

CheckingmovIngSPeed Whenausercomplainsthatthemachinecannotmoveatfu］［speed，firstmeasurethemovlngSPeedsin theworkmode（fixedinthelstgear）andtheninthetrave暮mode（AUTO）forboththefbrwardandreverse

directionsinordertodeterminewhethertheuserfee［sthemachinetobetoos10Walthoughthespeedsare normarorthevehicleistruelytoosLowduetosomemalfunction．

1・Su冊cientlywarmuptheenglneSOthatthecoolanttemperaturegaugeindicatesatemperatureinth greenZOne・

2・Makesurethatthefluidisatanoperatingtemperature（approximateIy40−600C）． 3・Makemeasurementwiththeo旧ntheaxleandreductiongearaIsowarmedup． 4．Keepthemachineinatravelpositionwiththebucketempty．

5・Measurethespeedsona］eve［，PaVedsurfacewiththeenglnerunn］ngatthemaximumspeed． 6・As this machineis not equ［PPed with a speedometer，either have a Vehicle with a speedometer accompanyitordriveagivendistance（20m）whi）e・meaSuringthetimetakenwithastopwatchand Ca［culatethespeedperhour． 7．Standardspeeds Mode

TraveImode（AUTO）

Ⅵbrkmode （fixedinlstgear）

Maximumspeed

Equivalent time of 20 m driving

L3−2

6．2

Km／h

15

Km／h

Approx．4．8 seconds

L4−2

7．5 Km／h

15

Km／h

Approx．4．8 seconds

L5−2

8．O

Km／h

15

Km／h

Approx．4．8 seconds

L6−2

8．O

Km／h

15

Km／h

Approx．4．8 seconds

Caution：Perfbrmmeasurementwhenhydraulicfluid，aX暮eoilandreductiongearoi暮are aIlatoperatingtempratures．1n10WtemPeratureS，Perfbrmanceofthismachine maynotbefu

ydi＄P）ayedduetoresistanceofhighviscosityofoilsandf［uid．

4−2−11

3．DroplnmOV］ng・SPeed 3−A・lnsufFicientenginepower（Jackofspeed）

Mea＄uretheenginemaximumspeedwithno10adandthespeedwiththeshove［Lifted．

MeasurementoftheenglnemaXimumspeedwithnoload l．ConnectatachometertotheengIne． 2．Warmuptheengineunti］thecoo［anttemperaturegaugeindicatesatemperatureinthegreenzone． 3．Warmthehydraulicf）uidtoanoperatingtemperature（approximate］y40−600C）． 4・SettheshovelcontroILevertothe．．Ho［d（Neutra］）llpositionandkeepthesteeringwheelinthe Neutrar position． 5．Readtheeng［neSPeedwhentheacceIeratorpeda＝sfu

ydepressed．

6．Standardvalue

1．Acce［eratorlinkageisfaulty，SOthe

maximumspeedpositioncannnotbe reachedevenifthepedalisfuIly depressed． 2．ThefuelfiIterandairfilterareclogged． 3．ThefueIpumpandnozzIesarefau［ty． 4．Thereareother飴ultsintheeng［ne．

1．Set the shoveIcontro［Lever to the．一Raise一■

POSition from the no−10ad speed measur［ng COndition，and raise theI汎arm to the highest

POSition． 2．Measurethe englneSPeedduring operationof theshove［mainreliefvaIvebykeepingthe［ever inthe■■Raise1．position． 3．Standardvalue

3．DroplnmOVIngSPeed

4−2−13

3．MovementspeedisnormaIin．

workmode

璽鱒W）buttopspeedisnotreachedin一■trave［moden（AUTO）．

Harnessonmachineside HSI motor

4−2−14

3．Movementspeedi＄nOrmalin 一workmode一■．（LOW）buttopspeedisnotreachedinT．travelmode （AUTO）． 3−B．FaultyoperationofmodeseJectorsoLenoidvaJve

Checkoperationofthesolenoidva］ve 1．lnsertandpushalong．roundstick②intothehole①（diameter：6mm）inthesoIenoidvalve． 2．Checkthat，WhenthestarterswitchisturnedONandthemodeselectorswitchismovedfromthe‖traveL mode，lposition（AUTO）tothe

■workmode

．position（LOW），theinsidepiston③movesinward．

3．Setthemodeselectorswitchtothe． traveLmode一■position，andpushthepiston③withthestick②． 4．Theso）enoidvalveisnormalifareactionforceofthespring④isfeItandthepiston③movesinward by2．8mmandreturnssmoothlyonreteaseoftheforceonthestick．

5．1fthepiston③doesnotmoveoritsmovementisnotsmooth，thespooIisstuckwithforeignmatter．

SOlenoidValve

4−2−15

3・MovementspeedisnormaLin■ workmode ＊iLOW）buttopspeedisnotreachedin ltrave［mode ■（AUTO）．

4−2−16

4．Poortraction

5・Machinetrave［swheneng■neisrunn■ngatIowidlespeed

Measurethel 1・Connectatachometertotheenglne．

2・Warmuptheeng［neunti＝hecoo［anttemperaturegaugeindicatesatemperatureinthegreen ZOne． 3・Raisethef［uidtemperatureequaltoanoperatingtemperature（approximately40−600C）．

4・Settheshove［controllevertothe hold（Neutra［）一■positionandkeepthesteeringwhee）inthe ．neutraI■■position． 5・Checktheeng−neSPeedwithoutdepress［ngtheacceleratorpedaI．

6．Standardva［ue

medin the accelerator

4−2−17

5．MachinetravelswhenengIneisrunnlngat［owid）e＄Peed

6．HSTfluidleve暮lowers

4−2−18

1，OilLeakagefromaroundnut②offrontaxledrivepinion①

taモinputflange

4−3−1

3．OitJeakagefromwheelhuboilsea［①

4．Oilleakage

4−3−2

OfoutputfIang

ヽJノ

4−3−3

6．Abnormalnoi＄eOrinabilitytotraveI

6．Abnorma］noiseorinability・tOtraVeI

①1﹂ Reductiongeartorearax】ejoint

4−3−5

6．AbnormalnoiseorinabiIitytotrav色I

lf noise−PrOducing10Cation（front axle，rear aXle．or reduction gear box）cannot beidentified，USe the fo［Iowngmethod． 1．Jackupthemachineandsupportitwithstands．

2．Removethe prope＝ershaft①（reduction geartofrontax［e）and moveonlytherearwheeIs．1fno abnormaInoiseisheai］，therewil［beaprob［eminthefrontaxle． 3．Ifabnormalnoisestillexistsinstep2above，installthepropeI［ersha債①，remOVetheprope11ershaft② （reductiongearboxtorearax［e），thenmoveonIythefrontwheels．1fnoabnormalnoiseisheard，there WiI［beaproblemintherearaxIe． ）fabnormaInoisestiJ（exists，therewi［［beaprobIeminthereductiongearbox．

Front axle

4−3−6

1．P00rbraking

1．Poorbraking

IfthereisinternalLeakageinthemastercylinder，thepedaldoesnotstopif thepedalisdepressedstrongfy． CausesofinternaL］eakageinthemastercyIinderare：

①Wornordamagedcup① ②wornordamagedboresu向ceofcy（inder Caution：lfthecup②isfau）ty，f［uidwi11Leakexternalty．

1．Poorbraking

NO ②

ltem Brakedisk

Standardvalue 2．25mm

Service、Iimit

BrakepIate

1．6mm

1．4mm

1．9mm

Caution：Abnormalorprematurewearofbrakedisks①andplates②maybecausedbydraggingbrakes． 4−4−3

2．Parking▼brakedoesnotfunction

switch and/or

lftheparkingbrakedoe＄nOtfunctionatalLwiththeengrnerunnlngandtheparkingbrake SWitchinthe

ON

position，thefo

owingdefectsmaybethecause．

1．［ftheparkingsoIenoidisenergized undertheabove−mentionedcondition，fau［tyswitch，

reIayorharnessmaybethecause． 2．TheparkingsoIenoidvalveisstuckinthe reIeasedcondition． Caution：［fboththeconditionsinitemsland

2above are normal，the parking brakeoi［pressuremeasuredatthe 10Cation shownini‖ustrationon the

rightshouldbe

ParkingbrakesolenoidvaIve

4−4−4

3．Parkingbrakedrags

4−4−5

3．Parkingbr？kedrags 3−B．FauttyparkingbrakecontrolhydrauJicsystem Measure納eparkingbrakeoilpressureontheparkingbrakesolenoidside． 1．Disconnect the parking so［enoid valve hose②

and90Jegree elbow③，then connect an oi［ PreSSUregauge・

2．Starttheenglne，Placethe parkingswitchinthe T−RESET position，and read the oi［pressure gaUge・

3．Measure the pressure with the hydraulic fluid Warmedtoanoperatingtemperature（40−600C）． brakere］easeoil 1．57MPa（16kg仇m2）

Stickingparkingbrakesolenoid

Brakedisk

Standardvalue 2．25mm

SelVicelimit 1．9mm

Brakep［ate

1．6mm

1．4mm

NO

ltem

① ②

1．SteeringT＄lmPOS＄ibleorhard

Measurethesteeringtime． WhenausercompLainsthatsteenngthemachineishard，firstmeasurethetimerequiredforsteenng． Thendeterminewhethertheuserfeelssteeringhard（S［ow）althoughthesystemisnormaIoritisreal［y hard（SIow）duetomalfunction． 1・PlacethemachineinatraveIpositionona］eveJ，PaVedsurfacewiththeparkingbrakereleased．

2．Warmthehydrau［icfluidtoanoperatingtemperature（40−600C）． 3．Makethebucketempty． 4．Checktiresforcorrectinf］ationpressures．

5・WiththemachineundertheaboveconditionsandtheenglnerunnLngatthemaximumspeed，meaSure thetimerequiredtosteerthewheelsfromtheLe代stoptotherightstopandfromtherightstoptotheleft StOP． Standardvalu Lef（tum：2．Oseconds・Orless

Rightturn：2．5second＄1ぽ1es＄

4−5−1

1．Steering［Simpossibleorhard 車払7boぬWSteeringmainreliefvalvepre＄Sure Mea＄urethesteerlngPreS＄ure． Measurement method

l．ConnectanoiIpressuregaugetothehydraulicpressureoutletpo托 ①（Rcl／8）onthesteeringcylinder．

2．他rmthehydraulic仙idtoanoperatingtemperature（40−600C）． 3．WiththeengLnerunnlngatthemaximumspeed，tUrnthesteenng Whee［totherighttoaclosecontactwiththestopperontheframe． Fromthiscondition，COntinueapp］yingturn［ngforcetothesteenng Wheelfurther．

4．Readtheoilpressuregauge．

1．TurnthesteerJngWheeItotheright，keepitinclosecontactwiththe StOPPerOntheframe，thenstoptheengIne． 2．Disconnectthehose①fromthecy［inderrodendofthesteenng

Cylinder，andinsta theplug②ontheendofthehose①． 3．Stantheenglne，aCCeIerateittothemaximumspeed，andcontinue

app［yingahghtturnlngfbrcetothesteerlngtOal10WPreSSUrized f［uidtof10WtOthecylinderbottom．

4．1fhidLeak＄OutOfthecyIinderpo止③，Pistonsealsinthecytinder maybedamaged．

4−5−2

1．Steer）ngIS［mPOSSib］eorhard 1−E・Faultyorbit−rOll（Stickingorwornspoolandsleeve）

Measuretheforcerequiredtoturnthesteeringwheel． 1・Placethemachineinatravelpositiononalevel，PaVedsuげace，andreleasetheparkingbrake． 2．MakethehydraulicfIuidtoanoperatingtemperature（40−600C）， 3．Makethebucketempty． 4・Underthis condition，meaSurethe forces requiredtoturn thesteerlng Wheelforboth whenthe eng）neisrunn［ngata［owidlingspeedandwhenitisrunnlngatthemaximumspeed．Atthesame time，Checkforanyirregu［arityintherequiredturningforce（Sticking）． Standardva［u

Forceonknob：Approximately15N（1．5kg）

1・TurnthesteerlngWheeItotherightor［eftuntilitmakesacJosecontactwiththestopperonthe framestopper（StrOkeend）．

2・Continueturn，ngthesteenngwhee［further；thesteer−ngWheelwilIbemadetorotatewhiIesIipp）ng duetotheinternalleakagethattakesp］aceintheorbit−rOJI． Measurethenumberofturn＄thewheelmakeinaminute． Standardvalu

4−5−3

1，SteeringlSImPO＄SibIeorhard

4−5−4

1．Liftarmfailstoriseori＄S10WtOrise．

MeasurerlSlngtimeofliftarm Whenausercomp（ainsthattheliftarmiss10WtOrise，firstmeasurethetimerequiredforther択arm

torisetothespecifiedheightinordertodeterminewhethertheuserfee］stheliftarmmotiontobe SIoworitisreaI［ys10Wduetomalfunction． 1．Makethebucketempty．

2．RuntheengLneatthemaximumspeed 3．Measuretimerequiredtoraisetheliftarmfromthegroundtothehighestposition．

藤森 L5−2

L6−2

Note：1．Thevalues shown aboveare standard valuesfor new machines．VVith machinesthat have

beenoperatedforsometime，thetimew‖beslightIyIongerthanthestandardtime・ 2，Beforemeasurement，WarmUPtheengIneuntiLthecoolanttemperaturegaugeindicatesa temperatureinthe9reenZOne・A［so，WarmthehydrauIicfIuidtoanopearatingtemperature （approximate［y40−600C）．

4−7−1

1．Liftarmfailstoriseorisslowtorise．

4−7−2

1．LiftarmfaiIstoris色Oriss10WtOri＄e．

4−7−3

1，LiftarrnfaiIstoriseoris岳lowtorise．

1−D．DropinshovelmainreJiefvaJvepressureorfaul Measuretheshovercontro】va［vemainpressure． Measurementmethod

1．Connectan oilpressure gauge to thetiltcy［inderoiI PreSSureOutletport①． 2．Raise the［椚arm，then move the contro［levertothe dump position and hoIdit there to operate the ti［t

Cy（indertothestrokeend． 3．Readtheoi［pressuregauge． 4．Standardmainoi］pressurevaLue

20．6MPa（210kg批m2） Note：Beforemeasurement，WarmuPtheenglneuntiJthecoolanttemperaturegaugeindicatesa temperatureinthegreenzone・AIsowarmthehydraulicf［uidtoanoperatingtemperature （approximately40−60OC）． methodl

1．Loosenthe［ocknut①．

Ndte：lbkeanoteoftheamountbywhichtheadjustingscrew②isturnedfromtheoriginal POSition．［ftheoj］pressuredoesnotchangeevenafterturningtheadjustingscrew②，turn

itbacktotheonglnalpositionastheproblemhasresu［tedfromothercauses． 2．WhiIereadingtheoi［pressuregauge，turntheaqjustingscrew②withahexagonalwrenchso

thatthereadingbecomesequaltothestandardvalue． Tighten（turnright）→tOraiseoilpressure． Loosen（turnle代）→tOIoweroiIpressure．

3．Setpressure 20．6MPa（210 Caution：Nevertightenquicklyasthereliefva［veisverysen＄itive． 4．Holdthea嘩ustingscrew②withahexagonalwrenchandsecureitwiththeIocknut①， 5．Causethemainreliefvalvetooperateagaintomakesurethatitopensatthesetpressure． ①

MainreIiefvalve

4−7−4

1．Liftarmfai［storiseoriss10WtOrise．

4−7−5

1．LiftarmfaiI＄tOriseorissIowtorise．

4−7−6

2．Liftarmexc［usivelylowers（drifts）whencontr01vaIveisin…H01d（Neutral）l■position MeasuretheamountoftheLiftarmdrik． Whenausercomplainsthattheliftarm］owerswiththecontrotvarveintherlHoLd（Neutra［）■■position， firstcheckthattheamountofthedriftiswithinthestandardvaIue（norma［）． 1．Warmthehydraulicfluidtoanoperatingtemperature（40−600C）・ 2．Raisethetiftarmtothemaximumheight．tiltbackthebucket，thenstoptheengLne． 3．Measurethecylinderrodlength（Al）inthiscondition・ 4．Waitfiveminutes，then measurethecylinderrod［ength（A2）andcalcu［atetheamountofdrift 瓦1＿A2し

5．Standardvalue（d硝）

L3，L4・2：6mm L5，L6・2：8mm

4−7−7

2こuftarmexcLusively］owers（drifts）whencontro［valveisin HoId（Neutra［）−■position

3・Liftcy［inderdoesnotgenerateenoughforcetora冨sefrontwheelsofFground

4・Liftarmdriftsquicklyatspecificposition

5・Withloadinbucket，撒armlower＄mOmentarily，thenriseswhen柵teverismovedfrom．THo［d（Neutral）…to． Raise■■position．

5−A．Faultyoperationof10adcheckvaJve Ifdriftofthe］椚armisnormarbuttheliftarmmomentarily10WerSandthenstartstorisewhenthelift leverismovedtothe‖Raise‖positionwiththe bucketloaded，remOVeand checktheload check Va］vefortheliftposition．

1．When the10ad checkva］veis normal， fIuidcanflowinthedirectionsindicated byarrows→，butnotin thedirections indicatedby−−−ナ．

2．Therefore，eVenif the pressure Pl acting on the］肌 cylinder piston

becomesgreaterduetotheloadonthe bucketthanthepumppressureP2，the ［iftarmdoesnot10Wer．

3．However，ifthepoppetseat①surface isdamaged，foreJgnmatterisjammed，MainreliefvaIve

210kgucm2

thepoppetisstickingorthesprings②

is damaged，the fluid on the PIside f10WS tO the P2side，CauSlng the慨

armto10WermOmentary，

4−7−10

．Troubleshooting：三 6．Buckettilt−backmotioniss10WOrtilt・backforceisinsufficient

MeasurethebuckettiIt・backtime．

Whenausercornp［ainsthatthebuckettilt−backmotionistoosIow．firstmeasurethetiIt−backtimeto

determinewhethertheuserfeeIsthemovementtobeslowalthoughthesystemisnormaloritrea［Iy movestooslowlyduetoma］function・

1．Runtheengneatthemaximumspeed

2▲Measur？thetimerequiredforthebuckettomovefromthemaximumdump（forwardtiIt）position tothemaximumtilt−back（rearwardtilt）positionwiththe［iftarmfulryraised． L3−2

L4−2

L5−2

L6「2

4−7−11

6．Buckettilt−backhlOtionis＄Iowortilt−backforceisinsufFicient

4−7−12

6．Bucketti）t−backmotioniss）oworti］t−backforceisinsufFicient

6・B・TboLowoverloadreliefvalveopeningpressure ＜Measurementofover［oadreliefvalveopenlngPreSSUre＞ 1，Connectanoilpressuregaugetotheoi［pressurecheckpo止

O of the tilt cylinder to measure the main relief valve OPenlng PreSSure．Aqjust the pressureif necessary accordingtotheprocedurebe［ow． StandardvaIueofmain

20．6川Pa（210kg批m2） 2．Screwintheadjustingscrewtoincreasethesetpressureof themainre］iefvalve①．1fthepressuredoesnotrisewith the adjusting screw turned down，the oiIpressure gauge indicatesthesetpressureoftheoverloadreliefvaLve②on thepistonrodend．Firstmeasureanda叫ustthesetpressure

Oftheover10adreIiefvalve．thenadjustthesetpressureof themainre［iefvaIve①tothestandardvalue． 3．Lower the bucket f［at on the ground，disconnect the ti［t CyIinderhoses④and⑤fromthe cyIinderandinterchange

thehoses．（Connectthehose④tothecylinderbottomend andthehose⑤totherodend．） Caution：Withthehosesconnectedasmentionedabove，ifthe COntrOlleveris placedin the 一Dump position，the bucket makes a tiIt−back1．motion；if theleveris

P［acedinthe＝¶［トback position，thebucketmakesa dump motion．

Screwintheaqjustingscrewtoincreasethesetpressureof themainreliefvalve①whileholdingthecontro‖everinthe ．tilt−back■■position（thebucketmakesa■一dump■一motion）．

Whenthepressuredoesnotrisewiththeaqiustingscrew tumed down，the oilpre＄Sure gaUgeindicates the set PreSSure Ofthe over10ad re［iefvalve③on the cylinder bottomend．

Firstmeasureandadjustthesetpressureoftheover［oad reliefvaIve，thenaqjustthe＄etPreSSureOfthemainreLief VatVe①tothestandardvalue．ARertheseaqjustments， interchangethetiftcy［inderhoses④and⑤againto

restorethemtotheonglnalcondition． 4．Standardsetpressureforover10adre［iefva［ves②and③ 22．5MPa（230kg批m2）

4−7」3

6．Buckettilt・backmotionis＄low・Orti］t−backforce毒＄insufFicient

6・B．Too10WOYerloadreliefva）veopeningpressure

＜Adjustingmethod＞ （1）MakepreparationsreadyforanoverLoadreliefvaIve②pressuremeasurementusinganoilpressure

gaugeasdescribedinstep2， （2）LoosentheIocknut⑥oftheoverloadreliefvalve②．

（3）WhiIereadingtheoi［pressuregauge，turnthea叫ustingscrew⑦withahexagonalwrenchsothatthe readingbecomesequa［tothestandardpressure． Turnctockwisetoraisethepressure． Turncounter−C10Ckwiseto10Werthepressure Standardset

reSSur

Caution：Neverturntheaqjustingscrewquick］yasthere［iefvafveisverysensitive．

・HoIdtheaqjustin9SCreW⑦withahexagonalwrenchwhensecuringitwiththe10Cknut⑥． ・Measurethe overIoad reliefvalveopentng pressureagain to makesurethatthe pressure

COnformstothestandardpressure． ・AdjustthepressureofthemainreIiefvalvetothestan−

dardpressure．

OverIoadreliefvaLve②，③ 4−7−14

⑥

6．Buckettilt−backmotionisslowortilt−backforceisinsufFici色nt

6−B・TooIowoverLoadreliefvalveopeningpressuresetting

＜Adjustingmethod＞ （1）Makepreparations readyforoverIoad reliefvalve③pressuremeasurementusingan oilpressure

gaugeasdescribedinstep3． （2）LoosentheIocknut⑥oftheover10adreFiefvaIve③． （3）Whilereadingtheoilpressuregauge，turntheadjustingscrew⑦withahexagona［wrenchsothatthe

readingbecomesequaltothestandardpressure． Turnc10Ckwisetoraisethepressure． Turncounter−C10Ckwiseto［owerthepressure． Standardset

,ressur

22．5MPa（230k9触m2き Caution：Neverturntheadjustingscrewquick［yasthere［iefva［veisverysensitive． ・HoIdtheaqjustingscrew⑦withahexagonaIwrenchwhensecuringitwiththelocknut⑥．

・Measuretheover10adre＝efvalveopenlngPreSSureagaintomakesurethatthepressureconformsto thestandardpressure． ・Adjustthesetpressureofthemainre］iefvaIvetothestandardpressure．

Over［oadreliefvalve②，③ （4）Restorethetiltcylinderhoses④and⑤totheoriginalconditionbyinterchangingtheirconnection．

4−7−15

7．BuckettiItsforwardwithcontro［vaIvein ．HoLd（Neutral） ．state（frontwhee］scannotberaisedofFground） Measuretheamountofdriftbfthebucket． When a usercomp［ainsthatthe buckettiltsforward spontaneouslywith thecontroIva）vein a Hold（Neutra［）

state，Rrstcheckthattheamountoftheforward用tiswithinthestandardamount

（normal）．

1，VVarmthehydraulicf［uidtoanoperatingtemperature（40−600C）， 2．Lowerthe［帆armtothelowestposition，tiltbackthebucketfully，thenstoptheenglne． 3．MeasurethecyIinderrod［ength（Al）， 4．VVaitfor缶veminutes．thenmeasurethecy［inderrodlength（A2），andcalculatetheamountof

dr椚匹頭． 5．Standardvalue（amountofdri托） L3，L4・2：Wjthinllmm

L5，L6・2：Withjn9mm

ノ

Al→A2

4−7−16

7．BuckettiItsforwardwithcontro［va］vein■■Hold（Neutra［）l state（frontwheelscannptberaisedofFground） 7−A．Checkthetiltcylinderforinternalleakage．

Check the 1．Checkthatthefrontwheel＄CanberaisedandheIdofFthegroundbythetiItcylinder．

2．IfforeIgnmatterisJammedintotheover10adreIiefvaIveorthevalveisinpoorcontactwithits Seat，PreSSuref［uidinthepiston rodendflowsdirectIytothetankcircuitviatheover［oad reFief

Valve，SOthe tiltcylinderrod cannotbe he）din an extended position（frontwheelsgradual［y 10Weけ

3．As the over10ad re［iefvalvesin the piston rod end and cylinder bottom end are the same，

functionalityofboththeva［vescanbecheckedbyinterchanglngthem． 4．If oil−tightness of the cylinder bo仕Om end over［oad relief valveis defective，the bucket SPOntaneOuS‡ytiltsforward lfoil−tightnessofthepi＄tOnrOdendoveHoadreliefvalveisdefective，

hefrontwheelscannotberaisedandheldo汗the

Over［oadreliefvalveon P†stonrodend

4−7−17

7．BuckettiItsforwardwithcontro［valvein■一H01d（Neutra［）一 state（frontwheelscannotberaisedofFground）

4−7−18

10・Too］argecontroIleveroperatingresistanc

洞easuretheforcesrequiredto When a usercomplains thatthe shovelcontrolleveris hard to move，firstcheckforthe forces requiredtooperatethecontrollever． 1・Warmthehydrau（icf［uidtoanoperatingtemperature（40to60OC）． 2．Stoptheenglneand暮owerthebuckettotheground．

3・Attachaspringba［ancetotheknobofthecontrollever，thenpuLIthespnngbaIancetomovethe levertoeachpositionwhi［emeasurlngeaChoperatingforceattheendofastroke． 4・Standardvalue

Lever operating direction

N（kgf）

L3−2

L4−2

L5−2

L6−2

Hold（Neutra［）→Raise

24．5（2．5）

24．5（2．5）

24．5（2．5）

24．5（2．5）

HoId（Neutral）→Lower

24．5（2．5）

24．5（2．5）

24．5（2．5）

24．5（2．5）

Ho［d（Neutral）→Tilt

24．5（2．5）

24．5（2．5）

24．5（2．5）

24．5（2．5）

Hold（Neutral）→Dump

24．5（2．5）

24．5（2．5）

24．5（2．5）

24．5（2．5）

Lower→F暮oat

44．1（4．5）

44．1（4．5）

44．1（4．5）

44．1（4．5）

Float→Lower

17．7（1．8）

17．7（1．8）

17．7（1．8）

17．7（1．8）

10／TbolargecontroI［everoperatingre＄istance 10−A．Tootargemovementrcsistanceofcable

Usingapush−Pu［lgauge，meaSuretheoperatingforceofeachspooL l．Tiltspool（HoId／Neutral）→80．4N（8．2kgf） 2．TiItspool（fuLIstroke：TiIt，Dump）→109．8N（11．2kgり 3．Liftspool（Hold／Neutra［）一→84．3N（8．6kgり 4．Liftspool（fuLIstroke：Raise，Lower）→137．3N（14．Okgf） 5，F）oatreIease（detentrelease）→80，4to178N（8，2to18．2kgf）

4−7−20

﹁ノ ↓ノ

〕

N0．MEW．600AE lssued：Julv，2002

丁甜。。。．。。A，l。 INTERNAn10NALMARKETINGDMSlON： 1−15−5，Nishi・Shimba＄hi，Minato・kLJ，lbky0 105・0003，Japan M：JAPAN＋別々■591さ152，8・35918153 Al＝短htsreserved

Z−1407010（HO）PrjntedinJapan

うノ ↓ノ

︑