TCM Wheel Loader L50-3 Service Manual SEW-682CE - PDF DOWNLOAD

No．SEW−682CE

Tt訓閲㊥ 壬≡三￣二￣二三≡三三二二＝ニニ

WHEJ：L L＿OADER

上5■0＿ヨ （SerialNo．02101andafter）

TCMCORPORAT10N

No．SEW−682CE

FOREWORD TCMofftrsawidevarietyofwheelloaderswhichhavebeenenthusiasticallywelcomedbyusersallover

theworld．TCMModelL50−3articulatedtypewheelloaderisthelatestproductdevelopedfromy

researchandexperience．Togetthemostoftheloader，itisrequiredthatyoubecomefamiliarw ftatures，COnStruCtion，OPeratlngandmaintenanceprocedures．

ThisServiceManualexplainsthestructureoftheaboveloaderforservicepersonnelandshopworkers． WehopeitwillbeyourreferenceguideduringservIClngjobs． Forthestandardservicevaluesandtheprocedureforinspection，SeetheInspectionManualandforthe PrOCedureformaintainlngeaChcomponentunit，SeetheShopManualoftheirrespectivecomponents・ ThedescrlPtlOnSandspecincationsdescribedinthismanualaresu句ecttochangewithoutnotice．

November，2004

丁伽。。。。。。Å

ThisServiceManualapplies tothe丘）1lowlngloaders： L50＿3：＃02101andafter

（Emptypage）

No．SEW−682CE

TABLEOFCONTENTS l

0．SPECIFICAT10NS

1

0．1 0UTERVIEWS 2

0．2 SPECIFICArIONS 5 5

l．ENGINEANDRELATEDCOMPONENTS

0 1

2

1

4

1

1．3 FUELSYSTEM

OO

1．2 COOLINGSYSTEM

／b

1．1 ENGINE

1．4INTAKEANDEXHAUSTSYSTEM 2 2

l．5 ELECTRICALSYSTEM 1．6 ENGINECONTROLUNIT

2．1 DRIVEUNIT

2．2 TORQUECONVERTER 2．3 TRANSMISSION 2．3．1CLUTCHSHAFT 2．3．2 POWERFLOW 2．3．3 TRANSMISSIONCONTROLVAINE 2．3．4 TRANSMISSIONCONTROL

2．3．5 ArC（AUTOMArICTRANSMISSIONCONTROLLER） 2．4 0ILCIRCULArIONROUTE 2．5 PROPELLERSHAFTS

2．6 AXLES（FRONTANDREAR） 2．6．1DRIVEAXLE 2．6．2 DIFFERENTIAL 2．6．3 FINALREDUCTIONGEARANDBRAKEUNIT

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

3．1 SERVICEBRAKE

3．1．1GENERALDESCRIPTION（BRAKELINE） 3．1．2 BRAKEVALVE 3．1．3 CHARGINGVAINE

1 2 2 00 0 00 00 8

3．BRAKESYSTEM

7 00 3 5 5 ︵X︶ 0 7 0 ′b 8 0 0 5 史U Oノ 0ノ 0 2 2 つJ 3 3 3 4 5 ′b ∠U ′b 7 7 7 7 7 7

2．POWERTRAIN

00 0ノ

No．SEW−682CE

0ノ

2

qノ

3

3．1．4 SLACKADJUSTER 3．1．5 DISKIiRAKE

0ノ

4

3．1．6 0THERCOMPONENTS

5 ／んU

qノ

3．2 PARKINGBRAKE

0ノ

3．2．1GENERALDESCRIPTION（BRAKELINE）

1 1 1 1

4

4．4 STEERINGVALVE

つJ

4．3 STEERINGWHEELUNIT

0 0 1 1 1

4．2 0ILCIRCULArIONROUTES

0 0 0 1 1

4．1GENERALDESCRIPTION

lノ l O

4．STEERLNG SYSTEM

0ノ

3．2．2 DISKBRAKE

00

4．5 CONTROLLINKAGE

4．6 STEERINGCYLINDER

4 1

2 2

1

qノ 4

1

5．1 FRAME

l

2

1

5．FRAMEANDCOCKPLT 5．2 CENTERHINGEPIN

7 1 3 ′b

6．10ILCIRCULATIONROUTES（HYDRAULICCIRCUITDIAGRAM）

7

6．HYDRAULICSYSTEM

OO 8 1

6．2 PUMP

3 5 ′b 2

6．2．2 STEERINGPUMP

3

6．2．1MAINPUMP

つ︼ つJ

6．3 VALVE

3 4 4 4 1

6．4．1SYSTEMINOPERATION

4 4

6．4 VALVECONTROLS

つJ つJ

6．3．2 PILOTVALVE

つJ

6．3．1MAINVAI」VE

1 1

6．4．2 STOPVALVE

1 1

6．5 0ILTANK

1 1

7．1BOOM，BELLCRANKANDBUCKET 7．1．1GENERALDESCRIPTION 7．1．2 BUCKET

7 00 8 1 2 1 1 1 1 4 41 4 5 5 1

7．LOADHANDLLNGSYSTEM

7．1．3 BUCKETLEVELER，BOOMKICKOUTANDGSS 1 1 1 1

No．SEW−682CE

5

1

5 5

5

5

1 1 1

′ユ

7．2．1BOOMCYLINDER

5

7．2 CYLINDER

7．2．2 BUCKETCYLINDER

父U

7．3 ANTI−PITCHINGSYSTEM（APS）［OPTION］ 3 3

8．ELECTR］CSYSTEM 8．1LIGHTINGEQUIPMENT

4 4 00 00 0ノ

8．2 METERSANDSWITCHES

0 ′0

8．2．1MONITORLAMPS（CLUSTERGAUGEUNIT）

／LU ′0

8．2．2 LIGHTINGSWITCH

′0 ／LU

8．2．3 TURNSIGNALSWITCH

′0 ∠U

8．3 LOCArIONOFRELAYS

7 1

8．4 ELECTRICCIRCUITDIAGRAM

1 1

1

1

5 ′0 ′0 00 0ノ 2 O 1 7 7 7 7 7 00 ︵X︶＋00 1

1

9．AIRCONDITIONER

1

1 1 1

9．1．2 AIRCONDITIONERUNIT

1

9．1．4 RECEIVERTANK 9．1．5 CONDENSER 9．1．6 AIRCONDITIONERPIPING

1

9．1．3 COMPRESSOR

1

9．1．10PERArINGPRINCIPLE

1

1

9．1 GENERALDESCRIPTION

（Emptypage）

0．SPECIFICAT10NS

0．SPECIFJCAT10NS 0．10UTERVIEWS Unit：mm［in．］

Fig．0．10uterViews −1−

0．SPEC（F（CAT［ONS

0．2 SPECIFLCATLONS Model

L50＿3・LX300＿7

r吋pe

Fronトendarticulatedloaderwithdieselenglne

Bucketcapaclty，heaped Breakoutforce，bucketcylinder SAEratedoperatlngload，fu11turn

5．0【6．5］

m3［y3］

237．3i24200）［53361］

kN（kgf）［1bf］

8000［17640］

kg［lbs］

Risingtlme，fu11load Lowerlngtlme Bucketdumplngtlme

s

6．8

S

3．5

S

1．7

Travelspeed，fwdlst

km／h［mph］

6．5［4．0］

fwd2nd

km／h［mph］

11．5［7．1】

fwd3rd

km仙［mph］

19．0［11．8】

fwd4th

km／h［mph］

33．5［20．8】

revIst

km／h［mph］

7．0【4．3］

rev2nd

km／h［mph］

12．5［7．8］

rev3rd

km／h［mph］

20．5【12．7］

rev4th

knJh［mph］

34．5［21．4］

くじ U

⊂ 田 ∈ L．．

qj

ロ■

Max．tractionfbrce

kN（kgf）［1bf］

279．5†28500）【62843］

250tilt

Gradeability，fwdlst Minimumturmngradius OutermOStPartOfbucket

mm［in・］

7910［311．4］

centerofoutermostwheel

mm［in．］

6780［266．9］

mm［in・］

9430【371．3］

mm［in・】

9330［367．3］

mm［in・］

3180［125、2］

mm［in．］

3480［137．0］

mm［in・］

3750［147．6］

Overalllength，bucketonground incarryposition Overallwidth，loaderbody bucket

⊂ ○

∈ q）

Overallheight，tOPOfROPS

∈

6145【241．9］

石 Overalloperatingheight，bucketfu11yraised mm［in・］ Wheelbase

mm［in．］

3700［145．7］

Tread，frontwheels

mm［in．］

2460【96．9］

mm［in．］

2460［96．9］

rearwheels

−2−

0．SPECIFICAT10NS

Model

L50．3・LX300＿7

Rearoverhangangle

O

26

Min．groundclearance，Centerhingepln

mm［in．］

425［16．7］

Buckethingepinheight

mm［in．］

4430［174．4］

mm［in．］

3130［123．2］

【： ○ Dumplngheight，at450dischargeangle

1480［58．3］

m［in・］

凹 【＝ U

∈

云

O

Bucketdumplngangle，bucketfu11yraised

O

50

50

Tbwingpinheight

mm［in．］

1210［47．6］

Weightofloader

kg［1bs］

29700［65489］

1トJ，．⊂

b心

−3−

0．SPECJFICATJONS

NOTE

−4−

1．ENGINEANDRELATEDCOMPONENTS

l．ENGJNEANDRELATEDCOMPONENTS 1．1ENGINE l．Generaldescription

TheenglnemOuntedonthisloaderisa4−CyCle，Water−COOled，in−1inedirect−1nJeCtiontypedieselengl EachenglneisequlPPedwithaturbocharger・

Theenglneismountedattherearoftheloaderanditspoweristransmittedthroughtheflywheelanddrive rlngtOthetorqueconverter・

−5−

1．ENGINEANDRELATEDCOMPONENTS

ISUZU CC−6WGIX DieselEngine 4−CyCle，Water−COOled，in−1ine6−Cylinder，direct−1qjectiontype

Withturbochargerandintercooler Numberofcylinders−borexstroke

6−147mm［5．8in．］x154mm［6．1in．］

Total displacement

15．681L［956．9in．3］

Compression ratio

16．4

Engineperformance

Ratedspeed

1800rpm

Ratedoutput

243kW（330ps）

Maximumtorque

1442N−m（147kgf−m）［10631bf−ft］（atapprox・1500rpm）

Full−loadmin．consumptlOnratio

203g此Wh（149g／psh）（at1300rpm）

（atratedoutput）

215g／kWh（158g／psh）（at1800rpm）

Dry weight

Aboutl150kg［25361bs］

Dimensions（OVeralllengthx OVerallwidthxoverallheight）

1500．5InmX999．0mmX1261．7mm［59．07in．x39．33in．x49．67in

Firing order

1−5−3−6−2−4

Rotational direction

Clockwisewhenviewedfromcrankpulley

Startsupportunit

Glow plug

Engineshut−0ffsystem

Key switch system

Unloadedmax．speed （whenseparatelymeasured）

2460rpmorless

Unloadedmin．speed （Whenseparatelymeasured）

Allowabletiltingangle

900月。rpm

300infourdirectionswhenviewedfromflywheel

Maintenancedata

Valveopenlngandcloslngtlme

Intakevalve（OPen）：21．20be丘）reTDC

Intakevalve（Closed）：26．90afterBDC Exhaustvalve（OPen）：52．70befbreBDC Exhaustvalve（Closed）：17．80afterTDC Valve clearance

Intakevalve（COld）：0．4mm［0．O16in．］ Exhaustvalve（COld）：0．4mm［0．016in．］

Injection timing

100beforeTDC

Iqiectionstartpressure

17．7MPa（181kg批m2）［2574psi］

Compressionpressure

2．94MPa（30kgf／cm2）【427psi］

Note：ForthemaintenanceoftheenglnePrOPer，SeetheModelAA−6WGl＆BB−6WGIDieselEngin

WorkshopManual（No．IDE−2390）publishedbyIsuzuMotorsIXD．

−6−

1．ENGINEAND RELATEDCOMPONENTS

2．OutervieⅥ7S

2 4 5

1．TURBOCHARGER 2．EXHAUSTMANIFOLD 3．WERDUCT 4．NOZZLEHOLDER 5．GENERATOR 6．0Ⅱ」円1LER 7．INJECTIONPUMP

8．OmPAN

15．BREATHERHOSE

9．FUELFILTER lO．WERSEDIMENTER

16．FLmEEL 17．OILLEVELDIPSTICK 18．GENERATORBEIJ

ll．STARTERMOTOR 12．AIRINTAKEHOUSING

13．AIRINTAKEDUCT 14．INTAKEMANIFOLD Fig．1．10uterViewsofEngine（1） −7−

A．COOLINGWER OUTLET B．COOLINGWERINLET

1．ENGINEANDRELATEDCOMPONENTS

A‥記；冨‡認U怒7J：写㌫蒜Sと腔誌。midw。y。nthes，a。b。tWee。 puLleyswhenpressedbyafingerpressureof98N（10kgf）【2・2Lbf］・ Newbelt（WhenrepLaced）：13tol至mmE9・き！！09・学9呵 Reuse：

15to17mm【0．59toO．67in．］

Note：Forthenamesofthepartsshowninthenguresbelow，SeePage7・ Fig．1．2 0uterViewsofEngine（2） −8−

1．ENGINEANDRELATEDCOMPONENTS

3．Enginemounting

TheenglneisconnectedtothedriveunitandmountedinsideoftherearframeatfourpolntS・Theenglne hasmountlngrubbersattherightandleftofthecylinderbodyfbrreducingvibration・

Note：B＞ぢ＝コ222N−m（22．8kgf−m）【1651bf−ft］ 匪＞ぢ＝コ232N−m（23．7kgfLm）【1711bf−ft］ 軒＞ぢ＝：：コ144N−m（14．7kgf−m）【1061bf−ft］

1．BRACKET 2．BRACKET 3．DRIVEUNIT

4．ENGINE 5．MOUNTINGRUBBER 6．PLATE Fig．1．3 MountlngOfEngine

−9一

7．HOSE 8．0ILFILTER

1．ENGINEAND RELATEDCOMPONENTS

1．2 COOLJNGSYSTEM Cooling

Water−COOledforcedcirculationtype，hydraulicmotordriven

Cooling fan

Platetype，discharge，850mm［33．5in．］dia．6−bladed Hydraulicmotordriven

Water pump

Centrifugaltype，directlyconnectedtogeartrain

Radiator

forenglne

Platefin＆tube，PF2−7（G−7）

fortorqueconverteroil

Multipleplates，PTO−LS（lowertankincorporated）

for hydraulic oil

Aluminumcorrugated（Straight）nn，CF40−1

forintercooler

Corrugated（Straight）fin

Dryweight

Approx・358kg［7891bs］

Approx．290kg［6391bs］forengine Approx・27kg［591bs］fortorqueconverteroil Approx．6kg［131bs］forhydraulicoil Approx・35kg［771bs］forintercooler

TheenglneCOOlingsystemisawaterてCOOledfbrced−Circulationtypebymeansofthewaterpump・ Thecoolingwaterisdrawnupfromtheradiatorbythewaterpump，flowsthroughtheoilcoolertothe Cylinderblockforcoolingthecylinderlinerandissenttothecylinderhead・

ThecoolingwatersentintothecylinderheadcooIsthecombustionchamberandtheareasaroundthe

Valveseatandflowsthroughthethermostattoreturntotheradiator．Whenthewatertemperatureislow，

thermostatisclosedsothatthecoolingwaterflowsthroughthebypassvalvetocirculatedirectlyinthewater PumP・

ー10−

1．ENGINEAND RELATEDCOMPONENTS

hlStalIationofradiatorhose

4

3

6

7

5

8

9

Note：B＞ぢ＝：：コ5・9N−m（0・6kgf−m）［4・31bf−ft］

匡＞14＝ゝTubeend：Sealingagent（JapanHermeticCo・，Ltd・Herme−SealSS−80）；itshouldnot

beappliedtotheinnersideofthehose．

1．HOSE

4．INTERCOOLER

2．RESERVOIRTANK 3．RADIATORUPPERTUBE

5．RADIATOR 6．HOSE Fig．1．4 EngineCoolingSystem −11−

7．RADIATORLOWERTUBE 8．OmCOOLER 9．CURRENTPLATE

1．ENGINEANDRELATEDCOMPONENTS

Hydraulicmotor−drivenfandrivesystem Thecoolingfanisdrivenbythehydraulicmotor，Whichisinturndrivenbythepressureoilsentfromthe

fandrivesystemandcoolerpumpunitofthemainpump・

MountingangleofeLbowonmotor

1．MAINPUMP 2．OmCOOLER 3．FAN 4．HYDRAULICFAN MOTOR （HydraulicCircuitDiagram）

Fig・l・5 FanDriveSystem −12−

1．ENGINEAND RELATEDCOMPONENTS

HydrauljcCircuitDiagram T PORT

1七PORT

Model：LMF28

Fig．1．6 HydraulicFanMotor

−13−

1．ENGINEANDRELAJEDCOMPONENTS

7

8

13

19

12

SectionA−A

Note：B＞ぢ＝コ147to186N−m（15to19kgf−m）［108to1371bf−ft］

1．OUTPUTSHAFT

9．MAINBEARING

2．CASE 3．THRUSTPLArE 4．PISTONASSEMBLY

lO．SUB−BEARING

16．VARIABLEFLOWCONTROL PILOT VALVE

ll．OILSEAL

17．FLOWCONTROLSPOOL

12．ENDCOVER

18．FLOWCONTROLSPOOL

5．CYLINDERBLOCK

13．CENTERSPRING 14．INTAKESAFETYVALVE

19．MAINSPOOL

6．VALVEPLATE 7．RETAINERGUIDE 8．RETAINERSHOE

SPRING 15．INTAKESAFETYVALVE

SPRING 20．PROPORTIONALSOLENOID 21．FILTER

Fig・1・7 StructureofHydraulicFanMotor

−14−

1．ENGINEAND RELAJEDCOMPONENTS

Intercooler

SincecompresslngairprlOrtOintroducingltintothecylinderincreasesthecharge−airtemperatur

massofairthatcanbeintroducedintotheenglneislessthanthatwhichwouldbepossibleifthecompressed

airwereatambienttemperature．Consequently，englneCharge−aircoolers，COmmOnlyreftrredtoasintercoo

areusedtoreducethetemperatureofthechargeair．Thisloaderhasanintercoolerinstalledbetweenthe turbochargerandintakemanifoldtoreducethecharge−airtemperature．

Theintercoolerisanair−COOlingsystemandlocatedinfrontoftheradiator．Itusesacoolingfanto

thecharge−airtemperature．

1．HOSE 2．TUBE 3．TUBE 4．HOSE 5．INTERCOOLER 6．BRACKET

DetaiJofareaA

Fig．1．8IntercoolerPiping

−15−

1．ENGINEAND RELATEDCOMPONENTS

l．3 FUELSYSTEM Injection pump

Bosh type

Irtiectionnozzle

Sealedporoustype Centrifugal，autOmatictimer

Injection timing regulator Fuelfilter

Piston type Papertypewithoverflowvalve

Governor

Centrifugal（mechanical），all−Speedcontro1

Fueltankcapaclty

450L【119U．S．gaり

Fuelfeedpump

Thefuelfeedpumpdrawsfuelfromthefueltankthroughthewatersedimenterandfbrcesitthroughthe fuelfilterintotheinJeCtionpump．Thefuelisthendistributedunderpressuretotheiruectionnozzleand

lqeCtedintothecylinder．

−16−

1，ENGINEANDRELATEDCOMPONENTS

Note：E＞ぢ＝コ452Nrm（46・1kgf−m）【3331bf−ft］ 1．SUCTIONHOSE 2．RETURNHOSE 3．FUELTANK 4．DRAINCOCK 5．COVER 6．CAP 7．STRAINER

Fig．1．9 FuelSystem

−17−

1．ENGLNEANDRELATEDCOMPONENTS

1．41NTAKEANDEXHAUSTSYSTEM Aircleaner

Dryfilterpapertype（EGB16

）

（usedwithstratprecleaner）

1．Generaldescription Theintakesystemoftheenglneisdesignedsothattheoutsideairdrawnthroughtheaircleaneriscompressed bytheturbochargerandsenttotheintakemanifbld・ Theexhaustsystemoftheenglneisdesignedsothattheexhaustgasissentfromtheexhaustmanifoldto

theturbochargertodrivetheturbochargerandisdischargedthroughthemufflerandtailpipe・

ABecarefuInottotouchthemumerorexhau？tmanifoldsincetheyarehotwhentheengineis runnlngandfbrawhiIeafteritisshutoff；Otherw）Se，yOumightburnyOurhand．

一18−

1，ENGINEAND RELATEDCOMPONENTS

Note：B＞超＝ゝJoint‥Exhaustseal（CHcementNo・600madebyIshikawaGasketoranequivalent） 臣＝＞Bracketmountingbolt ぢ＝コMlO：50・1N−m（5・1kgf−m）【36・91bf−ft］ M12：92．ON−m†9．4kgf−m）【68．Olbf−ft］

紹＝ゝThreadedarea：LOCTITE＃262

1．MUFFLER

5．TAILPIPE

9．PRECLEANER

2．PIPE

6．EJECTOR 7．BAND 8．EXHAUSTVALVE

lO．AIRCLEANER ll．PIPE

3．HOSE 4．ELBOW

Fig．l．10IntakeandExhaustSystem

−19−

1．ENG）NEANDRELATEDCOMPONENTS

2．Ttlrbocharger ItispossibletoattainhighenglneOutPutbysendinghigh1ycompressedairintothecylindersontheintake

StrOketoincreaseairsupply，thusincreaslngthequantityoffueltobeiIt）eCted・Tbachievethispurpose，t

loaderisequlpPedwithanexhaust−gaS−driventurbocharger．

Theturbocharger，sexhaustgasinletisconnectedtotheexhaustmanifold・Theexhaustgasrotatest turbinewheelatahighspeed，beforebeingroutedthroughtheexhaustgasoutletintothemufner． Therefore，theimpeller，mOuntedontheoppositeendofthesameShaftasthetu止ine，alsorotatesatahigh SPeedtocompresstheairdrawnthroughtheaircleanerandsendittotheintakemanifold．

3．Aircleaner TheaircleanerusedincombinationwiththestrutprecleanerseparatesdustfromtheairwithhighefBciency， COntributingtoextendtheservicelifeoftheaircleaner． Dustseparatedbythestrutprecleanerisautomaticallydischargedfromtheqjectorincorporatedintothe

POSt−mufflerexhaustsystem．

1．BODY 2．ELEMENT 3．ELEMENT 4．NUT 5．NUT 6．COVER

Fig．1．11AirCleaner

−20−

1．ENGINEANDRELATEDCOMPONENTS

4．Strutprec）eanerinoperation

Theairh Omthescreenhoodissuckedintothestruttubewheredustisseparatedfromtheairbycentrif fbrce．Then，thecleanedairissenttotheaircleaner．

ThedustinthestruttubeissentthroughthescavenglngPIPeandhoseintotheqjectorinthetailpipe．The

dustisthenautomaticallydischargedwiththeenglneeXhaustgasfromthetailpipetotheatmosphere・

Contaminated air

Cleaned air

From muffler

Fig．1．12 Strutprecleanerinoperation

ー21−

1．ENGINEANDRELATEDCOMPONENTS

1．5 ELECTRICALSYSTEM Battery Voltage and capacity

12V120Ah（5−hourrate）

Quantity

2

Weight（percase）

About38kg［83・81bs］

Startermotor

Type

Dry，gearreductiontype

Ⅵ）1tageandoutput

24V7．OkW

Start method

Pinion−Shifttype

AlternatOr r吋pe

A／Csemiconductorcommutationtype

Ⅵ）ltageandoutput

24V50A

Driving

Belt−drive

Automaticcharglngregulator

ICtype（integratedintothealternatOr）

Coldstartaid

Glow plug Keyswitchtype

Stopping device

1．Battery

Twobatteriesareinstalledinsidethebatteryboxattherightandleftsidesoftherearframe・ inspectionofthebatteryunitisneeded，OPenthebatteryboxcover・

ADanger！Useduecautionwhenhandlingthebatteryunit・

1．Nofire・Nospark・Neversmokeorusefireornakedflamenearthebatteryunitsinceflammabl gasisalwaysreleasedfromthebatteryboxcover1

2．ThebatteryelectrolyteisdilutesuIfuricacid・Itwi11causePainfulandseriousburnsifitgetso theskin．Itcancauseblindnessifitgetsintoeyes・Ifelectrolytegetsontoyourskin，fLushoff coplOuSamOuntOfwaterandgetmedicalhelp・Ifelectrolytegetsintoyoureyes，flushyour outwithcoplOuSamOuntOfwaterandgettoadoctoIこ

−22−

1．ENGINEANDRELATEDCOMPONENTS

2．Electriccircuit Fortheelectriccircuitdiagramoftheenglne，reftrto

Fig．8．4ElectricCircuitDiagram・

（1）Generaldescription ①Theenginecoldstartaidisaglowplug．Ifacoldenginewon

tstart，turnthestarterswitchtotheO

POSitiontoenerglZetheglowplug，thuspreheatingtheenglne・Then，turnthestarterswitchtot

STARTpositiontocranktheengine．（Theglowplugoperatesupto8seconds・However，itwo

OPerateWhenthecoolingwatertemperatureisabovelOOCor500F・） TheglowpluglSinstalledontheintakesideofthecylinderblock・

②Theengineshut−Offdeviceisakeyswitchtype．TurningthestarterswitchtoOFFwillactuatethest

motor（Wire motor）orthe stop solenoidto shutoffthe engine．（Engine Shut−OffDevice） FormoreinformationontheenglneShuト0ffdevice，referto

1・6ENGINECONTROLUNIT・

（2）Starterswitch

Thestarterswitchhas3positions：OFF，ONandSTART・

AEngineNeutraSart UnlessthetransmlSSlOnCOntrOIswitch（Shiftlever）isinneutral，theenginewon

tstart．（Refbrto

TRANSMISSIONCONTROL： ） Thispreventstheloader丘■OmmOVlnguneXPeCtedlywhenthestarterswitchisturnedon・

B BR ACC Rl R2 C OFF ○

ON

START

（REAR）

Fig．1．13 StarterSwitch

−23一

○

2．3．4

1．ENGINEANDRELATEDCOMPONENTS

1．6 ENGINECONTROLUNIT l．Acceleratorpedal

TheenglneSPeediscontrolledbyoperatlngtheacceleratorpedal・

Whentheacceleratorpedalispressed，thegovernorcontrolleveroftheenglneisactuatedthroughthe controIcablesothatanenglneSPeedmostsuitedtotheworkingconditionisobtained・

瓢

＼

転ゝダ ニノニ ／

／

1．ACCELERATOR PEDAL ASSEMBLY 2．CABLE 3．BRACKET 4．ENGINE 5．ACCELERATOR SWITCH

Fig・1・14 AcceleratorPedal −24−

♂

／

1．ENGINEANDRELATEDCOMPONENTS

2．Engineshut・Offdevice AdieselenglnedoesnothaveanyelectriclgnltlOndevicelikeagasolineenglne，SOitcannotusuallybe

Shutoffsimplybyturningthemainswitch（StarterSWitch）0ff．Forthisreason，thewheelloadersha

engineshut−0ffdeviceusingawiremotor（enginestopmotor）orastopsolenoidwhichshutsofftheeng Simplybyturnlngthestarterswitchoff．

WhenthestarterswitchisturnedOFF，aWiremotorgetsexcitedandactuatesthegovernorstoplever．

ThisreducesthequantltyOffuelinjeCtedfromtheirt］eCtionpumptotheiIt）eCtionnozzletozero，thusshutt

Offtheenglne．

−25−

1．ENG［NEAND RELATEDCOMPONENTS

NOTE

−26−

2．POWERTRAIN

2．POWERTRAIN

Thepowertrainconsistsofthedriveunit（torqueconverterandtransmission），PrOPellershaf［s，front

rearaxles，andtires． Powerfromtheenglneistransmittedtothedriveunitwhereitisconvertedinbothrotationalspeedand directionanddistributedthroughthepropellershaftstothefrontandrearaxles．Thepowertransmittedto

eachaxleisfurthersentthroughthewheeltothetiresothattheloadermoves． TheschematicdiagramofthepowertransmissionoftheloaderisglVenbelow．

C D ‥PROPELLERSHAFT

Fig．2．1PowerTrain −27−

2．POWERTRAIN

2．1DRIVE UNIT Name

TCM683−25

Tbrqueconverter Name

8FN−1500−14D（MS371）

Niigata Converter 乃pe

3−element，1−Stage，Slngle−Phasetype

Oilcooler

See

Pressure setting

0．27MPa（2．8kgf／cm2）［39．8psi】

Charging pump

See

1．2COOLINGSYSTEM：

6．2PUMPn．

Transmission Name

Solenoid，fu11power−Shift，COnStant−meShtype，fu11−mOdulation

Speeds

4fwd／4rev

Clutch（transmission） 乃pe

Wetmultiple−disktype

Operation

Hydraulic

Pressure setting

2．06to2．35MPa（21to24kgf／cm2）［299to341psi］

Oil capacity

45L［11．8U．S．gal．】

Weight

1100kg［24261bs］

GeneralDescription

Thedriveumitconsistsofacombinationofatorqueconverterandatransmission，formlngaCOmPaCtOn

PleCebody，WiththeconverterhouslngCOnneCtedtothetransmissioncase．

Thedriveunitisconnectedtotheenglneandismountedintherearframewithmountlngrubbers・ Powerfromtheenglneistransmittedthroughtheengineflywheelandtorqueconvertertothetransmission．

Theenglneandthedriveunitareconnectedtoeachotherbylinkingtheengineflywheeltotheconverter frontcoverwithadriverlng．

ー28−

2．POVVERTRAFN

Note：Fortheconnectionofthedriveunitandframe，SeeFig．1．3MountlngOfEngine．

Note：B＞ぢ＝コ46・4N−m（4・7kgf−m）［34・01bf−ft］，紹＝ゝThreadedarea：LOCTITE＃262 P＞（芯＝コ81・2N−m（8・3kgf−m）［60・01bf−ft］，f在⊃ゝThreadedarea：LOCTITE＃262

1．FLYWHEELHOUSING 2．FLYWHEEL 3．TORQUECONVERTERHOUSING 4．DRIVERING Fig．2．2 DriveUnitMount

−29−

（Emptypage）

−30−

2．POWERTRAIN

Clutchoilpressure：

2．1to2・4MPa（21to24kgf／cm2） ［299to341psi】

Safttyvalvereliefpressure：0・92MPa（9・4kgf／cm2）［134psi］

1．fromOILCOOLER 2．0ILFILLPORT 3．PARKINGBRAKERELEASE PRESSURE

18．OILTEMPERATURE GAUGEFITTINGPORT

4．toOILCOOLER

20．CONVERTERINPRESSURE CHECKPORT

5．丘omFILTER

Note：1．紹＝ゝThreadedareaofplug：

19．CONVERTEROUT

LOCTITE＃572

PRESSURECHECKPORT

3l．CHARGINGPUMP 32．SUCTIONTUBE 12．FWD．CLUTCHPRESSURECHECK 33．STRAINER 34．0ILGAUGE P（〕RT

2．ControIvalvesolenoidoperationtable （●：ON）

F sol R sol A sol B sol

ll．REVCLUTCHPRESSURECHECK

20

PORT

13．1STCLUTCHPRESSURECHECK

SectionA−A

35．CONTROLVALVE 36．HOSE 37．BREATHER

PORT 14．2NDCLUTCHPRESSURECHECK PORT 15．3RDCLUTCHPRESSURECHECK

39．PLUNGER（SAFETY

PORT 16．4THCLUTCHPRESSURECHECK

VALVE） 40．SENSOR

PORT 17．PRESSURESWITCHFITTINGPORT

Note：ForthesectionsD−D，E−EandJ−），reftrtothenextpage． Fig．2．3 DriveUnit（1）

−31−

38．SPRING

●

F4

●

F3

●

F2

●

●

Fl

●

●

●

N

Rl

●

●

R2

●

●

R3

●

R4

●

● ●

2．POWERTRAIN

2

1

1．CHARGINGPUMP 2．SLEEVE 3．GEAR 4．DRIVERING 5．CONVERTERWHEEL 6．CONVERTERHOUSING 7．IDLERSHAFT 8．GEAR

15．BACKGEAR 16．SHAFT

28．GEAR 29．DISTRIBUTORCAP

17．CAPASSEMBLY（SeeFig． 18．FWD／REVGEAR

30．3RD／4THSHAFT 31．HI−RANGEGEAR 32．PLÅrE

19．GEAR

33．ROTATIONSENSOR

2．25）

（FORSPEEDOMETER）

20．LO−RANGEGEAR

21．DISKHUB 9．CAPASSEMBLY（SeeFig． 22．SHAFT 23．PLUG 2．24） 24．PARKINGBRAKERELEASE 10．1ST／2NDSHAFT BOI＿J ll．FLANGE 25．OILBAFFLE 12．OILSEAL 26．REARCASE 13．SEALRETAINER 27．TRANSMISSIONCASE 14．DRAINPLUG

34．PISTONHOUSING 35．BRAKEHOUSING 36．DISK 37．PLATE 38．CAP 39．PISTON 40．SPRING 41．ENDPLATE

Note：B＞14＝ゝMatingareawithconverterhousing‥LOCTITEFMD−127 臣＞紹＝ゝThreadedarea：LOCTITE＃262 匝＞紹＝ゝThreadedarea：LOCTITE＃572 B＞ぢ＝＝コ88N−m（9kgf−m）［651bf−ft］ B＞AdjustingofgapC：Afterthesensortouchesthegear，backitoffby2turns． B＞MeasurethedifftrenceinheightXbetweenflangeandshaftwithoutshims，andselectand

insta且1approprlateShimssothatthedifftrenceinheightisX：3二？5mm・ Note：Oilsealassemblingprocedure

14＝ゝOilsealouterdiameter（metal）：LOCTITE＃262 【＝＝恥Areabetweenlipsofliptypeoilseal：Grease

l⊂＝：恥ChamferedareaandslidingareaOfcompanionflange：Grease

SectionJ−）（2points）

Section E−E Section D−D

Fig．2．4 DriveUnit（2） −32−

Detaj10farea F

2．POWERTRAIN

2．2 TORQUECONVERTER

Thetorqueconverterconsistsofaconverterwheelassembly，aPumPdrive，andaturbineshaf

COnVerterWheelassemblyconsistsofanimpe11erandaturbinelocatedoppositetoeachother，Withastator Wheelinbetween，andhousedinthetorqueconvertercasefilledwithoil・

ThepumpdrivedrivesthecharglngPumP，themainpumpandthesteerlngPumPthroughthepumpdrive

gearinstalledontotheimpellerhub．

Note：B＞ぢ＝コ39to45N−m（4．Oto4．6kgf−m）［29to331bf−R］ 桓＞ぢ＝コ51to58N−m†5・2to6・Okgf−mi［38to431bf−f［］

匡＞Alignthearrowsoftheoiloutletgroovesinthestatorholderandstatorhub・ 1．TAPERPLUG 2．COVERWHEEL 3．COUPLINGGEAR （DRIVERING）

4．TURBINEWHEEL 5．IMPELLERHUB

6．INPUTGUIDE 7．STATORHUB 8．STATORWHEEL 9．IMPELLERWHEELPLArE lO．IMPELLERWHEEL ll．PUMPDRIVEGEAR

Fig．2．5 ConverterWheelAssembly −33−

12．STATORHOLDER 13．TURBINESHAFT 14．OILSEALRING 15．OILSEALRING

2．POWERTRAIN

Powertransmission

Powerfromtheengineistransmittedthroughtheflywheel，COuPlinggear（drivering），丘ontcover，impe turbine，turbineshaft，andtothetransmission． Oilflowroute（SeeFig．2・3，2．5・）

ThetorqueconverteroildeliveredfromthetransmissioncontroIvalvepassesthroughtheoilpassagein thestatorsupportintotheconverterwheel・

Astheenglneisstartedandtheimpellerrotates，theoilbetweenthevanesoftheimpelleristhrownoutby

Centrifugalfbrce，flowinglntOthevanesoftheturbine・Ithitsthevanesoftheturbineatananglewhi

turnrotatetheturbineshaft・Thereactiontorqueortheoilproducedbytheoilflowhittingthevanesof turbinebecomestheoutputtorqueoftheturbineshaft． ThestatorcontroIstheoilflowleavlngthevanesoftheturbineinacertaindirection，directlngltintothe impeller，thusincreaslngthetorque・

Partoftheoilinsidetheconverterwheelpassesthroughtheoilpassageinthestatorsupporttotheoil

COOler・Asafetyvalveisinstalledatthetorqueconverteroilinletport，tOreleaseexcessoilintotheconvert

houslng．

ー34−

2．POWERTRArN

2．3 TRANSMISS10N Thetransmissionconvertsthespeedanddirectionofpowertransmittedfromthetorqueconverter．

Thetransmissionconsistsofthreeclutchshaftassemblies，abackgear，anOutPutShaft，aParkingbrake， andacontroIvalvt． 2．3．1CLUTCHSHAFT Theclutchshaftassemblyhasclutchdisksforeachspeed，andturnspowertransmissiononandoff・

61臣8 911

3 4 5

2

12 13 14

Note：B＞【＝＝鞠Slidingsurfaces：Grease Detai10fareaA

（Payattentiontothedirectionofassembly． Seetheenlargedviewsontheright．）

、＿トト Detai10farea B RETURN SPRING

1．SHAFT＆DRUM

9． 0 −RING

2．GEAR

lO．SEALRING（INNER）

3．DISK

11．PISTON 12．ENDPLArE 13．BELLEVILLESPRING 14．GEAR 15．SEALRmG 16．PLUG

4．RETURNSPRING 5．PLATE 6．SPACER 7．BLEEDVAINE 8．SEALRING（OUTER）

Fig．2．6 TypicalClutchShaftStructure

−35−

View100kingfromC

2．POWERTRAIN

（Fwd／Revshaft）

（1st／2ndspeedshaft）

（3rd／4thspeedshaf（）

Fig．2．7 ClutchShaft −36−

2．POWERTRAIN

Operation TheclutchisoperatedbypressurizedoilfromthetransmissioncontroIvalve．Thepressurizedoilfrom

thecontroIvalveflows，PaSSlngthroughthedistributorcapandtheoilpassagesintheclutchshaft，t backoftheclutchpistontomovetheclutchpiston．Theclutchpistonthenlocksuptheclutchdisksand

Clutchplates，thusengaglngtheclutchshaftandclutchhubtogethertotransmitthepowertothedrives

1

2 3

匡璽Pressurizedoi1 1．CLUTCHSHAFT 2．CLUTCHPISTON

Detai10fareaA

3．CLUTCHDISK 4．CLUTCHPLATE 5．CLUTCHHUB

fromCONTROL VALVE

Fig．2．8 ClutchinEngagement

WithnopressurizedoildeliveredfromthecontroIvalve，theoilinthepistonisdischargedfromthebleed Valvesothattheclutchpistonispushedbackbythereturnsprlngbetweentheclutchplates．Thisunlocksthe

Clutchdisksandclutchplatestoallowtheclutchshaftandclutchhubtorotateindependently，SOthatno

POWeristransmittedtothedriveshaft．

1

2 3 456 1．CLUTCHSHAFT 2．CLUTCHPISTON 3．BLEEDVALVE 4．CLUTCHDISK

Detai10farea B

5．RETURNSPRING 6．CLUTCHPLATE fromCONTROL VALVE

Fig．2．9 ClutchinDisengagement

−37−

7・CLUTCHHUB

2．POWERTRAIN

2．3．2 POWERFLOW （1）Shiftleverinneutral

Withneithertheforwardnorthereverseclutchengaged，thepowerfromthetorqueconverterrotatesthe forwardandreverseshaft，butisnottransmittedanyfurther・ （2）Shiftleverinn）rWard

Whentheshiftleverisputintooneofthefourforwardspeeds，thepowerfromthetorqueconverteris transmittedthroughtheforwardclutchandtheselectedspeedclutchtotheoutputshaft・

Fig・2・10 PowerFlowinForward −38−

2．POWERTRAIN

（3）Shiftleverinreverse Whentheshiftleverisputintooneofthefourreversespeeds，thepowerfromthetorqueconverteris

transmittedthroughthereverseclutch，thebackgearandtheselectedspeedclutchtotheoutputshaft・

Fig．2．11PowerFlowinReverse

ー39−

2．POWERTRAIN

2．3．3TRANSMISS10NCONTROLVALNE ThetransmissioncontroIvalveselectivelysendsoiltoeachclutchsoastochangeoverthedirectionsand speeds of the loader.

ThecontroIvalveconsistsofavalvebodyand4solenoidvalves・Thesolenoidvalvesareengag

disengagedbythetransmissioncontroIswitch（Shiftlever），tOShiftthespoolinthevalvetocontroltheclu lock−uPOil．

ThecontroIvalvealsohasamodulationmechanismwhichoperatesdifferentlyaccordin ranges・ItispossibletooperatethecontroIvalvemanuallyiftheelectricsystemfailstooperatenormally・

一一一一

3

11．SPOOLA 12．SELECTORSPRING 13．SPOOLB 14．SELECTORSPRING

1．PLArE（FORMANUAL

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

9．ADAPTER lO．SPRING

21．SPRING 22．FLOWSENSINGSPOOL 23．SPRING 24．PIN 25．ROD 15．ORIFICE，0．8mm［0．031in．］dia． 26．SPRINGINNER （FORSOLENOIDVALVE） 27．SPRINGCENTER 16．ORIFICE（W） 28．SPRINGOUTER 17．ORIFICE（Z） SeeNote． 29．LOADPISTONH 18．ORIFICE（Y） 30．REGULATORSPOOL 19．ORIFICE（Ⅹ） †

20．VALVEBODY（UPPER）

31．PISTON

Fig．2．12TransmissionControIValve（1） −40−

4

2．POWERTRAIN

8 9 0 1 2 3 4

161718 19

4 5 6 7 8 9 3 3 3 3 3 3

5 6 7 8 9 2 2 2 2 2

Section D−D

Note：Orincediameter，mm［in．］ OriBce（W）

Orince（X）

fbrmain

forlst／2ndgears

6．3［0．25］

1．3［0．057］

32．SPRINqOUTER 33．SPRINqINNER

Orifice（Y）

Or抗ce（Z）

わr2ndgear

for3rdAthgears

1．1［0．043】

36．SPRINGINNER 37．SPRINqCENTER

1．8［0．071】

40．MANUALSPOOL（FOR

EMERGENCYTRAVELSPOOL）

34．MODULATIONSPOOL 38．SPRINqOUTER

35．ROD

39．LOADPISTONL

Fig．2．13 TransmissionControllね1ve（2） −41−

2．POWERTRAIN

①〜④．①，㊥：CLUTCH

「￣￣￣￣ l

l

F／RSELECTOR SPOOL

l

l

．」l

「￣1 1」」」

r￣1

EE二［加 「−1 lし⊥

＿J l

；」］ よⅢ巫

1

l＋

lし⊥ ；RSOし・‡血

B SOし．！

1

t

「一文−−▲一一−−

l

1 l

SPOOLB

1 1

toT／C

1

．

1

l MANUAL し＿卓E99と＿−

l1

1

l

11 1r￣￣￣￣￣￣

d三［町

＿J

；ASOL．−

）lりK

l

＿＿＿ト一芸−−J−−−−一一

ト■−−−−−一一−−−−￣￣

SPOOLA

l

1

1 l

し＿＿

REGULATOR

1

l

「一一−「 ） I l

FLOW SENSlNG SPOOL

MODULAT10N SPOOL from PUMP

ACCUMULATOR （LOADPISTON）

Hydraulic CircuitDiagram

Fig．2．14 TransmissionControlValve（3）

Operation

ThemodulationmechanismofthiscontroIvalve changesthetimetheclutchlock−uPOiltakestobuild up，Ortheclutchoilpressurewaveform，aCCOrdingto thespeedranges，thusmakinggearshiftingsmoother・

Theoperationofthemodulationmechanismis explainedonpolntSAtoE・Inaddition，theoperationof

thesolenoidvalvesandmanualspool（emergencytravel spool）isalsoexplainedinpagesthatfbllow・

Fig. 2.15 Clutch Oil Pressure Waveform

−42−

2．POWERTRAIN

（1）Neutral，3rdspeedinNeutral（PointAinFig．2．15） ①Theoilwhichhasenteredtheinletport（1）ofthecontroIvalve，flowsthroughthesmallhole

a

inthe

regulatorspoolintothechamber（2）atthebackofthespool，tOShiftthespooltotheleftintheng

Theoilwhosepressurehasbeenregulatedtotheclutchlock−uPPreSSure，flowsthroughthecircuit（3）

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

②Theoilwhichhasreachedthecircuit（5）flowsthroughthetaperedoilpassageinthemodulationspo Circuit（6），Whichleadsthroughthemainorince（W），tOthecircuits（8，9，12）． ③Theoilwhichhasbeendeliveredtothecircuit（8）flowsthrough（8），（16），（17），（18）andtothe3rdspeed

Clutchchamber．Theclutchportsotherthanthatofthe3rdspeedclutchareconnectedwiththedrain ④Theoilwhichhasreachedthecircuit（8）flowsthroughthedrilledholeinthespooIAtothecircuit（19）・

Theoilthenpassesthroughthethrottle（Z）totheloadpistonchamber（20）・Therearetwoloadpistons：

low−PreSSureandhigh−PreSSureOneS・Afterthelow−PreSSureloadpistonmovestothestopper，thehigh

PreSSureloadpistonstartsmovlng・ ⑤Theoilwhichhasflowedintothecircuit（12）isstoppedbytheF／Rselectorspool．Boththeforwar

thereverseclutchesaredisengaged（neutral）．

⑥Thesolenoidvalvesareinthe OFF statesothattheoilwhichhasreachedthroughtheorincetoeach solenoidvalveisdrained．

−43−

2．POWERTRAIN

Fig．2．16 Neutral（3rdSpeedinNeutral） −44−

2．POWERTRAIN

（2）ShiftingintoIstn）rWard（PointBinFig．2．15）

①SolenoidvalvesFandAareturned ON． ②WiththesolenoidFturnedON，theoilflowisstoppedbythesolenoidvalveFsothattheoilsent theoilpassage（1）flowstothecircuit（26）wheretheF／Rselectorspoolisthenshifted，duetotheoil PreSSure，tOtherightinthengure．

③Ontheotherhand，aSthesolenoidAisturnedON，thespooIAmovestotherightinthefigure・ ④AstheF／Rselectorspoolmoves，theoilinthecircuit（12）flowstothecircuit（21）wherethefwdclutch islocated．Astheemptyfwdclutchchamberisfilledwithoil，adifftrenceinpressurebetweenthe PreCedingcircuits（6，22）andthesubsequentcircuits（8，9，12）ofthemainorince（W）iscreated・（The PreCedingcircuitshaveahigheroilpressure．）

⑤Thepressuredifftrentialbetweenthecircuit（9）andthecircuit（22）movestheflowsensingspooltothe

rightinthengure，Withtheoilinthecircuit（20）beingdrained・ ⑥Themodulationspoolmovestotherightinthengurebecausetheoilpressureinthecircuit（25）drops

tocontroltheoilflowfromthecircuit（5）tothecircuit（6），thusdeliveringonlythenecessaryamount oil．

−45一

2．POWERTRAIN

Fig・2・17 ShiftinglntOIstForward −46−

2．POWERTRAIN

（3）Clutchinengagement（PointCinFig．2．15）

①Whentheselectedclutchesarenlledwithoil，thepressuredifftrentialacrossthemainorince（W）

SOthattheflowsenslngSPOOlismovedtotheleftinthengurebysprlngtenSion，thuscloslngthedrain

circuit． Theoilinthecircuit（23）flowsthroughthedri11edholesinthespooIAtothecircuit（24），thenpassing throughtheorince（X），tOtheloadpistonchamber（20）・

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

③Whentheclutchoilpressurereachesthespecifiedvalue，theloadpistonstopsatthestopperpositi

（4）Afterclutchengagement（PointDinFig．2．15）

①Assoonasboththefwdclutchandlstspeedclutcharelockedup，theloadpistonmovestothesto

toincreasetheoilpressureintheloadpistonchamber（20）rapidlyuptotheregulatorpressure・ ②ThemodulationspooIcircuits（7）and（25）havethesameoilpressure，butthecircuit（25）hasaspring・ Forthisreason，themodulationspoolmovestothelef［inthefigure・

ー47−

2．POWERTRAIN

Fig．2．18 ClutchesinEngagement（1stSpeedForward） −48−

2，POWERTRAIN

Fig．2．19 AfterClutchEngagement（1stSpeedForward） −49−

2．POWERTRAIN

（5）Fwdand2ndspeedclutchesinengagement（PointEinFig．2．15）

①SincethesolenoidsAandBareintheONstate，thespeedspooIsAandBmovetotherightinthefig

②Theoilwhichenteredcircuit（8）nowsintocircuit（23）．Itthenpassesthroughthedrilledhole

SPOOl，tOCircuit（24），fromwhichsomeoftheoilpassesorifice（X）intotheloadpistonchamber（20）

Atthesametime，theotherflowsfromcircuit（24）intocircuit（27）ofthespooIB．Theoilleav Circuit（27）flowsthroughthecircuit（28）andorifice（Y）ifcircuit（29），intotheloadpistonchamber

（20）． Inotherwords，Whentheshiftleverisputin2ndspeed，theoilflowsthroughorinces（X，Y），SOthatthe timeneededfortheclutchoilpressuretobuildupisshorterthanwhenthelstspeedclutch（theoil PaSSeSthroughorince（X）alone）isselected・

−50−

2．POWERTRAIN

Fig．2．20 ClutchesinEngagement（2ndSpeedForward）

一51−

2．POWERTRAIN

（6）Solenoidvalveoperation Foursolenoidvalvesareinstalledonthelowervalve body．

Fsol Rsol Asol Bsol

4th ●

●

3rd ●

Thesolenoidvalvesareoperatedbyshi札ingtheshift Fwd

leverintheoperator scompartment，tOCOntrOltheF／R SelectorspoolandspeedspooIsAandB． Thetableontherightshowstherelationshipsin

2nd ●

●

1st ●

●

●

Neutral

OPerationbetweeneachspeedrangeandthesolenoids． （●：SOlenoidinON．）

Rev

1st

●

●

2nd

●

●

31d

●

4th

●

a．SolemoidinOFFstate Theoilwhosepressurehasbeencontrolledbythe

regulatorisalwaysflowlngthroughtheorinceintothe SOlenoidvalve．WhenthesolenoidisintheOFFstate， theoilpassesthroughinsidethesolenoidvalveandis

drained・TheoilpressureatthepointPisOMPa（Okgf／ Cm2）［Opsi］．

rig．2．21 b．SolenoidinONstate Whenthesolenoidisexcited，theinsideofthevalve isblockedtooilflow．Theoilisnolongerdrained．The OilpressureatthepointPbecomesequaltotheregulator

PreSSure・Thetransmissionspeedisswitchedoverby theF／RselectorspoolandthespeedspooIsAandB

uslngthisoilpressure．

Fig．2．22 −52−

●

●

2．POWERTRAIN

（7）Manual（emergencytravel）spooloperation Ifthesolenoidvalvesfailtooperateproperlyduetoabrokenwireoranyotherelectricalfailure，itis POSSibletomechanicallyswitchthecontroIvalveto3rdforwardorreversewiththisspool．Itisadvisableto usethisspooIwhentheloaderneedstobemovedtoanout−Of−trafBcareaforrepalr．

AMakesuretheeTgineisヲhutoffbefbretryingtouse！hemanualspool・Ifthemanualspoo OPeratedwiththeenglnerunnlng，theloadercanjerk，CauSlnganaCCident． a．Switchingto3rdfwd． Toswitchto3rdfwd，PullthemanualspooloutaboutlOmm［0．4in．］．

①Theoilwhosepressurehasbeencontrolledbytheregulatorflowsthroughtheorificeintothem

SPOOIcircuits（31，32）．Sincethecircuit（31）isblockedbythespool，theoilisroutedfromthecircu

（33）totheF／RselectorspooIcircuit（26），thusshiftingthespooltotherightinthenguresothatthef

Clutchoilpressureincreases． ②Theoilinthecircuit（32）flowsthroughthespoolandtheRsolenoidvalvetodrain．

③SinceboththesolenoidsAandBofthespeedspooIsareOFF，the3rdclutchpressureincreases，（See

Fig．2．16）thusmakingitpossibletotravelinforward3rdspeed．

from REGULATOR VALVE

Fig．2．23 ManualSpoo10peration（Fwd）

b．Switchingto3rdrev． Toswitchto3rdreverse，PuShthemanualspoolinaboutlOmm［0．4in．］．

TheoperatlngPrlnCipleisthesameasinthecaseof3rdfbrward． −53−

2．POWERTRAIN

（8）Accumulatorfbrclutches

Accumulatorsareattachedtothedistributorcapsonthetransmissionlst／2ndandF／Rshafts・

Theyareincorporatedinthehydrauliccircuitsofthe2ndspeedandfbrwardclutchpacks・

SectionA−A

Section B−B

SectionC−C

FROM C／V

1．PLUG 2．ADAPTER 3．SPRING 4．BALL 5．DISTRIBUTORCAP 6．PLUG 7．SPOOL 8．SPRING

9．SPRING lO．SPOOL ll．SPRING 12．ORIFICE 13．ADAPTER 14．SPRING 15．SPACER 16．SNAPRING

Hydrauliccircuitdiagram

Fig．2．24 DistributorCapAssembly（1−2） −54−

2．POWERTRAIN

1 2

Section B−B

FROM C／V

1．BALL

8．SPRING

2．SPRING 3．ADAPTER

9．ROD

4．PLUG 5．PLUG 6．PISTON 7．SPRING

lO．PLUG ll．SPOOL 12．SPRING 13．DISTRIBUTORCAP

Hydrauliccircuitdiagram

Fig．2．25 DistributorCapAssembly（F−R）

−55−

2．POWERTRALN

2nd・SPeedaccumulator

Whenthespeedgearsareshiftedfrom2ndtoIstby the DSSin scooplng Or digglng OPeration，the accumulatorhelpsstopoilflowtothe2ndclutchpack

SlowlyenoughtooverlapltWiththeriseoftheoil PreSSureOfthelstclutchpack・

Forwardaccumulator Whenthe gearsareshiftedfromlstto2nd，the forwardaccumulatorpreventstheforwardclutchpack oilpressurefromdroppingtoOMPa（Okgf／cm2）［Opsi］ （curveof③），thuspreventingtheloaderfromrolling back．

Fig．2．26Gearshif［ing（2ndtoIst）

Operation

Whenthegearsareshiftedfrom2ndtoIstspeed（byDSS）： （1）The2nd−SPeedclutchpressurebeginstodropfromPl．

（2）ThetimingspooIsensestheriseofthelstclutchpressureP3tocutoffthelinebetweenthe2nd−SP accumulatorandcontroIvalvesothatthe2nd−SpeedclutchpressureP2ismaintained．

（3）WhenthelstclutchpressurereachesthepressuresettingP4，thecut−Offbetweenthe2nd−SPee

accumulatorandthecontroIvalveisreleasedsothatthe2ndclutchpressurebecomesOMPa（O Cm2）【Opsi］．

【Forwardclutchpressureatthetimewhengearsareshiftedfrom2ndtoIst］

Conventional1y，Whenthegearswereshiftedfrom2ndtoIst，the食）rWardclutchpressuredroppedt MPa（Okgf／cm2）［Opsi］onceandthenbegantorisetogetherwiththelstclutchpressure．Ontheloader，the

ねrwardclutchpressuredoesnotdripbecausethefbrwardaccumulatorandblockspoolareprovided・ Note：Theaboveoperationdoesnottakeplacewhentheshiftleverisinreverse．

ー56−

2．POWERTRAIN

2．3．4TRANSM［SS10N CONTROL

ThetransmissioncontroIsystemisanelectrictypewhichturnsonandoffthesolenoidvalveofthe

transmissioncontroIvalvebytheoperationoftheshiftlever（transmissioncontroIswitch），tOSWitchovert

PaSSageSOftheclutchoil，thuscontrollingthetravelingspeedoftheloader・ ThetransmissioncontroIsystemconsistsofashiftlever，anArC（automatictransmissioncontroller）uni

adownshiftswitch（DSS），aClutchcut−0ffswitchandasensor． ThetransmissioncontroIsystemhasanengineneutral−StartSafetysystem，aDSS（downshiftswitc inchingmechanismandamodeselectionswitch． Note：Fortheinchingmechanismandtransmissioncut−0ffmechanism，referto

3・BRAKESYSTEM・

A EngineNeutralStartSafbtySystem Theneutral・StartSafbtysystempreventstheenginefrombeingstartedunlesstheshiftleve neutral．ThispreventstheloaderfrommovlnguneXPeCtedlywhenthestarterswitchisturnedto START． Makesuretheshiftleverisneutralbeforecrankingtheenglne． Theengineneutral−StartSafttysystem（neutralrelay）isincorporatedintheenginestartingcircuit・

Operation（See

8．4ELECTRICCIRCUITDIAGRAM．

）

①WhenthestarterswitchisturnedtoSTARTwiththeshiftleverinneutral，theneutralrelayisclosed allowanelectriccurrentto且owthroughthesafttyrelay，thusstartingthestartermotor（engine）・

②WhenthestarterswitchisturnedtoSTARTwiththeshiftlevernotinneutral，theneutralrelayremai OPen，SOthatnocurrentflowsthroughthesafetyrelay・Consequently，theenglneWOn

−57−

tstart・

2．POWERTRAIN

1．ShiftLever（TransmissionControISwitch）

＼ ＼︑∫．ノ

NEUTRAL−LOCK

4 3 2 1

COM

Fig．2．27 ShiftLever

−58t

R N F

2．POVVERTRAIN

2．DSS（DownShiftSwitch）Mechanism With the downshift switch pressed，the DSS mechanismprovides speedier，mOreefficientload handlingwithouthavingtooperatetheshiftlever． TheDSSmechanismconsistsofadownshiftswitch builtintheboomleverknobandanATCunit．

Fig．2．28 DownShiftSwitch

Operation WhentheDSSispressedin2ndgearforward，thetransmissionisautomaticallyshiftedintothelstgear

POSitionbytheoperationoftheArCunit，allowlngmOrehorsepowertobeconcentratedonloadingoperat

Whentheshif［leverlSPlacedinthereversegearaf［erscooplngOrdigglng，thespeedrangeisautomaticall

Shiftedinto2ndgearbrquickerdrivingback．

Thatis，uSlngtheDSS，itispossibletocontrolboththebucketthrustingforceandthetravelspeedo

loaderbyoperatingtheboomlever（downshiftswitch）alone，Withtheshiftleverkeptin2ndgear，du

scooping or digging operation.

3．USS（UpShiftSwitch）Mechanism Whentheup−Shiftswitchispressed，theUSSmechanismchangestheloader

stravelingspeedwithou

havingtooperatetheshiftlever．

TheUSSmechanismconsistsofanup−ShiftswitchbuiltintheboomleverknobandanArCunit・ Note：Thestructureoftheup−Shiftswitchisthesameasthatofthedownshiftswitch．

Operation

ThereverseoperationoftheDSSmechanismiscarriedouthere．Withtheup−Shiftswitchpressed，th

transmissionreacheshighergearbytheoperationoftheArCunit．Withthefwd／revleveroperated，th

SPeedreturnstothespecinedgear．

−59−

2．POWERTRAIN

2．3．5ATC（AUTOMATICTRANSMISS10NCONTROLLER） （OuterViews）

Sight glass

（Board）

Fig．2．29 ArCUnit −60−

2．POWERTRAIN

1．ATC仇1nCtions TheATC（AutomaticTransmissionController）unithasthefollowingfunctions：

・Automaticspeed−rangeChangeofthetransmissionaccordingtothetravelingspeedoftheloader（switchin Ofautomaticandmanualtransmissionmodes） ・Speed−rangeChangebyswitches

●OutputoftheradiatorhydraulicdrivingfancontroIsignalbasedonthecoolingwatertemperatureand hydraulic oil temperature ●Outputofthesignaltothespeedometerandtachometer ●SenslngOferrorsandoutputofwarnlngaboutthetransmissionsolenoid

Figure2・30showstherelationshipbetweentheArCunitandotherdevices・

Fig．2．30I／ORelationshipofArC −61−

2．POWERTRALN

2．Relationshipbetweenshiftleverpositionsandgearshiftpatterns

TheATC（AutomaticTransmissionController）unitautomaticallycontroIsthespeedrangeo transmissionbasedonthetruck

stravelingspeedandenglnerPm．TheATCfunctionsasfbllows：

（1）Gearshiftpatterns A．Relationshipwiththeshiftleverpositions

Usually，the2nd−SPeedgearisselectedfbrdiggingandscooplng，3rd−SPeedgearforload＆carryoperati

and4th−SPeedgearfortravelingandmovlng．Theautomaticspeedqrangeischangedaccordingtotheshi

leverpositions．（SeeFig．2．31．） Speedrange

Applicablework

1st 2nd 3rd 4th

WorkusInglst−SPeedrange

1ST

Shiftlever （ 、．

POSition

Diggingandscooplng Load＆carrywork ′、 、 Trave肋g

4TH

） 一r

○：Speedrangeinmanua［mode．

Fig．2．31RelationshipbetweenshiftleverpositionandgearshiRpatterns B．DSS（Downshiftswitch）operation（bothforATandMT）

①WhentheDSSispressedwiththegearsinthe4thspeed，thetransmissionshiftsfrom4thspeedt SPeed（PressDSSonce）．

②WhentheDSSispressedwiththegearsinthe3rdspeed，thetransmissionshiftsfrom3rdspeedt SPeed（PressDSSonce）．

③WhentheDSSispressedwiththegearSinthe2ndspeed，thetransmissionshiftsfrom2ndspeedt SPeed（PressDSSonce）．

④WhentheDSSispressedandhelddownwiththegearsinthe4thspeed，thetransmissionshiftsfr

SPeedto3rdandthento2nd．Forthelstspeed，releasetheDSSswitchandthenpressitonce．）

Whenthetransmissionhasbeenshif［edintothelstspeedbytheDSS，yOuCanreleasetheDSSIs

uslngeitherofthefollowlngtWOmethods： ●Usetheshi魚1ever．

●MoI℃than3secondsaf［erthetransmissionisshiftedintothelstspeedbypresslngtheDSSswitch，

transmissionautomaticallyshiftsuptothe2ndspeedwhenthetravelingspeedexceeds6km／h［3．

mph］（COmmOntOa11models）． C．USSswitch（Upshiftswitch）operation（bothforArandMT）

①WhentheUSSispressedwiththegearsinthe2ndspeed，thetransmissionshiftsfrom2ndspeedt

SPeed（PressUSSonce）．

②WhentheUSSispressedwiththegearSinthe3rdspeed，thetransmissionshiftsfrom3rdspeedt SPeed（PressUSSonce）．

③WhentheUSSispressedwiththeloadershiftedintothelstspeedbyDSSoperation，thetransmi isshiftedfromlstspeedto2ndspeed． Thetransmissionwon

tshiftupfrom2ndto3rdandto4theveniftheUSSispressedandhelddow

Inaddition，thetransmissionwon

tbeshiftedupbeyondthespeedrangeoftheshiftleverwiththe

−62−

2．POWERTRAIN

（2）Relationshipbetweenenginespeedandgearshiftpatterns

Shiftingdownisquickenedwhenenginespeedishighinclimbingaslope（kickdownfunction）・Inaddition，

thetransmissionisdesignednottoshiftupwhendescendingadownhilltoallowtheuseofenginebraking・

Figure2．32showstherelationshipbetweenenglneSPeed，traVelingspeedandgearshiftpatterns・

englneSPeedisdetectedbytheenglneSPeedsensorwhentheenglnerunSathighrpmanditisdetectedbya

SWitchattachedtotheacceleratorpedalwhentheloaderdescendsadownhill・（Thetransmissionwon upwhenthisswitchisnotturnedonorwhenthepedalisnotpressed・） TS32

TS43

Hi idle

q L G 作

︵∈d土p冨ds声高u﹈

TH23 TH43 Travelingspeed（km／h）

TH32

TH34

Fig．2．32 RelationshipBetweenEngineSpeed，TravelingSpeedandGearshiftPatterns （3）3−mOdeselection

ThetransmissionoperationmodecanbeswitchedamOngtraVeling，loadhandlingandintermediatemod Inthe Travelingmode＝，thegearshiftpolntSin2ndto3rdand3rdto4thspeedarequickenedtoallow smoothacceleration．

Inthe

Loadhandlingmode

，thegearshiftpolntSin2ndto3rdspeedisdelayedtosuppressshifting

thetransmissionwhenperformlngVcycleworkorothers・ The

Intermediatemode

representstheintermediatesettlngbetweentheabovetwosettlngS・

Specincally，theabovefunctionsareperformedbyswitchingoverthevaluesTH23，TH34，TH4

andTS32foreachoperationmode．Therespectivevaluesforeachoperationmodeareashownbelow：

km／h［mph］ 丁目23

9．2「5．71 8．5r5．31

Loadh訓溺【gmOde 凧e「mediatem∝】e

TH34

TH43

TH32

TS43

TS32

T「a〉e仙gmode

7．7「4．81

Loadhandti【gmOde

15．9「9．91

】【lermedialem∝】e

14．6【9．1】

Tra〉e‖ngmode

13．4r8．31

Load handiing mode

11．4【7．1】

−【termediatemode

10．1【6．3】

Travelingmode

8．9「5．51

Loadhand仙gmode

6．2【3．9】

ntermediatem∝】e

5．5［3．4】

T「a〉e】ingmode

4．7「2．91

Loadhandlingm（カe

12．9【8．0】

血ermediatemode

11．6【7．2】

T「ave‖【gmOde

10．4「6．51

Loadhandli【gmOde

7．7【4．8】

凧ermedialem∝】e

7．0【4．3］

Trave＝【m∝】e

6．2「3．91

Thble2．1GearshiftpolntSin30Perationmodes

−63−

2，POWERTRAIN

（4）GearshiftpatternsfromFtoRorviceversa WhentheoperatortriestoreversethedirectionoftravelwhiletheloadinglSrunnlngat3rdspeedor4th

SPeed，thewarnlngbuzzersoundsand4th−SPeedindicatorcomeson．Thedirectionoftravelcannotber

whentheloaderisrunnlngat4thor3rdspeed・Itisnotuntilthetransmissionautomaticallyshiftsdown 2ndspeedandtheloaderslowsdowntoaspeedwhichmakesitpossibletoswitchoverthedirectionoftravel thatthedirectionoftraveloftheloadercanbeperformed．

Ifthedirectionoftravelistriedwhentheloaderisrunnlnginfbrwardat4thspeedwiththeshiftlever inthe4thspeedposition： Directionof t「avelis

S10WSdown

S10WSdown ＞

reversed ＞

＞＝

When traveling SPeedisless thanSD32

When traveling speedis less thanSD43

WhentravellngSPeedisless than FR2 （Less！hanFR2when reverslngfromrevtofwd）

km／hrmphl SD43 SD32 FR2 RF2

75．9r47．21 33．9r21．11 11．6「7．21 12．6「7．81

1払ble2．2 Gearshiftpolntinreverslngdirectionoftravel

（5）APS（Anti・pitchingsystem）operation（OPtion）

Travelingspeed（km／h）

APSL

APSH

APSH（TravelingspeedatwhichAPSisactivated）：7km／h【4．3mph］ APSL（TravelingspeedatwhichAPSisreleased）：5km／h［3．1mph］

Fig．2．33 TravelingSpeedsatwhichAPSisActivatedandReleased

ー64−

2．POWERTRAIN

3． Hydraulically−drivenfancontrol （l）OutlineofcontroI TheenglneCOOlanttemPerature，hydraulicoiltemperatureandtorqueconverteroiltemperaturearelnPutted

intotheATCtocontroltheEPCvalve（PrOpOrtionalsolenoidvalvewhichcontroIshydraulically−driv rpm）sothatthefanspeedbeoptimal．

Fig．2．34 Hydraulically−drivenFanControl （2）DetailofcontroI

TheEPCvalveiscontrolledbychanglngthecurrentvaluesoutputted丘●OmtheArC．Thefanrunsatthe

maximumspeed（1720rpm）whentheoutputfromtheArCtotheEPCvalveisOmAandattheminim SPeed（1000rpm）whentheoutputislOOOmA・ TherelationshipsbetweenthetemperatureofeachitemandthefanspeedrequiredareglVenbelow： ・Enginecoolanttemperature

700C［1580F］：1000rpm 900C［1940F］：1720rpm

・Tbrqueconverteroiltemperature 900C［1940F］：1000rpm llOOC［2300F］： ・Hydraulicoiltemperature 600C［1400F］：10（犯rpm 800C［1760F］：1 720rm p

Thefanspeedrequired varies proportionally betweentherangeOfthe twotemperaturevalues．

ThecurrentvalueofanyltemWhichrequlreSthehighestfanrpmiscalculatedandoutputtedtotheEPC valve．

−65−

2．POWERTRAIN

2．4 0TLCIRCULAT［ONROUTE l．GeneralDescription

Theoilusedforthedriveunitissuppliedfromthetransmissionsumptank・

Astheenginestarts，thechargingpumpunit（doublepumps）picksupoilfromthetransmissionsumpt

throughthestrainerandsendsitunderpressure．Theoildischargedfromtheh・OntPumPPaSSeSthrough

OilfiltertothetransmissioncontroIvalve・ThecontroIvalvedividestheoilintoonefortorqueconve OPerationandonefortransmissionclutchoperation． OildischargedfromtherearpumpJOlntSWiththeflowfromtheconverterhouslngandflowsintotheoil

COOler・Theoilcooleddownbytheoilcoolerthenreturnsintothetransmissiontocoolandlubric Clutchshafts． Notes：ForthespecificationsandconstructionofthecharglngPumP，reftrto

6．2PUMP．

Theoilcoolerisincorporatedinthelowertankoftheradiator．Reftrto

fortheoilcooler．

Fig．2．35 0ilCirculationRoutes

ー66−

1．2COOLINGSYSTEM

2．POWERTRAIN

2．Filter

Thefilterisprovidedinthesupplylineofthedriveunitoilcirculationroute・Theoilflowsthrough nlterelementfromoutsidetoinsideandthenlteredoilisdirectedtothetransmissioncontroIvalve． Whentheoilnlterelementbecomesclogged，thepressureattheinletportsideincreasessothattheoil

bypassesthecloggedfilterelementandforcesopenthebypassvalvetoflowdirectlytotheoutletportsi

BypassvalveoperatlngPreSSure： 343±24．5kPa（3．5±0．25kgf／cm2） ［49．8±3．6psi】

Note：B＞ぢ＝コ49to59N−m（5．Oto6・Okgf−m）［36to431bf−ft］

Fig．2．3 Filter

−67−

1．HEADASSEMBIX 2．CARTRIDGEASSEMBLY

2．POWERTRAIN

2．5 PROPELLERSHAFTS UniversaljolnttyPe

CrossJOlnt

Length（inter−Pinlength）

Front

965m【38．Oin．］

Center Rear

401mm［15．8in．】

595mm［23．4in．］

Thepropellershafts，locatedbetweenthetransmissionandthefrontaxle，andbetweenthetransmi andtherearaxle，tranSmltPOWerfromthetransmissiontothefrontandrearaxles・Thepropellershaf frontaxlesideisequlPPedwithacenterbearlngWhichissecuredtotheh・Ontframeserveasastopperwh theloaderisarticulated．

Thepropellershaftsabsorbchangesindriveangleandchangesinlengthwhentheloadertravels，enSurlng smoothflowofpowerfromthetransmissiontotheaxles・

Note：B＞ぢ＝：：コ83tolO3N−m（8・5tolO・5kgf−m）【61to761bf−ft］， 紹＝ゝThreadedarea：LOCTITE＃262（20points）

P＞（芯＝コ294N−m（30kgf−m）【2171bf−ft］，紹＝ゝThreadedarea：LOCTITE＃262

1．FRONTAXLE

4．DRIVEUNIT

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

5．PROPELLERSHAFT（REAR）

6．REARAXLE

Fig・2・37 PropellerShaft

−68−

2．POWERTRAIN

（FRONTANDCENTER）

1

2 3

4

1

1．UNIVERSALJOINTASSEMBLY 2．GREASEFITTING

4．SHAFTYOKE

3．SLEEVEYOKEASSEMBIX

6．

5．PILLOWBLOCK H

YOKE

（REAR）

2

3

1．UNIVERSALJOINTASSEMBIX

3．SLEEVEYOKEASSEMBLY 4．SHAFTYOKE

2．GREASEFITTING

Fig．2．38 PropellerShaft −69−

2．POWERTRAIN

2．6AXLES（FRONTANDREAR） Driving

4−Wheeldrive

Frontaxle

Frame一員xed，fu11−floatingtype

Rear axle

Thnnion，full−floatingtype

Reductiongearanddifferential Model

TCM683−35

ヤpe

0rdinary，2−Stagereductiontype

Differentialgears

BaIt）OtyPe Straightbevelgear

Differential limiter

Limitedslipdi脆rential（OPtional）

Differential gear box

Finalreductiongearassembly Model

TCM683−30

取pe

Planetary gear

OilquantltytObeused

85L［22．5U．S．gal．］forfront， 87L［30．OU．S．gal．］forrear

Ⅵねight

Axle

（front）1983kg［43731bs］，（rear）2005kg［44211bs］

Differential

Hub＆brakeassembly

（front）303kg［6681bs］，（rear）333kg［7341bs］ 409kg［9021bs］

Axleshaft（PerShaft）

42．2kg［93．11bs］

Planetcarrier（PerCamier）

100kg［2211bs］

2．6．1DRtVEAXLE

Thedriveaxleconsistsofadifferential，aXlehouslng，aXleshaft，finalreductiongearandwettypebrake unit．

Thepowerfromthetransmissionistransmittedthroughthepropellershaftstothefrontandrearaxles Thepoweristhentransmittedtothedifftrentialwhereitisdividedintotherightandleftaxleshaftsandto thennalreductiongearandwheelhub，thusdrivingthewheels・ Note：Fortheoperationofthebrakeunitandslacka句uster，reftrto

3・BRAKESYSTEM・

AxleMount Thefrontaxleisbolteddirectlytothefrontframe． Therearaxleissupportedbythetrunnionmethodinwhichaxlesupportsareinsta11edacrosstherearaXle

andboltedtotherearframe．Consequently，therearaxleiscradledupanddownaroundthecenterlineof differentialaccordingtothegroundconditiontheloadertravels・

Thetrunnion−mOunteddriveaxlehelpslmPrOVeOPeratOrCOmR）rtbecauseloaderswithatrunnion−m

driveaxlejoltlessthanthosewiththeconventionalcradle−SuPPOrteddriveaxle，Whentheytravelon

groundcondition．

ー70−

2．POWERTRAIN

Note：D＞ぢ＝：：コ3668N−m（374kgf−m）［27051bf−ft］匪＞ぢ：：＝コ2687N−m（274kgf−m）【19811bf−ft］ 匪＞ぢ＝＝コ463N−m（47・2kgf−m）【3411bf−ft］B＞紹⊃ゝThnadedarea：LOCTTTE＃262

匝＞l⊂＝：袖Bushinginnersurface：Applygreasebefbreassembling． 直＞Aligngreaseholeswithgrooves．Supplygreaseuntilgreaseflowsoutoftheoppositeend・ B＞Installwithnotchedpartpointingrearofloader（axleside）andslitupward． 匪＞Installwithnotchedpartpointingrearofloader（thrustplateside）andslitupward． 匪＝＞Directliptowardaxleside． 駈＞Installwithgroovepointingtoitem5．

1．BREATHER

6．COVERPLATE

11．DUSTSEAL

2．FRONTAXLE

7．DUSTSEAL

3．REARAXLE 4．AXLESUPPORT

8．BUSHING 9．AXLESUPPORT lO．DUSTSEAL

12．BUSHING 13．THRUSTWASHER

5．THRUSTPLArE

Fig．2．39 AxleAssembly −71一

2．POWERTRAIN

Note：B＞ぢ＝：コ49N−m（5kgf−m）［361bf−ft］

匪＞ぢ＝コ461N−m（47kgf−m）【3401b瑚

B＞ぢ＝コ225・6N−m（23・Okgf−m）［166・41bf−ft］B＞ぢ＝コ91・2N−m（9・3kgf−m）［67・31bf−ft］

B＞ぢ＝コ34・3N−m（3・5kgf−m）［25・31bf−ft］匪ぢ＝コ35・3N−m‡3・6kgf−m）［26・01bfLft］

B＞ぢ＝：：コPipingflarenut：39to49N，m（4to5kgf−m）［29to361bf−ft］

匪＞紹＝ゝThreadedarea‥LOCTITE＃572 匪＞紹＝ゝThreadedarea：LOCTITE＃262

1．AXLEHOUSING 2．DIFFERENTIAL 3．WHEEL 4．SHAFT 5．PLANETGEAR

6．CAP 7．THRUSTPLATE 8．SUNGEAR 9．PLANETCARRIER lO．HUB＆BRAKEASSEMBIX

Fig．2．40 FrontAxle

−72−

11．AXLESHAFT 12．SLACKADJUSTER 13．BRAKETUBE

2．POWERTRAIN

Note：B＞ぢ＝コ49N−m（5kgf−m）［361bf−ft］

匪＞ぢ＝コ450・8N−m（46・Okgf−m）［332・71bf−ft］

匝＞ぢ＝：：コ225・6N−m（23・Okgf−m）［166・41bf−ft］B＞ぢ＝：：コ91・2N−m（9・3kgf−m）［6731bf−ft］ B＞ぢ＝：＝コ34・3N−m（3・5kgf−m）【25・31bf−ft］

匪＞ぢ＝コPipingflarenut：39to49N−m（4to5kgf−m）［29to361bf−R］

B＞正⊃ゝThreadedarea：LOCTITE＃572

匪⊃＞14＝ゝThreadedarea：LOCTITE＃262

1．AXLESUPPORT

6．PLANETGEAR

11．HUB＆BRAKEASSEMBLY

2．AXLEHOUSING 3．DIFFERENTIAL

7．CAP 8．THRUSTPLArE

12．AXLESHAFT

4．WHEEL

9．SUNGEAR lO．PLANETCARRIER

5．SHAFT

13．BLOCK 14．BRAKETUBE

Fig．2．41RearAxle

−73−

2．POWERTRAIN

Note：B＞ぢ＝＝コ46・9N−m（4・7kgf−m）［34・01bf−R］匡＞ぢ＝コ91・1N−m（9・3kgf−m）［67・31bf−ft］

B＞ぢ＝コ147N−m（15kgf−m）［1081bf−ft］ B＞ぢ＝＝コ225N−m（23kgf−m）［1661bf−ft］ B＞Donotapplygreasetothe

0

−ring，butapplygearoiltotheslidingsurfaceandinstall・

匪＝＞超＝ゝInnersurfaceofthebrakehousing＝NOKCrewbaL60（befbreassembly） 圧＞Procedureforshimadjusting

①Assemblethespindle，internalgearhubandretainer，andtightenthewheelhubholdbolt to98N−m（10kgf−m）［721bf−ft］temporally・

②RemovetheboltsandretainersandmeasuretheclearanceYwithadepthgauge・ ③ChooseshimssothattheclearanceisO．05toO・15mm［0・00020toO・0059in・］thinnerthan thevalueY．Installtheshimsandretainers，andtightenthemwithbolts・ 8．BRAKEPISTON

1．SPINDLE 2．ENDPLATE

9．D−RING

3．BLEEDER

lO．RINGGEAR

4．PLATE

ll．INTERNALGEARHUB

5．BRAKEDISK

12．RETAINER

6．BRAKEHOUSING

13．WHEELHUBHOLDBOLr 14．SHIM

7．D−RING

Fig．2．42 Hub＆Brake −74一

15．OUTERBEARING 16．WHEELHUB 17．SEALRETAINER 18．FLOArINGSEAL 19．GUIDEPIN 20．SPRING 21．INNERBEARING

2．POWERTRAIN

2．6．2DIFFERENTIAL Thedifftrentialisintegralwiththereductiongear． Thepowerfromthepropellershaftsistransmittedthroughthedriveplnionandtheringgeartothe

differentialgearcase．Itisthensentthroughthesidegearstotherightandleftaxleshafts．Thespee

reductionofthepowerisaccomplishedbythedriveplnionandtheringgear・ Thedi批rentialoperatesasfollows： （1）Conventionaldi鮎rential

Mostwheelloadersusetheconventionaldifftrentialwhichisthesametypeusedforautomobiles．

①Whiletheloadertravelsstraightforwar9，theringgear，differentialgearcase，andsidegearsr

together，Withtheplniongearsinsidethedifftrentialgearcasenotrotatlng・Thepowerofthesam

SPeedisthustransmittedfromtherightandleftsidegearsthroughtheaxleshaftstothewheels・

②Whentheloadermakesaturn，therightandleftwheelsrotateatdiffbrentspeeds；thepiniongearsi differentialgearcaserotatearoundtheirownaxesaccordingtothedifftrenceinspeedbetweentheright

andletsidegears． Whiletrave＝nqstraiqht

While makin

1．PINIONGEAR 2．SIDEGEAR 3．AXLESHAFT 4．DIFFERENTIAL CASE 5．SPIDER 6．DRIVEPINION 7．RINGGEAR

Fig．2．43 DifftrentialGearOperation

（2）LimitedslipdifFbrential（L．S．D．） Wheelloadersoftenneedtoworkonabadgroundconditionsuchasonsandorinaswampyplace．On

SuChabadgroundcondition，aloaderwiththeconventionaldifftrentialcanskid，thusmakingitdimcu

deliveritsperformanCe．Inaddition，thetireswillalsowearoutprematurely・Topreventthisfromhappenlng

SOmemOdelsmaycomeequlPPedwithalimitedslipdifftrentialwhichlimitsdifftrentialaction・ Thelimitedslipdifftrentialhasaclutchdiskinsertedbetweenthesidegearandthedifferentialcase rotation，tOkeepthesamerotationoftherightandlefttiresuslngtheresistanceofthefrictionalsurfaceofthe Clutchdisk，thuslimltlngdifftrentialaction．

ー75一

2．POWERTRAIN

Note：B＞ぢ＝：コ34・3N−m（3・5kgf−m）［25・31bf−ft］P＞l芯＝コ774N−m（79kgf−m）［5711bf−ft］

軒＞ぢ＝：コ225N−m（23kgf−m）［1661bf−q 駐＞ぢ＝コ980N−m（100kgf−m）［7231bf−ft］

B＞祀＝ゝThreadedarea：LOCTITE＃262 匪＞Installcagegroovesasshown・ B＞Pinionbearingpreload：9・8to14・7N−m（1・Otol・5kgf−m）【7・2tolO・81bf−ft］（aqjustwithspacers）

B＞Spiralbevelgearbacklash：0・41toO・56mm［0・0161toO・0220in・］ 1．RINGGEAR 2．DIFFERENTIALCASE 3．ADJUSTMENTNUTLOCK 4．CAP 5．ADJUSTMENTNUT 6．DIFFERENTIALCARRIER 7．SEALRETAINER

8．SPIDER 9．PINIONWASHER lO．PINIONGEAR ll．DIFFERENTIALCASE 12．SIDEGEAR 13．THRUSTWASHER 14．SPACER Fig．2．44 Difftrential（Front） −7（卜

15．PINIONGEAR 16．SPACER 17．SHIM 18．BEARINGCAGE 19．0ILSEAL 20．FLANGE

2．POWERTRA［N

Note：B＞ぢ＝コ34・3N−m（3・5kgf−m）［25・31bf−ft］臣＞ぢ＝コ774N−m（79kgf−m）［5711bf−ft］ B＞ぢ＝コ225N−m（23kgf−m）［1661bf−f［］匪＞ぢ＝コ980・7N−m（100kgf−m）［723・31bf−ft］

匪＞紹＝ゝThreadedarea：LOCTITE＃262 匝＞Insta11cagegroovesasshown・ 匡＞Spiralbevelgearbacklash：0・41toO・56mm［0・0161toO・0220in・］ 直＞Pinionbearingpreload：9．8to14．7N−m（1．Otol・5kgf−m）［7・2tolO・81bf−ft］（Aqjustwithspacers）

1．RINGGEAR 2．DIFFERENTIALCASE 3．ADJUSTMENTNUTLOCK 4．CAP 5．ADJUSTMENTNUT 6．DIFFERENTIALCARRIER 7．BEARINGCAGE

8．SEALRETAINER 9．SPIDER lO．PINIONWASHER ll．PINIONGEAR 12．DIFFERENTIALCASE 13．SIDEGEAR 14．THRUSTWASHER Fig．2．45 Di鮎rential（Rear） −77−

15．SPACER 16．PINIONGEAR 17．SPACER 18．AXLESUPPORT 19．SHIM 20．0ILSEAL 21．FLANGE

2．POWERTRAIN

2．6．3FINALREDUCT10NGEARANDBRAKEUNIT

Thennalreductiongearassemblyisaplanetarytypeandprovidesnnalspeedreductionofthepowerfro theenglneinthepowertransmissionline・

Thepowerfromthesungearsplinedontheaxleshaftrotatesthreeplanetgearsintheringgear，andth rotationoftheplanetgearsistransmittedthroughtheplanetcarriertothewheelhub・

Thebrakeunitisusedasaservicebrake丘）rtheloaderandadoptsawettypediskbrakewhichisinstal onthewheelhub．

Thebrakeunitconsistsoftheslackaquster，thediskbrakeandpiplng・Foritsoperation，See 3・ SYSTEM．

÷ニー Powerf10W

1

2 3 4 7

SectionA−A

6 8 9

1．RINGGEAR（Fixed）

2．SUNGEAR 3．PLANETGEAR

4．AXLESHAFT 5．PLANETCARRIER 6．WHEELHUB

Fig．2．4

ー78−

PowerFlow

7．WHEEL 8．GEARHUB 9．SPINDLE

2．POWERTRAIN

2．7WHEELASSEMBLY（TJFIEANDWHEEL） Tire

26．5−25−24PR，Tubeless，L−3

Wheel（rim）

22．00Ⅹ25WTB

Weight（PerPiece）

Tire

418kg［9231bs］

RiIll

245kg［5401bs】

Inflation pressure

441to490kPa（4．5to5．Okgf／cm2）［64to71．1psi］

2．7．1TIRE

Thestandardmodelisprovidedwithlock−tyPeL−3tireswhichftaturedamageresistanceandabrasio resistance．Selectapproprlatetiressincethereareavarietyoftiresavailableaccordingtotheapplicationand

PurPOSeOfwork． Thetiresizeisexpressedininches．ThestrengthoftiresareeXPreSSedinplyrating（PR）：forexample，

20PRmeansastrengthcorrespondingtothatof24piecesofcottoncords．（PRdoesnotnecessarilystand thenumberofcordpliesintire．）

Example：

24PR

26．5 ￣

Tirewidth（in．）

25

￣￣￣￣￣￣−

∴￣

Rimdiameter（in．） Tirestrength

（TreadPattern）

1．TIRE 2．RIM

Fig．2．47 Tire −79−

3． 0 −RING

4．AIRVAINE

2．POWERTRAIN

2．7．2 WHEEL

Thewheelconsistsoftherimanddisk．Thediskisboltedtothewheelhub． ThetireisinstalledontherimandbothserveaSOnePleCe・ItisthusverylmPOrtanttOuSeanaPPrOPrl rimwheninstallingatireontherim・Theuseofaninapproprlaterimmayresultinashortliftofthetirea intheworstcasemightleadtoaseriousaccident・Therimsizeisalsoexpressedininches・Thenrstnum standsfbrtherimdiameterandthenextonetherimwidth．

SectionaLVjewAOB

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

1．RIM 2．AUXILIARYRING 3．DISK 4．BEADSHEETBAND 5．SIDERING

6．HEAVY−DUTY

9． 0 −RING

DRIVER POCKET

lO．VAIJVEGUARD

7．HEAVY−DUTY

ll．HEX．NUT

DRIVER KEY 8．LOCKRING Fig．2．48 Wheel

−80−

3．DRIVEAXLE

3．BRAKESYSTEM Service brake Frontandrearwheelindependentbraking，Wetmulti−Platedisk

r吋pe

hydraulic，fu11−POWerbrake

Numberoffluidlines

Independent21ines

Brake valve

Dualbrakevalve

Disk brake

Wettypemultidiskbrakeonfourwheels

Brake pump

SB（1）14Installedonsteeringpump

Accumulator

Accumulator（2．8L［171in．3］x2pcs．）

Brakeoilpressuresettlng

6．68MPa（68kgf／cm2）［967psi］

Safety system

EmergencybrakinglSuSed

Parkingandemergencybrake

Wettypemultiplediskmechanicaltype，incorporatedintransmission

Type

Note：Therearpumpofthetwo−throwpump（POC＆brakepump）fbrthebrakepumpisused・Fordetails， see

6．HYDRAULICSYSTEM．

AIf？eenginestal1swhilethelo？derisrunning，thebrakemaybecomeinoperative・Donotshut theenglneWhiletheloaderisrunnlng．

AExceptinanemergencysituation，donotapplytheparkingbrakewhiletheloaderismovin Abusingemergencybrakingfunctionmightcausemalfunctionoftheparkingbrake・

Acautiontobetakenwhenservicingaccumulatoranditspiping．

●Theaccumulatorisfilledwithhigh・PreSSurenitrogengas．UseduecautionwhenservIClng accumulatoIl

●ServIClngOftheaccumulatorsuchasmlingofnitrogengas，Shouldbeperfbrmedonlybyquali

personnel． ●Donottrytomachineorweldtheaccumulatordirectly．

●Theaccumulatorpipinghaspressurizedhydraulicoilinsideit．Be払reworkingontheaccumulator PIPlng，releaseanyresidualpressurefromthepiping・

●WhenreleaslngreSidualpressurefromtheaccumulatorplplng，Parktheloaderonalevelsur

Shutofrtheenglneandlowertheboomsandbucketontheground．

−81−

3．DRIVEAXLE

3．1SERVICEBRAKE 3．1．1GENERALDESCRIPTION（BRAKEL］NE） （1）Servicebrakeline

Theservicebrakeisa4−Wheelwettypediskbrakesystemandusesthefu11powerbrakesystem・

Thehydraulicbrakelinehasanindependent2−1inesystemfortheh・Ontandrearwheels・Ifoneofth linesisdamaged，anOtherlinewilloperateproperlytobraketheloader・

Thebrakepumppicksuptheoilfromtheoiltankandaccumulatesitintheaccumulator・Whenthe pedalispressed，thediskbrakeisoperatedbytheaccumulatoroilpressure・

ThebrakepumpISalsousedasanassistpump・ForthespecincationsandconstruCtionofthepump・ref to 6．2PUMP．

（2）Safbtysystemandalarmsystem ●Anemergencybrakeisinstalledasasafetydevicefortheservicebrakeline・

Ifoilpressureinthehydrauliclineofthebrake（accumulator）dropstozero，theemergencybrakei actuated・Theemergencybrakeisalsousedasparkingbrake・

●TheaccumulatorisequlPPedwithapressureswitch・Iftheaccumulatoroilpressuredropstoacertai level，theoperatorwillnoticeitimmediatelybywayofthebuzzerandthe＝brakeoilpressure warn lamponthedashboard・

Note：Specincationsandapplicationsofswitches（Fig・3・1） Position

Application

Name

A

Stop lamp switch

B

Pressure switch （Clutchcut−0ffswitch）

OFFwhenpushrodispushed ONwhenpushrodisreleased

Stoplamp Transmissionclutchcut−

Operatingstate：3．4MPa（35kgf／cm2）［498psi］， Reset：2．5MPa（25kgf／cm2）［356psi］（TurnS

0ff（inching） Brakeoilpressure

C

Pressureswitch

Warn1nglampandbuzzer

Pressure switch

indicatorlampand

（Parkingswitch）

transmissionclutchcut−

Parkingbrake D

Specification

0仔

ー82−

ONatatmosphericpressure）

Operatingstate：2・2MPa（22kgf／cm2）［313psi］， Reset：1．5MPa（15kgf／cm2）［213psi］（TurnS

ONatatmosphericpressure）

3．DRIVEAXLE

＝＝＝コ SERVICEBRAKEしINE

㊥：fromSTEERINGPUMP

㊥：tOSTOPVAINEINPILOTHYDRAULICCIRCUIT

PARKING BRAKE LINE

壊）：tOSTEERINGPUMPSUCTIONTUBE（DRAIN） ㊥：tOOILCOOLER （∋：tOOILTANK

1．PARKINGBRAKESWITCH

6．ACCUMULATOR

2．WIREHARNESS 3．PARKINGBRAKEVALVE

7．TRANSMISSION

ll．CHARGINGVAI」VE

12．REDUCINGVALVE

4．BRAKEPEDAL

8．PARKINGBRAKE 9．WETTYPEDISKBRAKE

5．BRAKEVALVE

（builtinAXLE）

Fig．3．1BrakeLine −83−

lO．SLACKADJUSTER

3．DRIVEAXLE

ACCUMULA，。R

BRAKE VALVE

to STOP VALVE c

PARKING VALVE

P＝

RE

A（PARKINGB

n￣￣￣1⊆許諾音 ⊥r TB l】 」一＿」

PARKlNG BRAKE （BUILTINTRANSMISS10N）

■ ・

OIL COOLER †㍊；EERING

Note：Thiscircuitdiagramincludestheparkingbrakecircuit・ Fig・3・2 BrakeOilPressureCircuitDiagram −84−

3．DRIVEAXLE

（3）Inchingmechanism

Theinchingmechanism，interlockedtothebrakesystem，StOPSPOWertranSmissiontemporarilybypl

thetransmissioninneutral． Whentheinchingmechanismisactivated，thedrivingpowerisconcentratedintheload−handlingsys

・Whenthebrakeisapplied，theinchingswitchisturnedofftostopthepowersupplytotheforwar reversesolenoidsofthetransmissioncontroIvalve，thusputtlngthetransmissioninneutral． ・TheloaderisequlPPedwithamodeselectionswitchintheoperator

scompartment．Theinchingmecha

（Clutchcut−OfF）isswitchedovertoTravelingorLoadhandlingbyoperatingtheswitch． a．LoadhandlingmodewithmodeselectionswitchパOFF The

clutchcut−Off

indicatorlampgoesout，indicatlngthattheinchingmechanismisinactivat

Whenthebrakepedalispressed，thebrakeisappliedandtheinchingswitchisturnedofftoputthetransmission

inneutral．Whenthebrakepedalisreleased，theinchingswitchisturnedontolinkthetransmissionli agaln・

b．Travelingmodewithmodeselectionswitch㍍ONM，Startingofrongrades（non・inching） The clutchcut−Off indicatorlampturnson，indicatlngthattheinchingmechanismisnotworking・The

POWerSuPPlytotheforwardandreversesolenoidsofthetransmissioncontroIvalveissuppliedthroughthe

Clutchcut−0ffswitchregardlessoftheinchingswitchoperation．ThereR）re，Whenthebrakepedalispressed thetransmissionwon

tshiftintoneutral．

Note：ThisdiagramShowsacircuitwithboththeservicebrakeandtheparkingbrakereleased・

Fig．3．3 ElectricCircuitDiagramforModeSelection −85−

3．DRIVEAXLE

Operation （1）Accumulatorinoperation（brakepedalinneutral）

①Theoilsuppliedfromtheoiltank（hydraulicoiltank）bythebrakepumpflowsthroughthech

Valveandcheckvalve，andisaccumulatedintheaccumulator．ThisdischargeOilisalsosuppliedt Parkingbrakelineandpilotvalve（Z）ofthehydraulicunit．

②Theoil鈷・Omtheaccumulatorissenttothebrakevalveandisblockedbythespoolbecausethe Valveisnotinoperation．

③Whentheoilpressureinthebrakeline（accumulatedoilpressureintheaccumulator）exceedsthesp Value，thereliefvalveinsidethecharglngValveoperatesandtheoildischargedfromthepumpflows

throughthechargingvalvebacktotheoiltank・

④Whentheaccumulatedoilintheaccumulatorisconsumedbybrakeoperationandtheoilpr becomeslessthanthespecifiedvalue，thereliefvalveinthecharglngValvestopsoperationandtheoil

dischargedfrompumpISagalnaCCumulatedintheaccumulator．

⑤Thebrakeportcommunicatedtothediskbrakeisconnectedtothetankportinthebrakevalve． brakeisinthereleasestate．

Fig．3．4 Brakelね1veinNeutral（released） −86−

3．DRIVEAXLE

（2）Brakepedalpressed

①Whenthebrakepedalisdepressed，thebrakevalveoperatestoshutoffthecommunicationbetweenthe brakeportandthetankport．

Then，thebrakeportisconnectedtotheaccumulatorportsothatthepressurizedoilintheaccumula

issentthroughtheslackadjustertothediskbraketoapplythebrake・

②Whenthebrakepedalisreleased，thebrakevalvereturnStOneutral．Thepressurizedoilsenttothe

brakeflowsthroughthebrakevalveandisdrainedthroughthetankport・Thediskbrakegetsi releasestate．（SeeFig．3．4．）

Fig．3．5 BrakePedalPressed

−87−

3．DRIVEAXLE

3．1．2 BRAKEVÅLVE Thebrakevalveisadualtypeconsistingoftwoindependentbrakelines：frontandrear．

ThebrakevalvehastwospooIsprovidedinseriesatthecenterofthevalvebody，Witheachspoolhaving

aplungerbuiltintofeedbackthebrakecontroloilpressure・Inaddition，aSprlnglSinstalledbetwee

SPOOlinputandeachspooltotransmitoperationloadandstroketothebrakepedal・ Operation （1）Brakeinreleasestate（Fortheidentificationnumbersoftheparts，SeeFig・3・6・）

Whenthebrakevalveisnotactuated，thespooIs（8，17）arereturnedtothereleasepositionbythes （19）andthebrakeport（B）isconnectedtothetankport（T）．

Theaccumulatorport（A）andthebrakeport（B）areshutoffbythespooIssothattheoilpressureint accumulatoriskepthigh．

（2）Brakeinoperation ①Whenthebrakepedalispressed，thespoolinput（14）ispushedthroughtheroller（22）．Thespoo movesthespooIs（8，17）forwardthroughthespring（16）．

②WhenthespooIsaremovedforward，thebrakeport（B）isblockedofffromthetankport（T）．Whent

SPOOIsarefarthermovedforward，thebrakeport（B）isconnectedtotheaccumulatorport（A）an

highpressureoilintheaccumulatorflowsfromthebrakeporttostartbrakingoperation．

③ThepressurizedoilatthebrakeportsideflowsthroughtheorificesinthespooIsandactuates

PlungersbuiltinthespooIs，generatingthe丘）rCePuShingbackthespooIs（hydrauliccounterfbrce）・ total丘）rCeOfthehydrauliccounter氏）rCeandthespring（19）loadisbalancedwiththespring（16）loadto

COntrOlthebrakeoilpressureatthebrakeportside．

④Thecompressionandloadofthespring（16）arefedbackasthestrokeandoperatingforceofth PedaltoglVetheoperatortheoperatlngfeelofthebrakepedal．

（3）Whenbrakeisreleased

①Whentheoperatingfbrceofthebrakepedalisreleased，thespoolinputispushedbackbythespring（

②Whenthecompressedspring（16）isreleased，thespooIsarereturnedtothereleasestatebythetot

fbrceofthecounterfbrceactingontheplungerandthespring（19）force．Thebrakeport（B）and

accumulatorport（A）areshutoffbythespooIs，andthebrakeportisreleasedtothetankport（T）

PreSSurizedoilatthebrakeportsideisdrainedintothetankporttoreleasethebrakeoperation・

ー88−

3．DRIVEAXLE

臣臣りりりり

ト．∵い⁚∵5．．い

e t O N

【5．79to8．681bf一明 7．85to11．8N−m（0．8tol．2kgf−m） 【5．06to6．511bf−珂 6．86to8．83N−m（0．7toO．9kgf−m） ［7．23tolO．851bf一明 9．81to14．7N−m（1．Otol．5kgf−m） ［14．5to18．81bf一円 19．6to25．5N−m（2．Oto2．6kgf−m）

A．OILFEEDPORT B．DISCHARGEPORT T．TANKPORT

［32．5to43．31bf一氏】 44．1to58．8N−m（4．5to6．Okgf−m） ［21．7to25．31bf一年】 29．4to34．3N−m‡3．Oto3．5kgf−m）

1．SEAT

9．BODY

17，SPOOL

2．DUSTCOVER 3．PLATE

lO．BODY

18．PLUNGER

ll．PLUG 12．PEDAL 13．MOUNTINGPLATE

19．SPRING 20．MOUNTINGPLArE

14．SPOOLINPUT 15．RETAINER

22．ROLLER 23．SHAFT

4．0ILSEAL 5．SPRING 6．SPRING 7．COVER 8．SPOOL

16．SPRING

Fig．3．6 BrakeValve −89t

21．PEDALPIN

3，DRNEAXLE

3．1．3CHARGINGVALVE

TheservicebrakelineisequlPPedwiththecharglngValvewhichcontroIstheflowrateandpressureofoil sentfromthepumptotheaccumulator・

TANKPORT

Section B−B

PORT PORT HYDRAULICCIRCUITDIAGRAM

SectionA−A

Note：B＞ぢ＝＝】29．4to39・2N−m（3to4kgf−m）【21・7to28・91bf−ft］ 匡＞ぢ＝コ11・8to16・7N−m（1・2tol・7kgf−m）［8・7to12・31bf−ft］

匪＞ぢ＝＝コ118to137N−m（12to14kgf−m）［87tolOllbf−ft］ B＞ぢ＝コ49to83・4N−m（5to8・5kgf−m）［36to61・51b 匪＞ぢ＝コ9・81to14・7N−m（1・Otol・5kgf−m）【7・23tolO・851bf−ft］

医＞正＝ゝThreadedarea‥LOCTITE＃262 1．BODY 2．ORIFICE 3．SPRING 4．SPOOL 5．PLUG

10．SPRING

19．PLUG

ll．PLUG

20．り0 −RING

12． 0 −RING

21．PLUG

6． 0 −RING

15．SCREW

7．PILOTVALVE 8．SPRINGSEAr 9．SPRING

16．NUT

① PUMPPORT ② TANKPORT ③ SECONDPORT

17．PLUNGER 18．ORIFICE

④ACCUMULATORPORT

13．SEAT 14．‖0 −RING

（toOILCOOLER）

⑤ PILOTPORT Fig．3．7 ChargingValve −90−

3．DRIVEAXLE

Generaldescription

Thechargingvalvehasthepumpport，SeCOndport（1eadingtotheoilcooler），aCCumulatorport，Pilotpor

anddrainport．Italsoincorporatesthespool（4）thatcontroIsthepumpportandsecondport，theorince（2）

thatpr10ritizestheflowrateofoiltotheaccumulator，andthepressuregovernlngmeChanismthatcontroIs

theoilpressureattheaccumulatorportside． Operation

Whenthebrakepedalisreleased，thespool（4）ispushedbackbythespring（3）sothatthepumpport

thesecondportareclosed．

Theoilthatflowsthroughthepumpportpassesthroughtheorifice（2）totheaccumulatorport，thus

increaslngtheoilpressureattheaccumulatorport．

Anyexcessoilflowmovesthespool（4）towardthesecondportsideandisdrainedtothesecondport・

Thepressurizedoilattheaccumulatorportflows，PaSSingthroughtheorifice（18），intothepres

governor．Whentheoilpressureattheaccumulatorportincreasesenoughtoovercomethesprings（9＆1

brceactingonthepilotvalve（7），OPenStOStOPthepressureincreaseattheaccumulatorport（Cut−OutPreSSure）・ Atthistime，theplungergovernor（17）ispushedupbytheoilpressureintheaccumulatorconnected thepilotporttokeepthepilotvalve（7）open・

Whentheoilpressureattheaccumulatorportdropsandtheplungergovernor（17）ispushedbackbythe

SPringforceactingonthepilotvalve（7），thepilotvalve（7）closes・Thisallowstheoilpressure

accumulatorporttoincreaseagain（Cut−inpressure）・

ー91−

3．DRlVEAXLE

3．1．4SLACKADJUSTER

Theslackaqusterisabrakeauxiliaryunitwhichisinstalledbetweenthebrakevalveandthebrake cylinder（diskbrake）tokeepthebrakediskclearanceincreasedbyawornbrakememberconstant・

Inaddition，thisadjusterpreventstheinnerpressureinthehydraulicoiltankfromactlngOnthebrake Cylinder・

View100kingfromZ

1 2＜司

3

SectionA−A

Note：B＞（忘＝コ44・1to58・8N−m（4・5to6・Okgf−m）【32・5to43・41bf−ft］ 駐＞ぢ＝コ6・9toll・8N−m（0・7tol・2kgf−m†［5・1to8・71bf−ft］

1．BODY 2．AIRBREArHER

4．CYLINDER

3．PISTON

6．‖0 −RING

5．SPRING

Fig．3．8 SlackAqjuster

−92−

7．PLATE

3．DRIVEAXLE

3．1．5 DISKBRAKE

Thediskbrakeisawetmultiple−Platetypeandbuiltineachoffrontandreardriveaxles．Forthestru Ofthediskbrake，referto

2．5DRIVEAXLE．

Operation

① Whenthebrakepedalisdepressed，thebrakeoilpressureactsonthebackofthebrakepiston，mOVeSt

brakepistonandlocksupthebrakediskswithbrakeplates・ Theinnerperipheryofeachbrakediskissplinedtothewheelhub．Theouterperipheriesofthebrake Platesaresecuredtothebrakehouslngbyasplinesothatthelocked−uPbrakedisksstoprotatlngtO braketheloader．

② Whenthebrakeoilpressureisreleasedbyremovingyourbotfromthebrakepedal，thebrakepis

returnedtotheorlglnalpositionbythereturnsprlng．Aclearanceiscreatedbetweenthebrakedisksand

thebrakeplatestomakethebrakedisksfree，thusreleaslngthebrake．

1 2 3 4 5

轍BRAKEOIL

1．BRAKEPISTON 2．WHEELHUB 3．BRAKEHOUSING 4．BRAKEDISK 5．BRAKEPLATE 6．RETURNSPRING

Fig．3．9 DiskBrakeOperation −93−

3．DRlVEAXLE

3．1．60THERCOMPONENTS l．Inlinefilter 6

1．ELEMENT 2．HEAD 3．CASE 4． 0 −RING 5．BACK−UPRING

6．BYPASSVAIJVE

BYPASSVALVEOPERATINGPRESSURE： 490±73．5kPa（5±0．75kgf／cm2） ［71±11psi］

Fig．3．10Inlinenlter

2．Accumulator

Apistontypeaccumulatorisused・Theleakageofthesealedgasislessthantheconventionalplugtyp

ANi．r。gengaSSh。uldbe。Sedfb．thesealedgasintheaccm。1aton Domotuseanyexplosivegassuchasoxygen・

Sealedgas（N2）pressure：3・43MPa（35kgf／cm2）［498psi］ Capacity：2．8L［171in・3］ Ⅵ屯ight： 8．2kg［18・11bs］

Fig．3．11Accumulator −94−

3．DRIVEAXLE

3．2 PARKING BRAKE

ManuaIreleasingofparkingbrake（asanemergencymeasure）A Iftheparkingbrakecannotbereleasedwiththeparkingbrakeknobduetoadefectivepumporforany Otherreason，manua11ymovethebrakepistonbyuslngtheparkingbrakereleasebolttoreleasetheparking brake．

AManual1yreleasingtheparkingbrakesh。。1dn。tbeab。Sed．Itsh。uldbelimitedt。

loaderneedingtobemovedtoanout・Of−trafncarea・Iftheparkingbrakeneedstobereleasedwi loaderparkedonasIope，besuretoblockthewheels．

Manual）yre）eas）ngtheparkingbrake

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

Fig．3．12 ③Inserttheremovedbolt（1）throughtheplughole fromwheretheplugwasremovedinstep②，into

thescrewholeatthecenterofthebrakepiston（3） asshowninFig．3．13． ④Tightenthereleasebolt（1）towithdrawthebrake Piston（3），thusreleasingthediskbrake．

Fig．3．13 −95−

3．DRIVEAXLE

3．2．1GENERALDESCRIPT10N（BRAKELINE）

Theparkingbrakeisamechanical（SPring），Wetmultiple−Platediskbrakeandinsta11edonthelst

clutchshaftofthetransmission．

Theparkingbrakeisoperatedwiththeparkingbrakeswitchintheoperator scompartment・ Operatiom （1）Releasingparkingbrake ①Whentheparkingbrakeswitch（1）isturnedOFF，thepressureoilfromtheaccumulator（6）flows throughtheparkingbrakevalve（3）intothefrontchamber（A）ofthebrakepiston（8）・ ②Thebrakepiston（8）movesagainstthesp中g（7）byoilpressuretoreleasethediskbrake（9）・

Note：Theparkingbrakecannotbereleasedunlessanadequatepressureoilisstoredintheaccumulator・

Ifthemainswitchisturnedoffduringtrave11ing，theparkingbrakewillbeapplied・Donotturn

themainswitchduringtravelingexceptlnanemergenCySituation・Abusingtheemergency mightcausethemalfunctionoftheparkingbrake・

† From PUMP

Fig．3．14 ReleaslngParkingBrake −96−

3，DRIVEAXLE

（2）Applyingparkingbrake ①Whentheparkingbrakeswitch（1）isturnedON，theoilfromtheaccumulator（6）isblockedinthe

Parkingbrakevalve（3）．Thepressureoilinthefrontchamber（A）ofthebrakepiston（8）isdra throughthebrakevalve（3）．

②Thebrakepiston（8）ismovedbythespring（7）toactuatethediskbrake（9）．

toDRAIN ←

Fig．3．15 ApplyingParkingBrake

−97−

3．DRLVEAXLE

（3）Transmissionclutchcut・Off

a．Whenparkingbrakeisapplied； ①Whentheparkingbrakeisapplied，theoilpressureactingonthebrakepistonisdrained・Thepressu switch（Parkingswitch）instal1edonthepistonhousingturnsontochangeoverthetransmissioncut−0ff

relays．

②ThepowersupplytotheR）rWardandreversesolenoidsofthetransmissioncontroIvalveiscutoffsot thetransmissionisputinneutral．（transmissionclutchcut−0ff）

③The parkingbrake indicatorlampcircuitisclosedandthelampcomeson・

PARKING BRAKE

lNDICATORLAMP

Note：Thisdiagramshowsacircuitwiththeservicebrakereleasedandtheparkingbrakeapplied・ Fig．3．16 ElectricCircuitDiagram

b．Whenparkingbrakeisreleased： ①Whentheparkingbrakeisreleased，theoilpressureisproducedtoactonthebrakepiston・Theparki SWitchisturnedoffandthetransmissioncut−0ffrelayreturnstotheorlglnalcondition・

②ThepowersupplytotheforwardandreversesolenoidsofthetransmissioncontroIvalveisrestoredto makeitpossibletoshiftthetransmission・

The parkingbrake warnlnglampgoesout・

一98−

3．DRIVEAXLE

3．2．2 DISKBRAKE

Thediskbrakeisawetmultiple−Platetypeandinstalledonthelst／2ndclutchshaftofthetransmiss Thediskbrakeisactuatedbythebuilt−insprlngandreleasedbythepressureoilfromtheparkingbrakev Forthestructureofthediskbrake，reftrto

2．1DRIVEUNIT．

Operation （1）Diskbrakeinoperation

①Whenthepressureoilactingonthebrakepistonsisdrained，thebrakepistonismovedbythesp brcetolockupthebrakediskswiththebrakeplates．

②Theinnerdiametersofthebrakedisksaremeshedwiththetransmissionshaf［throughthediskhub・T

Outerdiametersofthebrakeplatesaremeshedwiththebrakehouslng・Asthebrakedisksaref

agalnStthebrakeplates，theystoprotatlng・Thisinturnstopstherotationofthetransmissionsh throughthediskhub，thusbrakingtheloader．

1．BRAKEPISTON 2．SPRING 3．ENDPLArE 4．BRAKEHOUSING 5．BRAKEPLArE 6. BRAKE DISK 7．DISKHUB 8．1ST／2NDSHAFT

8

7

Fig．3．17 DiskBrakeinOperation

（2）ReleasingBrake

①Whenthepressureoilissenttothebackofthebrakepiston，thebrakepistonovercomesthespringfor andshi氏sitsposition．

②Aclearanceiscreatedbetweeneachbrakediskandbrakeplatetomakethebrakedisksfree，thu

releaslngthebrake．

ー99−

3．DRIVEAXLE

NOTE

−100−

4．STEERING SYSTEM

4．STEERrNGSYSTEM 「吋pe

Frame−articulating

Mechanism

Follow−uPlinkage

Framearticulatingangle

370torightandleft

No．ofrotationsofsteerlngWheel

4．O

SteerlngWheelreductiongear

Ballnuttype

Pressure setting

20．6±0．5MPa（210±5kgf／cm2）【2987±71psi］

Flow setting

150±15L／min［40±4U．S．gal．］

Steering pump SteerlngCylinder

See

6．2PUMIl

T）11e

Double−aCtlngPIStOn

Q ty

2

Cylinder stroke

530mm［20．9in．］

Weight（PerPiece）

54kg［1191bs］

4．1GENERALDESCRJPT10N

Theloaderisaframe−articulatingtype．ItssteerlngSyStemissteeredbyoperatlngtWOCylindersinstalled

betweenthefrontandrearframes．

仁Ill TANK

Fig．4．1Follow−uPLinkageSystem −101−

4．STEERLNGSYSTEM

ThemechanismofthesteerlngSyStemadoptsthefollow−uPlinkagewhichoperatesthesteerlngValve SpOOIs・

ThesteerlngSyStemCOnSistsofthesteerlnggear，SteerlngValve，SteerlngCylinders，Steerlng hydraulictubing・

Note：Theabovesketchdoesnotillustratethetubing． Fig．4．2 SteerlngSystem −102−

4．STEERING SYSTEM

4．2 01LC］RCULAT］ON ROUTES TheoilpickedupfromtheoiltankbythesteerlngPumPISSentunderpressuretothesteerlngValve．

ThesteerlngValvea句uststhepressureandflowofthepressurizedoiltosteertheloader．Ithasaprl

SyStemWherethesteerlngCircuittakesprlOrltyOVertheothercircuitstosendexcesspressureoiltothemain

Circuit・WhenthesteerlngWheelisoperated，thesteerlngValveisactuatedtosendthepressurizedoi

thepumptothesteerlngCylinders，Steerlngtheloader．TheoilreturnlngfromthesteerlngCylinderf

l

throughthesteerlngValvebacktotheoiltank．

火

sTEERING CYL■NDER

．

火

「￣￣￣‥￣

A

B

l＿＿＿＿．＿．．．．．．．．．＿．．．．＿＿＿＿＿

STEERINGVALVE

P

←

toMAINVALVE（P）

l □ 】

l i託欝■NG

l

」＿ □

＿二＿＿」

OILTANK

Fig．4．3 HydraulicCircuitDiagram −103−

4．STEERINGSYSTEM

4．3 STEERLNGWHEELUNLT ThesteerlngWheelunitconsistsofasteerlngWheel，SteerlngCOlumnassemblyandsteerlnggear・ ThesteerlngWheelunitisatilttypesothatthetiltofthesteerlngWheelpostcanbea句usted．

Thesteerlnggearisaballnuttype．Itisalsocalledarecirculatingballtypeorballcirculatingtypeand

featureslightsteerlngOPeration．Intheballnutsteerlnggear，Steelballsareinstalledbetweenthewormand

ballnutsothatthewormrOtationisconvertedtotheaxialmovementofthebal1nutbytherollingcontactof theballs． Operatiom

① Whenthesteeringwheelistumed，therotationistransmittedthroughthesteeringcolumnwhichintu rotatesthewormofthesteerlnggear．

② Theouterrackofthebal1nutwhichisengagedwiththewormisalsoengagedwiththeteethoftheb

gearwhosesectorshaftistilted．Therefore，theballnutdoesnotturnandmovestotheaxialdirect

③ Theaxialmovementoftheba11nutisconvertedintotherotationofthesectorshaftbymeansoftheoute rack．

④ Therotationofthesectorshaftactuatesthesteeringvalvethroughthepitmanarmandlinkage・

（PartsnamesshowninFig．4・4SteeringWheelUnit）

1．STEERINGWHEELUNIT 2．STEERINGWHEELPOSTCOVER 3．STEERINGWHEELSUPPORT 4．STEERINGGEAR 5．STEERINGWHEELPOSTCOVER

6．BRACKET 7．SEAT 8．STEERINGCOLUMN ASSEMBLY 9．BOOT

−104−

lO．PITMANARM ll．TILTLEVER 12．NUT 13．LOCKBOIJ

4．STEERING SYSTEM

3

11

12

L

i

F二：二二ニトト

トーーーーーー

Note：B＞ぢ＝：コ104N−m†10．6kgf−m）［771bf−ft］ ］

匪＞ぢ＝：：コ101N−m（10・3kgf−m）［741bf−ft］

Fig．4．4 SteeringWheelUnit −105−

Detai10fareaA

J

4．STEERING SYSTEM

4 Detai10fareaA

Note：B＞紹＝ゝApplysynthetic−rubber−based adhesivebefbreinstalling． P＞正＝ゝApplywaterproofsealingagent・ R＞r⊂＝恥Applygrease・ 匡＞紹＝ゝApplyadhesivebeforeinstalling・ 匡＞r⊂＝恥Fillgrease・

1．SHAFT 2．BUSHING 3．BEARING

4．GROMMET 5．COLUMN 6．BUSHING

Fig．4．5 SteeringColumn −106一

7．COLUMNBUSHING 8．JOINT

4．STEERINGSYSTEM

SectionA−A

Note：B＞ぢ＝：コ20to29N−m（2to3kgf−m）［14to221bf−ft］

匪＞〆＝＝恥Insideofdustcover：Fillgrease B＞l⊂＝恥Shadedarea：Fillgrease

B＞r⊂＝恥Bearing：Fillgrease

1．0ILSEAL 2．BUSHING

7．BUSHING 8．SIDECOVER

13．WORM 14．TOPCOVER

3．GEARCASE

9．BALLNUT

4．SECTORSHAFT 5．SHIM 6．ADJUSTMENTSCREW

lO．BUSHING

15．0ILSEAL 16．BEARING 17．VAINECASE

ll．ENDCOVER 12．DUSTCOVER Fig．4．6 SteerlngGear −107−

4．STEERINGSYSTEM

4．4 STEERINGVALVE Name

KVMT‑200L

r吋pe

ControIvalvewithpressurecompensatlngmeChanism

Max．controlflow

150±15L／min［40±4U．S．gal．］

Mainreliefpressuresettlng

20．6±0．5MPa（210±5kgf／cm2）［2987±71psi］

Portreliefpressuresettlng

24．5±0．5MPa（250±5kgf／cm2）［3356±71psi］

Weight

22．5kg［49．61bs】

ThesteerlngValveisacontroIvalvewithapressurecompensatlngmeChanismwhichsuppliesflowin

proportiontothedisplacementofthesteeringspooIvalve，regardlessofloadpressure（Steeringcyl PreSSure）change．

ThesteerlngValveisalsoequlPPedwithacarryoverportsothattheexcesspressurizedoilwhichisnot used丘）rthesteerlngCircuit，flowstothemaincircuit・WhennosteerlngOPerationiscarriedout，theenti amountofoildischargedfromthepumpflowstothemaincircuit・

ThesteerlngValveconsistsofthevalvehouslng，SteerlngSPOOl，CarryOVerPlunger，mainreliefvalveand

twoportreliefvalves．ThemainreliefvalveaqiuststhehydraulicoilpressureinthesteerlngCircuit

thehydraulicoilpressureexceedsthepressuresettlng，themainreliefvalveoperatestodirectthepressurized oiltotheoiltank・Theportreliefvalve，insta11edoneachcylinderport，PrOteCtSthecircuittothesteerln cylinder from overload.

−108−

4．STEERFNGSYSTEM

9mm【0．35in．］ 9mmrO．35h．］

1．MAINRELIEFVALVE 2．PORTRELIEFVALVE

A：CYLINDERPORT B：CYLINDERPORT P：PUMPPORT PB：CARRYOVERPORT

（toMAINCIRCUIT） T：TANKPORT

Fig．4．7 SteerlngValve −109−

4．STEERING SYSTEM

5 61 2 27 29 28 9 7 8 6 417

28

29

SectionZ−Z

1．HOUSING 2．SPOOL 3．SPOOL 4．PLUG 5．PLUG 6． 0 −RING 7． 0 −RING

8．BACK−UPRING

9．SPRING lO．POPPET

11．SPRING 12．CAPSCREW 13．SPRINGSEAT 14．SPRING 15．CAP 16．SOCKETHEADBOLr 17．RELIEF 18．PLUG

21．SEALPLATE 22．SOCKETHEADBOIJ 23．SEAL 24．WIPER 25．PLUG

19． 0 一別NG

29． 0 −RING

26． 0 −RING

27．SHIM 28．PLUG

20．BACK−UPRING

Fig．4．8 SteerlngValveConstruction −110−

4．STEERiNG SYSTEM

Operation Note：ThesketchesofthesteerlngValvethatwillbeshowninthefollowlngpageSareglVenfbrreftrence PurPOSeS．Theymaybesomewhatdifftrentfromthatusedforyourloader・

1．Neutral ①Withthesteeringspool（1）inneutral，theportsAandBleadingtothesteeringcylindersareclose

②ThepressurizedoilfromthepumpflowsfromtheportIIpassingthroughtheorince（3）inthecarry− OVerPlunger（2），intothechamber

b．

③Thechamber a ontheoppositesideleadsthroughasmallholetotheloadcheckvalve（4）of Steeringspool（1）．Whentheoilpressureinthechamber Chamber

a

a

rises，theloadcheckvalveisopenedandthe

isconnectedtothelow−PreSSurePaSSage（T）．

④Thisputsthechamber b intothepumppressurestateandthechamber a inalow−PreSSureState thatthecarry−OVerPlunger（2）movestotherightsideallthewaytoopenthecarry−OVerPOrt（PB）・

⑤AllthepressurizedoilfromthepumpflowsfromtheportPtotheportPB・

† from PUMP

Fig．4．9 Neutral

−111−

4．STEERINGSYSTEM

2．Whenthesteeringwheelisturnedclockwise （1）Beginningofrotation

①Whenthesteeringwheelisturnedclockwise，thesteeringspool（1）ispushedinbythecontrollink ②ThepressurizedoilfromtheportPentersthesteeringspool（1），PaSSeSthroughthevariableorifice（6） andnxedorince（5）toopentheloadcheckvalve（4）insidethesteeringspool，andthenflows，PaSSing throughthecylinderportBtothesteerlngCylinder・

③Atthistime，theopeningareaofthevariableorifice（5）variesproportionatelywiththemovemen steeringspool（1）．Inaddition，thepressurizedoil（POrtB）downstreamfromthevariableorificeis

directedintothechamber a ofthecarry−OVerPlunger（2）whilethepressurizedoilupstreamfromthe variableorificeisdirectedtothechamber b．

④Thecarry−OVerPlunger（2）movesaccordingtothepressuredifftrentialbetweenthechambers a and b． Thiskeepsthepressuredifftrentialacrossthevariableorifice（5）alwaysconstantsothatthea

ofoilproportionaltothemovementofthesteeringspool（1）alwaysflowstoportBregardlessofth loadpressureonthecylinderport・

⑤Excessoilnotusedforthesteeringcircuitflowsoutofthecarry−OVerPOrt（PB）・

⑥TheoilreturningfromthesteeringcylinderpassesthroughtheportAtoopentheloadcheckvalve（4 ofthesteeringspool（1）andthenflows，PaSSingthroughthelow−PreSSurizedoilpassageandtankport （T），intotheoiltank．

Fig・4・10WhenSteeringWheelisTurnedClockwise −112−

4．STEERING SYSTEM

（2）Whensteeringwheelisturnedclockwisetothefu11

①Whenthesteeringspoolispushedintothefu11，theopeningareaofthevariableorince（5）becomes

maximumtoincreasetheflowrate．ThisalsoincreasestheflowrateofoilsentfromthecylinderportB tothesteeringcylinder．（Thesteeringspeedbecomesfaster．）

Note：Thefixedorince（6）keepstheflowrateofoilfromtheportPtothecylinderportconstantwhenth

SteerlngSPOOlisatthestrokeend． ②Whenthesteeringwheelisturnedfurtheruntilthefrontframecomesincontactwiththerearframe，t

Oilpressureinthesteeringcircuitrisestoactuatethehigh−PreSSurereliefvalve（7）toletthepressur

Oilescapefromthelow−PreSSurizedoilpassagetothetankport（T）・ ③Thecylinderportisblockedbytheloadcheckvalve（4）ofthesteeringspool（1）・

亡 Pushin

↑ from PUMP

Fig．4．11WhenSteerlngWheelisTurnedClockwisetotheFull （High−PreSSurereliefvalveinoperation）

3．WhensteerlngWheelisturnedcounterclockwise

WhenthesteerlngWheelisturnedcounterclockwise，thesteerlngSPOOlispulledout・Theoilinside

SteerlngValveflowsasfollows：ThepressurizedoilfromthepumpportflowsintothecylinderportAwhile

theoilreturnlngfromthesteerlngCylinderflows，PaSSlngthroughthecylinderportBandlow−PreSSurizedoil PaSSage，andtankport，intotheoiltank・

−113−

4．STEERINGSYSTEM

4．5CONTROLL］NKAGE ThecontrollinkageofthesteerlngSyStemisconnectedthroughthepitmanarmattachedtothesteerln

gearsectorshaft，rOdandlink，tOthesteerlngValvespool・Thelinkofthecontrollinkageissupportedbythe

pIVOtWhichisinstalledonthefrontframe・ThesteerlngValveisinstalledonthefrontframeandthest gearisonthecockpit（rearframe）respectively，SOthatthesteeringvalveandgearmoveaseachfram in steering the loader.

AsthesteerlngWheelisturned，thecontrollinkageoperatesthesteerlngValvewhilefeedsbackthe operationtothesteerlngValvethrougharticulationoftheffame・

＼＼J

＼、

語り＝〃＝＝叶

勺

■ ■■ ■ ■■

＼

〜

＼

】「

■

註し

l．STEERINGVAI二VE 】＿1

こ▼

二二二＼

＼

」−−丁十−l¶Å

［三≡≡二±二

2．STEERINGGEAR 3．STOPPER 4．PIVOT 5．LmK 6．BEARING

Note：B＞ぢ＝＝コ87・3N−m（8・9kgf−m）［64・41bf−ft］

臣＞ぢ＝＝コ150N−m（15・3kgf−m）［1111bf−ft］ 匝＞（忘＝コ401N−m（40・9kgf−m）［2961bf−ft］

匡＞ぢ＝コ91．2N−m（9・3kgf−m）【67・31bf−ft］ B＞疋＝ゝThreadedarea：LOCTITE＃262 B＞Alignwiththecenterofcenterhingepin・

B＞A句ustsothatthearticulatingstopperattheframesidehasaclearanceof20mm［0・78in・］ Fig．4．12 ControILinkage −114−

4．STEERING SYSTEM

0peration l．Steeringvalveinneutral

WhenthesteerlngWheelisnotturned，thesteerlngValveisinneutral・Thecylinderportsofthestee ValveareclosedandnooilflowsintothesteerlngCylinders．Theloadercontinuestotravel・

Fig．4．13 SteerlngValveinNeutral

−115−

4．STEERINGSYSTEM

2．nlrningsteerlngWheelclockwise （1）Linkageoperation

①Whenturningthesteeringwheelclockwise，thesectorshaftofthesteeringgearrotatestotu

Pltmanarminthedirectionoftheloaderrearside．

②Themovementofthepitmanarmturnsthelinkthroughtherod，PuShinginthesteeringvalvespo

③Wherlthesteeringvalveisactuated，thepressurizedoilfromthesteeringpumpissenttothesteeri

Cylinders，Whichflexesthefrontframeintherightdirectiontoturntheloaderclockwise． ④TherotationangleofthesteeringwheelcontroIstheanglesofthesectorshaftandpitmanarm，i．e．

ChanglngamOuntOfthelinkposition．Therefore，theturn1ngradiusoftheloadervarieswithther

angleofthesteerlngWheel．

⑤Theoperationspeedofthelinkageisdeterminedbytherotationspeedofthesteeringwheel，andchan

theopenlngOftheoilpassagetothecylinderport・ThesteerlngSPeedbecomesslowbyturnln SteerlngWheelslowlyanditbecomesfastbyturnlngitfast．

SUPPORTING POINT

Fig．4．14 Turn1ngSteerlngWheelClockwise −116−

4．STEERINGSYSTEM

（2）Feedbackoperationoflinkage

①Afterturningthesteeringwheelclockwise，StOPandkeepitasitis．Thenthesteeringlinkagestop

②Thesteeringvalvespoolisinserted，thesteeringcylinderoperationcontinues，andthefrontfra bentintherightdirection．

③Thelinkisturnedthroughthepivotbyflexingthefrontframe，andthesteeringvalvespoolispulled

theneutralposition．

④Then，thefrontframestopsflexingandtheloadercontinuestorotatewithitssteeringangle・Flex

radiusaccordingtotherotationangleofthesteerlngWheel．

PULLSPOOL［N NEUTRAL POSlTlON

Fig．4．15 FeedbackOperationofLinkage

−117−

4．STEERING SYSTEM

3．¶1rningsteeringwheelcounterclockwise

WhenthesteerlngWheelisturnedcounterclockwise，thesteerlngValvespoolispulledout・Thepressurized

oilflowsinthedirectionoppositetotheonethattheoilflowswhenthesteerlngWheelisturnedclockwise， thusarticulatingthefrontn・ametOthelefttoturntheloadertotheleft・

TheftedbackmotionofthelinkageisalsooppositetotheoneachievedwhenthesteerlngWheelisturned clockwise，thusreturnlngthesteerlngValvespooltoneutral・

SUPPORTING POINT

ー P「TMANARM

ROTAT10N

TURNINGSTEERINGWHEEL COUNTERCLOCKWISE

＃

Fig・4・16TurnlngSteeringWheelCounterclockwise

ー118−

4．STEERFNG SYSTEM

4，6 STEERINGCYLINDER TwosteerlngCylindersofdoubleactlngPIStOntyPeareuSed，Withthecylindertubeandpistonrodconnected tothefrontandrearframerespectively．ThesteerlngCylindersareoperatedbythepressurizedoilffomthe

SteerlngValve，andwhenonecylinderextends，theotherretracts．Theloaderissteeredinthedirectionofthe

retractlngCylinder．

二√＿ll二￣lll＿＿■￣ Note：B＞ぢ＝コ647N−m（66kgf−m）【4771bf−ft］，超＝ゝThreadedarea：THREEBOND＃1901 匪＞ぢ＝コ1450N−m（148kgf−m）［10701bf−ft］ R＞ぢ＝コ31．5N−m（3．21kgf−m）［23．21bf−ft］（Aftertightening，Calk2partsaroundthebolt．） B＞Pressurecheckport（PTl／8）

5．WIPERRING

8．BUSHING 9．SNAPRING lO．PISTONROD ll．CYLINDERTUBE 12．SLIDERING

6．U−RING

13．SEALRING／

7．BUFFERRING

14．PISTON

1．CYLINDERHEAD 2． 0 −RING

3．BACK−UPRING 4． 0 −RING

15．SETSCREW 16．STEELBALL 17．WIPERRING 18．BUSHING 19．PLUG 0

−RING

Fig．4．17 SteerlngCylinder −119−

4．STEERINGSYSTEM

NOTE

ー120−

5．FRAMEANDCOCKP［T

5．FRAMEANDCOCKPIT

5．1FRAME Theframeisasteel−Plateweldedtypeanddividedintotwoparts：frontandrearframes・Thecockpit OPeratOr

sseataremountedontherearframe．

ADonottrytomodifytheROPS（RoII・OVerprOteCtionstructure），ifmounted，withoTt

permissionfromthemanu払cturenIftheROPSshouldgetdamagedorden）rmedduetoturnlng

OrCOllision†itisadvisabletoreplaceitwithanewone）becauseadamagedorden）rmedROPShas lowstructura）strength．

−121−

5．FRAMEANDCOCKPIT

（Cockpit）

ThecockpitisinstalledontherearframebyuslngafloatlngmethodwithrubbermountsatfburpolntSSO thatvibrationandnoisetransmittedtotheoperatorisreduced・

虹

壷／2

仰山仁＝二

−＿

庁ピ竺＝∈三三阜壬坐三

ll＼ 脂

適出＝ニコ ＼

Note：B＞ぢ＝コ224N−m（22・8kgf−m）【1651bf−ft］，紹＝ゝThreadedarea‥LOCTITE＃262 1．COCKPIT

2．RUBBERMOUNT Fig．5．1CockpitAssembly

（Balanceweight） Thebalanceweightislockedontherearaxlewith4bolts・ l

︑−−・〜−−−11 ︑−︼

＼［二二二二二＝『」▲￣】￣▼▼ 〔￣】￣【▼一ハ ＼、＿ 』ご＝√ごニニ＿＝虻▼′＿′＿一｝ 4

5

Note：B＞6＝＝コ1570N−m（160kgf−m）［11571bf−f［］

1．BALANCEWEIGHT 2150kg［47411bs】

2．BOIJ 3．WASHER Fig・5・2 BalanceWeightAssembly −122−

4．LOCKWASHER 5．NUT

5．FRAMEANDCOCKPIT

Airsuspensionseat（option）

Theairsuspensionseatcanbeadjustedregardingthehardness（height）oftheseatpanbyusingtheai Valvecontrolleveratthefrontpartoftheseat．Thea4justmentoftheseatpanisperformedbytheair

COmPreSSOrbuiltintheseat． 、￣

釘／

、′

二

■■

■

J

■

；1

巨L

一

二？

二二

二賢

‥−

￣ 、一一− ￣ ￣￣￣■■￣■■ 、I

1．RECLININGSEATLEVER

3．AIRVALVECONTROLLEVER

2．SEArANGLEANDHEIGHT CONTROLLEVER

4．SLIDELEVER 5．LUMBARSUPPORT

Fig．5．3 AirSuspensionSeat

ー123−

、

5．FRAMEANDCOCKPIT

5．2 CENTER HINGEPIN

Theloaderisaframe−articulatedtype：thefrontframeisJOinedtotherearframewithtwohingeplnS aroundwhichtheloaderpIVOtSforsteerlng・

Awhentheloaderissteered，theareanearthe CenterhingepinsbecomessonarrOWthatyoumight getcaughtbetweenthefrontandrearframes．Ben）re tryingtoservicetheloadeI；makesuretosetthesafbty

link．

Priortomoving（traveling）theloader；makesurethe Safbtylinkissetattheoriginalposition．

Fig．5．4 SafetyLink

−124−

5．FRAMEANDCOCKPIT

（Upperhinge） Note：臣＞14＝ゝOuterringarea：LOCTITE＃262 駐＝＞l⊂＝：恥Innersurface：Grease B＞ぢ＝コ224N−m（22・8kgf−m） ［1651bf一氏］

1．UPPERHINGEPIN 2．CAP

3．SHIM（t＝0．4mm［0．016in．］） 4．BEARING 5．CAP 6．DUSTSEAL 7．BUSHING

（Lowerhimge） 1 2

Note：E＞超＝ゝOuterringarea：LOCTITE＃262 医＞ぢ＝コ224N−m（22・8kgf−m） ［1651bf一食］

B＞6＝＝コ1510N−m（154kgf−m） 3 4

［11141bf一食］

5

1．LOWERHINGEPIN J㌧．︵︑﹂

2．BUSHING 3．CAP

6

4．SHIM（t＝0．4mm［0．016in．］） 5．BEARING ▼▼ 「 一】

二i・7

6．CAP 7．DUSTSEAL

8

8．BUSHING

9．SHIM（t＝0．4mm［0．016in．】，

9

0．5mm［0．020in．】） 10．WASHER

10

Fig．5．5 CenterHingeAssemblyDrawlng −125−

5．FRAMEANDCOCKPIT

NOTE

−126−

6．HYDRAULICSYSTEM

6．HYDRAUL［CSYSTEM Thehydraulicsystemusesthemainpumpasitspowersourceanddirectsoilflowwiththemainvalve accordingtotheworkyouwanttodo． Thehydraulicsystemusesthepilotoperationcontrolmethodthatcombinesthepilotvalvewiththemain Valvetoreducethevalveoperatlngforce． Thehydraulicsystemconsistsofthemainpump，Valves，ValvecontroIs，OiltankandhydraulicpIPlng・

6，10ILCIRCULATJONROUTES（HYDRAULICCJRCUITDJAGRAM）

Thehydrauliccircuitoftheloaderconsistsofthemainhydrauliccircuit，Pilothydrauliccircuit，Steerl hydrauliccircuitandbrakehydrauliccircuit． Forthesteerlnghydrauliccircuit，refbrto Forthebrakehydrauliccircuit，reftrto

4．20ILCIRCULArIONROUTES・

3．BRAKESYSTEM・

1．Mainhydrauliccircuit

TheoilpickedupfromtheoiltankbythemainpumpISSentunderpressuretothemainvalve・

PreSSurizedoilwhichisnotusedforthesteerlngCircuitissentfromthesteerlngValvetothemainvalve

Whenthemainvalveisinneutral，thepressurizedoilpassesthroughthemainvalvebackintotheoilta

Whenthemainvalveischangedover，thepressurizedoilissenttotheboomcylindersorthebucket cylindertooperatethecylinder．Theoildischargedfromthecylinderreturnsintothemainvalvewhichin turnsendstheoilintotheoiltank．

Normallyunloadingsystem ①stationarystate Understationarystate，aPreSSuredifferentialis PrOducedacrosstheunloadervalvesothatthemain SPOOlispressedtotheleftinFig．6．1

ThepressureoildischargedfromthemainpumpIS directedfromthePportoftheunloadervalveto

theTportandthenflowsintotheoiltank・This PutSthemainhydrauliccircuitintheunloading

OPerationmode．

Fig． ．1

ー127−

6．HYDRAUL［CSYSTEM

② Loadhandlingphase

Whentheloadhandlingmeansisoperated（when theboomsareraisedorthebucketisrolledback），

thesignalislnPuttedfromthepilotvalvetothe unloadervalvePiportsothatthesub−SPOOlis pressedtotherightinFig・6・2・Thiseliminatesthe

pressuredifftrentialacrossthethrottletoreturnthe mainspooltotheright・

ThepressureoildischargedfromthemainpumpIS directedfromtheunloadervalvePporttotheC POrtandthenflowsintothemainvalve・

③ Loadhandlingphase（maincircuitathigh pressure）

Whentheloadhandlingmeansisoperated（When theboomsareraisedorthebucketisrolledback） andthemaincircultPreSSureeXCeedsthespecined pressure（17．2MPa（175kgf／cm2）［2489psi］），the

unloadervalvereliefvalveoperatesasshownin Fig．6．3．

Asthereliefvalveoperates，aPreSSuredifftrential occursacrossthethrottlesothatthemainspoolis pressedtotheleftinFig6・3・Thepressureoil

dischargedfromthemainisdirectedfromthe Fig・6・3 unloadervalvePporttotheTportandthenflows intotheoiltank，thusputtlngthehydrauliccircuitintheunloadingoperationmode・ 2．Pilothydrauliccircuit Inthepilothydrauliccircuit，thehydraulicoilcirculatesinthefollowlngSequenCe：

Thehydraulicoilispickedupfromtheoiltankbythebrake＆assistpump，PreSSure−regulatedbyth charglngValve，andthenchargedintotheaccumulator・

TheoildrainedfromthecharglngValveiscooleddownbytheoilcoolerbe丘）rereturnedintotheoilt Thepressureoilchargedintheaccumulatedissentthroughthereducingvalveandstopvalvetothepilot valve．

Whenthepilotvalveiscontrolledusingtheloadhandlinglevers，thepressureoilisdirectedtothepilot

portofthemainvalvetomoveamainvalvespooIwhiletheoilforcedoutoftheoppositesideofthespool returnstothepilotvalveandthenintotheoiltank・

Thepressureoilintheaccumulatorisusedforboththepilothydrauliccircuitandthebrakeoilcircu （See 3．2BRAKEOILCIRCUIT・ ）

3．Oilcoolercircuit

Thehydraulicoilpickedupfromtheoiltankbythefandrive＆coolerpumpdrivesthefanmotor・ thensenttothecoolerandcooleddowntherebefbrereturnlnglntOtheoiltank・Theoilcoolerisintegr theradiator．Theoilcoolerisbuiltintotheradiator． −128−

6．HYDRAULICSYSTEM

PILOTVAL〟E

−−一−−−

・・ D．VERTERⅦuE（。，n

．

RETURNF

L

ER

0■しCOOLER

．2∝′．。V

Fig．6．4 HydraulicCircuitDiagram −129−

；

（emptypage）

ー130−

6，HYDRAULICSYSTEM

6．2 PUMP Mainpump

「吋pe

SDR（30）90 Geartypewithaseparateunloadervalve

Discharge（underload）

154L／min［41U．S．gal．］

Model

（Engine：1850rpm，dischargepressure：17．2MPa （175kgf／cm2）［2489psi］） Ⅵねight

28．Okg［61．71bs］（includingfandrive＆coolerpump）

SteerlngPumP Model

SDR（30）90＋90

「吋pe

Gear type

Discharge（underload）

295L／min［78U．S．gal．】 （Engine：1850rpm，dischargepressure：20・6MPa （210kgf／cm2）［2987psi］）

Ⅵねight

about42．9kg［94．61bs］（includingbrake＆assistpump）

Brake＆assistpump Model

SB（l）14［installedonsteeringpump］

「吋pe

Gear type

Discharge（underload）

24L／min［6．3U．S．gal．］ （Engine：1850rpm，dischargepressure：9・4MPa （95kgf／cm2）［1351psi］）

CharglngPumP Model

Type Discharge

SDL（30）80＋（20）40

Gear type Front：133L／min［35U．S．gal．］ （Engine：1780rpm，dischargepressure：0・5MPa （5kgf／cm2）［71psi］）

Rear：67L／min［18U．S．gal．］ （Engine：1780rpm，dischargepressure：2・5MPa （25kgf／cm2）［356psi］）

Findrive＆coolerpump Model

SDR（20）32［installedonmainpump］

「吋pe

Gear type

Discharge

54L／min［14U．S．gal．】 （Engine：1850rpm，dischargepressure：16・2MPa （165kgf／cm2）［2347psi］）

−131−

6．HYDRAULICSYSTEM

Thepumpsareinstalledontheconverterhouslnganddrivenbythetorqueconverterpumpdriveunitand thustheyoperateassoonastheenglneisstarted・Fortheinstallationofthechargingpump，See㍑2・ UNIT．

Note：B＞Payattentiontothesnapringposition・ R＞ぢ＝コ232N−m（23・7kgf−m）［1711bf−ft］

1．MAINPUMP，FANDRIVE

＆COOLERPUMP 2．STEERINGPUMft BRAKEASSISTPUMP 3． 0 −RING

4．SLEEVE 5．（CHARGINGPUMP） 6．（TORQUECONVERTER） Fig．6．5 PumpAssembly

ー132−

6．HYDRAULICSYSTEM

6．2．1MAIN PUMP

（1）Mainpump

ThemainpumpISageartyPeSlnglepumpwhichpicksuphydraulicoil丘omtheoiltankandsupplie underpressuretothemainvalve．

Themainpumpcombineswithanunloadervalvetoformanorma11y−unloadingsystem・（Forthe OPeration，See

6．10ILCIRCULArIONROUTES，1・Mainhydrauliccircuit・

）

Note：ForthepumplnSta11ation，SeeFig・6・5・

Suction side

Dischargeside

Rotationaldirection：C10Ckwise −r■￣」、

1．MAINPUMP 2．FANDRIVE＆COOLERPUMP

Fig．6．6 MainPump −133−

6．HYDRAULICSYSTEM

13

1．DRIVEGEAR 2．0ILSEAL 3．BRACKET 4．SIDEPLATE 5．GEARCASE

15

14

6．SEAL 7．CARRIER 8．DRIVEGEAR 9．SIDEPLArE lO．GEARCASE

11．SEAL 12．COVER 13．DRIVENGEAR 14．DOWELPIN 15．DRIVENGEAR

Fig．6．7 MainPump

（2）Fandrive＆coolerpump

Thefandrive＆coolerpumprepresentstherearpumpofthemainpumpunit・Itpicksuphydrauli throughthesameportasthemainpumpandsendsittothehydraulicfanmotor・

−134−

6．HYDRAULICSYSTEM

UnJoadervaIve

「−−−一十−−−↑うキー

T P Circuit diagram

High−PreSSureSideunloaderpressure：17．2MPa（175kgf／cm2）［2489psi］

Fig．6．8 UnloaderValve −135−

6．HYDRAULICSYSTEM

6．2．2 STEERING PUMP （1）Steeringpump

ThesteerlngPumPISatWO−WaytyPegearPumPWhichjoinstheflowofoildischargedfromthefront pumpwiththeflowofoildischargedfromtherearpumptogetherinsideofthecarrieranddischargesthem through a single port.

ThesteerlngPumPISinsta11edontheconverterhouslnganddrivenbythetorqueconverterpumpdrive unit．Therefore，itoperatesassoonastheenglneisstartedandpicksuphydraulicoilfromtheoiltank SuPPlyittothesteerlngValve・

Note：ForthepumplnSta11ation，SeeFig・6・5・

R。tati。naldirecti。n：CJ。Ckwisel ■−−￣−ヽ

1．STEERINGPUMP（FRONT） 2．STEERINGPUMP（REAR） 3．BRAKE＆ASSISTPUMP

Fig．6．9 SteerlngPump −136−

6．HYDRAULICSYSTEM

1

2 3

4 5 6

7 8

9

10

11

12131415

18

19

1．DRIVEGEAR

8．DRIVEGEAR

15．COVER

2．0ILSEAL

9．GEARCASE

16．DRIVENGEAR

3．BRACKET 4．SIDEPLATE

lO．CARRIER ll．DRIVEGEAR

17．DOWELPIN 18．DRIVENGEAR

5．GEARCASE

12．SIDEPLATE

19．DRIVENGEAR

6．SEAL 7．CARRIER

13．GEARCASE 14．SEAL

16

17

Fig．6．10 Cross−SeCtionalViewofSteerlngPump

（2）Brake＆assistpump

Thebrake＆assistpumpisthethirdpumpofthesteerlngPumPunit・Itpicksuphydraulicoilthroughth SameSuCtionportasthesteerlngPumPSandsuppliesitintotheaccumulatorfbroperatlngthebrakesystem

andthepilotvalve．

ー137−

6．HYDRAULICSYSTEM

6．3 VAuJE Mainvalve Model

KE40−2

取pe

2−SpOOIslidingtyPe，Pilotoperationcontro1

Mainreliefpressuresettlng

20．6MPa（210kgf／cm2）［2987psi］

AIportreliefpressuresettlng

22．6MPa（230kgfγcm2）［3271psi］

BIportreliefpressuresettlng

17．2MPa（175kgf／cm2）［2489psi］

A2portreliefpressuresettlng

24．5MPa（250kgf／cm2）［3556psi］

Weight

95kg［2091bs］

Pilotvalve Model

PPClO−D

Type

2−SPOOIslidingtype

6．3．1MAINVAu／E

Themainvalveisamono−blocked，2−SPOOIslidingtype・Theoilpassagesinsidethevalveareofthe

tandemtypeinwhichthebucketoilpassagehasprlOrltyOVertheboomoilpassagesothatthepressureoilis

SuPPliedtotheboomcircuitonlywhenthebucketspoolisinneutral・ Thisprioritycircuithasthe丘）1lowingfeature：Whentheboomleverisplacedintheworking（movi

Ordown）position，thecylindersofboththebucketandtheboomscanbeoperatedbyoperatingon bucketlever．

ThemainvalveischangedoverwiththepilotoperationcontroluslngOilflowthroughthepilotvalve・ details，See

6．4VALVECONTROLS．

Themainvalveisprovidedwithamainreliefvalveandthreeportreliefvalves・Themainrelie SerVeStOPrOteCttheentirehydrauliccircuitoftheloadhandlingsystemwhilecontrollingtheoperatlng

PreSSure．Whenthepressureinthehydrauliccircuitexceedsthemainreliefpressuresettlng，themai

ValvesendstheoilpressureintothereturnpassagetoprotectthecylindersandthepIPlng， Eachportreliefvalvesendstheoilpressureintothereturnpassagewhenthecylinderreceivesaload heavyenoughtocausethepressureatthecylinderporttorisebeyondtheportreliefpressuresettlng，thus

PrOteCtingthecylinderandthepIPlng・

一138−

6．HYDRAULICSYSTEM

PBI

PB2

PAl．fromPILOTVALVEP2 PA2．fromPILOTVALVEP4 PBl．fromPILOTVALVEPI PB2．fromPILOTVALVEP3 P. fromMAIN PUMP Pl．fromPILOTVALVEP4 P2．fromPILOTVAIJVEP3

Al．toBUCKETCYLINDERTAILSIDE A2．toBOOMCYLINDERTAILSIDE Bl．toBUCKETCYLINDERRODSIDE B2．toBOOMCYLINDERRODSIDE Dl．DRAINPORT D2．DRAINPORT T．DRAINPORT Fig．6．11MainValve −139−

6．HYDRAULICSYSTEM

6

Section ZZ

1．MAINRELIEFVAIJVE 2．BUCKETSPOOLRETURNSPRING 3．BOOMSPOOLRETURNSPRING 4．BOOMSPOOL 5．BUCKETSPOOL 6．BODY 7．SUCTIONVAI」VE

8．UNLOADERVALVE 9．SAFETYVAIJVEWITHSUCTIONPORT lO．FLOATSELECTORVALVE ll．SAFETYVALVEWITHSUCTIONPORT 12．SAFETYVALVEWITHSUCTIONPORT

SectionWW

Fig．6．12 MainValve −140一

6．HYDRAULICSYSTEM

6．3．2 P］LOTVALVE

Thepilotvalveisastacked，2−SPOOIslidingtype・Eachplungerofthepilotvalvehasasolenoiddet mechanism．Whentheboomplungerismovedtothe movedto

Roll−back

Lift

or

Float

positionandthebucketplungeris

position，thedetentmechanismsautomaticallyholdthepositions，keeplngt

handlingleverfromreturnlngtOneutralwhentheoperatorremoveshishandfromthelever．Theload handlingleverautomaticallyreturnstoneutral丘omoperatlngPOSitionsotherthanthe Rolトback．

View100kingfromZ PI

P fromCHARGINGPUMP T．toHYDRAULICOILTANK Pl．toBUCKETTILTPORT P2．toBUCKETDUMPPORT P3．toBOOMLIFTPORT

P2 P3 draulicCircuitDia

P4．toBOOMDESCENT（FLOAT）

Fig．6．13 PilotValve −141−

P4

Lift

，

Float

a

6．HYDRAULICSYSTEM

7 6 5 4

3 2

口鍋闇 Section CC

1．SPOOL 2．METERINGSPRING 3．CENTERINGSPRING 4．SPRING 5．RETAINER 6．SOLENOID

Section DD

7．ROD 8．LEVER 9．RING lO．PLATE ll．RETAINER 12．PISTON Fig・6・14 Cross−SeCtionalViewsofPilotValve

−142−

13．BODY 14．BALL 15．DETENTSPRING 16．RETAINER

6．HYDRAULICSYSTEM

6，4 VALVECONTROLS ThevalvecontroIsystemisapilotoperationcontroltype．

Astheloaderbecomeslarger，thehydraulicsystemstobeusedwillbebigger，theoilflowthroughthe

Valvewillincrease（i．e．somehundredsliterperminute），thespooIchangingovertheoilpassages

largerandthestrongeroperationforceformovlngthespooIwillberequired・ Toreducethevalveoperationforce，thepilotoperationcontrolisused・ ThepilotoperationcontroIcombinesthemainandpilotvalvesandmovesthemainvalvespoolbytheoil PreSSurefromthepilotvalve，thuschanglngOVerthemainvalve．

AAsthesafbtydevicefbrthevalvecontroIsystem，aStOPValveisprovided．Themainvalv

beactuated（isnxedinneutral）byoperatingtheloadhandlingleveraccidental1y，Whichpreventsth loadingsystemfromoperatingbymisoperation．

Acautionst？betakenbeR）reSerVicingthepilothydraulicline ThepilotvalvelSOPeratedbythepressurizedoilaccumulatedintheaccumulaton BefbreservIClng thepipings，StOPtheenglneandpressthebrakepedalfrom20to40timestoreleasethepressurefrom

theaccumulatoIこIfthepipingsareremoveswithoutreleaslngthepressure，high・PreSSureOi SPOutOut，CauSlnganaCCident．

6．4．1SYSTEMINOPERATION

Thepilotports（PBl，PAl，PB2，PA2）areprovidedonbothendsofeachspooIsectionofthemainvalv areconnectedwiththedischargeports（Pl，P2，P3，P4）ofthepilotvalverespectively・

Theoilpassageinthepilotvalvearechangedoverbyoperatlngtheloadhandlinglever，andthepressurized Oilissentfromthedischargeportareselectedtothepilotportofthemainvalvetomovethemainvalve SPOOl．Theoildischargedfromtheoppositesideofthepilotportbythemovementofthemainvalvespool flowsbackthroughthepilotvalveintotheoiltank．

Note：IftheaccumulatorhasoilwithenglneStOPPed，theboomscanbeloweredbyoperatlngthebo

lever．

Hydraulic control type Thepilotoperationcontroloftheloaderisahydrauliccontroltype．

Astheoperationangleoftheloadhandlingleverincreases，Oilpressureatthedischargeportofthepilot

Valverises．Astheoilpressureofthepilotvalverises，themovementofthemainvalvespoolincreases Therefore，thewholesystemacqulreStheoperationspeedoftheloadhandlingsysteminproportionwiththe

OPerationangleoftheloadhandlinglever．

−143−

6．HYDRAULICSYSTEM

Note：B＞TherestrictionvalveisafunctionalcomponentoftheGSS・Reftrto 7・1・3BUCKET LEVELER，BOOMKICK−OUTANDGSS・

【TypicalOperation］Whenboomleverisat Lift position：

①Whentheboomleverismovedtothe Lift position，POrtSP3andP40fthepilotvalveareCOnneCtedt thePandTports，reSPeCtively・

②ThepressurizedoilintheaccumulatorissentthroughthestopvalvetothePportofthepilotvalve・

③ThepressurizedoilatthePportofthepilotvalveflowsthroughtheP3POrttOthePB2POrtOfth

valve，mOVlngthemainvalvespool・Then，thepressurizedoilofthemainvalveisdischargedfrom A2POrttOtheboomcylindertailsidetoextendtheboomcylinders，ralSlngthusthebooms・

④TheoildischargedfromthePA2POrtbymovementofthemainvalvespoolflowsintotheP4POrtOf pilotvalve，andreturnsthroughtheTportintotheoiltank・ Fig・6・15 HydraulicCircuitDiagramofValveControISystem

ー144−

6．HYDRAULICSYSTEM

6．4．2 STOPVALVE ThestopvalvecontroIstheoilsupplytothepilotvalve・

Whentheknobofthestopvalveispulled，theoilpressureinsidethevalveisclosedwiththesp SuPPlyingnooiltothepilotvalve．（Theloadhandlingsystemdoesn

toperate・）

Whentheknobofthestopvalveispushedin，theoilpassageinsidethevalveopenstosupplytheoiltothe Pilotvalve（inloadhandlingoperation）．

□ 」 ロ l ロ

⊥ □ i ロ

Theslitisopened inthissketch．

Fig．6．16 StopValve

ー145−

T

6．HYDRAULICSYSTEM

6．5 01LTANK Cap operating pressure

Pressurized，enClosedtype Positivepressure：44．1to53．9kPa（0・45toO・55kgf／cm2）［6・40to7・82psi］ Negativepressure：3．9to4・9kPa（0・04toO・05kgf／cm2）［0・57toO・71psi］

Return filter

2pcs．，15け

lもnkcapaclty

260L［68．7U．S．gal．］

rmnkweight（dry）

254kg［5601bs］］

吋pe

Note：B＞ぢ＝コ452N−m（46・1kgf−m） ［3331bf一印

10−−一也

13 ④ ⑧ ⑥ ⑳

1．PLATE

toSTEERINGPUMP toMAINPUMP fromFANMOTOR

丘omOmCOOLER

⑥

丘omPILOTVALVE

㊦

from MAIN VALVE

2． 0 −RING

9．PLATE

3．SPRING 4．RETAINER 5．FIuER 6．GAUGE 7．MAGNET

lO．PLUG

Fig．6．17 0ilTank −146−

8．り0 −RING

ll．HOSE 12．CAP 13．0ILTANK

7．LOAD HANDLINGSYSTEM

7．LOADHANDLINGSYSTEM Linkage

Z−Shape

Bucket shape

DEB「吋pel

Bucketcapaclty Heaped

5．Om3［6．54yd3］

Bucketleveler

Provided（non−COntaCttyPe）

Boomkickout

Provided（non−COntaCttyPe）

GSS

Provided（non−COntaCttyPe）

Ⅵたight

Boom

2030kg【44761bs］

Bellcrank

535kg［11801bs］

Pushrod

85kg［1871bs］

Bucket（withdoubleedge）

3051kg［67271bs］

Fig．7．1LoadHandlingSystem −147−

7．LOAD HANDLINGSYSTEM

7．1BOOM，BELLCRANKANDBUCKET 7．1．1GENERALDESCRIPT10N

Theloadhandlingsystemisoperatedbyhydrauliccylindersandisusedtodig，loadandunload

transportloads・ThelinkageemployedfortheloadingsystemisaZ−Shapedtypewhichissimplerindesi andproducesmorepowerfu1bucketbreak−Outforcethantheduplexorothertypes・

Theloadhandlingsystemconsistsofbooms，be11crank，PuShrod，bucket，bucketcylinder，boomc andpins・Thebucketleveler，boomkickoutandGSShelpsprovideefncientloadhandlingoperation・

TheloadhandlingsystemequlPPedwithbucketleveler，boomkickoutandGSSmechanismfbranemcient loadhandlingoperation．

AllconnectlngPlnSOftheloadhandlingsystemareoilsealed，floatlngPlnSandhavealongerlubrication interval，reSultinglnaneaSiermaintenance・

Note：E＞ぢ＝コM16：223N−m‡22．8kgf−m） ［1651bf一明

M18：304N−m（31．Okgトmi 【2241bf一什］

匡＞l⊂＝恥Innersurface：Grease

1．BUSHING 2．0ILSEAL

5．PLUG 6．FLANGE

3．PIN 4．CAP

7．BUSHING

Note：1．Cooling丘tshouldbeusedfbrthebushing． Cooling fit should be performed between −600Cto−700C［−760Fto−940F］inone

hourwithdryice． 2．Do not disassemble the oilsealwhen disassembling． 3．Afterassemblythewholeunit，1ubricate

theunitwithpinoil． Fig．7．2 ConstructionofFloatlngPin Note：Precautionstobetakenwhenassemblingtheboom． 1．1ねntairfromtheboomcylinder．

Afterinstallingtheboomcylinder，Standtheboomcylinderbefbreinstallingtheboomandpressurize

thecylindersoftherodandtailsides5timesinthisorder・Atthispolnt，theenglneisinalowidli State．

2．Procedureforalignlngthebucketstoppers

Raisethebucketby50degreesintransportationposture（hingepinheight‥610mm［24in・］）・Extendth

bucketcylindertothestrokeend，retraCtitbyapprox．5mm［0・197in・］andweldthestopperin

position． −148−

7．LOADHANDLINGSYSTEM

4 5

1．BUCKET

4．BUCKETCYLINDER

2．PUSHROD 3．BELLCRANK

5．BOOM 6．BOOMCYLINDER

7．FRONTARM 8．BUCKETSTOPPER

Fig．7．3 Booms，Bucket，andPushRod（1）

−149−

7．LOADHANDLINGSYSTEM

「′tノ1「￣＼、㌧一1

「、−′ ￣−、−「 −一

」

」．」

Section B−B

【▼一＿＿

Boom Boom cylinderinder ／

▼【【一＿＿T．

＼

＼

＼十−一′ ／

「

L

】

L ノ／／」

」ノ＼」

SectionC−C

Section D−D

Bucket Cylindertail BucketcyLinderrod Bellcrank Be

三L

crank

㌃−」−rFrame

Section F−F

Boom cylinder

SectionH−H

SectionG−G

Fig．7．4 Booms，Bucket，andPushRod（2） −150−

7，LOADHANDLING SYSTEM

7．1．2 BUCKET

Thegeneral−PurPOSebucketwithabolt−OnreVerSiblecuttingedge（DEB）isstandard．Thegeneral−PurP

bucketwithbolt−Onteeth（type3），thespaceedgebucketandthelockbucketwithaspaceedgeareopti

available．

Thebucketshouldbeselectedwithduecare，COnSideringtheconditionofjobsites，thenatureofloa

behandled，andtheoperatlngCOnditions．

（General−PurPOSebucketwithreversible edge，DEB）

Note：R＞ぢ＝コ1069N−m（109kgf−m） ［7881bf一氏］

臣＞ぢ＝コ2943N−m†300kgf−m） ［21701bf一氏］

Fig．7．5 Bucket

ー151−

7．LOADHANDLINGSYSTEM

7．1．3BUCKETLEVELER，BOOMKICKOUTANDGSS l．Bucketleveler

WiththebucketlevelerputintheRo11−backpositionafterdumplngthebucket，thebucketle automaticallyreturnsthebucketlevertoneutralwhenthebucketisputinhorizontalposition・ Operation（SeeFig．7．6andFig・7・7・）

①Withthebucketdumpedfromthehorizontalposition，thesensingsurfaceoftheproximityswitchfor bucketlevelerisclosetothelevelerbarSOthattheswitchstaysON．

WhenthebucketleverisputintheRoll−bucketposition，thebucketlevelersolenoidofthepilotv holdsthepositionofthebucketlever・

②Asthebucketisrolledback，thebucketcylinderpistonrodextendstoputthebucketinhoriz position，WhichallowsthelevelerbartoleavethesenslngSurfaceoftheproximltySWitch，thust theswitchOFF．

③Whenthebucketlevelersolenoidofthepilotvalveisde−energized，thedetentcomesofftoreturnt bucketlevertoneutral，StOPPlngtherollingbackoperationofthebucket・Then，thebucketstop horizontalposition・

Note：Withthebucketrolledbackbeyondthehorizontalline，theproximltySWitchofthebucke staysoFFsothatthebucketleverdetentmechanismintheroll−backphasewon twork・

（FRONTFRAME）

︑

﹂ノ

BUCKETCYLINDER

﹂

＝＝﹁1

≡

〜

︑⁚︑︑

1111111−−−

1．LEVELERBAR 2．PROXIMITYSWITCH （brLEVELER）

3．WIREHARNESS 4．BRACKET

Fig．7．6 BucketLevelerAssemblyDrawlng −152−

7．LOAD HANDuNGSYSTEM

2．Boomkickout

Theboomkickoutdevicestopstheboomsatapresetheightduringtheliftingphase・Withtheboomlever intheRAISEposition，theboomkickoutdeviceautomaticallyreturnstheboomleverintoneutralwhenthe boomsareraisedtoapresetheight，thusstopplngtheliftingoperationofthebooms・ Operation（SeeFig．7．7．）

①Whentheboomsareinthelowerpositionthanthepresetboomkickoutheight，thesensingsurf

theproximltySWitchfortheboomkickoutisclosetothelevelplateandtheswitchstays WhentheboomleverisputintheRAISEposition，theboomkickoutsolenoidofthepilotvalveholds thepositionoftheboomlever．

②Whentheboomsareraisedtoapresetboomkickoutheight，thelevelplateleavesthesensingsurfaceo theproximltyswitch，thusturnlngOfftheswitch．

③Whentheboomkickoutsolenoidofthepilotvalveisde−energized，thedetentcomesofftoreturnthe

boomlevertoneutral，StOPPlngtheliftingoperationofthebooms・Then，theboomsstopinthepre

height．

Note：Withtheboomsbeyondthepresetboomkickoutheight，theproximltySWitchoftheboomkic

StaySOFFsothattheboomleverdetentmechanismintheRAISEpositionwon

twork．

1．LEVELPLATE（forGSS） 2．LEVELPLArE（forKickout） 3．BRACKET

4．PROXIMITYSWITCH（fbrGSS） 5．PROXIMITYSWITCH（forKickout）

Fig．7．7 BoomKickoutDeviceandGSSAssemblyDrawlng −153−

7．LOADHANDuNGSYSTEM

3．GSS（GroundStopSystem）

TheGSSistheautomaticlowerlngStOPunitwhichautomaticallystopstheboomattheheightsetpreviou

Whentheboomisloweredbyshiftingtheboomlevertotheパ且oatlng＝position，theboomisautomatic

stoppedatthepresetheightandtheleverisreturnedtotheorlglnalposition・AIsothesoftstopfuncti

addedtorelieveashockwhenpowerlngdowntheboom・ Operation（SeeFig．7．7．）

① WhentheboomsareinthehigherpositionthanthepresetGSSheight，thesensingsurfaceoftheproxim

SWitchfortheGSSisclosetothelevelplateandtheswitchstaysON・ WhentheboomleverisshifttothefloatlngSteP，thepositioniskeptbythefloatdownsolenoidofthe pilotvalve．

② WhentheboomsareloweredtothepresetGSSheight，thelevelplateleavesthesensingsurface PrOXimltySWitch，thusturnlngOfftheswitch・

③ Whenthefloatdownsolenoidofthepilotvalveisde−energized，thedetentcomesofftoreturnthebo levertoneutral，StOPPlngthedropplngOPerationofthebooms・Then，theboomsstopinthepreset

height． Inthisstep，thepressurizedoilatthemainvalvepilotportPA2isdischargedthroughtherestrictionvalve

Orifice（1．6mm［0．063in．］）sothatthepilotoilpressureisgraduallydecreased・Therefbre，theb SPOOlreturnstoneutralslowlytostoptheboomquietly・（SoftStopfunction）

B MAINVALVE PA2PORT

1．56mmdia． 【0．063in．】

A ＿堤LB Fig．7．8 RestrictionlねIve

ー154−

7．LOAD HANDしINGSYSTEM

7．2 CYL］NDER Boom Cylinder 「吋pe

Double−aCtlngPIStOn

Q ty

2

CylinderborexCylinderrodouter diameterxCylinderstroke

200mmxllOmmx960mm［7．87in．x4．33in．x37．80in．］

Weight（percylinder）

356kg［7851bs］

Bucket Cylinder 「吋pe

Q ty

Double−aCtlngPIStOn 1

CylinderborexCylinderrodouter diameterxCylinderstroke

230mmx120mmx590mm［9．06in．x4．72in．x23．23in．］

Weight（percylinder）

370kg［8161bs］

7．2．1BOOMCYLINDER

Thetwoboomcylindersareofthedouble−aCtlngPIStOntyPe．Whentheboomcylindersareextended・O

retracted，theboomsareraisedorloweredrespectively．Theboomcylinderconsistsofacylindertube Cylinderhead，Pistonrod，andpackings．

7．2．2 BUCKETCYLJNDER

Thebucketcylinderisadouble−aCtlngPIStOntyPe．Asthebucketcylinderisextendedorretracted，

bucketisdumpedorrolledbackthroughthebellcrankandpushrodmechanism．Thebucketcylinderconsists Ofthecylindertube，Cylinderhead，Pistonrod，Pistonandpackings．

−155−

7．LOADHANDLINGSYSTEM

J＜山S↑ S n 凸 ． 〇 N ロZI些騨巳5面 か

ロNl出国qiJS 〇l

卜

口Nl出じ威凸○出

れ

じNI出d⊃・鍼U＜西￠

ロZ−虚・こ○︶J

d＜U ∞

ロN−HS 〇 四 ． ︵ こ

き山出USd O ↑ S ． ∽ ︻ じNl出・︵ ト ○ ︸ 一 ． 卜 l

ロN−出錮く 山 し 芦 ． 巴

じN−出じ怒NO ↑ S l d ． 空 寸

OS昌ロ⁚OUud︶S⁝nUl︷UJuuuI芹‖∪−∧盟

N≡l葛宕q︒2卓⁚む︒息．己dJO︶コ○パ﹈Y∧鮎

q−れ・専

苧息g巴声TN筑 苧宣言ヰ言TNq寸れ

N寸N♯山トi↑UOJ⁚dO議pOpdOhエ↑

ゴこq−等

N寸N♯田↑Ⅰ↑︺OJ⁚dO︼dpOp薫巴上↑

︵・ゴOqO蔓puコOJdS︶ト已N当日成已竃0玉音J遥S

ゴ

△△息△△ 息

口N−出d⊃・出じく西

口Z−HSn西n凸 C

ロNI鉱山凸 − J S ． 寸 ︻

NO↑ S l d ． m ︻

∞C箋凹ヒ↑︺OJ⁚首鼠︳d︼0︶コ○

−156−

dIJ山コU虚IUN Jく山S↑S⊃凸 ⊥

Fig．7．9 BoomCylinder

苧息g巴霹TN溌

O Z

冨⊥q︷等

苧宣書雪こ声TZ逗N．寸︷

qJ

冨⊥q−卜寸巴︵苧塩辛等︸声TNl卜寸 ﹇苧芸；○れ01

t■■

凸○出NO↑ S l d ． N l 山西⊃ト出国凸NI J ト U ．

皿舶描

7．LOAD HANDuNG SYSTEM

〇N

ロNIHSn田かl ∞︻

∞C葦p宕qO巴戸⁚訂阜−已JO︶コ○﹄ハリY∧凰

OS謡Jロ⁚OUu雲S∈コU↑−UhOuuI巨∧出

↑

篭uOqO巴戸⁚む0息−h乱︼0︶nO﹄ハリY∧盤

U竜王N寸N♯山ヒ↑UOJ⁚謡JdpDp謡J

NO ︵．s︶ちqpuコOJ≡︶J已N当日或u竃U︶鳥︷

∈⊥茸巴∈・N祭 ∈⊥茸卜．巴∈−N﹁設

△△△△△

−冨⊥q一等 冨⊥q︻N．〇卜

Fig．7．10 BucketCylinder

苧五首≡︸∈・Z票

手﹇︶l〒Z一こ．＝＝

O Z

冨⊥q−N卜

l〒﹂ヱ

む 一

冨⊥q；寸巴︷∈⊥茸OMこ∈・N卜N．− ニ﹂÷≡≡主

−157一

Jく山S↑Sn 凸

口NI出・︵︵O u ︶

￠−

L芦田出︺SdO↑Sトー ロNI出出＜山し 戸

口NI出︺威NOト S − d 肌こ 寸l

NO↑S ︻ d C l

ロNI出出く山 き

□○出NO↑S I d N − 山西nト出凹凸NIJ ト U

か

〇−

ロNI銘ノー○﹀ ︸

卜

∞

Jく山Sd山 ト S

UN−出︺g凸○出

￠

口N−銘d〇・鍼︺＜ 出 口NI出・−︵○︶ ︶

寸

ロZ−出dn・叉U d 出 れ dく じ

じNIHSn四n凸C d−J山J︺出 Ⅰ ︺ N

Jく山SトSn 凸 1

aa息a息召

7．LOADHANDLINGSYSTEM

7．3ANTl・P［TCHLNGSYSTEM（APS）［OPT10N］ Whentravelingathighspeedonbadroads，Pitchingorbounclngmightoccurandusuallythereisneedt slowdown．

TheAPSsuppressespitchingandbounclngOftheloaderbodytomakeitpossibletotravelinasaftand stablemanner．

Fig．7．11Anti−PitchingSystem（APS） −158−

7．LOADHANDLiNG SYSTEM

1．Generaldescription TheAPSconsistsbasicallyofanaccumulatorwhichisconnectedtothetailsideoftheboomcylinders WithhydraulicpIPlng，andasolenoidvalvewhichislocatedatthepiplngtOCOntrOltheoilpassage・

TheAPSisactivatedbyturnlngtheAPSswitchONanddeactivatedbyturnlngtheAPSswitch WhentheAPSisactivated，thegasfilledintheaccumulatorworksasasprlngtOallowtheloadhandling

SyStemandtheloaderbodytomoveindependently・Thisrelativemotionoftheloaderbodyandthe handlingsystemdissipatesvibrationenergytosuppresspitchingorbounclngOftheloaderbody，makinglt

POSSibletotravelinastablemanneronbadroads・ TheelectricandhydrauliccircuitsofthismechanismconsistprlnCIPallyoftheboomcylinders，aCCumulato travelingdampervalve，APSswitch，COntrOller（ArCunit），andtravelingspeedsensor・

2．Operation

①WhentheAPSswitchisturnedON，thetravelingspeedsensorandcontrollerfunctionandthemo

lampcomeson．

②Whenthetravelingspeedexceeds7km／h［4．3mph］，thesolenoidvalveinsidethetravelingdampe

Valveisswitchedbythesignalfromthecontroller，tOCOmPletethecircuitbetweenthetailsideofthe boomcylinderandtheaccumulator，thusactivatlngtheAPS・ ③Ifthetravelingspeeddropsbelow5kmnl［3．1mph］whiletheAPSisinoperation，APSwillbedeactivated・

④WhiletheAPSswitchisinOFF，theAPSisindeactivatedstate．

APSSVV

Fig．7．12 APSElectricCircuit

ー159−

7．LOADHANDLINGSYSTEM

ACCUMULATOR

Fig・7・13APSHydraulicCircuitandElectricUnit 3．Accumulator

室酢

0

◎

0

Gascapacity：5．5L［336in・3］x2 Gaschargepressure：0．78±0．05MPa（8±0・05kgf／cm2）［113・8±0・7psi］at20±50C［68±90F］・ Fig．7．14 Accumulator

Acautiontobetakenwhenservicingaccumulatorandpiping

●Usecautionwhenhandlingtheaccumulatorandpipingbecausetheaccumulatorhashigh・PreS nitrogen gas charged.

●Fillingnitrogengasintotheaccumulatorshouldbeperfbrmedonlybyqualifiedpersonnel・

●Donotmodi抒OrWeldtheaccumulatorl ●Ben｝retryingtoservicethepiping）makesuretoremovethepressurefrominsidetheaccumu

usingtravelingdampervalve，becausehydraulicoilremainsinthepiping・（Fortheprocedure，S 山4．Travelingdampervalve

・

●Whenremovingthepressurefrominsidetheaccumulator；parktheloaderonalevelsurface， downtheenglne，andlowertheboomsandbucketontheground・ ●Checkthegaspressureevery2000hoursofoperationoroneyearWhichevercomesfirst・ −160−

7．LOAD HANDLINGSYSTEM

4．Travelingdampervalve

D

SPl

■ヒ

Circuit diagram

Sect㈹−C

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

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

Fig．7．15 TravelingDamper＼ね1ve（l） ［Removingpressure］

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

0

0

−ring．Iftheplug（D）wasloosene

−ringwithanewone・

［Installi一喝］

①Tightentheplug（D）tothespecinedtorque． ②Tightenthepoppet（F）tothespecinedtorquetoseatittothevalvehousingsecurely． ③Tightenthelocknut（E）tosecurethepoppet（F）． −161−

7．LOADHANDLINGSYSTEM

23 22 20 21 Section B−B

SectionA−A

1．HOUSING

10．PLUG

19．SPACER

2．SPOOL

ll．ADJUSTER

20． 0 −RING

3．SPRING

12． 0 一RING

21．BACK−UPRING

4．PLUG

13．PLUNGER

22．SPRING

5．パ0 −RING

14．SPRING

23．POPPET

6．＝0 −RING

15．SPOOLSEAT

24．PLUG

7．CAP

16．SPOOL

25．SPOOL

8．SOCKETHEADBOLT

17．PLUG

26．SPRING

9．SOLENOIDVAI」VE

18．VAI」VE

27．PLUG

Fig．7．16TravelingDamperValve（2）

−162−

8，ELECTRFCSYSTEM

8．ELECTR］CSYSTEM 8．1uGHTJNG EQUIPMENT Name

Specification

Headlights

24V75／70W

Widthlamps

24V5W

Turnsignals（front）

24V25W

Brakelamps

Remarks

Q ty

2

Halogen

2

Front combination lamp

2

Rearcombinationlamp

24V25／10W

Taillamps Back−uPlamps

24V12W

Turnsignals（rear）

24 V 25W

Rear work lights

24V70W

2

Halogen

Auxiliary head lights

24V70W

2

Uppersideofthecab，halogen

Compartmentlights

24 V IOW

2

ー163−

8．ELECTRICSYSTEM

8．2 METERSANDSW］TCHES 8．2．1MONITORLAMPS（CLUSTERGAUGEUNIT）

TheoperatlngStatuSmOnitorsystemmonitorstheloaderoperatlngStatuSbymeansofthesensorsand

switchesinstalledontheloaderanddisplaystheinformationontheclustergaugeunitintheoperator compartmenttoinformtheoperatorofthecurrentoperatlngStatuSOftheloader・

Theclustergaugeunitconsistsofmetersincludingthespeedometer，mOnitorlamps（warninglamps whichindicatewhetherornoteachsystemisoperatlngPrOPerly，andindicatorlamps・

Fig．8．1ClusterGaugeUnit（1）

ー164−

8．ELECTRICSYSTEM

●Metercircuitdiagram

Connectedto

CONN． No． 」1000−MM引10

口 Brakeoilpressure

2 Engineoilpressure 3 Watertemperaturesensor 4 Shi丘indicatorl 5 Turnsignal（L）

6 Shiftindicator2

7 Mainlamp 8 Shi丘indicator3 CNl

9 Ground 10 Fuelsensor 田 Parkingbrake

12 Charge 13 Aircleaner 14 Notconnected 15 Shiftindicator4 16 TurnSignal（R）

17 Speedsensor 18 Emergencysteerlng 19 Powersource（24VDC）

CN2

20 Instrumentlamp 21 Oiltemperaturesensor 22 Brakeoi11evel 23 Transmissioncut−0ff 24

Powersource（24VDC）

25 OPTJl

26 Workinglight CN3

27 HourmeterGND

28 Hourmeterpowersource

●Connector 8 765

4 3 2

17 16∃吋14 13 12 田 10∈9 （Connectoratc［uster

gaugeunitside）

21 20 × 19 18 26 25 24

（Connectoratcluster gaugeunitside）

Fig．8．2 ClusterGaugeUnit（2） −165−

（Connectorat 10aderside）

8．ELECTRICSYSTEM

1．Meters

Enginewater

Meter

Transmissionoil temperaturegauge

temperaturegauge

誓

Scale

16．8n

Fuelmeter

10．4n

91．7n

Float

E

1／2

Resistance￡1 80 32

80n

10 52

Location

F Insidefueltank

10

Upperfrontofenglne

Thermosensor Engine water temperature gauge

rItmperature

Thermosensor Transmission oil temperature gauge

ResistanceE2 80 30

OC【OF］

F／

E／

Specification

Application

Sensor

Senderunit

団

融

670C【1530F］／ 1020C［2160F］／ 500C［1220Fj／♂ 1200C［2480Fレオ

Standardresistancevalue 49．8n

Fuellevel

E F

器隼 妄言冨琵 白墨

Measurementpolnt

Fuelmeter

50［122］ 80［176］ 120［248］

（COOlingfanside）

10 Tbrqueconverter

2．Monitorlamps（Warninglamps）

Theloaderisprovidedwith．atotalof7monitorlamps：3warninglamps（Nos・1，2and3）and4indic

lamps（Nos．4，5，6and7）．（Eightmonitorlampsareinstalledwhenanoptionallampisincluded・） The3warnlnglampscomeonwhenthestarterswitchisturnedtotheONposition・．Ifanywarnln doesn

tcomeon，itissuspectedthatthebulbisblownout・

No．

Name

Description（whenitcomeson）

口 ◆◎・Engine。i．press。，e

Oilpressurebelowspecifiedvalue

2 Q劫

Oilpressurebelowspecifiedvalue

Brake。ilp，eSSure

3 Eヨ Batteryv。1tage

Batteryundercharged

4 《誹

parkingbrake

Parkingbrake叩Plied

5 ノぶl

l抽klight

Light is on

6 O

clutchcut，0ff

Clutchcut−0ffisON（non−inching）

7

Aircleaner

Clogged

包

8 V

Emergencysteering（OPtion） EmergencysteerlnglSOPerated．

9 APS

APS（OPtion）

Activated

−166−

8，ELECTRICSYSTEM

（Specificationsandlocationsofswitches） Name

Application

Specifications

Location

OperatlngPreSSure： Oilpressureswitch EnglneOilpressure

49kPa（0．5kgf／cm2）［7．1psi］ （TurnsONatatmosphericpressure）

Rightsideofenglne

OperatlngPreSSure： 3．4MPa（35kgf／cm2）［498psi］ Pressureswitch

Brakeoilpressure

Return1ngPreSSure：

AccumulatorpIPlng

2．5MPa†25kgf／cm2）［356psi］ （TutnsONatatmosphericpressure）

OperatlngPreSSure： 2．2MPa（22kgf／cm2）［363psi］ Pressureswitch

Parkingbrake

Return1ngPreSSure：

Transmission disk brake

1．5MPa（15kgf／cm2）［213psi］ （TurnsONatatmosphericpressure）

OperatlngreSistance： Indicator

Aircleaner

6．37kPa（635mmH20） （TurnsOFFatatmosphericpressure）

−167−

Aircleaner

8．ELECTRICSYSTEM

8．2．2 LIGHTINGSWITCH

刑

Fig．8．3 LightingSwitch

8．2．3TURNSIGNALSWITCH （Turnsignalswitchconnectiontable）

Connected Flashe「 Left to

Right

unit

l七rminalNo． 6

5

L TFO

OTL

N

R TFO

TL

Connected

TerminaINo． 7

3

2

DMMER

○

○

MAIN

Fig．8．4 TurnSignalSwitch −168−

○

○

8．ELECTRICSYSTEM

8．3 LOCAT10NOFRELAYS

RELAY BOX

Rl：NEUTRALRELAY R2：EMERGENCYRELAY

R3：PARKINGBRAKERELAY（1） R4：PARKINGBRAKERELAY（2） R5：TRANSMISSIONCUT−OFF RELAY R6：BUZZERRELAY R7：HORNRELAY R8：STOPRELAY

R9：BACK−UPLIGHTRELAY RlO：CONDENSERRELAY Rll：BOOMKICKOUTRELAY R12：BUCKETLEVELERRELAY R13：GSSRELAY

Fig．8．5 LocationofRelays

−169−

8．ELECTRICSYSTEM

8．4 ELECTRJCLCJRCUJTDJAGRAM Note：Wirecolors：

Thewiresareclassifiedbycolor．ThenrstsymboIshowstheinsulationcolorandthe2ndthemarking color．

（WireNo．andWireColor） No CO No CO No CO No CO No CO No CO N8 CO No CO No CO No CO Nl） CO No CO No CO No CO No CO No COL 0 B

Y」

R

L

R

」W

R

G

R 5

W 30

W

40

41

100 P 110 G 120 YL 130 RY 1ヰ0 G」 150 LY 160 RB 200 RW 210 RB 220 WR 230 WR

101 G 111 WG 121 YB 131 RW 141 G 151 LR 161 W 201 WG 211 RG 221 LW 231 Br

YR

1D2 43

103

0 24 YW 34 R

25

YB

104 45

RB Y

LY

YG B

WB

GL

WY

122

YG

132

WG

142

0

152

162

GR

202

B」

212

113

W

123

LG

133

Gし

143

GR

153

163

WG

203

GB

213

214 WB 224

234

0

114 GL 124 LW 134 Br 144 105

106 107

W

G

154

RL

115

BW

125

YB

116

BL

126

RG

136

RB

Y

147

117

しW

127

WG

164 LR 204

B」

145

146

G

165

205

Br

● ●

206

156

157

48 108 WR Y 128 YR 138 WG 148 LY 158 109 WB 119 GB 12g RB 139 YB 149 YW 159

155 167

207

217

208 209

218 21g

228 22g

168 16g

222 」R 225

216 227

226

RB

232

223

233

WY

235 236

237

238 239

No CO No CO No CO No CO No CO N（】 CO No coJ No CO No CO

240 R 250 RG 300 GR 310 YG 400 Br 410 GW 500 Y 510 LG 520 WB 241 Gし 251 0 301 311 RW 401 B」 411 GB 501 WG 511 YW 521 Br 242 LW 252 LG 302 Br 312 402 RY 412 B」 502 0 512 YB 243 Br 253 WR 303 BW 313 403 GB 413 YB 503 GW 513 YL 244

254 Br 304 RG 314

404 L 414 R」 504 G 514 YG 525 WR

245 YG 255 WG 305 YW 315 405 BR 415 」Y 505 BL 515 GR 550 Br 246 W 256 306 BL 316 406 G 416 WG 506 Y8 516 0 247 257 307 317 407 417 G」 507 P 517 GL 248 258 308 YR 318 408 418 BW 508 LR 518 RB 600 YR

249

25g

309 LG 81g

409

47g

509 LW 519 GB 618 Y8

ABefbretryingtoworkontheelectricsystemorreplaceparts，makesuretodisconnectthebatter COnneCtOrS．Whendisconnectingthebatteryconnectors，瓜rstdisconnectthegroundingside（・）terminal andthenremovetheotherterminal．

−170−

8．ELECTRICSYSTEM

Notes＝1，ThewirediameterisO・85mm2［0，0013in・2］unlessothervisespecified・

2・ThecontactcapacitiesoftheswitchesandsensorsareglVenundertheQOnditionwhich theengineisshutdown，PreSSureisO（atmosphericpressure），andtheolllevelisproper． 3・Themarking showsanoptionalspecification．

STARTING SW

F〕SE BOX MA川 SⅥ

FLASH［R HEAD LAMP STOP JAMP

WORK川GJAMP CLUSTER MET【R LE〉ELER

T／M HORN AIR CONDIT10NER 肌PER（F） WIPER（R）

OPTI FAN MOTOR OPT2‑

ATC SELECT L50・3LX300−7

−171−

（EmptyPage）

ー172−

8．ELECTRICSYSTEM

Fig．8．6 WiringDiagram

−173−

（Emptypage）

−174−

9．AIRCONDrT［ONER

9．AJRCONDIT10NER Model

AIRCON：WHEELLOADER（R134acanbeused）

Heater

HeatdissIPation

5．49kW（4725kcal／h）

Blastvolume

400m3／h［14126氏3／h】

Power consumption

205W

Cooler

Coolingcapaclty

535kW（4600kcal／h）

Circulation air volume

550m3／h［19423が仙］

Power consumption Compressor Model Discharge

325W

DKS−16Hwithmagnetclutch 167cm3／rev［10．2in．3／rev］

Note：B＞ぢ＝＝コ15N−m（1・5kgf−m） ［111bf一明

E＞ぢ：：：：コ25N−m†2・5kgf−m） ［181bf一印

1．AIRCONDITIONERUNIT 2．FILTER 3．DUCT 4．GRmLE 5．GRmLE 6．DUCT 7．DUCT 8．DUCT 9．DRAINHOSE

Fig．9．1AirConditioner（installedinsidethecockpit）

−175−

9，AIRCONDIT10NER

9．1GENERALDESCRIPT10N 9．1．10PERATINGPRINCIPLE

ENGlNE COOLlNG WATER REFRIGERANT（GAS）

／ぞ／／／ノ／ REFRIGERANT（LIQUID）

Fig・9・2 0peratlngPrinciple

l．Functionalcomponents （1）Compressor

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

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

Thereceivertanktemporarilystorestherefrigerantliquefiedbythecondenserinit・ ー176−

9．AIRCONDIT10NER

（4）Expansionplug

TheexpansionpluglIt）eCtSthehigh−temPerature，high−PreSSureliquidrefrigerantsentfromtherecei

tank，throughsmallholestoexpanditrapidlyandmakeintolow−temPerature，low−PreSSure，mistyrefrige

Inaddition，theexpansionplugalsoadjuststhequantltyOftherefrigeranttobesuppliedtotheevaporator accordingtothecoolingload． （5）Evaporator TheevaporatorexchangeSheatbetweenthemistyrefrigerantandtheairinsidetheoperator Themistyrefrigerantthusvaporizestocooltheairintheoperator

scompartment．

scompartment．

（ ）Heatercore

TheheatercoreexchangesheatbetweenheatedenglneCOOlingwaterandtheairinsidetheopera COmPartmenttOheattheairinsidetheoperator

scompartment．

2．Heatingcycle TheheatingcycleisachievedbyuslngtheenglneCOOlingwater． High−temPeratureCOOlingwaterispassedintotheheatercoreandhotairisblownoutbythefan．

3．Coolingcycle Thecoolingcycleisachievedasfbllows：Therefrigerantisrecirculatedinthecycletotransfertheheat

fromthelow−heatsource（theairinsidetheoperator，scompartment）tothehigh−heatsQurCe（openair）．

methodiscalledthevaporrefrigeratlngSyStem．

Flowoftherefrigerant

①Therefrigerant（gas）evaporatedbytheevaporatorissucke9intothecompressorwhereitiscompre intoahigh−temPerature，high−PreSSuregaS．

②Thegaseousrefrigerantdischargedfromthecompressorflowsintothecondenserwhereitisco fbrcefu11yandliquenedbythecondenser．

③Theliquidrefrigerantthenentersthereceivertankwhereitisclearedofwatercontentanddustbefb beingsenttotheexpansionplug．

④Thehigh−PreSSureliquidrefrigerantisiqiectedthroughthesmallholesoftheexpansionplugsoth

expandsrapidlytobecomelow−temPerature，low−PreSSure，mistyrefrigerantbeforeflowlngl evaporator・

⑤Themistyrefrigerantdeprivesthesurfaceoftheevaporatorpipeofheattoevaporate．Atthistime，

airissuppliedbythefan，theairisdeprivedofheatandblownoutascoolair．Sincetheairiscoole

rapidly，thewatercontentintheairiscondensedtodehumidifytheairinsidetheoperator scompartment． ⑥Therefrigerantleavingtheevaporatorchangesintothegasandsuckedintothecompressor．

ー177−

9．AIRCONDIT10NER

9．1．2AIRCONDIT10NERUNIT

Theairconditionerunitconsistsoftheevaporator，heatcore，eXPanSionplug，blowermotor，andfan・

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

A．toCOMPRESSOR B．fromRECEIVERTANK C．ENGINECOOLINGWArERINLET D．ENGINECOOLINGWArEROUTLET

5．BLOWERMOTOR，FAN

Fig・9・3AirConditionerUnit

ー178−

9．AIRCONDIT10NER

9．1．3 COMPRESSOR

1．MAGNETCLUTCH ASSEMBIX 2．COMPRESSOR ASSEMBLY 3．MAGNETCLUTCH LEAD WIRE

Fig．9．4 Compressor

≪軒〕 G．i 畠

1．COMPRESSOR Note：距＞ぢ：：：：コ27N−m（2・8kgf⊥叫［201b柑］

2．COLLAR 3．BRACKET

Fig．9．5 CompressorInstallation

−179一

9．AIRCONDIT10NER

9．1t4RECEIVERTANK Thereceivertankhasastraineranddesiccantinside it，tOremOVedustandwatercontentfromtherefrigerant duringcoolingcycle・

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

Thesightglassisusedtocheckthestatusofthe refrigerant・

Fig・9・6 SightGlassandFuseBolt

1．PRESSURESWITCH 2．DRIER 3．Om 4．FUSEBOLr 5．SIGHTGLASS 6．REFRIGERANTINLET 7．REFRIGERANTOUTLET

Fig．9．7 ReceiverTank −180−

9．AIRCONDIT10NER

9．1．5 CONDENSER REFRJGERANT

＿′■■￣￣￣￣

、

REFRIGERANT OUTLET

Fig．9．8 Condenser

ー181−

9．AIRCONDLTlONER

9．1．6AIRCONDIT］ONERPIPING

一→Enginecoolingwater 一＝− ＞Refrigerant

」＿＿＿＿＿＿」

5．9N−m（0．6kgf−m）［4・31bf−ft］

27Nrm（2．8kgf−m）［201bf−ft］ 15N−m（1．5kgf−m）［111bf−ft］ 20N−m（2．Okgf−m）［141bf−ft］ 25N−m（2．5kgf−m）【181bf−ft］

Fig・9・9AirConditionerPiping

−182−

1．AIRCONDITIONERUNIT 2．CONDENSER 3．COMPRESSOR 4．RECEIVERTANK

No．SEW−682CE

lssued： November，2000 Revised：May，2003 Revised： November，2004

丁伽c。R，。RA，． lNTERNAT10NALMARKETINGDIVIS10N： 1・15−5，Nishi−Shimbashi，Minato−ku，lbky0 105−0003，Japan FAX：JAPAN＋81・3・35918152，3−35918153

A＝rightsreserved

JB−0411005（OS）PrintedinJapan

TCJmc。。，。。AT．