SEBD05610311 Shop Manual

SEBM05610311
Shop
Manual
HD785=3
HD!85=3
DUMP TRUCK
SERIAL NUMBERS
HD785-3 - 2001
HD985=3 1001 mdup n
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
October 1997 Copyright 1997 Komatsu America International Company oo- 1

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CONTENTS
No. of page
IO STRUCTURE AND FUNCTION ........................................................... IO-I
20 TESTING AND ADJUSTING ................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY .................................................... 30-1
40 MAINTENANCE STANDARD ............................................................... 40-1
90 OTHERS ................................................................._............................................. go-1

2
z
z
j, For details of the applicable serial numbers for the contents of each item in this shop manual, see
CONTENTS for each section.
<Explanation of applicable serial numbers>

1. When no model is listed after the CONTENTS : Applicable to both HD785 and HD985
2. When a model is listed in ( ) after the CONTENTS : Applicable only to the model given in ( 1.
00-2
0
The affected pages are indicated by the use ofthe
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the
0 Pagetobe newlyadded Add
table below.
11
Pages having no marks are those previously re-
vised or made aditions.
LIST OF REVISED PAGES

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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol g is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for weid- ing signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
IO. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
-‘l
I I. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-) terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains t,he necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@....I is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one

volume to cover all REVISIONS
Attachments volume:
models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
A
2. Following examples show how to read the
Safety necessary when performing
page number. the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3 or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
TT T Places that require special at-
ighteninc I
Unit number (1. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Xl, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the Places where oil or water
page number. File as in the example. Drain must be drained, and quan-
Example: tity to be drained.
IO-4 12-203
1o-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
WIRE ROPES untwisting of the rope, or slipping of
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

(Standard “Z” or “S” twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter l- Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg} when hoisting is made
IO 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg] vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN (2000 kg1 of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 (1000 kg} when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg) if they sling
30 98.1 10.0
a 19.6 kN I2000 kg) load at a lifting angle
40 176.5 18.0 of 150”.
0
50 274.6 28.0
6
60 392.2 40.0 t11:,
@A
16.7 0
* The allowable load value is estimated to ~~~~
(1400) 9.0
be one-sixth or one-seventh of the break- (1000) z
ing strength of the rope used. (500)
2) Sling wire ropes from the middle portion 150

30 60 90 120
of the hook. Lifting angle (deoree) SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
* The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
* For coating materials not listed below, use the equivalent of products shown in this list.
Category omatsu code Part No. Main applications, features
l Used to prevent rubber gaskets, rubber

LT-IA
cushions, and cock plug from coming out.
l Used in places requiring an immediately

effective, strong adhesive. Used for plas-
20 9 Polyethylene
LT-1 B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
l Features: Resistance to heat and chemi-

Polyethylene cals
LT-2 50 g container l Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790-I 29-9060 Adhesive: l Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT-3 sive and iardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene Used as sealant for machined holes.
790-I 29-9040
l
LT-4 250 g
container
Holtz . Used as heat-resisting sealant for repair-

790-126-9120 75 g Tube
MH 705 ing enoine.
. Quick hardening type adhesive

rhree bond ‘olyethylene l Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container - Used mainly for adhesion of metals, rub-
bers, plastics and woods.
l Quick hardening type adhesive

l Quick cure type (max. strength after 30 min-
Aron-alpha
201
790-I 29-9 13r 29 utes)
. Used mainly for adhesion of rubbers, plas-
tics and metals.
l Features: Resistance to heat, chemicals

Loctite Polyethylene
79A-129-911t 50 cc l Used at joint portions subject to high tem-
648-50 container
peratures.
l Used as adhesive or sealant for gaskets

LG-1 790-129-9OlC 200 g Tube
and packing of power train case, etc.
. Features: Resistance to heat

l Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant 790-l 29-907( to prevent seizure.
LG-3 1 kg Can
l Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'W Container Main applications, features
l Features: Resistance to water, oil

l Used as sealant for flange surface, thread.
l Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
l Used as sealant for mating surfaces of fi-
nal drive case, transmission case.
l Used as sealant for various threads, pipe

Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg Used as sealant for tapered plugs, elbows,
container l
nipples of hydraulic piping.
. Features: Silicon based, resistance to heat,

Gasket cold
sealant LG-6 09940-00011 250 g Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.
l Features: Silicon based, quick hardening

type
LG-7 09920-00150 150 g Tube l Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
. Used as heat-resisting sealant for repairing

1 engine.
l Used as lubricant for sliding portion (to pre-

LM-G
Molybde- ) 09940-00051 1 60 g ) Can ) vent from squeaking).
num
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
SYG24OOLI l General purpose type

SYGZ-350LI
GZ-LI SYGZ-400Ll-A Various Various
SYGZ-16OLl
SYGA-IGOCNLI
l Used for normal temperature, light load

SYGZ-400CA bearing at places in contact with water or
Grease
SYGZ-350CA steam.
GP-CA SYGZ-IOOCA-A Various Various
SYGZ-160CA
SYGA-EOCNCA
Molybdenum 400 g l Used for places with heavy load

disulphide SYGZ-400M (IO per Belows type
lubricant case)
00-9
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS
Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter Width

of bolt across flats
mm I mm I Nm I bm
6 10 13.2+ 1.4 1.35f0.15
8 13 31f3 3.2f 0.3
10 17 66*7 6.7f 0.7
12 19 113+10 11.5&l
14 22 177+19 18+2
16 24 279530 28.5*3
18 27 382+39 39+4
20 30 549&59 56f6
22 32 745f83 76f8.5
24 36 927*103 94.5+ 10.5
27 41 1320+140 135f15
30 46 1720f190 175+20
33 50 2210f24il 225+25
36 55 2750f290 280+30
39 60 3290f340 335*35
Thread diameter Width

of bolt across flats
mm I mm I Nm I kam
6 10 7.85k1.95 0.8f0.2
8 13 18.6k 4.9 1.950.5
10 14 40.2* 5.9 4.1f0.6
12 27 82.351i7.85 8.4f.0.8
TIGHTENING TORQUE OF HOSE NUTS

Use these toraues for hose nuts.
( Threaytmeter Width across flat Tightening torque

Nominal No.
mm Nm kgm
02 14 19 24.5* 4.9 2.5kO.5
03 18 24 49f 19.6 5+2
04 22 27 78.5+ 19.6 8f2
05 24 32 137.3f29.4 14f3
06 30 36 176.5f29.4 18+3
10 33 41 196.1+49 20*5
12 36 46 245.2+49 25+5
14 42 55 294.2*49 30?5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
Thread diameter 1 Width across flat 1 Tiahtenina toraue
mm mm Nm kgm
10 14 65.7Ifi
6.8 6.7* 0.7
12 17 112k9.8 11.5*1
16 22 279*29 28.5rt3
00-10
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector
Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
02 14 34.3f 4.9 3.5kO.5
03,04 20 Varies depending on 93.1 f 9.8 9.5* 1
05,06 24 type of connector. 142.1+ 19.6 14.5+2
10, 12 33 421.4f58.8 43+6
14 42 877.1 f 132.3 89.5 + 13.5
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Nominal No.
Thread diameter Width across flat T Tighteni j torque
mm mm Nm kgm
08 8 14 7.35k1.47 0.75* 0.15
10 10 17 11.27+ 1.47 1.15+0.15
12 12 19 17.64rt1.96 1.8f0.2
14 14 22 22.54& 1.96 2.35 0.2
16 16 24 29.4* 4.9 3f0.5
18 18 27 39.2* 4.9 4f0.5
20 20 30 49* 4.9 5kO.5
24 24 32 68.6f9.8 7+1
30 30 32 107.8f 14.7 llk1.5
33 33 - 127.4k19.6 13k2
36 36 36 151.9f24.5 15.5f2.5
42 42 - 210.7k29.4 21.5f3
52 52 - 323.4? 44.1 33+ 4.5
,Sealingsurface
TIGHTENING TORQUES OF FLARE NUT

SAD00483
Thread diameter Width across flat Tightening torque

, I
mm mm I Nm I bm
14 19 24.5k 4.9 2.5f0.5
18 24 49i 19.6 552
22 27 78.5+ 19.6 8k2
24 32 137.3f29.4 14k3
30 36 176.5i29.4 18k3
33 41 196.lf49 20+5
36 46 245.2f49 2555
42 55 294.2+ 49 30+5
00-l 1
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque

mm Nm kgm
6 IO rf2 1.02 f 0.20
8 24 f 4 2.45 f 0.41
IO 43 f 6 4.38 k 0.61
12 77 f 12 7.85 + 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

mm Nm kam
6 8f2 0.81 5 0.20
8 10 f2 1.02 * 0.20
IO 12+2 1.22 f 0.20
12 24 f4 2.45 k 0.41
14 36 + 5 3.67 f 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.

inch Nm kgm
l/16 3fl 0.31 f 0.10
l/8 8+2 0.81 k 0.20
l/4 12 +2 1.22 It0.20
318 15+2 1.53 XL0.41
l/2 24 f 4 2.45 I!Z
0.41
314 36 f 5 3.67 * 0.51
1 60 f 9 6.12 5 0.92
00-12
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Applicable circuit
100 217 0.80 109.1 17.6 Starting
CLASSIFICATION BY COLOR AND CODE

FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @_
(2) Locate the number 5 in the row across the top, take this as @I, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by IO, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5; 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197: 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591; 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984; 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378; 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772; 1.811 1.850 1.890 1.929
0 i
50 1.969
,....._._...,............. 2.008 2.047 2.087 . . 2.126
. . . . . . . . . . . . 12.1651 2.205 2.244 2.283 2.323
. . . .. . . . . .. . . . .. . .. .. . . . . . . . . . . . . . .. . .. .. .
@- 60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-l 4
FOREWORD CONVERSIONTABLE
Millimeters to Inches
1 mm = 0.03937 in
1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
- - - - -
Kilogram to Pound
1 kg = 2.2046 lb
1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
IO 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-l5
Literto U.S. Gallon

IC = 0.2642 U.S. Gal
1 2 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
IO 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Literto U.K. Gallon

IC = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-16
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-17
kg/cm* to lb/in*
lkg/cm2 = 14.2233lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-l 8
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-CentigradeConversion ; a simple way to convert a Fahrenheit temperature reading intoa Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldfacecolumn of figures.
These figuresrefer to the temperature in eitherFahrenheitor Centigrade degrees.
Ifitis desired to convert from Fahrenheitto Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
lfitis desiredtoconvertfrom Centigradeto Fahrenheit degrees,considerthe center column asatable of Centigradevalues,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8"F
“C “F “C "F “C "F “C “F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-19
GENERAL WEIGHT TABLE
WEIGHT TABLE
AThis weight table is a guide for use when transporting or handling component.
Unit: kg
Model HD785-3 HD985-3
Applicable serial No. 2001 and up 1001 and up
Engine assembly 3,100 3,100
Output shaft assembly 170 170
Radiator assembly 410 410
Fuel tank 500 515
Torque converter 580 580
Transmission assembly 1,380 1,455
Drive shaft assembly (front) 50 50
Drive shaft assembly (rear) 120 120
Rear axle assembly 9,350 10,030

. Differential 1,225 1,225
. Final drive (one-side) 1,980 2,185
E?
z . Rear brake (one-side) 610 610
s . Parking brake (single) 95 95
. Parking brake (double) 150 150
Front axle assembly 1,575 1,605
l Front axle 890 920
l Front brake 190 190
Frame 8,285 8,285
Front suspension cylinder 680 680
Rear suspension cylinder 240 230
Operator’s seat 37 37
Steering cylinder 75 75
Hoist cylinder 330 330
Demand valve 70 70
Steering valve 25 25
Hoist valve 55 55
Hydtaulic pump
(SAR(4)-285+285) 55 55
(SAR(4)-180+180) 45 45
Dump body 14,900 16,250
01-21
0
GENERAL TABLE OF COOLANT QUANTITIES
TABLE OF COOLANT QUANTITIES

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY (I?,

KIND OF
RESERVOIR 14 32 50 68 86°F
FLUID Specified Refill
Engine oil pan 98 90
Transmission case
105
(incl. torque converter)
Engine oil
Front brake oil tank 2 2

Hydyaulic tank
Steering hoist oil tank 255 162
Rear brake cooling oil 378 268
tank
Front suspension 19.3 (each: -
Rear suspension 18.2 (each: -
Differential case 130 130

Final drive case 64 (each) 64 (each)
- 8
Fuel tank Diesel fuel 1,240
;;;
g
Cooling system Water Add antifreeze 1 230 -
% ASTM D975 No. 1
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than O”C, be sure to use
tenance hours described in this manual. engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table if SAE15W-40, even though an atmospheric
fuel sulphur content is above 0.5%. temperature goes up to 10°C more or less in
the day time.
Change interval of oil (3) Use API classification CD as engine oil and if
Fuel sulphur content in enaine oil Dan
API classification CC, reduce the engine oil
0.5 to 1.0% l/2 of regurar interval change interval to half.
Above 1.0% l/4 of regular interval
01-22
0
10 STRUCTURE AND FUNCTION
Radiator, torque converter oil cooler .......... IO- 3 Suspension system ...................................... IO-42
Brake oil cooler.. ........................................... IO- 4 Suspension cylinder.. ................................... IO-44
Power train skeleton.. ................................... IO- 5 Front suspension cylinder.. .......................... IO-44
Output shaft .................................................. IO- 6 Rear suspension cylinder (HD785-3). .......... IO-48
Torque converter and transmission Rear suspension cylinder (HD985-3) .......... .91-12
hydraulic piping .......................................... IO- 7 Air circuit diagram ........................................ IO-51
Torque converter and transmission Air piping ................................................... 1O-52-1
hydraulic circuit diagram ........................... IO- 8 Air governor.. ................................................ IO-53
Torque converter and transmission Safety valve.. ................................................. 1O-55
hydraulic circuit schematics ...................... IO- 9 Check valve ................................................... IO-55
Hydraulic pump (SAR4-160) ........................ IO-IO Double-check valve ...................................... IO-56
Torque converter (HD785-3) ......................... IO-I 2 Auto drain valve ........................................... IO-57
Torque converter (HD985-3). ....................... .91- 2 Hand brake valve
Torque converter valve ................................ IO-14 (Retarder control valve) ............................. IO-58
Lockup solenoid valve.. ................................ IO-19 Brake valve .................................................... IO-60
Transmission (HD785-3) ............................... IO-20 2-way control valve (Parking brake valve,
Transmission (HD985-3) ............................... 91- 4 emergency brake valve) ............................. IO-63
Transmission valve ....................................... IO-22 Emergency brake control valve
ECMV (Electronic control (Variable control type) ............................ 10-64-I
Modulation Valve) ...................................... IO-23 Parking brake pilot valve.. ............................ IO-65
Lubrication relief valve ................................. IO-28 Relay valve
Front axle (HD7853). .................................... IO-29 (Acts also as emergency relay) ................. IO-66
Front axle (HD985-3). .................................... 91- 6 Parking brake relay valve ............................. IO-69
Rear axle (HD785-3) ...................................... IO-30 Quick-release valve ...................................... IO-71
Rear axle (HD985-3). ..................................... 91- 7 Brake chamber.. ............................................ IO-72
Differential.. ................................................... IO-31 Parking brake chamber ................................ IO-74
Differential lock control ............................ 10-31-2 Slack adjuster.. .............................................. IO-75
Structure of system ................................. 10-31-2 Hydraulic piping
Differential lock system diagram .......... 10-31-3 (Steering and hoist, and brake cooling). .. IO-77
Switch ....................................................... 10-31-3 Hydraulic circuit diagram
Differential lock solenoid valve ............. 10-31-4 (Steering and hoist, and brake cooling). .. IO-78
Final drive (HD785-3). ................................... IO-32 Dump body control ...................................... IO-79
Final drive (HD985-3) .................................... 91- 8 Hydraulic tank and brake cooling
Front brake .................................................... IO-33 oil tank.. ....................................................... IO-80
Rear brake ..................................................... IO-34 Hydraulic pump ............................................ IO-81
Parking brake ............................................. 10-34-2 Brake cooling oil control valve (BCV). ......... IO-82
Wheels (HD785-3) ......................................... IO-36 Steering valve ............................................... IO-83
Wheels (HD985-3) ......................................... 91- 8 Clossover relief valve ................................... IO-87
Axle support (HD785-3) ................................ IO-37 Demand valve ............................................... IO-88
Axle support (HD985-3) ............................... .91-IO Hoist valve .................................................... IO-92
Steering system (HD785-3) .......................... IO-38 Steering cylinder .......................................... IO-94
Steering system (HD985-3) ........................ ..91-11 Hoist cylinder ................................................ IO-94
Steering wheel .............................................. IO-39 Dump body(HD7853) ................................... IO-95
Steering linkage ............................................ IO-40 Dump body(HD985-3) ................................... 91-14
10-l
0
Main fram (HD785-3) .................................... IO-95 Automatic emergency steering
Main fram (HD985-3) ................................... .91-14 system (HD785-3) .................................... 1 O-l 24
Electrical circuit diagram ......................... 10-96-2 Automatic emergency steering
Pressure switch.. ......................................... IO-I 01 system (HD985-3) .................................... 91- 21
Stop lamp swich ......................................... IO-101 Electrical circuit diagram ......................... IO-125
Horn valve ................................................... IO-102 Flow switch ............................................... IO-126
Parking brake switch .................................. IO-102 Relay timer.. .............................................. IO-128
Front brake cut-off valve ........................ 10-102-I Automatic suspension system ................. .10-l 29
Automatic retarder valve ........................... 10-I 03 Automatic suspension mode
Exhaust brake valve ................................... IO-103 selection control ..................................... IO-131
Tilt switch .................................................... IO-104 Suspension controller .............................. IO-132
Air conditioner ......................................... 10-104-1 Sensors, switches.. ................................... IO-133
Piping diagram .................................... ..lO-104- 1 Steering angle sensor .............................. IO-133
Electrical circuit diagram ..................... 10-104-2 Pressure sensor.. ...................................... IO-133
Refrigerant circuit diagram .................. 10-104-2 Payload meter.. ........................................... IO-134
Condenser.. ............................................ 10-104-3 Structure of system .................................. IO-134
Compressor ........................................... 10-104-3 Electrical circuit diagram ..................... 10-134-I
Engine control system Principle of calculation.. ....................... 10-134-2
(Mechanical governor type). .................... IO-105 Features of equipment.. ....................... IO-I 34-4
Electrical circuit diagram ......................... IO-106 Electronic monitor system ......................... IO-135
Hydraulic circuit diagram.. ....................... IO-106 Electronic monitor panel.. ........................ IO-136
Servo cylinder.. ......................................... IO-107 Electronic monitor dislays, functions......lO-137.
AISS Sensors, switches.. ................................... IO-140
(Automatic Idling Setting System). ....... IO-108 Engine speed sensor ................................ IO-140
Engine control system Engine oil pressure sensor ...................... IO-140
z?
(Electronic governor) ............................. 10-108-I Engine water temperature sensor.. ......... IO-141
z
System diagram .................................. ..lO-108- 1 Retarder oil temperature sensor ............. IO-141 g
Electrical circuit diagram ..................... 10-108-2 Torque converter oil temperature
Fuel injection pump with electronic sensor.. .................................................... IO-141
governor .............................................. 1O-l 08-3 Air pressure sensor .................................. IO-141
Hydraulic circuit diagram.. ................... 10-108-4 Fuel level sensor.. ..................................... IO-142
AISS Maintenance monitor system.. ................ IO-143
(Automatic Idling Steering System). . 10-108-4 System diagram ....................................... IO-143
Engine controller ................................... 1O-l 08-5 Monitor panel ........................................... IO-144
Sensors, switches .................................. 1O-l 08-5 Monitor display, functions ....................... IO-145
Accelerator sensor ................................ IO-I 08-5 Functinos of switches.. ............................. IO-147
Engine speed sensor.. .......................... -IO-108-5 Sensors, switches ....................................... 1O-l 49
Exhaust brake .......................................... 1O-l 08-6 Engine oil level sensor.. ........................... IO-149
System diagram .................................... 1o-1 08-6 Radiator water level sensor.. ................... IO-149
Automatic shift control system ................. IO-109 Transmission oil level sensor .................. IO-149
Transmission controller ........................... IO-I 10 Hydraulic oil level sensor.. ....................... IO-150
Shift lever positions and automatic Retarder oil level sensor .......................... IO-150
gear shifting ranges ............................... 10-111 Air filter clogging sensor ......................... IO-150
Shift lever switch ........................................ IO-I 14 Retarder brake water sensor ................... IO-151
Sensors, switches ....................................... IO-115 Hydraulic filter sensor.. ............................ IO-151
Transmission speed sensor ..................... IO-I 15 Retarder oil filter sensor .......................... IO-151
Transmission oil temperature Transmission oil filter sensor .................. IO-151
sensor ...................................................... IO-115 Battery electrolyte level sensor.. ............. IO-152
Fill switch .................................................. IO-I 16 ABSIACR system ........................................ 1O-l 54
Accelerator sensor ................................... IO-I 16 ABS/ACR controller (ECU). ......................... IO-161
Shift limit switch ....................................... IO-I 17 ABS pressure control valve ....................... 10-I 62
Mode selector switch ............................... IO-I 17 ASR control valve ....................................... IO-I 65
Shift-indicator system ................................ IO-120 Wheel speed sensor ................................... IO-I 67
Shift indicator ........................................... IO-121
1o-2
0
RADIATOR, TORQUE CONVERTER OIL COOLER
561 FO3002
1. Upper tank Specifications

2. Shroud Radiator
3. Net Core type: CD-5
Total radiation surface: 151.82 m2
4. Lower tank
(torque converter oil cooler built in)
5. Core Oil cooler
water level sensor Element type: Multiple plate
6. Pick-up for radiator
Radiation surface: 3.12 m2
7. Pressure cap
A: Oil outlet
B: Oil inlet
1o-3
BRAKE OIL COOLER
Section X -X Section Y - Y
d 4
561 FO3003
1. Cooler element Oil cooler specifications

2. Cover Element type: Multiple plate
3. Flange Radiation surface: 9.92 m2
4. Case Pressure resistance (oil side): 30 kg/cm2
A: Oil outlet
B: Oil inlet
C: Cooling water outlet
D: Cooling water inlet
1 o-4
POWER TRAIN SKELETON
1. Engine (SAI 2V140)
lool 2. Output shaft

3. Front drive shaft
lool 4. Brake cooling pump

(SAR4-285+285)
loo/ 1
5. Torque converter
00 transmission charge
pump (SAR4-160)
00, 2 6. PTO
+iiG
7. Torque converter
8. Transmission
0 3 9. Rear drive shaft
10. Differential gear
0 0
11. Drive shaft

.4 12. Brake
13. Tire
14. Final drive
15. Parking brake
16. Steering, hoist pump
(SAR4-180+180)
56 1 FO3004
1o-5
OUTPUT SHAFT
1. Rubber cushion (small)

2. Rubber cushion (large)
3. Outer body
4. Flange
5. Bearing
6. Shaft
7. Coupling
8. Inner body
9. Cover
10. Breather
Section A - A
561 FO3005
FUNCTION
The output shaft is installed to the engine
flywheel, and absorbs the twisting vibration
caused by changes in the engine torque.
1 O-6
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC
PIPING
561 FO3006
1. Torque converter valve

2. Transmission
3. Breather
4. Transmission oil filter
5. Hydraulic pump (SAR4-160)
6. Torque converter oil cooler
(radiator lower tank in built)
1o-7
CIRCUIT DIAGRAM
8 1
, ---
10 r _
3
1.2
kg/cm2
c
hd-+ 16
561 FO3007
1. Strainer 10. ECMV for R clutch 19. Lockup valve

2. Hydraulic pump (SAR4-160) 11. ECMV for 1 st clutch 20. Lockup solenoid valve
3. Oil filter 12. High clutch 21. Lockup clutch
4. Oil filter 13. Low clutch 22. Torque converter relief
5. ECMV for low clutch 14.4th clutch valve
6. ECMV for 3rd clutch 15. 3rd clutch 23. Main relief valve
7. ECMV for 2nd clutch 16. R clutch 24. Oil cooler
8. ECMV for high clutch 17. 2nd clutch 25. Transmission lubrication
9. ECMV for 4th clutch 18. 1 st clutch valve
26. Transmission lubrication
1O-8
CIRCUIT SCHEMATICS
(Engine running, transmission shift lever in “NEUTRAL”, lock-
up clutch “OFF”)
md16
561 FO3008
1o-9
HYDRAULIC PUMP (SAR4-160)
(For torque converter and transmission)
F56A02015
1. Drive gear Specifications

2. Bracket l Type: SAR4-160
3. Oil seal l Theoretical delivery: 162.2 cc/rev.
4. Side plate l Maximum pressure: 2iO kg/cm2
5. Gear case l Maximum speed: 2200 rpm
6. Cover
7. Driven gear
10-10
TORQUE CONVERTER
Model: TCA49- 1A
Type: 3 element, l-stage,
2-phase with lockup clutch
Stall torque ratio: 2.4
Lockup clutch: Oil-cooled multiple-disc clutch
Hydraulic control
(with modulation valve)
\
21 20 18
Section X - X
561 FO3009
Section V - V Section W - W
5
View Z
561 FO3010
1. Gear (No. of teeth: .63) 11. Disc A: From pump

2. Gear (No. of teeth: 53) 12. Plate B: To transmission valve
3. Spline for brake 13. Turbine C: To transmission
cooling pump drive 14. Drive case lubrication
4. Spline for steering and 15. Stator a: Torque converter outlet
hoist pump drive 16. Pump pressure measurement
5. Spline for torque 17. Rear housing port
converter and 18. Stator shaft b: Torque converter outlet
transmission charging 19. Retainer temperature pick port
pump drive 20. Drain plug
6. Torque converter valve 21. One-way clutch
7. Solenoid valve 22. Gear (No. of teeth: 56)
8. Front housing 23. Input shaft
9. Lockup clutch housing 24. Coupling
IO. Lockup clutch piston
10-13
TORQUE CONVERTER VALVE
a b
Section Y - Y
Section W - W
View Z
i
Section X - X 561 FO3011
1. Piston 7. Body A: From hydraulic pump

2. Piston 8. Spool a: Plug for measuring
3. Spool (lockup valve) (torque converter relief valve) hydraulic pressure of
4. Spool (main relief valve) 9. Piston load piston
5. Piston 10. Spring b: Plug for measuring
6. Spring 11. Piston lockup pressure
12. Spring c: Plug for measuring main
pressure
d: Plug for measuring
torque converter inlet
pressure
10-14
MAIN RELIEF VALVE
FUNCTION
l This valve acts to ensure the main hydraulic To transmission
control valve
pessure of the transmission valve, the main
hydraulic pressure of the lockup valve, and
the pilot pressure.
-OPERATION
l The oil from the hydraulic pump enters port
A, then passes through orifice a and goes
to port C.
When the hydraulic pressure in the circuit
rises, the pressure at port C also rises and
pushes main relief spool (1) to the left in
the direction of the arrow. The oil at port
To &ain To iorque Fro; pump To drain
A passes through port B and flows to the converter
torque converter circuit.
l Actuating pressure: 37 ?c 1.5 kg/cm2 F56103001
(engine at 2100 rpm)
TORQUE CONVERTER RELIEF VALVE
FUNCTION From main

This valve acts to protect the torque converter To drain relief valve 2 To drain
citcuit from abnormally high pressure.
OPERATION
The oil from the main relief valve enters port

D and then passes through orifice b and goes
to port F. When the pressure in the circuit rises,
the pressure at port F also rises, and moves
torque converter relief spool (2) to the right in
the direction of the arrow. The oil at port D flows
to port E and goes to the transmission
tion circuit.
lubrica-
F// b
I
To transmission
l Actuating pressure: 8 f 1 kg/cm2 (engine at lubrication
2100 rpm)
F56103002
10-15
LOCKUP VALVE
FUNCTION
This valve sets the specified pressure for the
lockup clutch hydraulic pressure, and also S7
E
switches the lockup clutch. 9 /
It has a modulation valve, which engages the
lockup clutch smoothly, and reduces the shock
Lockup
when shifting gear. Furthermore, it prevents the delay
generation of peak torque in the power train. h t time
As a result, the machine gives a good ride, and 9
Y
the durability of the power train is greatly ::
J
increased. 0
0
-
Time:
561 FO3013
OPERATION
Driving in torque conveter range
l When the machine is driving in the torque
converter range, solenoid valve (5) is switched
OFF by an electrical signal, and valve (5a) is
pushed to the right in the direction of the
arrow by the tension of spring (5b). so port
B and port P of solenoid valve (5) are opened.
The oil from the pump enters port A of lockup
valve (6), passes through port B and port P
of solenoid valve (5), and goes to port D.
Piston (8) is pushed to the left in the direction
of the arrow because of the hydraulic
pressure applied to port D. This force pushes
lockup valve (6). compresses spring (4), and
closes port A and port E.
The oil at port E and port H is drained, and
the lockup clutch is disengaged. 561 FO3014
lo-16
Driving in direct range (torque converter range Lockup Torque
clutch converter
-direct range) -
1) When the machine travels in the direct

range (lockup), solenoid valve (5) is switched
ON by the electrical signal, and valve (5a)
is pushed to the left in the direction of the
arrow, so port B is closed, and port P and
port C are opened.
As a result, the oil at port D flows from port
P of solenoid valve (5), passes through port
C and is drained. Lockup valve (6) and piston
(8) are pushed to the right by spring (4), and
port A and port E arexopened.
To drain From To drain

pump
561 FO3015
a When port A and port, E are opened, the Lockup

clutch
Torque
converter
oil from the pump is sent to the lockup clutch.
In addition, the oil at port E flows to port
F and applies back pressure to load piston
(2).

pump
561 FO3016
3) As the hydraulic pressure of the lockup Lockup Torque

clutch converter
clutch rises, the pressure of the oil passing
through orifice a and entering port G also
rises, and pushes pistons (7).
Because of the reaction force, lockup valve
(6) compresses spring (4) and pushes it to
the left in the direction of the arrow to
throttle port A and port E.
a
To drain Fuo;p To drain
561 FO3017
10-17
4) The oil from port E to port F applies pressure Lockup Torque
clutch converter
to load piston (2), and pushes piston (2) to \ -
the right in the direction of the arrow to
compress spring (4).
Compressed spring (4) pushes lockup valve
(6) to the right in the direction of the arrow,
and opens port A and port E. When this
happens, the increase in hydraulic pressure
to the lockup clutch starts again.

pump
561 FO3018
5) By repeating the actions in Steps 3) and 4), Lockup Torque

clutch converter
the load on spring (4) is increased, and the
hydraulic pressure gradually rises.
Finally, when load piston (2) contacts stopper
(3), the rise in hydraulic pressure stops. The
pressure at this point is the set pressure of
the lockup valve.
l Set pressure: 16 kg/cm’
From To drain
pump
561 FO3019
lo-18
LOCKUP SOLENOID VALVE
11
561 FO3012
1. Cover A. From torque converter valve

2. Coil 6. To torque converter valve
3. Spring C. To torque converter valve
4. Plunger
5. Valve seat holder
6. Valve seat
7. Spring
8 Valve seat
9. Cap
10. Cable
11. Connector
10-19
TRANSMISSION
3 G F E D C
i
View Z
Xd
-8
561 FO3020
1. Speed sensor mount port A: Low clutch port I: From torque converter
(for input shaft rotation) B: 1st clutch port (main circuit)
2. Speed sensor mount port C: 2nd clutch port J: From torque converter
(for intermediate shaft rotation) D: R clutch port (lubrication circuit)
3. Input shaft E: 3rd clutch port K: To pump (suction)
4. Transmission lubrication valve F: 4th clutch port L: From torque converter
5. Speedometer cable pickup port G: High clutch port (drain circuit)
6. Coupling H: From oil cooler
7. Drain valve
a. Speed sensor mount port
(for output shaft rotation)
9. Strainer
1O-20
1. Input shaft
2. No.1 sun gear (No.of teeth: 34)
3. No.1 clutch inner drum
4. No.1 clutch
5. No.1 planetary pinion
(No.of teeth: 32)
6. No.1 planetary carrier
7. Counter gear
(for input shaft, No. of teeth: 130)
9. No.1 ring gear (No.of teeth: 98)
10. No.2 clutch
11. No.2 clutch housing
12. No.3 clutch housing
13. Counter gear (for intermediate
shaft, No. of teeth: 130)
15. No.3 clutch
16. No.3 clutch outer drum
17. No.4 clutch
(No. of teeth: 20)
19. No.4 ring gear (No. of teeth: 86)
20. No.4 sun gear (No. of teeth: 46)
21. No.5 clutch
(No. of teeth: 20)
25. No.6 clutch
(No. of teeth: 28)
29. No.6, 7 planetary carrier
3
30. No.7 clutch
32. Output shaft
33. Counter gear
(for output shaft, No. of teeth: 60)
Speed reduction ratio (No. of teeth: 35)
Speed reduction 35. No.7 clutch piston
Speed range Clutches engaged ratio
36. No.6 clutch piston
Fl No. 2 - No. 7 (L - 1 st) 4.692 37. Intermediate shaft
42 41 39 38
F2 No. 2 - No. 6 (L - 2nd) 3.333 (No. 7 sun gear; No. of teeth: 26)
L_-
F3 No. 1 -No. 6 (H - 2nd) 2.475
F4 No. 2 - No. 4 (L - 3rd) 1.838
(No. of teeth: 19)
F5 No. 1 -No. 4 (H - 3rd) 1.365
No. 4 clutch _ No. 5 clutch L 40. No.4 clutch piston
F6 No. 2 - No. 3 (L - 4th) 1 .QOO No. 1 clutch No. 2 clutch No. 3 clutch
41. No.4, 5 planetary carrier
561 FO3021 42. No.3 clutch piston
F7 No. 1 - No. 3 (H - 4th) 0.742 (High) (Low)
R No. 2 - No. 5 (L - R) 3.934
Section X - X 44. No.1 clutch piston
10-21
TRANSMISSION VALVE
a b d
i 1 i i /
i i i
561 FO3022
1. ECfVlV (for high clutch) a. High clutch pressure measurement port

2. ECMV (for low clutch) b. Low clutch pressure measurement port
3. ECMV (for 4th clutch) C. 4th clutch pressure measurement port
4. ECMV (for 3rd clutch) d. 3rd clutch pressure measurement port
5. ECMV (for reverse clutch) e. Reverse clutch pressure measurement port
6. ECMV (for 2nd clutch) f. 2nd clutch pressure measurement port
7. ECMV (for 1 st clutch) 9. 1 st clutch pressure measurement port
8. Valve oil filter
ECMV clutch operation table
9. Seat
10. Breather
1 o-22
ECMV (Electronic Control Modulation Valve)
a 1 B A C
View Z
9
/ I
8 561 FO3023
1. Connector 6. Proportional solenoid A: To clutch

2. Spring 7. Pressure control valve B: Drain
3. Flow sensor valve spool spool c: From pump
4. Spring 8. Load piston a: Clutch pressure
5. Fill switch 9. Spring measurement port
1 O-23
E , 0
I-
Structure of ECMV
The ECMV(Electronic Control Modulation Valve)
consists of two valves: a pressure control valve
and a flow sensor valve.
Pressure control valve
The pressure valve contains a proportional
solenoid which takes the current sent from
the transmission controller and the pressure o-- Time (sec.) -
-
I I ,
control valve converts this current into

hydraulic pressure.
Flow sensor valve
This valve is actuated by a trigger from the
pressure control valve, and has the following
functions.
1) The valve is opened until the clutch is filled
with oil, thereby reducing the time (filling
time) taken for oil to fill the clutch.
2) When the clutch becomes full of oil, the
valve closes, and seends a signal (full
signal) to the controller to inform that filling
Time (sec.)
is completed. 561 FO3024
3) While there is hydraulic pressure applied A range: Before gear shifting (drained)
to the clultch, it outputs a signal (full signal) B range: Filling starts (trigger issued)
to the controller to inform whether there C range: Filling completed
is hydraulic pressure or not. D range: Regulation
E range: Filling
ECMV and proportional solenoid Characteristics of proportional solenoid

current and propulsion force
Each ECMV is equipped with one proportional I
solenoid.
The propulsion force shown in the diagram on
the right is generated according to the command
current from the controller.
The propulsion force generated by the propor-

tional solenoid acts on the pressure control valve
I
spool and this generates the hydraulic pressure 0
__t Current (A)
shown in the diagram on the right. In this way,
by controlling the command current, the
Characteristics of proportional solenoid
propulsion force is changed and this acts on the propulsion force and hydraulic pressure
1
pressure control valve to control the oil flow and
hydraulic pressure.
ECMV and fill switch

Each ECMV is equipped with one fill switch.
When the clutch is completely filled, the flow
sensor valve acts to switch the fill switch on.
As a result of this signal, the oil pressure starts
I
to build up. I’ 0
- Propulsion force (kg)
561 FO3025
1 O-24
Action of ECMV
The ECMV is controlled by the command current
from the transmission controller to the propor-
tional solenoid, and the output signal of the fill
switch. The relationship between the ECMV
proportional solneoid command current and
clutch input pressure and the output signal of
the fill switch is as shown in the diagram on
the right.
o-- Time (sec.) -
I
A range: Before gear shifting (drained) z
B range: Filling starts (trigger issued) 2
:
C range: Filling completed ‘a
D range: Regulation
E range: Filling
Time (sec.)
561 FO3024
1. Before shifting gear (drained) (A range of

graph)
When no current is being sent to proportional
solenoid (6), the reaction force for spring (9) of
the pressure control valve pushes pressure
control valve spool (7). As a result, proportional
solenoid (6) is pushed back, so pressure control
valve spool (7) connects the oil at clutch port
C to drain port E and drains the oil.
In this condition, there is no hydraulic force
acting on spool (3) of the flow sensor valve, so
the reaction force of spring (4) for the fill switch
moves flow sensor valve spool (3) away from
fill switch (5), and stops it in a position where
it is in balanced with return spring (2) of the
flow sensor valve.
561 FO3026
1o-25
2. Starting to fill (trigger command input to
pressure control valve) (6 range of graph)
(1) When there is no oil inside the clutch and
the trigger current is sent (maximum current
is applied) to proportional solenoid (6) the
proportional solenoid moves the full stroke
and pressure control valve spool (7) moves
to the left. As a result of this, pump port
A and pressure control valve output port B
are opened, and oil passes through orifice
“a” of flow sensor valve spool (3) and starts
to fill fhe clutch.
561 FO3027
(2) When this happens, a pressure difference

is created between the upstream and
downstream sides of orifice “a” of flow
sensor valve spool (3). Because of this.
difference in pressure, flow sensor valve
spool (3) moves to the left and compresses
sensor valve return spring (2).
As a result, flow sensor valve spool (3) opens
pump port D, and oil flows from here through
orifice “a” and goes to the clutch port.
3. Filling completed (pressure control set to

initial pressure) (C range of graph)
(1) When pump port D of the flow sensor valve 561 FO3028
opens, and the oil flows out from here, a
difference in pressure is created between
the upstream and downstream sides of
orifice “a” of flow sensor valve spool (3).
This continues to push flow sensor valve
spool (3) to the left. When this happens, and
the current of proportional solenoid (6) is
lowered momentarily to the initial pressure
level, almost the complete pump pressure
comes to bear on load piston (8). As a result,
pressure control valve spool (7) is pushed
back to the right, and a small amount of oil
leaks from pressure control valve outlet port
B to drain port E. However, only a small
amount of oil leaks, so almost all the oil from
the pump flows to the clutch, and flow
sensor valve spool (3) continues to be push- 561 FO3029
ed to the left.
1O-26
(2) When the clutch is filled with oil, the flow
of oil from pump port D to clutch port C stops.
The size of areas receiving pressure on the
left and right sides of flow sensor valve spool
(3) is different (the area on the left side is
larger), so when the pressure on both sides
becomes the same, the spool is moved by
hydraulic force to the right. When this
happens, pump port D and clutch port C are
closed. Because of this difference in area
on the left and right sides, and the force
of return spring (2) of the pressure control
valve, flow sensor valve (3) compresses fill
switch spring (4) and is pushed to the right.
It then contacts fill switch (5) and transmits
the clutch filling completed signal to the shift
controller. At this point, the current for the 561 FO3030
initial pressure level is flowing to propor-
tional solenoid (6), so the hydraulic pressure
is set to the initial pressure by pressure
control valve spool (7).
4. Regulating (D range of graph)

When current is sent to proportional solenoid
ZZ (6). the solenoid generates a force proportional
Z to the current. This propulsion force of the
S solenoid, and the sum of the propulsion force
produced by the hydraulic pressure at the clutch
port applied to load piston (8), and the rea.ction
force of pressure control valve spring (9) are
regulated so that they are in balance.
The difference in hydraulic pressure applied to
both sides of flow sensor valve spool (3) pushes
the spool to the right, and the fill signal
continues to be sent to the transmission
controller.
561 FO3031
1 O-27
LUBRICATION RELIEF VALVE
-I-
A
561 FO3032
Section A- A
1. Valve body FUNCTION

2. Lubrication relief spool l This valve is installed to the left side of the
a. Lubrication pressure measurement plug transmission and prevents abnormal pres-
sure in the transmission lubrication circuit. .
Cracking pressure: 2.7 kg/cm’
1O-28
FRONT AXLE
561 FO3033
1. Cover
2. Holder
3. Wheel hub
4. Retainer
1O-29
REAR AXLE
Section A - A
F56103003
1. Parking brake Specifications

Reduction ratio
2. Differential
Differential: 3.467
3. Axle housing
Final drive: 6.500
4. Brake
Oil
5. Final drive
Differential: E030-CD (130 liters)
Final drive: E030-CD (64 liters each side)
Tire size: 24.00-49 or 27.00-49
Rim size: 17.00-49 or 19.50-49
1O-30
DIFFERENTIAL
561 FO3035
1. Coupling Specifications
2. Cage Type: Spiral bevel gear, splash-type lubrication
3. Cage Reduction ratio: 3.467
4. Case Differential: Straight bevel gear, splash-
5. Nut type lubrication
6. Cap Oil: E030-CD (130 liters)
7. Differential gear case
8. Cross shaft
9. Bevel gear (No. of teeth: 52)
10. Defferential case
11. Side gear (No. of teeth: 24)
12. Pinion gear (No. of teeth: 20)
13. Bevel pinion (No. of teeth: 15)
70-31
DIFFERENTIAL
WITH DIFFERENTIAL LOCK
//
i i
F56103641
1. Coupling Specifications
2. Cage Type: Spiral bevel gear, splash-type lubrication
3. Cage Reduction ratio: 3.467
4. Case Differential: Straight bevel gear, splash-
5. Nut type lubrication
6. Cap Oil: E030-CD (120 liters)
7. Differential gear case
Differential lock: Wet, multiple disc clutch type
8. Piston
9. Plate
10. Disc
11. Cross shaft
12. Bevel gear (No. of teeth: 52)
13. Defferntial case
14. Side gear (No. of teeth: 24)
15. Pinion gear (No. of teeth: 20)
16. Bevel pinion (No. of teeth: 15)
10-31-l
8
DIFFERENTIAL LOCK CONTROL
STRUCTURE OF SYSTEM
F56103642
1. Air tank OUTLINE

2. Solenoid valve The differential lock is installed to allow the
3. Differential machine to travel through or escape from areas
4. Differential lock switch such as mud, sand, or snow and ice where the
5. Differential lock pedal tire friction coefficient is low and it is easy for
6. Pilot lamp the tires to slip. It is operated by using the
differential lock pedal in the operator’s compart-
ment. When the differential lock pedal is turned
ON, and actuates the differential lock solenoid
valve. Compressed air is then sent from the air
tank to the differential lock to actuated the
differential lock.
1O-31-2
@
DIFFERENTIAL LOCK SYSTEM DIAGRAM
lock
= : Air circuit
- : Electrical circuit
I
I
___2g__ A
Ca_b_(inner) Differential lock
Differential lock
solenoid valve
Air tank
F56103643
SWITCH
1. Roller
2. Lever
3. Housing
4. Cable
5. Connector
Circuit diagram
F56103644
10-31-3
@
DIFFERENTIAL LOCK SOLENOID VALVE
OUTLINE
The differential lock is actuated by using the
electric signal (current) from the differential lock
switch to turn ON the flow of compresssed air
to the differential lock from the air tank.
1. Exhaust valve
2. Coil
3. Spool
4. Spring
5. Valve seat
6. Body
F56A02090
FUNCTION
1. Solenoid valve (ON)
Spool (3) is lifted up, and the port of exhaust
is closed. At the same time, valve seat (5) I I
F56A02091 A
is lifted up, so the port to the differential
lock is opened and air flows into the
differential lock to actuates the differential
lock.
2. Solenoid valve (OFF)

Spool (3) goes down, and closes circuit to
differential lock at valve seat (5). The air
passes between coil (2) and exhaust valve
(1). and flows to the atmosphere, and release
the differential lock.
From To differential lock
I I
F56A02092A
1o-31 -4
@
FINAL DRIVE
12 11 10 9 8
561 FO3036
1. Carrier Specification
2. Planet gear shaft Type: Planetary gear, splash-type lubrication
3. Planet gear (No. of teeth: 39) Reduction ratio: 6.50
4. Sun gear (No. of teeth: 18) Oil: E030-CD (80 liters each side)
5. Button
6. Cover
7. Ring gear (No. of teeth: 99)
8. Spacer
9. Holder
10. Inner hub
11. Drive shaft
12. Wheel hub
1O-32
FRONT BRAKE
18’ Detail P
561 FO3037
1. Plate Specification
Type: Air over hydraulic, caliper disc type
2. Pin
3. Piston
4. Bleeder
5. Plate
6. Pad
7. Disc
8. Seal
9. Ring
10. Seal
1o-33
REAR BRAKE
561 FO3038
1. inner gear Specifications

2. Floating seal Type: Air over liydraulic, oil-cooled, multiple-
3. Floating seal disc brake (acts also as retarder)
4. Hub Oil: Brake oil EOl O-CD
5. Plate Cooling oil EOlO-CD
6. Disc
7. Outer gear
8. Piston
9. Cylinder
1o-34
PARKING BRAKE
SINGLE CALIPER DISC TYPE
View Z
View Y
2 r--‘-
fY
F56103004
1. Brake caliper assembly Specification

2. Parking brake chamber Type: Caliper disc brake
3. Disc
1O-34-2
0
DOUBLE CALIPER DISC TYPE
View Y
View if!
-.
\
‘\
561 FO3039
1. Brake caliper assembly Specifications

2. Parking brake chamber Type: Caliper disc type
3. Disc
1o-35
0
WHEELS
. FRONT WHEEL
1. Stud (xl 6)
2. Clamp (x8)
3. Nut (x16)
4. Valve
5. Rim assembly
6. Tire
Specifications
Rim size
Standard: 17.00 x 49
Option: 19.50 x 49
Tire size
/4 Standard: 24.00-49-48PR
-5 Option: 27.00-49-42PR
-6
Y
561 FO3040
. REAR WHEEL
1. Stud 5. Clamp
(inside wheel, x3) (outside wheel, xl 0)
2. Clamp 6. Nut (inside and
(inside wheel, x3) outside wheel, x20)
3. Nut 7. Rim assembly
(inside wheel, x3) 8. Valve
4. Stud 9. Tire
(outside wheel, x20) 10. Spacer
Specifications
Rim size
Standard: 17.00 x 49
Option: 19.50 x 49
Tire size
Standard: 24.00-49-48PR
Option: 27.00-49-42PR
561 FO3041
1O-36
AXLE SUPPORT
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
‘-’
1 2 3 4
\ I i /
Section A - A Section C - C
Section B - B
561 FO3042
1 o-37
STEERING SYSTEM
561 FO3043
1. Tire OUTLINE
2. Steering cylinder The steering system is of the self-metering
3. Tie rod power steering type. When the steering wheel
4. Crossover relief valve (5) is manipulated, the steering control valve (6)
5. Steering wheel is actuated, the oil to flow into the steering
6. Steering control valve cylinder (2). By extending or contracting this
7. Knuckle steering cyclinder (2). a truck can be steered
8. Arm (A frame) as desired.
If the steering wheel rotation is stopped before
A: From demand valve the stroke end, the steering control valve (6) will
B: To hydraulic tank instantly be returned to neutral position and
C: To demand valve stopping the steering cylinder (2) at once.
1O-38
STEERING WHEEL
561 FO3044
1. Steering wheel Specifications

2. Steering shaft l Tilting range: 94 mm
3. Steering column l Telescoping range: 50 mm
4. Steering post
5. Lock lever
6. Yoke
7. Joint shaft
8. Steering valve
1o-39
STEERING LINKAGE
561 FO3045
1. Center lever
2. Tie rod
3. Arm (A-frame)
4. Knuckle arm
1O-40
Section A - A Section B - B
‘Section C - C Section D - D
Section E - E Section F - F
561 FO3046
10-41
SUSPENSION SYSTEM
0”
z
k2
561 FO3047
Front suspension cylinder

Rear axle support
Rear suspension cylinder
Radius rod
Arm (A-frame)
OUTLINE
The suspension system supports the weight of cylinder is charged (sealed) with oil and nitrogen
the chassis, and absorbs the shock from uneven gas. This acts as a shock absorber (spring and
road surfaces to provide a comfortable ride for damper) by contracting and expanding the
the operator. At the same time, it maintains the nitrogen gas and oil to absorb the load from the
stability of the machine by ensuring that all four road surface.
wheels are always in contact with the ground In addition to these functions, the front suspen-
surface. In this way, it allows the machine to sion employs an automatic suspension system.
demonstrate its full performance in items such In this system, the force of the suspension is
as acceleration, braking, and turning, even when automatically changed by selecting the damping
traveling at high speed. force to match the travel conditions and load
Hydropneumatic cylinders are used for the conditions. This further increases the stability
suspension cylinders to reduce the shock. With and riding comfort of the machine.
hydropneumatic cylinders, the suspension
1 O-42
FUNCTION
1. Front suspension
The front suspension cylinder functions as
a shock absorber and spring, and is con-
nected by spherical bearings to the lower
arm (A-frame) and main frame. The wheels
move up and down in accordance with the
retraction and extension of the suspension
cylinder to maintain the proper alignment
for the wheels and to improve the stability
of the machine.
561 FO3048
2. Rear suspension
T: The differential housing is supported by the
5 frame and two radius rods at the bottom,
0
and at the top by two inverted-V-shaped rods
and two suspension cylinders. It is con-.
netted to these at both ends by spherical
bearings. It transmits the load and motive
force through the top and bottom rods.
The inverted-V-shaped rods at the top also
function to maintain the center of the
machine (axle).
Employment of the inverted-V-shaped link
improves the rolling steering characteristics.
561 FO3049
1o-43
SUSPENSION CYLINDER
l FRONT SUSPENSION CYLINDER
View Y View 2
Section W - W
TT
Section X - X
F56103005
1. Feed valve 8. Air bleed valve A: Port

2. Retainer 9. Air bleed valve B: Port
3. Flange 10. Tube
4. Stopper 11. Valve assembly
5. Cylinder (with axle) 12. Orifice plate
6. Rod 13. Leaf spring
7. Wear ring
1 o-44
l FRONT SUSPENSION CYLINDER
(With variable damping force selector valve)
View Y View 2
8
1 Section W - W
2 9
3
10
4
Section X - X
11
5
1
12
561 FO3050
1. Feed valve 9. Air bleed valve A: Port

2. Retainer 10. Tube B: Port
3. Flange 11. Air cylinder
4. Stopper 12. Valve assembly
5. Cylinder (with axle) 13. Orifice plate
6. Rod 14. Leaf spring
7. Wear ring 15. Damping force selector
8. Valve (for bleeding air valve
and mounting pressure 16. Damping force selector
sensor) valve lever
1 o-45
FRONT SUSPENSION CYLINDER
1) Structure and operation
The suspension cylinder acts as a shock
absorber and spring. The inside of the
cylinder is divided into gas chamber (A)
which is charged with nitrogen gas, and oil
chamber (B) which is filled with oil. Oil
chamber (B) and oil chamber (C) are con-
nected by tube (11) and valve body (12).
a. Nitrogen gas
When machine
the is traveling, the
wheels follow the unevenness of the road
surface, and an external force in the up-
down direction is applied to the suspen-
sion cylinder. When this happens, the
volume of the nitrogen in gas chamber
(A) changes elastically under the input
force, and absorbs the external force. The
nitrogen gas is sealed by a rod and oil,
so it is always subjected to a pressure
corresponding to the external force, and
acts as an air spring.
561 FO3210
b. Principle of generation of damping force
Inside valve body (12) are orifice plate (8)
and leaf springs (9a) and (9b). They restrict
the flow of oil between oil chamber (B)
and oil chamber(C), and create a damping
force.
i) Action when retracting
When the nitrogen gas is compressed
by the external force from the road
surface, the oil in oil chamber (B) flows
from oil chamber (B) through valve (12)
and tube (11) to oil chamber (C). The
oil flowing through the valve from
direction Z to orifice plate (8) is throttled
by orifices in four places to generate
a damping force.
ii) Action when extending
When the external force from the road
9a 9h ‘8
surface weakens, the pressure of the 561 FO3052
nitrogen gas extends the rod, and the
oil in oil chamber (C) passes through
tube (11) and valve (12) and flows to
oil chamber (B). The oil inside the valve
flows from direction X and passes
through two orifices from orifice plate
(8) to generate a damping force.
rifice
Orifice View 2
View X
561 FO3053
1O-46
c. Variable shaft mechanism
In the valve body, bypass circuit (D) is
provided before and after orifice plate (8),
SO the oil flow is divided into oil flowing
through orifice plate (8) and oil flowing
through the bypass circuit (D).
The oil flowing through bypass circuit (D)
passes through a shaft with orifices at two
places on the inside circumference, and
flows to oil chamber (C) or oil chamber
(B) according to whether it is retracting
or extending.
The shaft is connected to an air cylinder
driven by a signal from the suspension
controller, and the size of the orifices
automatically changes according to the 9a 9b 8 D
condition of the machine. 561 FO3054
The damping force is set at three levels
(MEDIUM, HARD, SOFT) according to the
size of the orifices through which the oil
is passing.
(Orifice-small) MEDIUM
(Without orifice) HARD
561 FO3056
(Orifice-large) SOFT
561 FO3055
1 o-47
l REAR SUSPENSION CYLlNDEFi
1 6
2
7
F56103006
1. Feed valve 5. Rod

2. Retainer 6. Air bleed valve
3. Flange 7. Air bleed valve
4. Cylinder 8. Ball
1 O-48
REAR SUSPENSION CYLINDER

The suspension cylinder has the functionof
both a shock absorber and a spring.
When a fixed amount of oil is sent from oil
chamber (7) through orifices (5) and (6) to
cavity (3), the oil is throttled by the orifices
and a shock-absorbing effect is obtained.
a) Retracting action
When the machine is traveling and it hits
a bump or object on the road, the wheels
are pushed up, and the cylinder rod is
pushed inside the cylinder.
When this happens, the nitrogen gas
inside chamber (8) is compressed, the oil
in chamber (7) is sent through both
orifices (5) and (6) to cavity (3), and cavity
(3) is filled more quickly than when
extending.
Extending action
When the machine has passed any bump
or object on the road surface, the cylinder
rod is pushed up by the weight of the
wheels and axle and the pressure of the
nitrogen inside chamber (8).
As a result, the amount of oil in cavity
(3) is reduced, and pressure is applied to
the oil remaining in cavity (3).
This pressurized oil closes orifice (5) with
check ball (4), and is sent to chamber (7)
through only orifice (6), so the flow of oil 561 FO3057
passing through the orifice is controlled

so that it is less than during retraction. 1. Feed valve 7. Oil chamber
In this way, the amount of oil returning 2. Air bleed valve 8. Nitrogen gas chamber
to chamber (7) is restricted to provide a 3. Cavity 9. Cylinder rod
shock absorbing effect. 4. Check ball 10. Cylinder
5. Orifice 11. Air bleed valve
6. Orifice
1o-49
AIR CIRCUIT DIAGRAM
HD785-3 : Serial No. 2001 - 2515
HD985-3 : Serial No. 1001 - 1012
f
38
ez m
1. Front brake
2. Brake oil tank
3. Front brake chamber
4. Air charge socket
5. Safety valve
6. Air tank (wet)
7. Air tank (dry)
8. Check valve
9. Relay valve
(with emergency)
10. Air tank (pilot)
11. Drain valve
12. Air governor
13. Air compressor
14. Horn valve
15. Muffler
16. Brake valve
17. Hand brake valve
(retarder)
18. Air gauge
19. Parking brake valve
20. Emergency brake valve
21. Auto retarder valve
22. Double check valve
23. Low pressure switch
24. Emergency brake switch
25. Brake lamp switch
26. Parking brake switch
27. Retarder lamp switch
28. Quick release valve
29. Parking pilot valve
30. Relay valve
(with emergency)
31. Parking relay valve
32. Brake oil tank
33. Air tank (rear)
34. Parking brake chamber
35. Rear brake chamber
36. Drain valve
37. Slack adjuster
38. Rear brake
- NYLON TUBE 39. Brake cooling suction line
40. Brake cooling return line
= STEEL TUBE
- RUBBER TUBE
F56103007-1
10-50-l
63
EQUIPPED WITH EXHAUST BRAKE, FRONT BRAKE CUT OFF SYSTEM, DOUBLE
DISC CALIPER TYPE AND AUTO SUSPENSION
HD785-3 : Serial No. 2001 - 2515
HD985-3 : Serial No. 1001 - 1012
1. Air cylinder
r rI
-I
I
(for suspension control)
2. Front brake
Exhaust brake cylinder
Brake oil tank
Front brake chamber
7. Safety valve
8. Air tank (wet)
9. Check valve
11. Air tank (dry)
12. Relay valve
(with emergency)
13. Drain valve
14. Air governor
15. Air compressor
16. Horn valve
17. Muffler
18. Muffler
19. Muffler
20. Air pressure sensor
21. Exhaust brake switch
45 26. Brake valve
(retarder)
30. Front brake cut off solenoid
va Ive
31. Exhaust brake solenoid valve
32. Auto retarder solenoid valve
33. Suspension control solenoid
valve
36. Parking brake pilot valve
37. Relay valve
(with emergency)
-NYLON TUBE 39. Air tank (rear)
= STEEL TUBE 46. Parking brake chamber
m RUBBER TUBE 42_
Brake oil tack
43. Drain valve
44. Slack adjuster
45. Rear brake
46. Brake cooling suction line
HD785-3 : Serial No. 2516 and up (Standard)
HD985-3 : Serial No. 1013 and up (Standard)
r
c
_..-.‘-.‘-__-__-__-----------_-__---, 1. Front brake
I 2. Brake oil tank
c I 38 3. Front brake chamber
I 4. Air charge socket
I 5. Safety valve
1
ii I 6. Air tank (wet)
7. Air tank (dry)
8. Check valve
9. Relay valve
(with emergency)
11. Drain valve
12. Air governor
13. Air compressor
j2
14. Horn valve
15. Muffler
16. Brake valve
I-
(retarder)
23. Reducing valve
37 . Retarder lamp switch
_.
30. Relay valve
(with emergency)
32. Brake oil tank
33. Air tank (rear)
36. Drain valve
37. Slack adjuster
38. Rear brake
SVH00409
1 o-51
0
HD785-3 : Serial No. 2516 and up (for Australia)
HD985-3 : Serial No. 1013 and up (for Australia)
1. Front brake
2. Brake oil tank
5. Safety valve
6. Air tank (wet)
7. Air tank (dry)
8. Check valve
9. Relay valve
(with emergency)
11. Drain valve
12. Air governor
13. Air compressor
14. Horn valve
15. Muffler
16. Brake valve
(retarder)
23. Reducing valve
30. Relay valve
(with emergency)
32. Brake oil tank
33. Air tank (rear)
36. Drain valve
37. Slack adjuster
38. Rear brake
41. Front brake cut off solenoid
valve
SVH00410
1o-52
0
AIR PIPING

2. Safety valve
3. Air tank
5. Relay valve (with emergency)
6. Drain valve
7. Slack adjuster
12. Air tank
13. Brake oil tank
15. Drain valve
16. Rear brake
21. Hand brake valve (retarder)
22. Muffler
23. Brake valve
24. Air compressor
25. Horn valve
26. Air governor
27. Front brake
28. Brake oil tank
33. Low pressure switch
F56103008
10-52-l
0
FOR MACHINES WITH EXHAUST BRAKE, FRONT BRAKE CUT OFF SYSTEM AND
DOUBLE CALIPER DISC TYPE

2. Safety valve
3. Air tank
6. Drain valve
7. Slack adjuster
12. Air tank
13. Brake oil tank
15. Drain valve
16. Rear brake
18. Autoretarder solenoid valve
19. Exhaust brake solenoid valve
20. Front brake cut off solenoid valve
21. Front brake cut off solenoid valve
24. Hand brake valve (retarder)
25. Muffler
26. Brake valve
27. Air compressor
28. Horn valve
29. Exhaust brake cylinder
30. Air governor
31. Front brake
36. Exhaust brake switch
28’
i2
\
23
561 FO3058
24
1. Spring
2. Exhaust port
3. Piston
4. Unloader port
5. Exhaust stem
6. Inlet valve
7. Tank port
8. Filter
Specifications
l Cut-out pressure: 8.3 + 0.3 kg/cm*
l Cut-in pressure: 7.0 + 0.3 kg/cm*
\ 6
423FO91 A
E?
z
s FUNCTION
l The air governor maintains the pressure in
the air circuit to the specified range.
OPERATION
Compressor working
l The air pressure in the wet tank (9) passes 5-
from the tank port (7) through the filter (8)
and acts on the bottom of the piston (3).
When the air pressure in the tank (9) is below
the specified pressure (cut-out pressure) the
piston (3) pushed down by the spring (1).
l When this happens, the air at the unloader
port (4) passes through the exhaust stem (5) To dry
+
to the atmosphere and the compressor is Check valve
actuated.
Compressor loaded
,421 F057A
10-53
Compressor stopped
When the pressure in the wet tank (9) rises,
and reaches the set pressure (cut-out pres-
sure), the piston (3) is pushed up against the
spring (1).
When the piston (3) is pushed up, the exhaust
stem (5) is closed and the inlet valve (6) opens.
The pressure from the tank passes through
the inlet valve (6) and unloader port (4) and
acts on the unloader valve of the compressor.
This putp the compressor in a no-load Compressor
condition.
When the air pressure inside the tank drops, II
the piston (3) is pushed down by the spring

To dry
(1). a= Check valve
When the pressure drops below the specified
pressure (cut-in pressure), the inlet valve (6)
closes and the exhaust stem (5) opens. The
pressure at the unloader port (4) passes
through the exhaust stem (5) and is released
in the atmosphere, so the compressor starts
to work again.
Compressor no-load
421 F058A
1 o-54
SAFETY VALVE
This valve is installed in the air reservoir to

prevent excessive pressures from developing in
the air circuit, by permitting the compressed air
to escape when the pressure exceeds 9.5 + 0.4
kg/cm*.
1. Valve seat
7 6 5 2 1 2. Ball
3. Release pin
4. Spring
5. Spring cage
6. Adjusting nut
7. Locknut
51 F054
CHECK VALVE
When the air enter the check valve from the

E?
normal direction (PI), thevalve will leave itsseat,
z
allowing the air to flow to each port without
g
any obstruction to the flow.
If the air flows in from the opposite direction,
the valve will be returned into the seat by the
spring action and air pressure, to cut off the
air flow.
1. Body
2. Disc valve
3. Screw cap
4. Spring
5. Guide
6. Body
PI P2
51 F045
1 o-55
DOUBLE-CHECK VALVE
The double check valve has two inlet ports and

serves as a selector valve to send air from either
inlet port to outlet port. This double check valve
is used at a port in the foot brake valve, hand
brake valve, and auto retarder valve.
51 F031
1. Body
2. Shuttle guide
3. Shuttle
4. Gasket
5. Cap
6. Plug
FUNCTION
When the foot brake valve is actuated, the t
compressed air will move shuttle (3) in the
double-check valve so as to close the inlet port
to the hand brake. Thus, the flow-direction of
the air will be changed and air will flow to the
rear brake relay valve.
When the hand brake valve is actuated, the
shuttle will close the inlet port to the brake valve,
causing the pressurized air to flow to the rear
brake relay valve. 51 F032
51 F033
1O-56
AUTO DRAIN VALVE
This valve drains dust by taking an advantage

of the variation of the pressure in the air
reservoir.
1. Lead wire
2. Body
3. Diaphragm
4. Heater
FUNCTION
g When the compressed air pressure in the
z reservoir became high, the diaphragm is pushed
8 down and air and water-drop stay in (A) part.
When the pressure of (A) part became equal
to the pressure in the reservoir, the diaphragm
In the tank
returns to the original position. :::::
When the pressure in the reservoir became
lower than the pressure of (A) part, the
diaphragm is pushed up, so water and dust are
drained.
0
Drain
1o-57
HAND BRAKE VALVE (Retarder control valve)
Section 6 - B
View Z
Section A - A
561 FO3059
1. Clamp 11. Body OUTLINE

2. Pin 12. Stem l The hand brake valve is an air valve for the
3. Handle 13. Spring retarder control, and is installed to the
4. Plunger 14. Head steering column.
5. Spring 15. Ring l The air discharge pressure changes according
6. Lock washer 16. Spring to the angle that the valve handle is rotated,
7. Cam follower 17. Piston so the retarder can be controlled as desired.
8. Cam 18. Spring
9. Cover 19. Valve
10. Valve guide 20. Valve seat
lo-58
FUNCTION
When the handle is placed in “BRAKE” position,
then piston (5) will be pushed down by cam (1)
through spring (2).
The valve seat provided at piston (5)
exhaust
will be pushed against exhaust valve (4) to close
the valve. The inlet valve (6) and exhaust valve
(4) form onebody.
After the exhaust valve (4) is closed, inlet valve
(6) is opened. Compressed air is fed to the relay
valve through the inlet valve, actuating the rear
brake chamber cylinder and applying the
retarder brake.
z;v;laY From air Drain
tank
51FOlOA
Air balancing position with the spring force

When the air pressure imposed on the underside
of piston (5) balances with the force of spring
(2) piston (5) will be raised slightly, closing the
inlet valve (6). In this condition, the valve seat
(3) remains closed, keeping the air pressure at
the relay valve constant.
In this manner, the brake valve is kept in a
balanced condition, holding the air pressure
constant depending on the position of the
handle.
valve tank
51FOllA
Brake releasing position
When the handle (7) is moved to the brake
“RELEASE” position, the force of spring (2) will
be reduced. Then, piston (5) will be raised by
the air pressure on the underside of the piston,
causing the exhaust valve to open, which will,
in turn, cause the pressurized air at the relay
valve to flow out into the atmosphere through
the exhaust valve.
If the pressure
air on the piston underside
balances with the force of spring (2). the exhaust
valve will be closed again to hold the balanced
condition, and the air pressure at the relay valve
will be kept constant. When the handle (7) is
moved to the “COMPLETE RELEASE” position,
the force on spring (2) will be removed causing
piston (5) to be pushed up, which, in turn, will
cause all of the pressurized air to flow out into From hay Drain
valve
the atmosphere. Thus, the brake will be
completely released.
51 FOI 2A
10-59
BRAKE VALVE
F56903014
1. Plunger 11. Lower valve guide

2. Seat 12. Check valve
3. Pedal 13. Lower valve return spring
4. Piston 14. Relay piston return spring
5. Stop bolt 15. Upper ring retainer
6. Piston return spring 16. Upper valve return spring
7. Upper valve (upper inlet valve) 17. Inner relay piston
8. Outer relay piston 18. Valve body
9. Lower valve (lower inlet valve) 19. Rubber spring
10. Cover
1O-60
FUNCTION
A. In normal action B. When balancing is made between air

pressure and spring force
:he
From the
tank
F56903016
F56903015 (When the brake pedal (3) is depressed to and held
(When the braking effect begins to be given.) at a certain point on its stroke.)
If the pedal (3) is depressed, the pedal movement If the air pressure in the brake chamber acting
will be transmitted to the piston (4) through the on the lower part of piston (4) is euqal to the
rubber spring (19), causing the piston (4) to move force of the rubber spring pushing piston (4)
downward. Then, the exhaust port (A) will be downward, the upper inlet valve will close,
closed and the upper inlet valve (7) will be stopping the flow of pressurized air from the
opened. Thus, the pressurized air from the air reservoir to the brake chamber. The exhaust port
reservoir (tank) will flow to the rear brake remains closed. Then, the air presure in the
chamber, causing the application of the rear brake chamber will be kept constant and
brake to start. consequently, the braking force will be main-
If the upper inlet valve (7) is opened, the tained at the same value.
pressurized air will flow to the relay piston (8) If the upper and lower air pressure values in
through passage (B), pushing inner relay piston the relay piston are equal to each other, the
(17) downward, which, in turn, will open the piston return spring (14) will move the relay
lower inlet valve. piston (8) slightly upward, and the lower inlet
Then, pressurized air from the air tank will flow valve will be closed by the action of spring (13).
to the front brake relay valve, to start applying However, the exhaust valve (C) remains closed
the front brake. and the air acting on the front relay valve cannot
Actually, the force required to move the relay escape, thus the front braking force is kept
piston (8) is very small and therefore, there is constant.
little difference in timing for the upper and lower * If pedal (3) is depressed to the end of its stroke,
inlet valves to begin opening. the upper and lower inlet valves (7) and (9)
will remain opened, equalizing the air
pressure in the brake chamber with that in
the air tank.
1 O-61
C. When the brake is released.
From the
tank
From the
tank
F56903017
When the effort depressing pedal (3) is reduced,

the force on the upper part of piston (4) will
be eliminated, and piston (4) will be pushed up
by the air pressure and spring force acting on
its lower part. Exhaust port (A) will be opened,
to allow escape of the pressurized air in the
brake chamber into the atmosphere. As a result,
the force actuating the rear brake will be
reduced.
Consequently, the air pressure acting on the
upper part of relay piston (8) will also be reduced.
Since relay piston (8) is also pushed up by the
air pressure and spring force acting on its lower
part the exhaust valve (C)will be opened. Then,
the pressure at the relay valve actuating the
front brake will be reduced, causing release of
the front brakes.
1 O-62
2-WAY CONTROL VALVE
(Parking brake valve, emergency brake valve)
A 2-way control valve is used as the parking

brake valve or emergency brake valve. When
the valve is used as a parking brake valve, the
parking brake can be applied or released by
turning the lever to PARKING or TRAVELING
position. When the valve is used as an emerg-
necy brake valve, the emergency brake can be
applied or released by turning the switch to
BRAKING or TRAVELING position.
561FO3068
1. Body A: Exhaust port

2. Plunger B: Outlet port
3. Plunger spring C: Inlet port
4. Valve
5. Lever
6. Pin
7. Valve spring
1O-63
FUNCTION
Running position
1. Air intake
Turning the lever (1) to the “TRAVELING”
position will cause the valve (5) to be pushed
down by the plunger (12), which will in turn,
furnish pressurized air to the parking brake
cylinder.
In the emergency brake, the pressurized air
is supplied to an emergency port of the rear
relay valve. To the parking
brake cylinder
(To rear relay
valve)
From air
tank
2. Air exhalation
Turning the lever (1) to the “PARKING” or Parking
“BRAKING” position will cause the plunger

(12) to be returned upward by the spring (9).
Then, the valve (5) will be in the seat in the
body (4), letting the plunger (12) come off
the valve (5). Thereby, the pressurized air
in the parking brake control line is exhausted
through a small center orifice in the plunger Drain >w!# Drain
(12). / LII
After exhausting air from the spring cylinder,
parking brake is actuated by spring force.
In the emergency brake, the pressurized air
in the emergency port line of the rear relay
valve is purged out through a central orifice
in plunger (12). If the air pressure at an
emergency port in the rear relay valve drops,
the relay valve will actuate, causing the rear
brake to apply.
51FO15
1 O-64
EMERGENCY BRAKE CONTROL VALVE (Variable control type)
6.
E 7.0
=- t 6.0
1-E 5.0
$2 4.0
- y” 3.0
z- 2.0
1.0
-Handle turning
angle ( o 1,
561 FO3062
Actuation characteristics graph
(tank pressure: 7kg/cmz )
561 FO3061
@ : When braking
@ : When traveling
1. Handle 7. Valve spring Function

8. Main spring This valve allows manual actuation of the
2. Cam ring l
3. Handle head 9. Feed valve emergency brake.

The emergency brake can be controlled by
4. Body 10. Feed valve seat
5. Piston 11. Return spring operating the handle.
6. Cover 12. Exhaust valve seat * When traveling, the handle is set at a handle
angle of 55” (position @ ).
A. Outlet port (to emergency brake valve)
B. Inlet port (from air tank)
C. Exhaust port
10-64-l
0
OPERATION
1. Braking position (handle turning angle at

0”)
At the braking position, the inlet port is
connected to the tank, but the air is shut
off by feed valve (9). The exhaust port is open,
* From emergency
so the air at the exhaust port is all released. relay valve
As a result, the emergency relay valve is
actuated to brake the machine. From air tank
fZ$B Exhaust air
561 FO3063
2. Actuation at air supply end (handle turning

angle 0” 55’)
When the handle is turned, the exhaust
valve seat (12) is pressed down by a cam.
It contacts feed valve (9) and closes the 12
To emergency
exhaust port. relay valve
If the handle is turned further, feed valve
(9) is pushed down, so the inlet port and
outlet port are connected and air flows.
9 From air tank
.xhaust air
I I
561 FO3064
3. Balancing effect (handle turning angle

between IO” and 45”)
If the handle is stopped at a midway position
(any desired position), the air pressure in
12
chamber B acts also on the top surface of
To emergency
piston (5). relay valve
9
If this force becomes greater than the force
of main spring (8), piston (5) is pushed down
From air tank
and feed valve (9) is closed. When this
5
happens, exhaust valve seat (12) is also
closed, so the pressure at the outlet port is c3 Exhaust air
maintained at a constant pressure. I I
8'
561 FO3065
1 O-64-2
0
4. Travel position (full stroke: handle turning
angle 55”)
If the handle is turned further, piston (5)
contacts the stopper surface of cover (6), so
feed valve (9) is opened and the pressure
To emergency
at the outlet port rises to the tank pressure. relay valve
As a result, the emergency relay valve
releases the emergency brake, and the
From air tank
machine is placed in the travel condition.
E:xhaust air
561 FO3066
5. Actuation at exhaust end (handle turning

angle 55” 0’)
If the handle is turned in the 0” direction,
the cam rises, and exhaust valve seat (12) 12
rises because of return spring (11). It
separates from feed valve (9). so the air at
the outlet port is drained. 11
From air tank
561 FO3067
1 O-64-3
0
PARKING BRAKE PILOT VALVE
‘D
Section A-A
569FO14
1. Piston A. To atmosphere
From emergency
2. Valve body B. From emergency brake circuit circuit
3. Seat C. To parking brake relay valve
4. Seat D. From rear air tank
FUNCTION
If the air for the emergency brake circuit is cut;
the circuit between the parking brake valve and
To parking
parking relay valve is shut off and the parking relay valve
brake is applied.
OPERATION
From rear air tank
1. When air is being sent to the emergency
569FO15
brake circuit.
Piston (1) is moving down in the direction
of the arrow, so the air from the rear air
tank is sent to the relay valve.
As a result, the parking brake is set to the
TRAVEL position.
2. When no air is being sent to the emergency
brake circuit. To
atmosphere @
Piston (1) is moved up by the spring, the From parking
0 relay valve
air from rear air tank is shut off, and the
air from the relay valve is released to the
atmosphere, so the parking brake is applied.
From rear air tank

569FO16
1O-65
RELAY VALVE (Acts also as emergency relay)
In normal operations, when the brake pedal is

depressed, it moves the relay valve and the air
in the air reservoir is sent to the brake chamber.
If any failure in the air supply circuit or leakage
of air causes the air pressure in the wet tank
to drop below the specified pressure (3.2 kg/
cm2), it also acts as an emergency relay valve.
7
8
566F136A
E 1. Cover A. From air tank

2. Spring 6. From brake valve
3. Exhaust valve seat C. From emergency
4. Inlet exhaust valve brake valve
seat D. To brake chamber
5. Body E. To brake chamber
6. Relay piston
7. Valve guide
8. Emergency piston
1O-66
FUNCTION
1. Provision of pressurized air to dry reser-

voir.
Pressurized air in the pilot air tank through
emergency valve will pass through
brake
filter(1) and pushed up check valve (2) to
- emergency
flow into the dry air tank. It will continue
To the
to rise until the dry air tank pressure air tank -
becomes roughly equal to the wet air tank

pressure.
Also air will flow into dry air tank from wet
51 F039A
air tank directry.
2. When the brake pedal is depressed.

Pressurized air wi’ll enter (A), the upper
section of the relay piston, causing the piston
to lower. Then, the exhaust valve seat (1) From the
- brake valve
will close the exhaust port (C) and open the
valve (2).
From the
If the valve the pressurized
is opened, air - emergency
brake valve
from emergency brake valve and dry air tank
will be fed to the brake chamber through
the valve.
8
z 3. When depression of the pedal is stopped. 5 1 F040A
8 The air pressure valves in the upper and
lower (A) and (B) of the piston will
section
be equal to each other. At this time, the relay
piston (4) will be pushed up under the force
From the
of the piston return spring (3). -brake valve
In this position of the relay piston, the

exhaust port (C) will remain closed, main- From the
+ emergency
taining the pressure in the lower section (B) brake valve
From the_
at the same value. air tank
4. When the pedal is released.

The pressurized air in the piston upper
section (A) will be exhausted through the 51 F041A
brake valve, reducing the pressure in (A).
Consequently, the relay piston will be
thrusted up by the pressurized air in the
section (B), causing the exhaust port to open.
Thus, the air in the section (B) will be
exhausted.
5 1 F042A
1 O-67
5. Emergency brake operation
1) The emergency piston return spring (14) will
operate when the pressure at the emergency
brake valve (pilot air tank) side drops below
about 3.2 kg/cm2 or emergency brake valve
is put in “BRAKE” position, causing the
emergency piston (13) to be pushed up. As
a result, seat (1) of the exhaust valve will
close the exhaust port (C) and open valve
(2). When the valve opens, the pressurized
air from the air tank will pass through the
valve to the brake chamber. In this way, the
emergency brake will start to operate from
the point where the pressure in the air circuit
of the pilot air tank falls below 3.2 kg/cm*.
2) When the air pressure in the air circuit on

the pilot air tank side is within the range
of about 4.7 kg/cm*, the emergency brake
will not come on automatically, however if
the brake pedal is depressed while the brake
system is in this condition the residual
pressure in the brake valve will maintain the
emergency brake operational even when the
foot is released from the brake pedal.
3) Emergency brake release.

To release the emergency brake it is
necessary to either open the drain valve of
the dry air tank or once again raise the air
pressure to 5.6 kg/cm*.
1O-68
PARKING BRAKE RELAY VALVE
566F129
1. Cover
2. Relay piston
3. Body
4. Exhaust cover
A. From parking brake pilot valve

B. From air tank
C. To parking brake chamber
1O-69
FUNCTION
1
1. When the parking brake valve in
“TRAVELING”
Pressurized air will enter (A), the upper
section of the relay piston, causing the piston
to lower. Then, the exhaust valve seat (1)
To the
will close the exhaust port(C) and open the parking
valve (2). brake
chamber
If the valve is opened, the pressurized air
will be fed to the parking brake chamber
through the valve.
51 F034
2. When the parking brake valve in

“PAR KING” To the
ix?-
The pressurized air in the piston upper parking
brake pilot
section (A) will be exhausted through the B valve
parking brake valve, reducing the pressure
in (A). From the
Consequently, the relay piston will be parking F:rom the
brake a ir tank
thrusted up by the pressurized air in the chamber
section (B), causing the exhaust port to
openThus, the air in the section (B) will be
51 F036
exhaled.
1O-70
QUICK-RELEASE VALVE
The quick-release valve serves to let the

pressurized air in the pilot line for retarder flow
out quickly.
1. Body
2. Diaphragm
3. Diaphragm valve
4. Cover
5. O-ring
5 1 F044
FUNCTION From hand brake valve

1. If the hand brake valve (retarder control
valve) is palaced in “BRAKE” position, the
pressurized air wi1’l reach the upper section
c3 (A) of the diaphragm, pushing the diaphragm
0.
Z downward.
8 Then, exhaust port (C) will be closed and
the diaphragm will be distorted as shown,
allowing the air to be fed to the parking brake
spring cylinder through the periphery of
diaphragm.
5 1 F045
2. If the hand brake valve is moved to the brake

“RELEASE” position, the pressure in the
upper section (A) of diaphragm will be
reduced and the diaphragm will be pushed
upward by the pressurized air in (B), causing
the outlet port to open. Consequently, the
From relay
pressurized air in (B) will be exhausted. valve
Air exhausted
51 F046
10-71
BRAKE CHAMBER
l FRONT
561 F03069
1. Piston 1. Air cylinder

2. Push rod Fluid used: Air
3. Air cylinder Effective area: 314 cm2
4. Master cylinder Stroke: 100 mm
5. Piston Max. operating pressure: 9 kg/cm’
Normal operating pressure: 8.3 kg/cm2
2. Master cylinder
Fluid used: Engine oil (SAEl OW)
Effective area: 12.6 cm2
Delivery oil quantity: 120 cc
(at stroke 97 mm)
Max. operating pressure: 207 kg/cm2
Normal operating pressure: 200 kg/cm2
1O-72
. REAR
569F207
1. Piston 1. Air cylinder

2. Push rod Fluid used: Air
3. Air cylinder Effective area: 314 cm2
4. Master cylinder Stroke: 100 mm
5. Piston Max. operating pressure: 9 kg/cm2
6. Ball Normal operating pressure: 8.3 kg/cm2
2. Master cylinder
Fluid used: Engine oil (SAEl OW)
Delivery oil quantity: 480 cc
(at stroke 97 mm)
Max. operating pressure: 51 kg/cm2
Normal operating pressure: 47 kg/cm2
1o-73
PARKING BRAKE CHAMBER
Section A - A
426FO92
1. Spring FUNCTION
2. Piston The air pressure from the parking brake valve
3. Cylinder pushes the spring (1) and compresses it to
4. Boot release the parking brake.
5. Rod Usually the parking brake is kept applied by
spring (l), so the machine is prevented from
moving.
1 o-74
SLACK ADJUSTER
//I \
10 9 8 7
D C
I I
A- _B
Structure of circuit
561 FO3070
1. Body A: To brake piston OUTLINE

2. Cylinder B: To brake piston l The slack adjuster is installed in the circuit
3. Piston C: From brake chamber between the brake chamber and brake piston.
4. Spring D: From brake chamber l The slack adjuster controls the return stroke
5. Bleeder of the brake piston (by controlling the amount
6. Cover of return oil), and provides a movement with
7. Spring a constant time lag for the brakes, regardless
8. Cap of whether the disc brakes are new or worn.
9. Valve
10. Seat
Specification
Replacement oil volume: 231.2 cc (each side)
Stroke: 46 mm
Normal pressure: 53 kg/cm2
Max. available pressure: 65 kg/cm2
1o-75
FUNCTION
S D 5
1. When the brake pedal is depressed:
The oil discharged from the brake chamber
flows into each cylinder, causing piston (4)
to move by stroke S. Thereby, the oil
equivalent to stroke S flows into the brake.
At this time, no clearance exists between
the brake piston and discs, and the braking
force does not occur. When the oil pressure,
in the chamber exceeds the specified
pressure. Poppet valve (5) opens, allowing
the oil to flow through the pilot-operated
circuit. Thereby, the oil pressure is imposed
on brake piston, creating the brake force.
From brake chamber
F567CH064A
2. When the brake pedal is released:

When the brake is released, the back
pressure is imposed on the brake piston by
the brake cooling oil pressure, causing a
returning pressure to occur between the
adjuster and the brake chamber. Thereby, B
the piston (4) is moved back by stroke S and z
the clearance between the disc and the :rom bl .ake g
brake piston is kept at a dimension equi-
valent to the adjuster volume.
\\ ,
0
To brake chamber
F567CH066A
3. Adjuster function:
(When the brake piston volume is larger than
the adjuster volume.) When the brake pedal
is depressed, oil in a volume equal to stroke
S will be discharged by piston (4). The oil
equal to the shortage in the brake piston
volume will be. supplied through poppet
valve, creating pressure in the brake
chamber. Consequently, the braking effect
will be the same as when the brake piston
volume and the adjuster volume are equal.
0 Ic_,
From brake chamber
F567CH065A
1 O-76
8
HYDRAULIC PIPING
(Steering and hoist, and brake cooling)
1. Hydraulic pump (SAR4-285+285)

(for brake cooling)
2. Hydraulic pump (SAR4-180+180)
(for steering and hoist)
3. Brake cooling oil control valve (BCV)
4. Rear brake (retarder)
5. Hoist cylinder
6. Hoist valve
7. Hydraulic oil and brake cooling oil tank
8. Demand valve
9. Steering valve
10. Crossover relief valve
11. Brake oil cooler
12. Steering cylinder
13. Work equipment oil cooler
561 FO3073
1o-77
HYDRAULIC CIRCUIT DIAGRAM
(Steering and hoist, and brake cooling)
--- '18
12.
r
I I
1.27 kg/cm*
14 _L- J
561 F03074A
1. Steering and hoist circuit 11. Hoist cylinder

2. Brake cooling circuit 12. Oil cooler
3. Hydrualic pump (SAR4-180fl80) 13. Oil filter
4. Emergency steering pump 14. Hydraulic oil tank
5. Demand valve 15. Hydraulic pump (SAR4-285+285)
6. Steering valve 16. Brake
7. Clossover relief valve 17. Oil cooler
8. Steering cylinder 18. Brake cooling oil control valve
9. Hoist valve 19. Oil filter
10. Slow return valve 20. Brake cooling oil tank
DUMP BODY CONTROL
8
z
Lo
0
561 FO3075
1. Rod OUTLINE
2. Cable (for hoist control) The hoist control lever and hoist control valve
3. Hoist control lever are connected by a mechanical control system
4. Hoist valve consisting of a push-pull cable.
5. Body positioner This control system is equipped with a body
6. Cable (for body positioner) positioner, so when the body is rising, the
7. Hoist cylinder positioner is automatically actuated when the
body reaches the position set for the positioner.
1o-79
HYDR,AULIC TANK AND BRAKE COOLING OIL TANK
Section A - A
I!
Section 6 - B Section C - C
1. Filter element
2. Bypass valve
3. Oil filter
4. Sight gauge
5. Sight gauge
6. Brake cooling oil tank
7. Drain valve
8. Drain valve
9. Hydraulic tank
10. Breather
View Z
561 FO3076
1O-80
HYDRAULIC PUMP
l STEERING AND HOIST
l BRAKE COOLING
Section A - A
F56103010
1. Drive gear .(No. of teeth: 17) Specifications

2. Front cover Steering and hoist
3. Gear case Type: SAR4-180+180
4. Rear cover Theoretical delivery: 182.5 -I- 182.5 cc/rev
5. Front cover Delivery pressure: 210 kg/cm2 (max.)
6. Drive gear (No. of teeth: 17) Max. speed: 2000 rpm
7. Gear case Brake cooling
8. Rear cover Type: SAR4-285+285
9. Driven gear (No. of teeth: 17) Theoretical delivery: 287.4+287.4 cc/rev
10. Driven gear (No. of teeth: 17) Delivery pressure: 30 kg/cm2
Max. speed: 2000 rpm
1O-81
BRAKE COOLING OIL CONTROL VALVE (BCV)
S A P B
Section X - X
561 FO3077
1. Pilot relief valve assembly FUNCTION

2. Body When the retarder is not being used, this valve
3. Solenoid valve bypasses part of the brake cooling oil to reduce
4. Main valve spool the power loss when traveling. The main valve
spool is actuated by switching the solenoid valve
A: Pilot port ON/OFF.
6: Pilot port If any abnormal pressure is generated in the
s: To tank hydrauliccircuit, the pilot relief valve isactuated,
P: Pilot port and this actuates the main relief valve, so the
0: From pump brake cooling valve also acts as an unload valve.
R: To tank
1O-82
STEERING VALVE
Section B- B
Section C-C
Section D- D
R LT
561 FO3078
1. Input shaft 9. Torsion bar P: From demand valve

2. Upper cover 10. Link R: To tank
3. Valve spool 11. Sleeve LT: To steering cylinder
4. Housing 12. Rotor RT: To steering cylinder
5. Ball 13. Manifold LS: To demand valve
6. Stator 14. Commutator
7. Lower valve 15. Orifice
8. Ball
1O-83
OPERATION
1. When at neutral
561F :03079
l The oil from the pump passes through the

demand valve and enters port P of the steering
valve.
l Valve spool (3) is at the neutral position, so
port P and the ports (RT and LT) to the cylinder
are closed. No oil flows to the cylinder, so
the cylinder does not move.
l At the same time, port LS is connected
through port R to the tank. As a result, there
is no oil pressure at port LS, so all the oil
from the pump at the demand valve flows to
the hoist valve.
1 O-84
2. When turning right
561 FO3080
l When the steering wheel is turned (to the In this way, the two cylinders are actuated
right), input shaft (1) rotates. When this and the wheels turn to the right.
happens, valve spool (3) moves down. The oil returning from the steering cylinder
(Input shaft (1) has a spiral groove in which flows from port LT through port E and port
ball (8) moves, so when input shaft (1) rotates, R and goes back to the tank.
torsion bar (9) is twisted, and ball (8) moves At the same time, the oil pressure at port P
up or down to move valve spool (3).) is restricted by valve spool (3) and passes
The oil from the demand valve flows from port through port A, so a lower oil pressure-(the
P through port A and port G and goes to port drop in pressure (pressure difference) differs
F. to according to the area of the opening of
The oil at port F then passes between stator the spool) than the pressure at port P is
(6) and rotor (12) in the metering portion. applied to port LS.
After the amount of oil flowing to the steering The demand spool is actuated by the differ-
cylinder is measured here, it enters the inside ence in pressure between the oil pressure
of valve spool (3), passes through hole “a” at port P end and the oil pressure at the port
in the valve spool through port RT and flows LS end. As a result, only the necessary
to the steering cylinder. amount of oil flows to the steering circuit,
and remaining oil flows from the demand
valve to the hoist valve.
1 O-85
3. When turning left
561 FO3081
When the steering wheel is turned (to the The oil returning from the steering cylinder
left), input shaft (1) rotates. When this flows from port RT through port D and port
happens, valve spool (3) moves up. R and goes back to the tank.
The oil from the demand valve flows from port At the same time, the oil pressure at port P
P enters port B, passes through hole “a” in is restricted by valve spool (3), so a lower oil
valve spool (3), and enters the inside of the pressure than the pressure at port Pis applied
valve spool. to port LS.
The oil inside valve spool (3) passes between The demand spool is actuated by the differ-
stator (6) and rotor (12) in the metering ence in pressure between the oil pressure
portion. at port P end and the oil pressure at the port
After the amount of oil flowing to the steering LS end. As a result, only the necessary
cylinder is measured here, it flows to port F. amount of oil flows to the steering circuit,
The oil at port F passes through port LT and and remaining oil flows from the demand
flows to the steering cylinder. valve to the hoist circuit.
In this way, the two cylinders are actuated
and the wheels turn to the left.
1O-86
CROSSOVER RELIEF VALVE
PA
A1 Bl
-- --
PA
Pf3
t-L__
A2 B2
\ \
A2 B2
561 FO3087 ’
1. Relief valve FUNCTION

2. Body When external force causes abnormal pressure
in the hydraulic circuit for the steering cylinder,
Al :To steering cylinder the crossover relief valve relieves the hydraulic
A2:To steering cylinder pressure.
Bl :To steering cylinder
B2: To steering cylinder
PA: From steering valve
PB: From steering valve
1O-87
View V
561 FO3082
1. Plug FUNCTION
2. Relief valve The deamnd valve acts to divide the oil sent
3. Spring from the steering pump and the hoist pump
4. Demand spool for the work equipment, and sends it to the
5. Check valve steering circuit and hoist circuit according to
the pressure signal from the steering valve.
A: To steering valve The demand valve is a load sensing type and
B: To tank is controled the steering valve according to
C: Emergency steering pump port the operation of the steering. In other words,
D: To hoist valve if the steering is not being operated (when
E: From steering valve (LS port) no oil is needed in the steering circuit), the
demand valve sends all the oil from the pump
to the hoist valve. When the steering circuit
is operated, the amount of oil needed for
steering is sent to the steering circuit, and
the rest is sent to the hoist valve. In this way,
the hydraulic power loss in the steering circuit
is reduced.
1O-88
Section X - X
Section Y - Y
Section 2 - 2
561 FO3083
1 O-89
OPERATION OF DEMAND VALVE
1. When steering valve is at neutral.

The oil from the steering pump enters port
A. At the same time, the oil from the hoist
pump enters port B. When the steering valve
is at neutral, port P of the steering valve
is closed, so the pressure at port P rises.
The pressure from port P passes through
orifice “a”, enters the chamber C,and moves
spool (4) to the right.
Port LS and chamber D are connected to
the tank, and the force moving spool (4) to
the left is only the force of spool return spring
(3). The pressure in chamber C rises until
it overcomes the set pressure of spool return
spring (3). As a result, spool (4) stops in the
position shown in the diagram on the right,
and all the oil from the steering pump and
hoist pump flows to the hoist valve.
561 FO3084
2. When steering valve is operated.

When the steering is operated, port P and
port LS are connected, and the circuit
between the tank and port LS is shut off.
The hydraulic pressure before entering the
orifice of the steering valve acts on chamber
C of spool (4), and the hydraulic pressure
coming out from the orifice acts on chamber
D.
There is a difference in the area of the
opening of the steering valve orifice when
the steering is turned quickly and when it
is turned slowly. Therefore, the hydraulic
pressure on both sides of the orifice also
changes and a pressure difference is
created. In this way, spool (4) is actuated
by the balance of the force of return spring
(3) and the differential pressure between
both sides of the orifice. In other words, it
moves according to the balance of the oil
in chamber C pushing to the right, and the
force of the oil in chamber D pushing to the
left + return spring (3). The larger the
difference in pressure at the orifice is, the
more spool (4) moves to the right.
1O-90
(I) When steering wheel is operated quickly.
The area of the opening of the steering valve
orifice is large, so the difference in pressure
between the two sides of the orifice is small.
As a result, spool (4) only moves a short
distance to the right, and all the oil from
the steering pump together with some of the
oil from the hoist pump passes through
check valve (5) and flows to the steering
valve to provide a large amount of oil to the
steering valve.
561 FO3085
(2) When steering wheel is operated slowly.

The area of the opening of the steering valve
orifice is small, so the difference in pressure
between the two sides of the orifice is large.
As a result, the movement to the right
increases, and all some of the oil from the
steering pump flows to the steering valve.
The remaining oil from the steering pump
and all the oil from the hoist pump flows
to the hoist valve.
561 FO3086
10-91
HOIST VALVE
/ \
C E
View V
561 FO3088
1 O-92
1’ 2 ‘3 ‘4 6
Section X - X Section Y - Y
Section Z - Z
Section W - W
561 FO3089
1. Body 6. Shaft A: To drain

2. Spool 7. Lever B: To tank
3. Check valve 8. Relief valve C: From demand valve
4. Spring 9. Housing D: To hoist cylinder (head end)
5. Detent E: To hoist cylinder (bottom end)
1 o-93
STEERING CYLINDER
561 FO3090
1. Head
2. Cylinder
3. Rod
4. Piston
5. Nut
HOIST CYLINDER
561 FO3091
1. Head
2. Rod
3. Cylinder (No. 2)
4. Cylinder (No. 1)
5. Piston
6. Nut
1 o-94
DUMP B O D Y
561 FO3092
Specification
Capactv
0” Heapid: 53 m3
: Struck: 36 m3
,000 kg
Max. payload: 78
o MAIN FRAME
561 FO3093
I o-95
PRESSURE SWITCH
FUNCTION
If compressed air at a pressure higher than the
specified pressure is applied to piston cup (7),
the piston cup is pushed up, and at the same
time, contact disc (4) is also pushed up.
When this happens, contact plate (8) and contact
disc (4) are separated, so the circuit is opened.
1 2
\ /
1. Cover
2. Contact plate (A)
3. Spring
4. Contact disc
5. Gasket
6. Body
7. Piston cup
8. Contact plate (B) \
8 6
28751 F042
STOP LAMP SWITCH
FUNCTION
When the brake pedal is depressed, air pressure
acts on the switch to light up the lamps.
1. Terminal (A)
2. Terminal (B)
3. Spring
4. Plate
5. Block
6. Diaphragm
7. Body
F28603018
1 o-1 01
HORN VALVE
FUNCTION
When the horn button on the steering wheel
is pressed, the electric circuit is closed and
electricity flows to the coil to form an electro-
magnet that raises the piston.
Compressed air then flows to sound the horn.
1. Coil assembly
2. Core
3. Plunger
4. Filter
5. Terminal
561 FO3097
PARKING BRAKE SWITCH
c!f>
561 FO3098
1. Port FUNCTION
2. Diaphragm If the parking brake is released, the compressed
3. Cover air from the air tank acts on the diaphragm, and
4. Connector closes the contacts of the switch.
10-102
FRONT BRAKE CUT-OFF VALVE
rmJ--EZY
Wiring diagram
561 FO3071
1. Coil cover A. Inlet port FUNCTION

2. Plunger B. Outlet port l This valve is installed in the pilot circuit
3. Coil assembly C. Exhaust port between the brake valve and relay valve. It
4. Core is used to cancel the actuation of the front
5. Rod brake according to the travel conditions.
6. Body When the front brake OFF switch in the
7. Connector operator’s compartment is pressed, current
8. Valve body flows in the coil of the solenoid valve, and
9. Valve the solenoid valve is actuated. When this
10. Spring happens, the circuit from the brake valve to
the front brake relay valve is shut off, and
the front brake is released.
10-102-l
0
AUTOMATIC RETARDER VALVE
EXHAUST BRAKE VALVE
Q 8
B 0
0
8
561 FO3072
1. Core A: Input port FUNCTION

2. Coil assembly B: Output port The input port and output port are connected
3. Spring C: Exhaust port by passing electricity through the coil of the
4. Plunger solenoid valve. When this happens, the auto
5. Valve seat retarder or exhaust brake is applied.
6. Rod
7. Valve
8. Spring
9. Body
10. Connector
10-103
0
TILT SWITCH
I-P
1
2
561 FO3096
g
z
s
1. Magnet FUNCTION
2. Plate When the chassis tilts to the left or right, the
3. Gasket disc-shaped margnet moves to the left or right.
4. Print card If the tilt angle exceeds the danger limit, either
5. Bracket the left or right switch is turned OFF, a lamp
6. Plate lights up, and the buzzer sounds to warn of
7. Plate danger.
8. Plate
9. Connector
10-104
AIR CONDITIONER
PIPING DIAGRAM
1. Compressor Function
2. Condenser l The air conditioner makes a pleasant oper-
3. Hot water return port ating environment for the operator and acts
4. Hot water take-off port to reduce fatigue.
5. Receiver dryer Heating
6. Pressure switch l Heating is carried out using the cooling water
7. Air conditioner unit from the engine.
8. Vent High-temperature cooling water from the hot
water take-off port flows to the air conditioner
unit, and hot air is blown out by a fan.
When the temperature of the cooling water
drops, it is returned to the hot water return
port and flows as cooling water for the engine.
Cooling
l The refrigerant gas compressed and pressur-
ized by the air conditioner compressor enters
the air conditioner condenser where it is
cooled by dissipating the heat. It then enters
the air conditioner unit and cold air is blown
out by the fan. When the temperature of the
refrigerant gas rises, it is returned to the
compressor.
1 o-1 04-l
0
ELECTRICAL CIRCUIT DIAGRAM
Control lever Ass’v Air conditioner unit

r-
BT3
Fuse box z
rl
Relay
Q
L.P.S H.P.S
Blower
I II
motor
II I
I I & I I
I I I
I 2
I_ , I
LB
.._
ACI R
L ,
,z 13’ VP I
I
56lFO3100
T:
REFRIGERANT CIRCUIT DIAGRAM
r Condenser
Pressure switch
Air conditioner
indor unit
Receiver dryer
561 FO3101
lo- 104-2
a
CONDENSER
1 2
1. Fin
2. Tube
A. Refrigerant
gas inlet port
B. Refrigerant
gas outlet port
561FO3103
COMPRESSOR
1. Clutch
2. Case
A. Suction service
vavle
B. Discharge service
valve
A B
Specifications
Type: Piston type, 2-cylinder
561FO3104
1 o-1 04-3
0
ENGINE CONTROL SYSTEM (Mechanical governor type)
F56103013
1. Servo cylinder ONTLINE

2. Torque converter Engine speed control
3. Hydraulic hose The accelerator pedal and fuel injection pump
4. Accelerator pedal lever for the engine are connected by a
5. Accelerator sensor linkage. There is a servo cylinder installed
6. AISS motor between the accelerator pedal and the fuel
7. Engine stop motor injection pump lever, and this reduces the
operating force of the accelerator pedal.
AISS (Automatic Idling Setting System)

l This switches the engine low idling speed
manually or automatically between low speed
and high speed according to the condition of
the machine.
With this device, use of the low speed reduces
the fuel consumption and noise, while use
of the high speed improves the starting and
acceleration, and also improves the exhaust
gas.
1 o-105
0
AISS motor
AISS switch
AISS connecter witch table
Engine water
temperature
Se”SOr
Batwry relay
Hold relay
9
‘3’qI6 CNJOI
Pilot lamp
AISS relay
Diodo 1q):v
Re erder switch
F56103014
TIM 011pan
J
TIC: Torque converter
T/M, Transmission F56103015
10-106
SERVO CYLINDER
The servo cylinder is in the m.iddle of the engine

control linkage, and reduces the operating force
for the accelerator pedal.
The servo cylinder is actuated by the hydraulic
pressure in the transmission circuit.
i 2
1. Rod 4. Body A: Supply port
F56A02007
2. Cover 5. Piston B: Drain port
3. Spring 6. Piston rod
1 5 C D E
OPERATION
g
z
:: 1. Accelerator pedal depressed
When the accelerator pedal is depressed,
rod (1) moves to the left.
When rod (1) moves, chamber C and
chamber E are connected by port D. F56A02008
The oil (hydraulic pressure: 30 - 40 kg/cm*)
from the transmission enters port E and
moves piston (5) to the left. (Follows up)
2. Balanced condition
When rod (1) moves to the left, hydraulic
pressure also moves piston (5) to the left.
When rod (1) is stopped in any position,
piston (5) moves to the position where port
D closes, and piston (5) also stops.
F56A02009
3. Accelerator pedal released

When the accelerator pedal is released, rod
(1) moves to the right.
When rod (1) moves to the right, chamber
E and chamber F of the drain circuit are
connected by port D.
Piston (5) is pushed back to the right by the
force of spring (3), and moves to a position
where port D closes.
F56A02010
1 O-107
OUTLINE Conditions for setting high speed and low speed

This system switches the engine low idling
speed manually or automatically between low
speed and high speed according to the condition
of the machine.
Set speeds for idling

Low speed: 600 rpm Engine water temperature
High speed: 1000 rpm over 42°C (water temper-
Automatic
ature sensor ON) and I I
below 42’C (water temper Automatic

~
Retarder lever not

operated
IAufomatic 1
OPERATION s
Set to high speed
When AISS motor (1) enters the set conditions
for high speed idling, cable (2) is pulled in. When
this happens, bolt (4) of lever (3) pushes lever
(5) down.
As a result, accelerator pedal (6) is slightly
depressed, and the idling speed increases.
F56103016
Set to low speed

When AISS motor (1) enters the set conditions
for low speed idling, cable (2) is pushed out.
When this happens, lever (3) and lever (5)
become free, and the idling speed decreases.
F56103017
lo-108
ENGINE CONTROL SYSTEM (Electronic governor type)
SYSTEM DIAGRAM
Monitor panel
Y-0 8
*rC:IgnL
Starting signal
L
Rack position signal (R.L)

Engine controller
Mode
0” selection signal
I
0
r
il
00 Engine
speed signal A
I
Selfdiagnostic
display
Engine speed signal B
Accelerator sensor
AISS signa
Variable pre-stroke m
Electronic
governor
I --El
EP
I I
i!zi ISS t, Retarder signal 1@ 1
561 FO3105-1
OUTLINE
l A fuel injection pump with electronic gover- l The system has an AISS function that sets
nor is used. the low idling speed manually or automat-
* The engine controller receives signals from ically to two levels (low speed and high speed)
the sensors and switches, and sends the in accordance with the condition of the
control signal to the governor solenoid and machine.
pre-stroke solenoid (proportional solenoid).
1 O-l 08-l
0
561FO3106-1
1 O-l 08-2
FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR
STRUCTURAL DIAGRAM
6215FO76
1. Delivery valve FUNCTION

2. Plunger barrel After the governor actuation pressure is
3. Plunger adjusted by the hydraulic control valve in
_
4. Hydraulic piston accordance with the command trom the
5. Hydraulic control valve (quantity adjustment) engine controller, it acts on the piston at the
6. Hydraulic control valve rear of the rack and moves the control rack
(injection timing adjustment) to adjust the fuel injection amount.
7. Gear pump (as seen from rear, The fuel injection timing is adjusted by
left: oil, right: fuel) changing the length of the injection pump
8. Center bearing plunger.
9. Cam shaft The plunger is formed of two parts, and by
10. Roller sending electronically controlled hydraulic
11. Tappet pressure between these two parts, the length
12. Pump housing is changed to adjust the pre-stroke.
13. Tappet guide The governor solenoid and pre-stroke sole-
14. Spring nut noid are proportional solenoids, and they
convert the input current from the controller
into propulsion. This propulsion controls the
spool of the hydraulic control valves (two
valves: one for the governor and the other
for the injection timing adjustment), and
converts the input current into hydraulic
power.
10-108-3
0
--
Mechanism of plunger barrel
Jariable pre-stroke
No.1
No.5 Control rack
No.6
To engine oil pan

561 FO3108
Outline
l The AISS is a system that changes the engine
low idling speed to low speed or high speed
manually or automatically in accordance with
the condition of the machine.
In this way it is possible to reduce fuel
consumption and to improve the starting and
acceleration performance.
Idling speed settings
Low speed: 600 rpm
High speed: 1000 rpm
High/low speed setting conditions
Method of High/low
Conditions operation speed
Set to low position Manual
Engine water temperature 50°C or above (water
Automatic
temperature sensor ON) and parking brake actuated Low speed
Engine water temperature 50°C or above (water
Automatic
temperature sensor ON) and retarder lever actuated
Engine water temperature 50°C or below
Automatic
(water temperature sensor OFF)
High speed
Parking brake released 1Automatic
Retarder lever not actuated Automatic
1 O-l 08-4
0
ENGINE CONTROLLER
1. Case FUNCTION
2. Print board l The engine controller receives signals from
3. Self-diagnostic display window the sensors and switches installed on the
machine, such as the accelerator sensor,
power mode selector switch, and AISS
switch. It then outputs signals that control
the engine injection pump.
The controller has a self-diagnostic function,
and it displays abnormalities by a combination
of two LEDs (ON, flashing, OFF).
SENSORS, SWITCHES
ACCELERATOR SENSOR
For details, see the section on the automatic
shift control system.
ENGINE SPEED SENSOR

For details, see the section on the electronic
monitor system.
1 O-l 08-5
0
EXHAUST BRAKE
SYSTEM DIAGRAM
F56103645
1. Exhaust brake 9. Exhaust brake OUTLINE

switch switch The exhaust brake shuts off the exhaust pipe
2. Toque converter 10. Brake valve at the exhaust brake cylinder and makes the
lock-up valve 11. Accelerator sensor engine exhaust stroke act as an air compressor
3. Brake switch 12. Pilot lamp to increase the effect of the braking force of
4. Reterder switch 13. Reterder control the engine. The exhaust brake is also used as
5. Exhaust brake lever a retarder when traveling downhill. The exhaust
solenoid valve 14. Exhaust brake brake is actuated by a signal the trans-
from
6. Transmission cylinder mission controller, when the
and acts as follows
controller 15. Battery relay exhaust brake switch in the operator’s compart-
7. Relay 16. Battery ment is turned ON or OFF.
8. Engine controller
ON position: Actuated when the accelerator
pedal is released (but only when
the torque converter is in the lock-
up condition)
OFF position: Actuated when the foot brake or
retarder brake are operated (but
only when the torque converter is
in the lock-up condition)
1 O-l 08-6
@I
SYSTEM CIRCUIT DIAGRAM
Battery
r
Exhaust Rear -. _-
brake brake
bode
I
E
I I
F56103646
1 O-l 08-7
8
OPERATION
Transmissidn
Exhaust brake ON r-- controller
When the drive current flows from the trans-
mission controller to the solenoid valve, the
solenoid valve is actuated. When this happens,
the port from the air tank to the exhaust brake
cylinder is opened, and compressed air flows
from the air tank. The compressed air acts to
make the exhaust brake cylinder shut off the
exhaust pipe, and the exhaust brake is actuated.
Air tank
F56103647
Exhaust brake OFF

When the flow of drive current from the
transmission controller to the solenoid valve is
shut off, the solenoid valve closes the port from
the air tank to the exhaust brake cylinder, and
at the same time opens the port from the exhaust
brake cylinder to the exhaust.
F56103648
1o-1 08-8
@
AUTOMATIC SHIFT CONTROL SYSTEM
(Transmission control system with individual electronically
controlled modulation system)
SYSTEM DIAGRAM
Transmission
shift controller
Engine speed signal
1 561FO3112
OUTLINE
The automatic shift control system receives the In this way, the initial pressure for each clutch,
shift lever position signal, accelerator pedal build-up ratio, and torque-off time are controlled
acceleration signal, transmission speed signal, to match the conditions of the machine-(the
and signals from other switches and sensors hydraulic wave pattern for each clutch, each
are received, and the shift controller acts to acceleration angle, each shift up, and each shift
automatically control the shift of the transmis- down are changed). As a result, it contributes
sion to the optimum speed range. The shift to the reduction of shock when shifting gears,
controller also drives and controls the torque prevention of shift hunting, and improvement
converter lockup solenoid and overrun preven- in the durability of the clutches.
tion solenoid valve in addition to the shift control.
Each clutch in the transmission is equipped with
an electronically controlled modulation valve,
and each clutch is independently controlled.
1o-1 09
TRANSMISSION CONTROLLER
i
0
1. Self-diagnostic display area

0 C 2. Connector
0
3. Case
4. Print board
II r n lr n
di 561FO3120
OUTLINE
This transmission controller controls the system 5. Speed sensors are installed at three places
and has a built in computer. (on the transmission input shaft, interme- o
0
It possesses the following functions and diate shaft, and output shaft). These can
z
features. detect if the transmission clutch is slipping,
??
and they also act to protect the transmission
1. It has a high-power mode and economy when there is some abnormality in the
mode, and the gear shifting pattern can be hydraulic system.
selected. (This function is available only on
engines with an electronic governor. For 6. It has a self-diagnostic function that is
engines with a mechanical governor, only divided up for both the input and output
the high-power mode is available.) systems.
2. In the high-power mode, it has an accel- 7. The content of the self-diagnostic test is
eration sensing shift point function that displayed in a two-digit code.
changes the shift-up point according to the
acceleration of the machine when the 8. The content of the self-diagnostic test is
accelerator is depressed fully. stored in the memory, so it is possible to
check the content of the failure even after
3. In the braking mode, the mode where the the main switch is turned off.
brake is used, the gear shifting point is raised
and the speed of the retarder cooling pump 9. If there are any failures, they are displayed
is increased to increase the cooling effect in the monitor panel or on the shift indicator.
on the retarder. At the same time, it also
10. An escape function is provided for use if
improves the effect of using the engine as
there is any failure in the electrical system.
a brake.
11. It is positioned separately from the shift

4. It drives and controls the torque converter
lever.
lockup solenoid valve, overrun prevention
solenoid valve, and exhaust brake solenoid
valve.
10-l 10
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES
The automatic gear shifting ranges for each

Mode Setting conditions
position of the gear shift lever are as shown
in the table below. When either of the following
conditions are satisfied.
Braking 1. Rear brake signal ON
mode (foot brake, retarder, or
emergency brake applied)
2. Accelerator pedal released.
When the following three condi-

tions are satisfied.
1. Rear brake signal OFF
High-power
(foot brake, retarder, or
mode
emergency brake not applied)
t i i i i i I 2. Accelerator pedal depressed.

3. Economy mode switch OFF
When the following three condi-

tions are satisfied.
1. Rear brake signal OFF
Economy
(foot brake, retarder, or
mode emergency brake not applied)
2. Accelerator pedal depressed.
3. Economy mode switch ON
Braking mode:
The shift-down point and shift-up point are both
raised, and the engine speed is kept higher to
3 -
ON c ensure the amount of oil for retarder cooling,
and to increase the effect of using the engine
as a brake.
High-power mode:
This mode is aimed at providing maximum
production by using the machines power to its
Characteristics of gear shifting utmost limit. However, when the machine load
The shifting up or down of the transmission is is light (high acceleration), such as when the
carried out according to the shift map stored machine is traveling empty, the machine
in the memory of the controller. acceleration is detected and the gear is shifted
There are three types of shift map according up early to improve the acceleration. It uses an
to the condition of the input signals (for acceleration sensing shift point to improve fuel
machines mounting an engine with mechanical consumption, noise, and shock when shifting
governor, there are two types, excluding gear.
economy mode). The settings for each mode are
as shown in the following table. Economy mode:
When the machine is being used under light
load, such as when traveling empty or when
traveling on flat ground, the shift-up point and
shift-down point are made lower to keep the
engine speed low, thereby improving fuel
consumption, noise, and shock when shifting
gear. In this mode, the engine output is kept
to 85% of the maximum engine output.
10-111
Automatic gear shifting line graph Automatic shifting method
The automatic shift-up/shift-down points, (1) Shift lever D position
torque converter lockup ON/OFF points and auto When shifting up (when in high-power
brake ON/OFF points are as shown in table mode)
below. 0 If the shift lever is placed in the D
Auto Auto position, the transmission will enter the
Shift brake Shift g;ke
down OFF “p F2 torque converter range.
ii) When the accelerator pedal is depress-
ed, the engine speed will rise, and when
the transmission input shaft speed
reaches 1500 rpm, the lockup clutch is
engaged to connect the torque converter
directly and provide direct travel.
iii) When the speed goes up further to 2230
rpm (2100 rpm for high acceleration), the
transmission is shifted up to F3. At the
shift-up point, the lockup clutch ‘is
automatically disengaged momentarily
to reduce any shock when shifting gears.
iv) Immediately after shift up, the engine
speed drops, but if the load is small, the
engine speed rises again. The situation
in item ii) is repeated and the transmis-
sion is shifted up in turn from F4 up to
F7. (Shift-up point for F5-F7 are only g
Transmission input shaft speedbpm) 2230 rpm)
z
561F03121-1A
0
When shifting down (when in high-power
mode)
Note:
1. In economy mode, the shift-up point from i) When the load is increased and the
Fl to F2 is 1850 rpm. engine speed drops below 1500 rpm, the
2. In economy mode, the shift-down point from transmission is shifted down one gear.
F2 to Fl is 1200 rpm. (For example, when traveling in F6, the
3. In high-power mode, the shift-down point transmission shift down to F5)
from F2 to Fl is 1400 rpm. ii) If the load increases further, the trans-
4. In high-power mode, the shift-up point from mission shifts down in turn to F2, and
Fl to F2, F2 to F3, F3 to F4 at high when the input shaft speed drops to
acceleration is 2100 rpm. 1200 rpm when the transmission is in
5. Lockup F2, the torque converter lockup clutch
When traveling only in reverse, the lockup is disengaged and the transmission
is not actuated. changes to torque converter drive.
When coasting and decelerating (accel- * The above explanation gives a general
erator pedal released, and brake not outline of gear shifting. However, the
operated), for positions to F4, the lockup set speed and actuation may differ
stays ON and for F3 and below, the lockup according to the travel conditions, so
stays OFF. for details, see the Automatic Gear-
When machine starts down-hill with shifting Line Graph.
accelerator pedal is released, the lockup
is not actuated until accelerator pedal is
depressed or brake pedal is depressed.
1o-ii12
(2) Shift lever at 5, 4, 3, or L position Safety functions
These positions give an automatic shift 1) Down-shift inhibitor function
range from Fl to F5 (F4, F3, or F2).The When the gear shift lever is operated during
method for automatic shifting is the same travel from D to 5 - L, from 5 to 3 - L,
as when the shift lever is at the D position. from 4 to L, or from 3 to L:
(3) Shift lever at R position For example, when traveling at position D
This is the position for traveling in reverse. (F7), and the shift lever is moved to position
The lockup is not actuated. 5, the transmission is not shifted directly
The safety functions when traveling in from F7 to F5. It is shifted down F7 to F6
reverse are the FORWARD/REVERSE to F5 in turn according to the engin speed.
inhibit and REVERSE safety, and if the (The (engine overrun, prevention circuit
operation is not correct, the transmission is prevents the transmission from shifting
held in neutral. down two gears at a time when the operator
shifts down too far by mistake.)
(4) Shift lever at N position
This is the neutral position. None of the 2) Neutral safety function
clutches in the transmission are actuated. If the shift lever is in any position other than
N, this circuit prevents the engine from
starting even when the key switch is turned
Gearshifting time lag to the START position.
In the automatic shift range, to prevent any (The safety circuit prevents the machine
misoperation caused by excessive change in the from moving off by mistake when the engine
rotating speed when shifting gear, there is a is started.)
gearshifting time lag, and the transmission will 3) FORWARD/REVERSE inhibitor function
not shift during this time. When the machine is traveling forward at
The length of the gearshifting time lag is more than 4 km/h, the transmission will not
%
z controlled by the individual electronically enter REVERSE ‘even if the shift lever is
8 controlled modulation system, which controls placed in the R position by mistake.
each gearshifting pattern in fine detail. (This improves durability and reliability by
The following table gives an outline of the preventing any excess load on the power
gearshifting pattern and the gearshifting time train.)
lag. 4) Rear brake function for power train overrun
prevention
When the engine speed goes above 2600
Gearshifting Gearshifting Example of gearshifting
time lag rpm, the rear brake is automatically
pattern (m: Gearshifting time lag)
(set) actuated.
(This improves durability and reliability by
Shift up F3+F4 F4+ F5 preventing overrun of the engine, torque
0.5-1.3
+ Shift up
(short) converter and transmission.)
5) REVERSE safety
The machine will not travel in reverse when
the dump body is in any position other than
FLOAT.
(This prevents the machine from reversing
over a cliff by mistake.)
F4+F5
SHIFT LEVER SWITCH
View Z
Section A - A 561 FO3119
1. Lever FUNCTION
2. Detent When the operator moves the lever to select
3. Lock button the travel conditions, such as FORWARD or
4. Screening plate REVERSE, electric signal is sent to the shift
5. Photo interruptor controller (AESC). The lever position is displayed
on the indicator (with night lighting) to the left
of the shift lever.
For machines with monitor panel, the shift
position is also displayed on the monitor panel.
In addition, to prevent mistaken operation, the
gear shift lever is fitted with a lock button.
10-l 14
SENSORS, SWITCHES
TRANSMISSION SPEED SENSOR
cz@
i 2 B 561FO3114
1. Connector FUNCTION
2. Flange This speed sensor is installed to the input,
3. Sensor intermediate, and output gears of the transmis-
sion. It generates a pulse voltage according to
the speed of the gear teeth and sends the signal
to the controller and monitor panel.
TRANSMISSION OIL TEMPERATURE

SENSOR
561FO3115
1. Thermistor FUNCTION
2. Body This sensor is installed to the transmission filter,
3. Connector and the change in temperature is taken as a
change in resistance in the thermistor, and the
signal is sent to the shift controller.
10-l 15
FILL SWITCH
561 F03116
1. Terminal FUNCTION
2. Case This switch is installed to the side face at the
3. Nut flow sensor valve end of the ECMV. When the
4. Connector clutch is engaged, the end face of the spool
contacts the terminal of the switch and turns
the switch ON. The fill completed signal is then
sent to the shift controller.
ACCELERATOR SENSOR
L I
Low idling Full

Output characteristics
I
7
\ \5 Connecting diagram
6
561FO3117
2. Lever The accelerator sensor is installed at the bottom
3. Body of the operator’s cab, and the accelerator pedal
4. Potentiometer and sensor are connected by a link. When the
5. Coupling accelerator pedal is depressed, the movement
6 Shaft is transmitted through the link to rotate the shaft
7. Stopper of the potentiometer inside the accelerator
sensor, and the resistance value changes. A
certain voltage is impressed between pins (1)
and (3) of the potentiometer, and a voltage signal
corresponding to the amount the accelerator
pedal is depressed is sent to the controller from
No. 2 pin.
lo-116
SHIFT LIMIT SWITCH
MODE SELECTOR SWITCH (For machines with electronic governor)
6
I \ 5
Layout of terminals
Detail of interior
The shift limiter sbitch and mode selector

switch differ only it-i the color of the actuation
display lamp.
Shift limiter switch! Red
Mode selector switch: Green
Circuit Diagram
561FO3118
1. Knob OUTLINE
2. Body Shift limit switch
3. Spring l This switch is installed at the rear of the shift
4. Connector lever switch. When the shift lever is in the
5. Spring D or L range, it controls the speed ranges
6. Spring that are covered by automatic gear shifting.
This switch is very effective if used when
going downhill or when working in jobsites
where there are speed limits.
Mode selector switch

l This switch is installed on the top surface of
the console, and it is used to change the
output characteristics of the engine and the
gear shifting map of the transmission to
match the setting of the course and the
conditions of the jobsite.
10-117
0
SHIFT INDICATOR SYSTEM
(For machine without electronic monitor panel)
SYSTEM DIAGRAM
Central warning
lamp Alarm buzzer
Transmlission controller
Engine controller
Suspension controller
Controller
assembly
Indicator assembly
Sensor Battery
F56103018
OUTLINE
l The shift indicator system processes signals
sent from the transmission solenoid valve (or
fill sensor), shift, engine, or suspension
controllers and various sensors. It then
displays the speed range for the machine and
also displays warnings.
l The shift indicator system consists of the
following: controller assembly, indicator
assembly, various sensors, switches, relays,
warning lamp, alarm buzzer, and power
source.
1 o-1 20
0
SHIFT INDICATOR
c /
F56103019
8
z
8
1. Speed range display OUTLINE
2. Lockup display
3. Check display The shift indicator consists of the controller
[Engine (mechatronics) system abnormality,’ assembly and indicator assembly, and these
Automatic gearshifting (mechatronics) two are joined by a wiring harness.
system abnormality,Suspension (mecha- The controller assembly contains a microcom-
tronics) system abnormality] puter. It processes the signals sent from fill
4. Indicator assembly sensor or etc. and outputs drive signals to
5. Controller assembly the indicator assembly.
6. Wiring harness The indicator assembly uses LEDs for its
display, and it displays the speed range and
other information according to the signals
sent from the controller assembly.
10-121
Sift indicator display
Symbol Display item Display range Display method
When there is abnormal-

Engine (mechatronics) ity in engine (mecha-
tronics) system
When normal, the display is
Automatic gearshifting ~a~t~~~~~~$~s~i~~~~ OFF; when abnormal, it flashes
CHECK and the lamp and buzzer are
(mechatronics)
(mechatronics)system actuated.
When there is abnormal.
Suspention
ity in suspension
(mechatronics)
(mechatronics) system
LOCKUP Lockup When actuated Lights up when actuated.
Shift indicator l-8, R,N Digital display
Controller output
Symbol Display item Display range Display method
Warning input signal A,

External warning A
When abnormal lamp and
Gi buzzer are actuated.
(z;;r$al External warning B when abnormal
(GND level) I
lights )
If abnormal when engine is
When below specified
Engine oil pressure running, lamp and buzzer are
pressure
actuated.
When charging is If abnormal when engine is

Charge
defective. running, lamp is actuated.
10-122
Model selection
The relationship between the speed range HD785-3 is type No. 1 (individual electronically
display on the shift indicator and the combina- controlled modulation), so both A and B for
tion of transmission solenoid valves (or fill model selection give L (connected to chassis
sensor) from model selection input signals A or ground by chassis wiring harness).
B is as shown in the table below.
I No. II , I
2
I I
Individual electronically
F8 type F6 type F7 type
Tra”smissio” tvpe controlled modulation (F7. Rl)
A L H L H
Model selec-
tion input 6
L L H H
Transmission
solenoid valve HLR1234HLRl 23LR123 HLR1234
(or fill sensor)
1
H: OPEN or DC24V
L: GND or Max. DC1.7V
The blanks are all H level.
1 O-l 23
AUTOMATIC EMERGENCY STEERING SYSTEM
SYSTEM DIAGRAM
561FO3122
1. Battery OUTLINE
2. Emergency relay switch If the engine should stop whenthe machine is
3. Timer
traveling, or there is any
abnormality in the
4. Emergency steering switch hydraulic pump and the specified amount of oil
5. Flow switch
does not flow to the steering circuit, the
6. Steering pump emergency system automatically actuates an
7. Check valve
electric pump to ensure the hydraulic pressure
8. Demand valve for the steering, thereby making it possible to
9. Emergency steering pump use the steering.
10. Hydraulic oil tank This system can also be operated manually.
* Same machines have only manual operation.
lo-124
LN.CI
Flow switch
To hoist valve
To steering valve
---
CNDMJ
___--
J 1 .J UJ Parking switch
58
z
HI L---J
Em*
I _._.:*_L
I steeringi
L_.-___ -.i
Relay timer
561FO3123
1 o-1 25
FLOW SWITCH
J--eic%
A A
Lead switch
Y
Structure of
circuit
Section A - A
561 F03124
1. Wire cable OUTLINE

2. Housing The flow switch is a switch for the auto
3. Magnet emergency steering and is installed in the piping
4. Pivot pin of the steering hydraulic circuit. If the flow of
5. Disc oil inside the hydraulic piping drops below the
6. Spring specified level or stops, the flow switch detects
7. Lead switch this and actuates the lead switch.
10-126
OPERATION
l When oil flow is above specified level
Plate (5) is pushed in the direction of the oil
flow by the oil in the piping. When this
pushing force overcomes spring (6), magnet
(3) is moved to the right (pivot pin (4) is taken
as the center of rotation).
When this happens, the contact with the lead
switch is opened and the circuit is switched
OFF.
Q Flow of oil
561 F03125
0”
z
z l When oil flow is below specified level or stops.
The force of the oil in the piping pushing plate
(5) is weaker than spring (6), so magnet (3)
returns to the left.
When this happens, the contact with the lead
switch is closed and the circuit is switched
ON.
T-----J_
561FO3126
IO-127
RELAY TIMER
1. Dial
2. Lock
3. Pin
Set time: 3 seconds
NO NO
Wiring for pins
561 F03127
OUTLINE
The relay timer is a delay timer to prevent the
emergency steering system from being actuated
when the flow switch is actuated mistakenly by
the pulse of the oil or fluttering of the flow
switch.
With this relay timer, the relay points are
switched after electric current is passed through
the coil for the time set by the timer.
lo-128
AUTOMATIC SUSPENSION SYSTEM
STRUCTURE OF SYSTEM
561FO3128
1. Air cylinder OUTLINE

2. Suspension cylinder The front suspension mode (damper force) is
3. Pressure sensor automatically switched according to the travel
4. Solenoid valve condition and load condition to give a more
5. Suspension controller comfortable ride to the operator and to improve
6. Limit switch (Float switch) the travel stability.
7. Steering angle sensor * For details of the mechanical parts related
to the suspension mechanism, see SUS-
PENSION SYSTEM.
10-129
SYSTEM DIAGRAM
Air flow for SUS. control CYL.

0: IN x :OUT
Suspension mode Port

A Port
B PErt
000
I
-lard or Med. 0 Soft 0xX
I
Med. 0 Hard 0 x 0
Self-diagnostic
display Defore
0.5 s x 0 0
Soft 4Hard After

0.5 s 0 x 0
Hard or Soft 0 Med. x 0 0
561 F03129

Tranrmlw
speed
Ien!
561 FO;l30-1
AUTOMATIC SUSPENSION MODE SELECTION CONTROL
With the front suspension, the mode (damping force) is automatically changed according to the
travel conditions and load conditions to ensure a comfortable ride and to improve the travel stability
of the machine. The control patterns and functions of the modes (damping force) are as shown
in the table below.
s: Soft
M: Medium
H: Hard
Control pattern Function Content of control F S

Empty
M
Set mode
H
r
S
Loaded
M H
Internal pressure of front sus-

Distinguishing
empty/loaded
To set damping force
according to load on
pension cylinder is measured 0 0
;;;impared with standard
machine
Anti-roll . To prevent the chassis

from rolling when
This detects the travel speed
md steering angle, and switches
,“\ _
\, ,’ CO
(When
turning at high speed :he mode according to certain turning)
:onditions.
[Not controlled when
traveling empty)
Anti-dive To prevent nose-diving

when braking
The damping force is made
stronger when the brakes are
/- ‘\
L - .O
l-4,
‘_ / -0
Brake bake Brake (Brake
applied. OFF) ON) OFF) ON)
Anti-lift To prevent the front The damping force is made (7

\_a’
-0 LO
from lifting up when stronger when the dump body Float) Other (Other
dumping control lever is at any position than than
except FLOAT. Float) Flaot)
0
High speed To improve stability Detects travel speed and selects
stability when traveling at high damping force. (No control
speed when traveling empty)
Mode
t
,, ___
0 I-
55 60
10-131
SUSPENSION CONTROLLER
561FO3133
1. Self-diagnostic display window FUNCTION

2. Print board This detects the signals from the on-board
3. Connector sensors and switches, and sends a signal to the
4. Connector damping force selector solenoid valve to switch
5. Case the suspension mode.
1O-l 32
SENSORS, SWITCHES
STEERING ANGLE SENSOR
Sensor
561FO3134
1. Body FUNCTION
2. Tube A round disc with teeth like a comb is installed
3. Connector to the steering column, and as this passes
through the slit in the sensor, the sensor outputs
a pulse signal. The suspension controller can
obtain the steering speed from the number of
pulses per unit of time.
Principle of action: Magnetic, non-contact

proximity switch
Form of output: ON when detected body is close.
PRESSURE SENSOR
Sensor
I -
I I \ Structure of circuit
1 2 3 561 F03135
1. Sensor FUNCTION
2. Tube This sensor is installed to the suspension
3. Connector cylinder, and when the input pressure from the
pressure induction portion is impressed on the
diaphragm of the pressure detector, the diaph-
ragm bends. A bridge isformed by a strain gauge
on the other side of this diaphragm, and when
the shape of the diaphragm changes, the
resistance value of the strain gauge changes.
A certain voltage is impressed on the strain
gauge, and the change in the resistance value
of the strain gauge is sent to the amp as a change
in voltage. At the amp, this change in voltage
is amplified and output to the controller as a
change in current.
10-133
PAYLOAD METER
STRUCTURE OF SYSTEM
561 F03136
1. Transmission shift lever OUTLINE

2. Body float detection switch l The dump truck is supported by four suspen-
3. Clinometer sion cylinders. By measuring the total for the
4. Pressure sensor (front left) loads bearing on each cylinder, it is possible
5. Pressure sensor (front right) to know the load on the springs of the
6. Pressure sensor (rear left) machine.
7. Pressure sensor (rear right) The payload can be calculated by subtracting
8. Suspension cylinder the unladen machine weight from the laden
9. Payload meter machine weight.
10. Lamp drive relay The payload meter displays the payload
11. External display lamps calculated above on the panel, and at the
12. Battery same time, its displays the load level using
13. Fuse (for external display lamps) the external display lamps. In addition, the
14. Fuse (for controller) recorded data can be printed out together
with the loading time and number of cycles.
Furthermore, it can also estimate what the
total load will be if one more bucketful is
loaded. The estimate display function makes
the appropriate lamp flash to prevent
overloading.
1o-1 34
0
Front (right) Rear (nght)
suspension cylinder
display lamps
n Angle sensor
* Enernal display lamp colors Rear M)

1.2.3.Green suspension cylind Suspension cylinder
4. YeHOW
5. Red
561FO3137
PAYLOAD METER BLOCK DIAGRAM

I n (Product)
+
Front right w Pavload
pressure sensor
Front left
pressure sensor
Rear right
pressure sensor
Rear left
pressure sensor
Clinometer
Gain adjustment
trimmer
561FO3138
1 o-1 34-1
0
PRINCIPLE OF CALCULATION
1. Outline
The dump truck is supported by four
suspension cylinders. By measuring thetotal
for the loads bearing on each cylinder, it is
possible to know the load on the springs of
the machine.
The payload can be calculated by subtracting
the unladen machine weight from the laden
machine weight.
The load on each cylinder can be calculated 561 F03139
from the cross-sectional area and internal
pressure of the suspension cylinder.
[Load bearing on suspension cylinder]
w = PB se - PT (SB - ST)
Where
W = Load bearing on suspension
cylinder
PB = Bottom pressure
PB
PT = Top pressure
Se = Cross-sectional area of cylinder
ST = Cross-sectional area of rod
Because of the structure of the suspension

cylinder,
PB + PT
Therefore, the load can be calculated as

ST
follows.
W = P&T
PT
561FO3140
lo- 134-2
0
2. Calculation of unladen weight (calibration)
The unladen weight is measured by calcu-
lating the average load when the dump truck
travels unloaded for approx. 30 seconds on
flat level ground at a speed of approx. 10
km/h.
Time
The measurement is carried out while
travbeling because when the machine is
traveling it is possible to cancel the sliding
resistance of the suspension cylinder by
extending and retracting the cylinder give
F582AU003
an average over a period of time.
The measured unladen weight is stored in
the memory inside the controller as calibra-
tion data.
3. Measuring payload
The weight when the load is loaded is
measured. Loading is carried out with the
shift lever at N, the body control lever at
FLOAT, and the machine at a front-to-rear
angle of within +5’.
4. Compensating on slopes
When loading is carried out on slopes, the
weight of the load is different from the value
measured on flat ground, so the front-to-
rear angle of the machine is detected and
compensation is carried out according to the
angle. (Angle colmensation within +5O)
561 F03142
1 o-1 34-3
0
FEATURES OF EQUIPMENT
1. Payload meter
The payload meter inputs signals form the
pressrue sensors, clinometer, body float
detection, and shift lever, calculates the
payload using its built-in microcomputer,
and displays the value on the panel. In 1
addition, it also displays the load level using
2
the external display lamps.
It is also possible to print out the recorded
data together with the loading time and
34 56 7
number of cycles by pressing the print out
561 F03143
switch.
1) Basic functions of payload meter
The payload meter has the following
1. Calibration
basic functions.
2. Night-time dimmer switch
i) Power reset
3. Time set, adjustment switch
When the power is switched ON, all
4. Time adjustment, shift switch
functions are checked.
5. Time adjustment, display increase switch
ii) Measurement of unladen weight
6. Memory data clear switch
(calibration)
7. Printer feed switch
The unladen weight is measured and
8. Display panel
used as calibration data.
9. Print switch
iii) Display of load measurements
10. Print switch
The input signal for the payload
meter is used to display the
following.
Actual load display:
When the body control lever is at
FLOAT (body float signal at 20V
or more) and the shift lever is at
N (shift lever signal at 20V or
more).
Load display 0 ton:
l When the payload is less than 5%
of the rated payload.
l When the body control lever is at
a position other than FLOAT (body
float signal GND).
Time display:
When the body control lever is at
FLOAT, and the shift lever is at
a position other than N.
iv) External display lamp drive (estimate From 47 tons - less than 62 tons
display)
When the actual load is displayed, From 62 tons - less than 78 tons
the lamps light up as shown in the From 78 tons - less than 86 tons
s
diagram on the right. (The actual load
From 86 tons - less than 94 tons
display is given only when the shift
lever is at N and the body control 94 tons and above
lever is at FLOAT. At other times, all
561F03144A
lamps go out. Note that for 10
seconds after the power is switched
ON all lamps light up.)
1 o- 134-4
0
The estimate display estimates what
the total load will be if one more
bucketful is loaded, and makes the
appropriate lamp flash to prevent
overloading.
The previous time, did the load
v) Storing load data become less than l/5 of the rated
load 5 seconds after the dump
a) According to the relationship control lever was moved from a
between the load and the body position other than FLOAT to
FLOAT (lever returned from
float switch, the load data is stored LOWER to FLOAT after dumping
the load) ? AND
in RAM. Load data
recorded
l The data stored in the memory is This time, was the load more than in memory
l/2 of the rated load when the
not deleted even when the starting dump control lever was moved *
switch is turned OFF. from FLOAT to a position other
than FLOAT. (Lever moved from
l A maximum of 200 items of data FLOAT to RAISE when dumping
can be stored in the memory. If load) ?
this quantity is exceeded, FULL is @nditions for recording

load data in memory 3
displayed on the panel.
l The load data is stored in memory 561 F03145
when the load data storage con-

ditions are satisfied. (See diagram
on right)
b) Printing out data in memory ** PAY-LOaD**
‘88-18-17
When the print switch is pressed, **OPERflTOR**
the data is printed out on the *MACHINE NO.*
printer paper.
*TOTAL CVCLE*
c) Deleting data in memory 7 (crcle)
When the clear switch is pressed, *TOTAL WEIGHT
535< ton)
all data in RAM is cleared. ** Pn’f-LOAD**
‘88-18-17
vi) Time __+_-___+_-__-_ NO DATb
If the body control lever is at FLOAT, NO: TIME: ton
_-_-+_-_-___+--_-_-_
and the shift lever is at a position 1111:42: 71
other than N, the time is displayed 2111:43: 78
on the panel.
vii) Dimming display at night Condition when
t;;ami;&arad
The level of lighting can be adjusted 3
to ten stages by using the night-time
dimmer switch.
1 o-1 34-5
0
* Condition of dump truck and display on payload meter and external display lamps.
-
-
No. Condition of dump truck T Payload meter External display lamps
0 Loading
561FO31150-1 561FO3154
Load calculated with Lamps light up according

shift lever at N to payload
561FO3146
-
0
Traveling
(loaded)
Ea
661FO3151-1 561FO3165
Time display (display is Lamps out

held during travel)
561FO3147
-
0 Dumping 661FO3152-1 561FO3155
When dumping, display

value is 0 ton. At the
Lamps out
same time, the value
immediately before dump
ing is stored in memory.
561FO3146
-
co Traveling
(empty)
561FO3153-1 561FO3155
Time display Lamps out
- 561FO3149
10-134-6
0
2. Pressure sensor
The pressure sensor is installed at the bottm
end of the suspensin cylinder, and acts to
measure the pressure at the cylinder bottom.
561 F03158
When replacing the pressure sensor, first

loosen the nipple, and remove it from the
Pressure sensor
valve. (The pressure sensor is removed while
still installed to the nipple.) Next, remove the
pressure sensor from the nipple and install
a new pressure sensor to the nipple.
After this, turn the nipple to install it to the
valve. When removing or installing the
nipple, be careful that the valve does not
rotate.
When the nipple is removed, the valve core
acts to prevent the suspension pressure 561 F03159
from decreasing.
The output characteristics of the sensor are as

shown in the diagram on the right. (mA) WI
4.93
When pin number 17 of the connector
(21 -pin) of the payload meter controller
is GND, the output (12, 13, 14, 15)
voltage of each sensor is read in the
2.96
voltage range shown in the diagram on
the right.
1.97
0.99
0 50 100 150 200
Pressure sensor Pressure(kg/cm2)
561F03160A
561 F03391
10-134-7
0
3. Clinometer
This measures the front-to-rear angle of the
machine to carry out compensation on
slopes.
561FO3161
The output characteristics of thee clinome-

ter are as shown in the diagram on the right.
Voltage between No. 1 pin (GND) and

No. 2 pin (output) of the clinometer
connector
- 10 0 10
Angle of machine (0)
561FO3162
Uphill grade is marked as *
561FO3142
4. Lamp drive relay

This drives the external display lamps
according to the signal from the payload
meter.
561 F03164
lo- 134-8
0
ELECTRONIC MONITOR SYSTEM
SYSTEM DIAGRAM
Central warning lamp

Monitor panel
Sensor for external

monitor
(turn signal, high beam)
Shift controller Engine Suspension Shift Lockup Shift lever Fill switch / \
controller controller limiter relay 1. Air pressure
2. Engine water temperature
3. Torque converter oil
temperature
4. Retarder oil temperature
5. Fuel level
6. Engine oil pressure
7. Travel speed
8. Engine speed
561FO3165
OUTLINE
l The electronic monitor system observes the
condition of the machine through sensors
installed at various parts of the machine. It
then processes that information rapidly and
displays it on the monitor panel to inform the
operator of the condition of the machine.
l The electronic monitor system consists of the
monitor panel, various sensors, switches, and
relays, alarm buzzer, warning lamps and
power source.
l The items displayed can be broadly divided
into the various caution items on the monitor
used to display warnings if any abnormality
should occur in the machine, and the gauge
section that always displays the conditions,
such as the gauges, speedometer, tachome-
ter, service meter, odometer, and pilot lamps.
1o-1 35
0
ELECTRONIC MONITOR PANEL
F56103020
g
z
11. Turn signal (right) 23. Power mode: High power
1. Air pressure gauge .g
12. Speedometer 24. Power mode: Economy
2. Cooling water tem-
13. Tachometer 25. Suspension: Hard
perature gauge
oil 14. Shift limiter 26. Suspension: Medium
3. Torque converter
15. Lockup 27. Suspension: Soft
temperature gauge
oil temperature 16. Shift indicator 28. Service meter
4. Retarder
17. Shift position 29. Service meter pilot lamp
gauge
5. Air pressure caution 18. Abnormality in engine 30. Odometer
control (mechatronics) (total distance traveled)
6. Cooling water tem-
perature caution 19. Abnormality in automatic 31. Gauge and monitor module
shift control 32. Speedometer module
7. Torque converter oil
caution (mechatronics) 33. Monitor module
temperature
oil temperature 20. Abnormality in suspension 34. Service meter
8. Retarder
caution control (mechatronics) 35. Odometer
9. High beam 21. Fuel level caution
10. Turn signal (left) 22. Fuel level gauge
l The monitor panel consists of the gauge and l The monitors and gauges inside the monitor
module, mon- module and speedometer module are actu-
monitor module, speedometer
itor module, service meter, odometer, and ated by the signal from the gauge and monitor
module, and the odometer is actuated by
plate, and those parts connected to them.
module and spee- signals from the speedometer module.
l The gauge and monitor
dometer module each have a microcomputer;
they process the signals from the sensors and
display them.
Liquid crystal is used for the display area.
10-136
0
ELECTRONIC MONITOR DISPLAYS, FUNCTIONS
DisplaY
cate Symbol Display item Display range Display method
gory I
Air pressure Below specified pressure
Cooling water
Above 102” C
temperature
Torque converter
Above 120°C
oil temperature
When normal, the display is OFF;
Retarder oil when abnormal, it flashes and the
Above 120°C
temperature lamp and buzzer are actuated.

Engine (mechatronics) ity in engine (mecha-
trohics) system
S When there is abnormality
‘3 Automatic shift contra
s - in automatic shift contrpl
(mechatronics) (mechatronics) system
s
Suspension
ity in suspension
(mechatronics)
(mechatronics) system
When normal, the display is OFF;

Fuel level Below LOW level when abnormal, it flashes and the
lame is actuated.
(External If abnormal when engine is
When below specified
display Engine oil pressure running, lamp and buzzer are
pressure actuated.
lights up)
(External
display Charge
lights up)
(External
External monitor When external monitor When abnormal, lamp and buzzer
display
warning
lights up)
High beam When actuated
Turn signal lamps

(left, right)
Lockup When actuated Light up when actuated.

I
Shift limiter switch 01 When actuated
When shift lever is at

Shift position R
position R.
10-137
0
Symbol Display item Display range ~ Display method

Shift position N
position N.

Shift position D
position D.

Shift position 5
position 5.

Shift position 4
position 4.

Shift position 3
position 3.

Shift position L ~Light up when actuated.
position L.
Power mode: High When power mode is at

power high power.
When power mode is at

Power mode: Economy economy
When suspension is at
Suspension: HARD
HARD.
Suspension: MEDIUM
MEDIUM.
Suspension : SOFT
SOFT.
0 - 99 km/h
Travel speed Digital display
O-99 MPH
Engine speed 0 - 2800 rpm Bar graph display
Shift indicator 1-8, R, N Digital display
Operates when charging is

Service meter 0 - 99999 h normal, advances one for every
hour of time.
Flashes when service meter is

Service meter indicator
operating.
lo-138
Symbol Display item! Display range Display method
Total distance Operates when speedometer is

3 - 999999.9 km
:raveled operating.
4ir pressure
L
CC)
108 H
102
Zooling water 97
:emperature 90
80
.IE/ii!
67
561 F03168
C 7-level display, appropriate lamp
03 (1 place) lights up.
H
Ill
130
120
rorque converter 110 .5 . . . . . .
::::::::.:::::::::::::
)iI temperature
. ..i. . .. . . . . . .
90
70
i61 F03169
50
c
CC)
H
B‘1
730
1203
Retarder oil 110 VA”.:
::::::::::.:.:.:.:.>
. .._......
:emperature 90
70
50 C
i6lFO3170
FULL F
P %el level ‘12

14-level display, all lamps below
appropriate level light up
EMPTY E
561FO3171
10-139
SENSORS, SWITCHES
;-+a
I
ENGINE SPEED SENSOR
@
2
I
1 2 3 4
? \
i i 5
0
6 _--
202FO5161-1
1. Magnet FUNCTION
2. Terminal The engine speed sensor is installed to the ring
3. Case gear at the flywheel housing. It generates the
4. Boot pulse voltage according to the rotation of the
5. Connector gear teeth, and sends a signal to the controller
and the monitor panel.
ENGINE OIL PRESSURE SENSOR
1 2 3 4 5 6
@ @
0
202FO5175
1. Plug FUCTION
2. Contact ring This sensor is installed to the engine block, and
3. Contact a diaphragm detects the oil pressure. When the
4. Diaphragm pressure drops belowthe specified pressure, the
5. Spring switch is turned ON, and the lamp flashes to
6. Terminal warn of abnormality.
ENGINE WATER TEMPERATURE SENSOR
RETARDER OIL TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
202FO5176-1
2. Plug These are installed to the engine cylinder block,
3. Thermistor retarder oil piping, and transmission case. The
changes in temperatures are taken as changes
in the resistance of the thermistor, and a signal
is sent to the monitor to display the temperature.
When the monitor panel display reaches a
certain point, a lamp flashes and the buzzer
sounds to warn of abnormality.
AIR PRESSURE SENSOR
3-
L--l EQ Structureof
circuit
561FO3172
2. Tube This sensor is installed to the air piping behind
3. Frame the operator’s seat, and it converts the changes
in the air pressure of the wet air tank into
changes in resistance, and sends a signal to
the monitor panel to display the air pressure.
When the air pressure drops below the specified
pressure, the monitor panel lamp flashes and
the buzzer sounds to warn of abnormality.
10-141
0
FUEL LEVEL SENSOR
u Section A - A
561 FO3173
2. Float The fuel level sensor is installed to the side of
3. Arm the fuel tank and a float moves up and down
4. Body in accordancer with the fuel level. The move-
5. Spring ment of the float is transmitted through an arm
6. Contact to actuate a variable resistor, and this sends
7. Spacer a signal to the monitor panel to display the fuel
level. When the monitor panel display reaches
a certain level, a warning lamp flashes.
1 O-l 42
MAINTENANCE MONITOR SYSTEM
SYSTEM DIAGRAM
Battery
Electronic monitor panel Torque converter oil

Alternator
terminal R
Starting
motor
Sensor
1. Engine oil pressure

2. Engine oil level
3. Transmission oil level
4. Hydraulic oil level
5. Retarder oil level
6. Brake oil level
7. Retarder wear
8. Battery electrolyte level
9. Air cleaner clogging
10. Full-flow filter clogging
11. Transmission filter clogging
12. Hydraulic filter clogging
13. Retarder filter clogging
561FO3174
OUTLINE
The maintenance monitor system uses

sensors installed to various parts of the
machine to observe the condition of the
machine. This system then processes the
information swiftly, and displays it on the
maintenance monitor to give the operator
maintenance information about the machine
(timing for replacement of filters and oil
changes, etc.).
The maintenance monitor system consists of
the maintenance monitor, various sensors,
and the power source.
The items displayed can be broadly divided
into the monitor portion (CHECKS) that gives
warning if there is any abnormality in the
machine, and the maintenance timer that
shows the timing for changing the oil and
replacing filters.
1o-1 43
0
MONITOR PANEL
1 13 12 11 10 9 20 14
L1.5
2, rxr xx \, '\ \ II
-18
8'
21 22 23 24
\ iii I\\
26 27 28 29 30 31 32
561FO3175
I. Engine oil level 18. Hydraulic filter OUTLINE

2. Transmission oil (clogging)
level 19. Retarder filter The maintenance monitor consists of the
3. Hydraulic oil level (clogging)
maintenance module, monitor module, and
4. Retarder oil level 20. Maintenance time display
5. Brake oil level 21. Replacement time other structural parts such as the plate.
6. Retarder wear confirmation switch (oil) There is one microcomputer in the mainte-
7. Battery electrolyte 22. Replacement switch nance module: this processes signals from
level 23. Misoperation cancel the sensors, calculates the time that oil and
8. Air cleaner switch
filters have been used, and displays this
9. Engine oil 24. Replacement time
10. Transmission oil confirmation switch (filter) information. It uses a liquid crystal display.
11. Hydraulic oil 25. Maintenance module The monitor module is actuated by signals
12. Retarder oil 26. Monitor module from the maintenance module.
13. Final drive, 27. Switch A
differential oil 28. Switch JI
14. Full-flow filter 29. Switch B
(clogging) 30. Switch C
15. Fuel filter 31. Switch I
16. Corrosion resistor 32. Switch D
17. Transmission
filter (clogging)
1 o-1 44
a
MONITOR DISPLAY, FUNCTIONS
Display
Display item Display range Display method
category I
Engine oil level I Below low level
Displays when engine is stopped.

Display is normally off.
Flashes when abnormal.
Retarder oil level Below low level
Brake oil level Below low level
Displays at neutral.
More than specified Display is normally off.
Retarder wear
wear Flashes when abnormal (the retarder wear has an
abnormality recording function)
Displays when engine is stopped.

Battery electrolyte level Below specified voltage
Display is normally off, flashes when abnormal
More than specified Displays when engine is running (has an abnormality

Air filter clogging pressure difference recording function).
Display is normally off, flashes when abnormal.
More than specif.ied

Full-flow filter clogging
pressure difference Displays when engine is iunning and torque converter
oil temperature is above 50°C.
Transmission filter More than specified Display is normally off, flashes when abnormal.
clogging pressure difference
Displays when engine is running and brake oil

Hydraulic filter More than specified
temperature is above 5O’C.
zlogging pressure difference
Displays when engine is running and brake oil

More than specified
Retarder filter clogging temperature is above 5O’C.
pressure difference
Time display: Out when 1 - 250 h.

Engine oil
Lights up when abnormal.

Transmission oil
Time display:
Less than 0 h
Hydraulic oil
------i Lights up when abnormal.

Retarder oil
10-145
0
Display Display item Display range Display method
category
Final drive, Time display: Out when 1 - 2000 h.

differential oil Lights up when abnormal.

Full-flow filter

Fuel filter
Time display: Time display: Out when 1 - 500 h.

1 Corrosion resistor
Less than 0 h Lights up when abnormal.
L
Transmission filter
t
Hydraulic filter

Retarder filter
I I
E
‘E
Time display 0 - 9999 h
(A negative display is Displays the time for the item indicated by an
8
shown by the time arrow (4, D).
E
display flashing.)
S 88BB
.s h
s”
1o-1 46
0
FUNCTIONS OF SWITCHES
Switch item Function
Each time the switch is pressed, the arrow (a) changes in the following order,
and the time display changes accordingly.
Replacement time * Hydraulic oil

Engine oil - Transmission oil
confirmation (oil)
t 1
Final drive, differential oil 4 Retarder oil
Each time the switch is pressed, the arrow (D ) changes in the following order,
and the time display changes accordingly.
Full-flow filter - Fuel filter c Corrosion resistor

Replacement time
confirmation (filter)
t i
Retarder filter 4 Hydraulic filter - Transmission filter
When the oil is changed or the filter is replaced, use the above switches to
select the item that has been replaced, then press the switch for 2 seconds
and the time display will be set to the initial set time (see table on next page).
Replacement
Note: This function is only effective when the engine is stopped.
[The time setting is confirmed by starting the engine (generation of

electricity by alternator). I
If any mistake is made in the item for which the initial time is set when
carrying out the above operation, press this switch to return the time to its
Misoperation cancel
original setting.
While this switch is being pressed, the maintenance timer is in the manual set
mode, and the time for the item selected by switch II can be manually set
using the following switches.
Switch I Each time either switch A, B, C, or D is pressed, the time display for that digit
Operate this switch only will change 0 + 1 + 2 + ........ + 9.
I
wen replacing the
4th digit 3rd d,igit 2nd digit 1 st digit
maintenance module.
Switch A Switch B Switch C Switch D
Each time all the digits become 0, the (+) or (-) will change.
[When the numeral is flashing it indicates (-).I
10-147
0
Switch item Function
This is the replacement time confirmation switch in the manual set mode.
Each time the switch is pressed, the arrow (U , D) changes in the following or
order, and the time display changes accordingly.
Engine oil Full-flow filter
Fuel filter
4 -1
Switch II
Hydraulic oil Corrosion resistor
4, 4,
Retarder oil Transmission filter
Final drive, differential oil ‘Hydraulic filter
4
\ Retarder filter
Initial set times for maintenance timer
Item Initial set time (H) Item Initial set time (H)
Engine oil 250 Full-flow filter 250
Transmission oil 1000 Fuel filter 500
Hydraulic oil 2000 Corrosion resistor 1000
Retarder oil 2000 Transmission filter 500
Final drive, differential oil 2000 Hydraulic filter 1000
Retarder filter 1000
1 O-l 48
0
SENSORS, SWITCHES
ENGINE OIL LEVEL SENSOR
1 2 3 561FO3176
1. Float Function
2. Sensor l This sensor is installed to the side face of
3. Connector the oil pan, and when the oil level goes below
the specified level, the float goes down and
the switch goes OFF. The maintenance
monitor display then flashes to warn of
abnormality.
RADIATOR WATER LEVEL SENSOR
1 561FO3177
1. Float Function
2. Sensor . This sensor is installed to the top of the
3. Connector radiator, and when the cooling water level
goes below the specified level, the float goes
down and the switch goes OFF. The caution
lamp then flashes and the buzzer sounds to
warn of abnormality.
TRANSMISSION OIL LEVEL SENSOR
m
Structure
2
of circuit
561 FO3178
1. Float Function
2. Sensor l This sensor is installed to the side face of
3. Connector the transmission case, and when the oil level
goes below the specified level, the float goes
down and the switch goes OFF. The main-
tenance monitor display then flashes to warn
of abnormality.
1 o-1 49
a
HYDRAULIC OIL LEVEL SENSOR
RETARDER OIL LEVEL SENSOR
0 O-
0
0
0
2&FO5174-K
1. Connector Function
2. Bracket l This sensor is installed to the side face of
3. Float the hydraulic oil and brake cooling oil tank,
4. Switch and when the oil level goes below the
specified level, the float goes down and the
g
switch goes OFF. The maintenance monitor
z
display then flashes to warn of abnormality. 2
AIR FILTER CLOGGING SENSOR
1. Hose 6. Spring
2. Connector 7. Terminal
3. Case 8. Filter
4. Diaphragm 9. Boss
5. Guide
Function
l This sensor is installed to the side face of
the outlet port of the air cleaner, and when
the air cleaner becomes clogged and the
specified pressure (negative pressure) is
reached, a diaphragm turns the switch OFF.
The maint
enance monitor display then flashes to warn
of abnormality.
Structure of circuit 561 F03179
10-150
0
RETARDER BRAKE WEAR SENSOR
561FO3180-1
1. Shaft
2. cylinder
3. Spring
4. Bushing
5. Magnet
6. Switch
7. Body
8. Connector
HYDRAULIC FILTER SENSOR

8 RETARDER OIL FILTER SENSOR
z TRANSMISSION OIL FILTER SENSOR
z
I Structure of circuit
j 561 FO3181
1. Body Function
2. Tube l These sensors are installed to each filter, and
3. Connector when the filter becomes clogged, and the
difference in pressure between the low-
A. Low pressure pickup port pressure side and high-pressure side reaches
B. High pressure pickup port the specified pressure, the switch goes OFF.
The maintenance monitor display then
flashes to warn of abnormality.
Actuating pressure
Hydraulic filter sensor: 1 .O + 0.2 kg/cm2
Retarder oil filter sensor: 1 .O & 0.2 kg/cm2
Transmission oil filter sensor:
2.8 * 0.2 kg/cm2
Principle of switch: Pressure difference sliding
piston type
10-151
0
BATTERY ELECTROLYTE LEVEL SENSOR
561 FO3182
1. Body Function
2. Connector l This sensor is installed to the battery, and
3. Filter when the battery electrolyte goes below the
4. Packing specified level, the tip of the sensor comes
5. Pin out of the battery electrolyte into the air, and S2
zl
a signal showing a change in voltage is sent
g
to the maintenance monitor. The mainte-
nance monitor display then flashes to warn
of abnormality.
10-152
0
STRUCTURE AND FUNCTION ABS/ASR SYSTEM
ABS/ASR SYSTEM
n I
6HHh I
1. Front brake 6. Brake valve % : System installed as ABS/

2. Speed sensor x 7. Air tank ASR
3. Brake chamber 8. Air compressor Ir: Not installed where ABS is
4. Relay valve 9. ASR control valve %* available independently as
5. ABS control valve % 10. Rear brake an option
(ET range)
System operation logic
Wheel speed sensor
i\m; Calculation of slip ratio for
r-------
I
1_______~
Reduction of brake air pres-
:
I
ECU (ABS/ASR)
1 sures for slipping wheels 1 Control valve for drive wheel that is slipping
L-__------______J
10-154
0
OUTLINE
ABS (Anti-skid Brake System)
The ABS automatically controls slippage that is
caused by locking of the wheels when the brakes
are applied suddenly or on snow or other slip-
pery road surfaces. In this way, the ABS keeps
the machine stable and insures that it can be
steered.
With the ABS, the ECU (controller) calculates the
machine travel speed and the speed of each wheel
from the signals sent by the wheel speed sensors
installed to each wheel. It then sends a signal to
the pressure control valve for the wheel where
the brakes may possibly lock, thereby controlling
the brakes on the four wheels independently.
Ir When the ABS is actuated on a slippery road

surface, the braking distance becomes slightly
longer.
* When traveling at extremely low speed, the
wheels may lock.
ASR (Automatic Spin Regulator)

The ASR prevents the drive wheels from slipping
when there is excessive torque. In this way it
improves the starting ability and drive-through
ability on poor or frozen road surfaces.
When the machine starts to move on snow-cov-
ered or split road surfaces (where the condition
of the road surface is different on the left and right:
such as when one side is snow and the other side
is dry road), if an excessive torque is applied to
the wheels, both or one of the wheels will spin
and it may be impossible for the machine to start.
However, if the machine is equipped with an ASR,
the brake is automatically applied to the wheel
that is spinning and the torque applied to the
wheel is controlled, so the machine can move off.
* If both rear wheels slip at the same speed,

the ASR function is not actuated, so reduce
the pressure on the accelerator to control the
engine output.
10-155
0
STRUCTURE AND FUNCTION ABSIASR SYSTEM
PRINCIPLE OF OPERATION
ABS t8 : When the brake pressure is reduced, the

wheel speed shows a tendency to recover.
When not actuated When it returns to a0, the ECU judges that
(when there is normal braking) the wheel has returned to the stable range,
With the normal brake operation, if it does not and sends a maintain signal.
seem that the wheels will lock, the ABS pressure
control valve is not actuated, and air from the re- t9 : Same as t6
lay emergency valve is supplied directly to the
brake chamber. Stages t4 - I2 are repeated.
When actuated
As shown in the graph on the next page, the air
pressure applied to the brakes is controlled to
automatically suppress any locking of the wheels.
t1 : Braking is started and the brakes start to

have effect on the wheels. At the same
time, the wheel speed shows a possibility
of locking.
t2 : If the wheel acceleration exceeds a0, the

ECU judges that the wheels have started
to become unstable, and it sends a main-
tain signal.
t3 : If the wheel speed goes down further and

reaches slip ratio hl, the ECU judges that
the wheel is unstable, and it sends a de-
crease signal.
t4 : When the brake pressure is reduced, the

wheel speed shows a tendency to recover.
When the wheel acceleration speed passes
a0, the ECU judges that the wheel has re-
turned to the stable range, and sends a
maintain signal.
t5 & t6 : The brake pressure is maintained, so af- v Wheel speed

ter the wheel acceleration speed exceeds VRef Calculated machine speed
al, it decelerates and returns again to al. VRad Wheel speed
When this happens, the ECU judges that a0 : Acceleration (-1
the wheel acceleration speed has become The signal forthe condition when the wheel
stable and sends the increase signal. The deceleration speed has exceeded the set
increase signal increases in steps to pre- limit.
vent any big change in the wheel speed. al : Acceleration
(It is already judged that the road surface The signal for the condition when the wheel
will cause locking.) acceleration speed has exceeded the set
limit.
t7 : Because of the stepped increase, the wheel hl : Slip ratio
speed again shows a tendency to lock. The signal for the condition where the
When the wheel acceleration speed passes wheel speed is less than the travel speed
a0, the ECU judges that the wheel is un- and has exceeded the set limit
stable and sends the decrease signal.
lo-156
0
WHEN ABS IS ACTUATED
V V
Speed
Wheel acceleration
t-1
a0
-
Slip ratio AI
c-
d--
Hold valve P(
H v OFF
Valve signal
AV’
Exhaust valve L
Brake Pressure
Time t
SVH00416
10-157
0
STRUCTURE AND FUNCTION ABSIASR SYSTEM
WHEN ASR IS ACTUATED
Amount that accelerator pedal is depressed
(Brake control)
(brake Pressure)
Brake pressure
1
Time t
V :Travel speed
Vl:Rear left wheel speed z?
W:Rear riaht wheel speed
z
SVH00417 g
When not actuated When actuated (when machine starts)

When starting the machine off or when turning As shown in the graph above, the difference in
on slipper road surfaces, and there is no big dif- the rotating speed of the left and right wheels is
ference in the speed of the left and right drive detected, and the brake is applied to the wheel
wheels, the ASR is not actuated, and the brakes that is slipping in order to control the speed of
are not applied to the drive wheels. the left and right wheels to the same speed.
to : Starting to depress accelerator pedal when

moving machine off.
t1 : If the rear right wheel starts to slip and the

difference between the speed of the left and
right rear wheels is more than the set value,
the ECU sends a stepped increase signal
to apply the brake gradually to the wheel
that is slipping.
t2 : When the acceleration of the wheel on the

side that is slipping goes below the set
value, the ECU sends the maintain signal.
t3 : When the slippage starts to decrease, the

ECU gradually sends the signal to exhaust,
and repeats the control so that the speed
of the left and right wheels is the same.
lo-158
0
SYSTEM STRUCTURE DIAGRAM
1. Pulse wheel (for front right) I?

2. Wheel speed sensor (for front right) *
3. ABS pressure control valve
(for front left) *
(for front right) Y!X
5. Air tank
6. Brake chamber (for front right)
8
7. Relay emergency valve (for front right)
7
8. Brake chamber (for front left)
6 9. Relay emergency valve (for front left)
\
10. Warning lamp (red)*
11. ASR information lamp (yellow) *
12. Wheel speed sensor (for rear right) &
13. Rear brake (right)
14. Pulse wheel (for rear right) *
(for rear right) *
16. Relay emergency valve
(for rear right)*
17. Brake chamber (for rear right)
18. Relay emergency valve (for rear left) *
(for rear left) *
20. Brake chamber (for rear left)
21. ASR control valve
(machines with ASR only) *
22. Rear brake (left)
23. Pulse wheel (for rear left) *
24. Wheel speed sensor (for rear left) Q
25. Warning lamp relay*
26. Power relay *
27. Fuse (for lamp) I?
28. Fuse (for ECU power source) *
29. Fuse
(for front left and rear right brake)*
30. Fuse
(for front right and rear left brake) *
31. ECU (ABS/ASR) controller*
32. Troubleshooting switch *
33. ABSIASR main switch *
34. Pulse wheel (for front left) *
35. Wheel speed sensor (for front left) A
36. Front brake (left)
37. Retarder lever
38. Brake pedal
39. Compressor
40. Front brake (right)
* : Parts added to standard machine
10-159
0
ABS/ASR ELECTRICAL CIRCUIT DIAGRAM
ECU SVR
B35P TYPE) (SWP 14iiii)
Rear left speed sensor
Rear right speed sensor
Rear left ASS valve
Rear right ABS valve
ASR valve
(not installed when ASS is independent option)
Front left speed sensor
Front right speed sensor
Front left ABS valve
Front risht ASS valve
Valve relay
Valve relay
Warnina lamp relay
Warnine lamp relay
Warnine lamp
ASR actuation and troubleshootina lamp
Troubleshootina switch
ABS/ASR main switch
CN2
4 601.0.6.
To battery relay
IIIII GND
To circuit breaker
FBX
SVH00418
10-160
0
STRUCTURE AND FUNCTION ABS/ASR CONTROLLER
ABS/ASR CONTROLLER (ECU)
SKH00007
1. Connector Outline
2. Connector stopper This calculates the wheel speed and dummy
machine speed from the signals sent by the wheel
speed sensors installed to each wheel. It then
sends a control signal to the control valve for the
wheel which is slipping or where there is a pos-
sibility of locking.
If the built-in troubleshooting function judges that
an abnormality has occurred in the system, it
lights up the warning lamp, and also stops actua-
tion of the system and operates as the normal
brake.
10-161
0
STRUCTURE AND FUNCTION ABS PRESSURE CONTROL VALVE
ABS PRESSURE CONTROL VALVE
w
C
B A-4
c-c
6 4
B-B
10-162
0
STRUCTURE AND FUNCTION ABS PRESSURE CONTROL VALVE
1. Connector OUTLINE
2. Hold diaphragm This valve consists of two solenoid valves and
3. Exhaust diaphragm two diaphragm type valves, and is actuated by a
4. Hold solenoid signal from the ECU.
5. Hold spool
6. Exhaust solenoid
7. Exhaust spool
OPERATION 4 3
Pressure going up (increase)

Both hold solenoid valve (I) and exhaust sole-
noid valve (2) are OFF, so the brake circuit pres-
sure closes exhaust diaphragm (3) (it applies back
pressure to the diaphragm to close it), and pushes
open hold diaphragm (4) to supply pressure to
the brake chamber.
SKH00009
Hold IN OUT
Only hold solenoid (1) is ON, hold diaphragm (4)
is closed (back pressure is applied to the dia-
phragm to close it), and the pressure inside the
brake chamber is maintained.
,/ ON OFF
SKHOOOlO
lo-163
0
STRUCTURE AND FUNCTION ASS PRESSURE CONTROL VALVE
Pressure going down (decrease)

Both hold solenoid (I) and exhaust solenoid valve
(2) are ON, the brake circuit pressure is main-
tained, and the pressure inside the brake cham-
ber is exhausted.
/ ON ON \
t 2
1
SKHOOOll
lo-164
0
STRUCTURE AND FUNCTION ASR CONTROL VALVE
ASR CONTROL VALVE
B
C
SKH00012
1. Connector Outline
2. Valve This valve consists of two independent solenoid
3. Spool valves, and supplies air to the left and right pres-
4. Solenoid valve sure control valves.
A. Inlet port
B. Outlet port (to right brake)
C. Outlet port (to left brake)
D. Exhaust port
10-165
0
STRUCTURE AND FUNCTION ASR CONTROL VALVE
OPERATION
When not actuated
The left and right solenoid valves are OFF, and
there is no flow of air.
Solenoid Solenoid
valve I valve 2
Atmospheric pressure
SVH00419
When actuated From air tank

The solenoid valve on the side where the tire is 1
slipping is turned ON, and air is supplied to the E
m
>
ABS valve.
(The diagram shows the condition when both the
left and right are actuated.)
Solenoid Solenoid
valve 1 valve 2
Atmospheric Pressure
SVH00420
10-166
0
STRUCTURE AND FUNCTION WHEEL SPEED SENSOR, RELAY
WHEEL SPEED SENSOR
SKH00015
1. Spring spacer OUTLINE

2. Sensor This is a non-contact sensor. A pulse voltage is
3. Tube generated by the rotation of the teeth of the gear
4. Connector installed to the outside of the pulse wheel, and a
signal is sent to the ECU.
RELAY
rl
Q
24V10/20A
oE2mPl
1. Body
SKH00016 2. Terminal
lo-167
0
20 TESTING AND ADJUSTING
Standard value table for engine related Bleeding air from brake circuit ................... .20-23
parts (HD785-3) ........................................... 20- 2 Testing wear of front brake pad.. ................ .20-24
Standard value table for engine related Testing wear or rear brake disc .................. .20-24
parts (HD985-3) ........................................... 92- 2 Adjusting parking brake .............................. .20-25
Standard valve table for chassis Testing brake performance ...................... 20-25-I
(HD785-3) .................................................... 20- 3 Testing and adjusting suspension
Standard valve table for chassis cylinder.. ...................................................... 20-26
(HD985-3) .................................................... 92- 3 Testing and adjusting suspension air
Standard valve table for electrical cylinder.. ...................................................... 20-31
system ......................................................... 20- 8 Testing and adjusting air pressure
Tool for testing, adjusting, and in air circuit ................................................. 20-32
troubleshooting .......................................... 20-12 Adjusting hoist lever linkage ...................... .20-33
Adjusting valve clearance ........................... .20-13 Adjusting body positioner .......................... .20-34
Measuring compression pressure.. ............ .20-14 Testing and adjusting hydraulic
Measuring blowby pressure ....................... .20-15 pressure in steering, hoist circuit.. ........... .20-35
Cheching and adjusting fuel Air bleeding from steering cylinder ........... .20-37
injection timing.. ..................................... .20-15-l Adjusting engine speed sensor .................. .20-38
Adjusting accelerator pedal ........................ .20-17 Adjusting Q [Fuel injection amontl
Adjusting of AISS linkage ........................... .20-18 when replacing engine controller.. ....... 20-38-I
Adjusting engine stop motor cable ............ .20-18 Procedure for operating shift checker
Testing hydraulic pressure of torque and modulation checker ........................... .20-39
converter valve ........................................... 20-19 Method for emergency operation of truck
Testing ECMV hydraulic pressure .............. .20-20 when there is failure in electrical
Testing transmission lubrication system of transmission control
pressure .................................................. .20-20-l system of engine control system ............. .20-53
Testing torqure converter stall speed ....... ..20-2 1 Troubleshooting ............................................ 20-55
Testing brake pressure ............................... .20-22
A Before performing inspection, adjustment

check the safety pin and chock.
or faultfinding, park the machine on level ground and
A When performing
the machine.
joint work, make appropriate signals and allow only authorized personnel near
a When checking the water level, allow the engine to cool down before removing the radiator cap to
prevent the risk of being scalded by hot water which may spurt out if the engine is hot.
a Take great care to avoid getting caught in rotating parts such as the fan, etc.
20-l
0
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Applicable model HD785-3

I
Engine
I
I
SA12V140-1
Measurement conditions Unit Standard value Permissible valve

Item I .
High idling
Engine Low side 650 f 25 600 t 25

Low idling rpm
speed
High side 1,000 r 30 1,000 fl 30
With mechanical
governor 2,100 t 50 2,100 f 50
Rated speed rpm

With electronic
governor V
At sudden acceleration Bosch index 7.0 8.0

Exhaust
gas color At high idling Bosch index 1.5 2.5
mm 0.43 -
I
mm 0.80 -
Compression
Oil temperature: 40-6O’C kg/cm 2 Min. 29 Min. 20
pressure
(Engine speed) (rpm) (160 - 200) (160 - 200)
(SAE30 oil)
Blowby
(Water temperature:
pressure
Operating range) mmHs0 Max. 150 Max. 300
(Reference
value) At rated output
(Water temperature:
Operating range)
At high idling kg/cm 2 2.5 - 4.0 Min. 2.3

Oil pressure
At low idling (SAE30) kg/cm’ Min. 1.0 Min. 0.8
At low idling (SAEIOW) kg/cm’ Min. 1.0 Min. 0.8
“C 90 - 120 Max. 120

-;
With mechanical governor 24 r 1 24* 1

Fuel injection 0
Before top dead center
timing
With electronic governor 18? 1 18+- 1
Deflection when pressed
1
Belt tension
with finger force of 20 * 1
(Alternator) 20
approx. 6 kg
20-2
0
STANDARD VALUE TABLE FOR CHASSIS
Com-
Item Measurement conditions Jnit Standard value Permissible value
Standard Large dia-

. Engine water tempera- Standard tire: Large diameter tire:
tire: meter tire:
ture: Within operating (24.00-29) (27.00-29)
I (24.00-29) I (27.00-29)
range
Fl l Transmission oil tempe 10*50/o 11 zt5% lOzt5% 11+5%
ature: 70 - 90°C
F2 14*59/o 15f5% 14*5% 15+5%
l At engine speed of
F3 2300rpm 19*50/o I 21+5% 1 19+50/o 1 21dz5%
Travel
m/l 1-
speed When empty
F4
l
26f5% 28f5% 26*5% 28*5%
F5 35+5% 37It5% 35+50/o 37It5%
F6 48f5% 51 zt5% 48+59/o 51 rt5%
F7 64f5% 68+5% 64f5% 681t5%
R 11 f5% I 12+5% 1 llf5% 1 12zt5%
Shift up 2,230 zt 50 2,230 + 50

l Engine water tempera-
ture: Within operating
1,500 + 50 1,500* 50
Shift down range
* Transmission oil tempe 1,450 + 50 (F2 - Fl on(v) 1 1,450 * 50 (F2 - Fl onlv)
ature: 70-90°C
Shift
Hydraulic oil tempera- 2,230 * 50 2,230 * 50
up l
I
Power ture: 50-80°C
mode Shift 1,500 f 50 I 1,500 * 50
l “Braking mode” refers.1
down when the accelerator is 1,400 * 50 (F2 - Fl only) 1,400 + 50 (F2 - Fl only)
OFF or the rear brake is
ON. 1,800 + 50 1,800 f 50
Shift ‘pm
Econ- up 1,850 * 50 (Fl - F2 onlv) 11,850 Z!I50 (Fl - F2 onlv)

omv
Shift 1,250 + 50 I 1,250 f 50
down
1,200 xt 50 (F2 - Fl only) 1,200 f 50 (F2 - Fl only)
Shift
Brak- 2,450 & 50 2,450 i 50
up
ing
Shift
1,550 f 50 1,550 f 50
down
Fl, F2 1,500 1,500

Set
F3-F7 1,250 + 50 1,250 f 50
Fl, F2 1,200 1,200

Reset
F3-F7 1,100* 50 1,100 It 50
Set 2,500 + 10 2,500 + 10
Reset 2,350 + 10 2,350*10

Same as shift down for
Same as shift down for automatic shift
Down-shift inhibitor automatic shift control
control given above.
given above.
Transmission oil tem- For engines with
2,040 + 100 2,040 i 100
l
oerature: 70-90°C ”mechanical governor

Engine spped at l ‘Hydraulic oil tempera-
torque converter pgp Power
ture: 50-80°C 2,040 * 100 2,040 * 100
.E p $ mode
l Engine water tempera- @e B
ture: Within operating “5 F Economy
ranoe ,o ‘5 ‘2 1,780 f 75 1,780 dz 75
mode
For engines with
. Operating force at a 2.7 f 0.5 2.7 f 0.5
nmechanical governor
point 150 mm from
pedal fulcrum. For engines with
2.0 f 0.5 2.0 f 0.5
e lectronic governor
l Travel at a point 150 :gm
mm from pedal fulcrum For engines with
4.2 f 0.5 4.2 rt 0.5
nmechanical governor
Released
For engines with
3.5 * 0.5 3.5 * 0.5
e lectronic governor
nm 32 i 5 32+5
20-3
0
Item Measurement conditions Unit Standard value Permissible value
Operating force l At center of lever knob kg 1.6 f 0.4 Max. 2
R-N
N-D
Transmis-
sion shift D-5
lever Travel 18.5 zb 1 18.5+2
5-4
4-3
3-L
. Oil pressure: 70-90°C 1.3 It 0.5 1.3 + 0.5

Oil pressure at inlet port * Engine: Low idle and
High idle 8fl 81f-1
1 .o It 0.5 1 .o * 0.5
Oil pressure at outlet port
4*1 4fl
Torque
converter kg/cm2
16 + 0.5 161tO.5
Lockup pressure
16kO.5 16 rt 0.5
34.5 * 2 34.5 + 2
Main relief pressure
39f2 39f2
.,H, 4th clutch * Oil temperature: 50 - 80°C 16.5& 1.5 16.5 f 1.5
l Engine: Low idle and Hi idle g
20.5 + 1.5 20.5 * 1.5 z_
8
31.5 * 1.5 31.5* 1.5
30+ 1.5 30f 1.5
16f2 16+2
Transmission kg/cm2 20f2 20 * 2
33&t 331t2
l Water temperature:
Within operating range.
. Oil temperature:
Lubrication pressure 1.25 * 0.5 1.25 * 0.5
50 - 80°C (Using EOl O-CD)
70 - 90aC (Using E030-CD)
. Engine: High idle
Standard tires 24.00-49-48PR . When empty

6.65 6.65
(Front and rear wheels)
Tires
(inflation kg/cm2
pressure) Large diameter tires 27.00-49-
5.60 5.60
48PR (Front and rear wheels)
. Oil temperature: 50 - 80%
Operating force (turning speed l With machine stopped (if it is

impossible with the machine kg Max. 3.0 Max. 3.6
for steering wheel: 30 rpm)
stopped, travel at low speed with
engine at low idling)
wheel _
. Lentgh at circumference of steer-
Play ing wheel 130+30 130+30
l Engine stopped
20-4
@
Measurement conditions Unit Standard value Permissible value
No. of turns l Lock - lock Turns 3.5 It 0.4 3.5 + 0.6
Steering Left - Right ’ Oil temperature: 50 - 80°C

wheel l Engine speed: Whole range
Turning time ’ Lock - lock sec. Max. 4 Max. 5
Right - Left
l Oil temperature:
50 - 80°C Low 180+:, 180+to
Steering
’ Demand valve relief
Relief pressure valve kg/cm*
valve
’ Engine: Low idle and
High idle High 210+:, 210+:,
Operating force ’ Tip of pedal kg Max. 30 Max. 30

Brake peda I -
Travel 78rt8 78f 15
Operating force ’ 10 mm from tip of lever kg 1 .o - 4.0 0.5 - 6.0

Retarder
control lew 3r
degree
Travel o-90*3 O-90*6
(mm)
Parking * Tip of lever

kg Max. 2.0 Max. 3.0
brake lever
Emergency Tip of lever

Operating force kg Max. 2.0 Max. 3.0
brake lever
Run engine at full throttle, startinE

with air pressure at 0 kg/cm*,
Air governc,r :Set pressure kg/cm2 8.3 + 0.3 8.3 f 0.3
accumulate air and measure pres-
sure when unloaded.
Service 78 ton payload Initial speed: 32 km/h m Max. 29 Max. 29

Ibrake Distance from starting to lose
Ibraking speed stopping
,distance Max. actuating air pressure: m Max. 21 Max. 21
Empty
8.3 kg/cm2
Max. hydraulic pressure
Rear: 45 kg/cm2
IRetarder 78 ton payload Front: 127 kg/cm2
m Max. 29 Max. 38
Israke On flat, drv road surface
Israking
,distance m Max. 21 Max. 30
Empty
Brake Front chamber Max. actuating air pressure: 8.3 Min. 187 Min. 187
kg/cm2
Engine: Stopped
Brake When first operated
Rear chamber
actuating kg/cm2 Min. 45 Min. 45
(Service)
pressure
Rear chamber
Min. 45 Min. 45
(Retarder)
Stopping distance when Carrying 78t payload Initial speed:

m Max. 60.9 Max. 60.9
emergency brake is applied 32 km/h On flat, dry road surface
20-5
0
Componen Measurement conditions Unit Standard value Permissible value
I
. With 78t payload Double caliper: Double caliper:
l After adjusting clearance betweer Min. 15 Min. 15
Parking disc and pad
Braking capacity %
brake
Single caliper: Single caliper:
Min. 15 Min. 15
Service brake . F2 Min. 1600 Min. 1600

. Torque converter stall
l Water temperature:
Retarder brake Within operating range
Min. 1200 Min. 1200
l Air pressure: 8.3 + 0.3 kg/cm2
* Transmission oil temper&e:
Braking 70 - soot
Emergency brake
capacity ’ Hydraulic oil temperature: wm
50 - 80°C
Parking brake
HOLD - RAISE Center of control lever knob
RAISE - HOLD Automaticallyreturn Automaticallyreturn

I
HOLD - FLOAT 5-10 5-10
Operating
force
FLOAT - HOLD 3-6 3-6
T:
LOWER - FLOA Automatically return Automatically return z
3
Hoist lever FLOAT - LOWEr Max. 13 Max. 13
RAISE -
HOLD @ 15+2 15f2
HOLD -
Travel 11 f2 11+2
FLOAT @
I
FLOAT -
LOWER @ 11 f2 11+2
F56103023
v Oil temperature:
50 - 80°C Low 185 +A0 185 +A0
’ Engine: Low idle and I
Hoist valve Relief oressure high idle g/cm2
mMeasure at end of stroke
when raising body High
Lifting speed ’ Oil temperature: 50 - 80°C

’ Engine: Full throttle
’ Use FLOAT when lowering set
Lowering speed
Body
’ Oil temperature: 50 - 80°C

Hydraulic drift
’ Set with No. 2 cylinder extended mm/
200 mm Max. 85 Max. 170
5min.
’ Hydraulic drift for 5 minutes
* The value differs according to the body specification,

so this value is given only for reference.
20-6
8
Item I Measurement conditions Unit Standard value Permissible value
I
A 262f 10 262 t 20
l On flat road surface I
Front l When empty
B 484f 10 484 i 20
Installed i
length
239 + 10 239 f 20
Suspension
cyliner Rear
451 * 10 451 f 20
kg/cm2
569F108 569Fl OS
20-7
CB
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
nspection Measurement
System Uame of component Connector No. Judgment table
method conditions
Engine oil pressure Measure If the condition is as shown in the table 1) Start engine.
sensor resistance below, it is normal. 2) Disconnect
wiring.
Oil pressure above
- 0.7 kg/cm’
No continuity
Oil pressure below

Continuity
0.3 kg/cm2
Alternator Between alter. Measure With engine running (above l/2 1) Start engine.
nator terminal voltage throttle) : 27.5 - 29.5 V
R and chassis *With deteriorated batteries or after
starting in cold areas, it may take
time for the voltage to rise.
Air pressure sensor DL (Male) Measure If the condition is as shown in the table 1) Turn starting
resistance below, it is normal. switch OFF.
2) Disconnect
Air pressure Below approx. DL.
9.5 kg/cm2 I I3a or approx.
!EqBetween
F
Air pressure (1) & (2) Approx. 64052
* Engine water 26 (Male) Measure If the condition is as shown in the table 1) Turn starting
temperature sensor resistance below, it is normal. switch OFF.
- Torque converter TC, SE 2) Disconnect g
oil temperature (Male) 26, TC, SE, z
sensor 64. g
* Retarder oil tem- 64 (Male)
perature sensor
Fuel level sensor 61 (Male) Measure If the condition is as shown in the table 1) Turn starting
resistance below, it is normal. switch OFF.
2) Disconnect
61.
Speed sensor N3 (Male) Measure If the condition is within the range 1) Turn starting
resistance shown in the table below, it is normal. switch OFF.
2) Disconnect
1 Between (1) and (2) 1 500 - 100052 N3.
Engine speed sensor El2 (Male) Measure If the condition is within the range 1) Turn starting
resistance shown in the table below, it is normal. switch OFF.
2) Disconnect
Between (I 1and (2) 500 - lOOOn E16.
20-8
0
Inspection Measurement
System Component Connector No. Judgement table conditions
method
MM13 (Male) Continuity If the condition is as shown in the 1) Start engine.

table below, it is normal. 2) Disconnect
Full flow filter MM10 (Male) Continuity If the condition is as shown in the table 1) Start engine.
clogging sensor below, it is normal. 2) Disconnect
I I I I MMIO.
Transmission filter 52 (Male) Continuity If the condition is as shown in the table 1) Start engine.
I I I I 52.
f
Hydraulic filter 54 (Male) Continuity If the condition is as shown in the table 1) Start engine.
E
E clogging sensor I I below, it is normal. 2) Disconnect
Retarder filter 53 (Male) Continuity If the condition is as shown in the table 1) Start engine.
53.
Alternator * Between Measure When engine is running (l/2 throttle 1) Start engine.
alternator voltage or above): 27.5 - 29.5 V
terminal R and * If the battery is old, or after starting
chassis in cold areas, the voltage may not
rise for some time.
2oFF
System Component Connector N 0. ’Inspection
method
Judgement table
Measurement
conditions
Engine oil level MM9 (Male) Continuity If the condition is as shown in the table 1) Turn starting
sensor below, it is normal. switch OFF.
I 2) Disconnect
Engine oil MM9.
level normal / Between / Continuity
(I) and
Engine oil (2) No
level abnormal continuity
Transmission oil MM16 (Mak ?) 1Continuity If the condition is as shown in the table 1) Turn starting
level sensor below, it is normal. switch OFF.
2) Disconnect
MM16.
Hydraulic oil level MM14 (Male !) IContinuity If the condition is as shown in the table 1) Turn starting
sensor below, it is normal. switch OFF..
2) Disconnect
MM14.
Retarder oil level MM1 5 (Male !) 1Continuity If the condition is as shown in the table 1) Turn starting
2) Disconnect
Retarder oil MM15.
level normal Continuity
Between
Brake oil level MM12 (Male !) (Zontinuity If the condition is as shown in the table 1) Turn starting
2) Disconnect
Brake oil level
Continuity MM12.
normal Between
(1) and
Brake oil level (2) No
abnormal continuity
Battery electrolyte MM11 (Male ‘1 Measure If the condition is as shown in the table 1) Turn starting
sensor voltage below, it is normal. switch OFF.
2) Disconnect
MMII.
Retarder wear VIM19 (Male 1 (Zontinuity If the condition is as shown in the table 1) Start engine.
sensor VIM20 (Male 1 below, it is normal. , 2) Disconnect
MM19, and
MM20.
3) Actuate
retarder
brake.
Connector No Judgement table conditions
method
El3 Measure If the condition is as shown in the table 1) Start engine.

voltage below, it is normal. 2) Insert
T-adapter.
I---
Between (I) and (2) 4.6 - 5.4V 3) Check that
there is short
Left bank rack E9 circuit or dis-
sensor connection in
the wiring
harness.
Right bank governor El5 (Male) Measure If the condition is as shown in the table 1) Turn starting
solenoid resistance below, it is normal. switch OFF.
2) Disconnect
El1 and
Between (I) and (2) 10 - 21a
E15.
Left bank governor El1 (Male)

solenoid
Right bank governor R22 (Male) Measure If the condition is as shown in the table 1) Turn starting
cut relay resistance below, it is normal. switch OFF.
2) Disconnect
t R22 and
R23.
Left bank governor R23 (Male)
cut relay
&
z Right bank pre- El4 (Male) Measure If the condition is as shown in the table 1) Turn starting
8
z stroke solenoid resistance below, it is normal. switch OFF.
z
i 2) Disconnect
s El4 and
al
.E Between (I) and (2) 10 - 21v EIO.
? Left bank pre- El0 (Male)
w
stroke solenoid
Engine speed El6 (Male) Measure If the condition is as shown in the table 1) Turn starting
sensor A resistance I below. it is normal. switch OFF.
2) Disconnect
Between (I) and (2) 500 - IOOOG? El6 and
E12.
Engine speed El2 (Male)
sensor B
Accelerator sensor SRI (Male) Measure If the condition is as shown in the table 1) Turn starting
k
voltage below, it is normal. switch ON.
2) Connect
T-adapter
to SRI.
3) Move acceler-
ator pedal
LOW- FULL.
Water temperature 26 (Male) If the condition is as shown in the table 1) Turn starting
sensor below, it is normal. switch OFF
Disconnect
26.
System Name of component Connector No Judgment table
method conditions
FR pressure sensor 39 Measure If the condition is as shown in the table 1) Turn starting
voltage below, it is normal. switch ON.
2) Insert T-
adapter.
3) Remove sensor
from suspen-
FL pressure sensor 13 sion cylinder.
4) There must be
no disconnec-
tion or short
circuit in the
wiring harness.
Transmission output N3 (Male) Measure If the condition is as shown in the table 1) Turn starting
shaft speed sensor resistance below, it is normal. switch OFF.
2) Disconnect
Between (I) and (2) 500 - 100052 N3.
I 1 I
Emergency brake AS4 (Male) Continuitv If the condition is as shown in the table 1) Turn starting
switch below, it is normal. switch OFF.
2) Disconnect
AS4.
SusPen- Service brake switch AS5 (Male) Continuity If the condition is as shown in the table 1) Turn starting
sion below, it is normal. switch OFF.
control 2) Disconnect
AS5.
below 0.2kg tinuity
Suspension control SLI (Male) Measure If the condition is as shown in the table 1) Turn starting
solenoid valve resistance below, it is normal. switch OFF.
2) Disconnect
SL2 (Male) Between (1) and (2) 20 - 6Ofi SLI, SL2,
and SL3.
3) Put block pole
SL3 (Male) in contact with
(I), and red
pole in contact
with (2).
-
Limit switch RH2 (Male) Continuity If the condition is as shown in the table 1) Turn starting
(Body float) below, it is normal. switch OFF.
2) Disconnect
Lever at RH2.
FLOAT Continuity
position
Between
Lever at (7) & (9)
position No con-
other than tinuity
FLOAT
I nsmpe;zin Measurement
System Connector No Judgement table
conditions
Transmission shift SF (Male) Measure I Voltage value I I) Turn starting

lever voltage switch ON.
When When not
2) Insert T-
selected selected
adapter.
yi)mae(e2; R Max. l.OV Min. 15.OV
Between
N Max. l.OV Min. 15.OV
(4) & (2)
~~~~~~) D Max. l.OV Min. 15.OV
~~)~~e~~) 5 Max. l.OV Min. 15.OV
Between
4 Max. l.OV Min. 15.OV
(7) & (2)
Pressure control HPS (Male) 1) Turn starting

valve solenoid LPS (Male) switch OFF.
2) Disconnect g
RPS (Male)
connector z
IPS (Male) Between (1) and (2) 5-25G!
2PS (Male) of SP. ;3
3PS (Male) * 13.85a (20°C) f 5%
4PS (Male)
Lockup solenoid L/CT (Male) 1) Turn starting

switch OFF.
2) Disconnect
L/CT.
Exhaust brake SL5 (Male) Measure 1) Turn starting

solenoid resistance switch OFF.
2) Disconnect
Between (1) and (2) 20 - 6Oa
SL5.
Measure 1) Turn starting

Rear brake solenoid SL4 (Male)
switch OFF.
resistance
2) Disconnect
Between (1) and (2) 20 - 6Oa
SL4.
Transmission oil CNT (Male) Measure 1) Turn starting

temperature sensor resistance switch OFF.
2) Disconnect
CNT.
Relay (Check as ROI - R25 Measure Check as individ-

individual part) (except R09, resistance
I I, 12,16-
20)
11 Between (3) and (5) 1 Min. IMa
System Name of component Connector No. Judgment table conditions
method
Relay (Check as R9 Measure 1 Between (5) and(6) ( IOO- 500R 1 Check as indi-
individual part) RI2 resistance vidual part.
Between (3) and (4) Min. 1MR
Between (13 and (2) Min. 1MR
Fill switch HSW (Male] Measure Between 1) Turn start-

LSW (Male) resistance !$!$switch (1) and Min. lMC2 ing switch
chassis OFF.
RSW (Male)
1 SW (Male) 2) Disconnect
2SW (Male) switch
Trans- 3SW (Male) connector.
mission 4SW (Male)
control
Acceleration sensor SRl (Male) Measure If the condition is as shown in the 1) Insert
voltage table below, it is normal. T-adapter.
2) Turn start-
ing switch
ON.
FR pressure sensor 39 Measure If the condition is within the range 1) Remove

voltage shown in the table below, it is normal. sensor from
suspension
Between each cylinder
connector (2) and 0.45 - 1.50 v 2) Insert T-
FL pressure sensor chassis adapter.
3) Check that
there is no
disconnec-
tion or short
circuit in
the wiring
harness.
4) Turn start-
ing switch
Payloa ON.
meter
Clinometer PM3 Measure If the condition is within the range 1) Park
voltage shown in the table below, it is normal. machine on
level ground.
) Between(l)and(2) 1 2.1 -3.1 V 1 2) Check that
there is no
disconnec-
tion or short
circuit in
the wiring
harness.
3) Insert T-
adapter.
4) Turn start-
ing switch
ON.
Controller PM1 Measure If the condition is within the range 1) Turn start-
voltage shown in the table below, it is normal ing switch
ON.
2) Insert
1 Between (16) and (17) 1 21 - 30V 1 T-adapter.
20-l 1
0
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Measurement and item symbol Part Number Part Name Remarks
L : 60 - 2,000 rpm
1 799-203-8000 Multi-tachometer Digital display H: 6. _ , g ggg rpm
6210-81-4111 Gear box
Engine speed 9
2 07000-03050 O-ring
0143520630 Bolt
3 6215-81-3500 Tachometer drive ass’y

-
Water and oil temperatures 8 799-l 01-6000 Digital temperature gauge -50 to 1,200Yz
Pressure gauge:
799-l 01-5001 Hydraulic tester
25,60,400,600 kg/cm2
Oil pressure C
790-261-l 102 Digital hydraulic tester Pressure gauge: 500 kg/cm2
0 - 70 kg/cm*
1 795-502-l 590 Compression gauge ass’y
Kit Part No. 795-502-1205
Compression pressure D
? 2 795-502-l 500 Adapter
1 799-201-l 504 Blow-by checker 0 - 500 mmHs0

Blow-by pressure E
? 2 799-201-l 511 Nozzle
Valve clearance F ommercially available Feeler gauge -
799-201-9000 Handy smoke checker Discoloration 0 - 70%

Exhaust color G (with standard color)
ommercially available Smoke meter (Discoloration x 1 /lO% Bosch index)
Operating force H ommercially available Push-pull scale -

g
Stroke, hydraulic drift ommercially available Scale -

:
0
Work equipment speed J ommercially available Stop watchh -
Disc wear K 566-98-41120 Disc gauge -
Voltage, resistance L ommercially available Tester
This includes all the T-adapters

used on this machine. Depending
on the attachments and specifica-
Check sensor wiring harness M 799-601-7400 T-adapter kit tions, the following part numbers
are also available.
. 799-601-7200
l 799-601-7300
Measure transmission clutch

N 799-607-l 000 Modulation checker
pressure
792-201-6104
*792-201-6103 checker has been
Measure torque converter stall 792-201-6105 A-type shift checker
0 modified for use with a 7-speed
speed =792-201-6103 >
transmission.
799-605-l 000 B-type shift checker
799-607-2000 C-type shift checker
Injection pump for engine with

P 799-605-3000 Governor tester
electronic governor
Output performance for engine Used for dynamo test of engine.

Q 799-605-5000 Throttle box
with electronic governor
Lubricating oil pressure (torque

converter, transmission) 10 kg/cm2
S 799-401-2320 Hydraulic gauge
Torque converter inlet port, outle
port pressure
Measurement and Item Symbol Part Number Part Name Remarks
792-415-1110 Cover
I 792-415-1120 I Spacer (for 1 st, 2nd R clutch!
792-415-l 130 Spacer (for 3rd. H clutch)

1
792-415-l 140 Spacer (for 4th. L clutch) Assembly part No.
Measurement of transmission
clutch pressure 792-415-l 200
175-l 5-l 5540 Valve
238-l 5-12930 Spring
792-415-1150 Wrench
2
792-415-1160 Adapter
20-12-l
@
ADJUSTING VALVE CLEARANCE
+ Adjust clearance between crosshead and
rocker arm.
Adjusting method of valve clearance

1. Remove the rocker arm. housing cover.
2. Rotate the crankshaft in the normal direction,

While watching the movement of the intake
valve of the R6 cylinder, bring the RI cylin-
der into the top dead center position of the
compression stroke and align the “R1.6 TOP”
line on vibration damper (1) with pointer (2).
+ When the Rl cylinder comes near the top * Firingorder:Rl-Ll-R5-L5-R3-L3-R6
dead center of the compression stroke, - L6 - R2 - L2 - R4 - L4
the R6 intake valve will start to move
(open).
3. Loosen locknut (6) of adjustment screw (5)

of Rl cylinder, insert the feeler gauge A
corresponding to the specified clearance be-
tween crosshead (4) and rocker arm (31, and Front Rear
adjust the clearance with the adjustment
screw until the thickness gauge can slide 62 I5FO44
lightly.
g
z + Valve clearance (When engine is hot or
0” cold)
Unit: mm
Intake valve Exhaust valve
0.43 0.80
4. Tighten locknut in this position, secure ad-

justment screw.
w Locknut: 6 f 0.6 kgm
F621201066
5. Follow the same procedure to aligh the line
with the pointer and adjust the valve clear-
ance of each cylinder according to the firing
order.
* The lines and marks shown in the dia-

gram are on the outside circumference of
the damper.
MEASURING COMPRESSION PRESSURE
Method of measuring compression pressure
A When measuring the compression pres-

sure, be careful not to touch the exhaust
manifold or muffler, or to get caught in
rotating parts.
+ Warm up the engine before measuring
the compression pressure.
(Oil temperature 40 - 6O’C)
1. Adjust valve clearance.

t For details, see ADJUSTING VALVE
CLEARANCE.
2. Remove the nozzle holder assembly from the

cylinder to be measured.
3. Install adapter (1) in the mount of the nozzle

holder of cylinder to be measured, then
secure with retainer (2).
F5610302t
Qa Mounting bolt : 6.75 + 0.75 kgm
4. Connect compression gauge D 1 to the adapter.
5. Disconnect the connector of the engine stop

motor. (Turn the starting switch OFF before
disconnecting.)
A If the fuel control lever is not placed in
the NO INJECTION position, fuel will
spurt out.
6. Crank the engine with the starting motor and

measure the compression pressure.
Measure the compression pressure at the L
point where the gauge indicator remains

steady.
If the adapter mount is coated with a small
amount of oil, it will prevent leakage.
For details of the standard values for com-
pression pressure, see STANDARD VALUE
TABLE FOR ENGINE RELATED PARTS
20-l 4
0
MEASURING BLOWBY PRESSURE
Measuring conditions
1) Water temperature: Within operating Gauge
range
2) Transmission oil temperature: 70- 90 OC
3) Hydraulic oil temperature: 50 - 80 OC
* If the temperatures are not as given
above, warm up the engine until the
temperature conditions are reached.
1. Install tool El to one end of the blowby hose, Gas

Gas
and install tool E2 to the hose at the other 561 F03351
end.
* Block the gauge mounting hole of E2.
Start the engine, and measure the blowby
D
2.
El-Q
pressure when the engine is run at near the 0 0
rated speed.
* For details, see the STANDARD VALUES
TABLE.
561 F03352
20-l 5
0
CHECKING AND ADJUSTING
FUEL INJECTION TIMING
There are two methods for checking and
adjusting the fuel injection timing of an injection
pump.
The “MATCH MARK ALIGNMENT” method,
which is used when the injection pump is
installed to the original engine and the pump
is not being repaired.
The “DELIVERY VALVE” method, which is
used when a repaired or replaced injection
pump is installed to the engine.
Before inspection and adjusting the fuel F5610363K
Injection timing stamp line
injection timing, bring the Rl cylinder piston on vibration damper
to the top dead center of the compression
stroke. For details, see ADJUSTING VALVE
CLEARANCE.
When testing and adjusting the fuel injection
timing, use the injection timing stamp lines
as follows:
l For the RIGHT bank, use the line for view Y
l For the LEFT bank, use the line for view Z
CHECKING AND ADJUSTING BY THE

MATCH MARK ALIGNMENT METHOD
1. Aligning 1.6 TOP line
Align the TOP stamp line on vibration
damper (1) with pointer (2) as follows:
For the RIGHT bank: R 1.6 TOP
For the LEFT bank: L 1.6 TOP
2. Rotate the crankshaft 35O to 40° in the
reverse direction.
3. Align the injection timing stamp line
(injection timing using the Standard Value
Table) on vibration damper (1) with pointer
(2) by slowly rotating the crankshaft in the
normal direction.
4. Confirm that stamp line a on the injection
pump is aligned with stamp line b on the ‘3 b ‘a_ F5610302:
coupling.
* If the stamp lines are out of alignment,
loosen bolt (3), align the stamp lines by
shifting the coupling, and tighten the bolt.
m Coupling bolt: 9 -t 0.5 kgm
20-15-l
0
CHECKING AND ADJUSTING BY THE
DELIVERY VALVE METHOD
. FOR MACHINES WITH MECHANICAL

GOVERNOR
1. Aligning line
Rotate the crankshaftr in the normal direc-
tion and align the line on vibration damper
(1) with the injection timing according to the
Standard Value Table.
Align with the injection timing position as
follows:
l For the RIGHT bank, use the line for view Y
l For the LEFT bank, use the line for view Z
2. Disconnecting fuel injection pipe _

Disconnect fuel injection pipe (4) for the No.
1 engine.
l For the RIGHT bank, disconnect the pipe
for Rl
l For the LEFT bank, disconnect the pipe for
Ll
3. Remove delivery valve holder (5). take out
delivery valve (6) and spring (7), then install -%--+-=- F5610302
delivery valve holder (5) again.

m
0 4. Place the governor lever at the FULL position.
z 5. Loosen bolt (3) in the oblong hole of the
g mounting flange of the fuel injectin pump,
then move the injection pump a little at a
time while operating the priming pump, and
stop at the point where the fuel stops flowing
6
from the delivery valve holder.
* If the fuel does not stop whichever way
the injection pump is moved, rotate the
crankshaft one more turn.
* Adjust the fuel injection timing by moving
the fuel injection pump as follows.
To RETARD timing, move towards
OUTSIDE. I 423F302
To ADVANCE timing, move towards

CYLINDER BLOCK.
6. Tighten bolt (3) in the oblong hole of the
mounting flange of the fuel injection pump.
m Coupling bolt: 9 + 0.5 kgm
7. Remove delivery valve holder (5). assemble

delivery valve (6) and spring (7), then install
delivery valve holder (5) again.
m Delivery valve holder: 11.5 t 0.5 kgm
8. Connect fuel injection pipe (4).
m Sleeve nut: 2.4 f 0.1 kgm
20-15-2
0
CHECKING AND ADJUSTING BYTHE
DELIVERY VALVE METHOD
. FOR ENGINES WITH ELECTRONIC

GOVERNOR
1. Aligning line
Rotate the crankshaft in the normal direction
and align the line on vibration damper (1)
with the injection timing according to the
Standard Value Table.
l For the RIGHT bank, use the line for view
Y
l For the LEFT bank, use the line for view
Z
2. Disconnecting fuel injection pipe

Disconnect fuel injection pipe (4) for the No.1
engine.
l For the RIGHT bank, disconnect the pipe
for Rl
l For the LEFT bank, disconnect the pipe
for Ll
3. Remove spring (6) and delivery valve (7)from

delivery valve holder (5), then install delivery
valve holder (5) again.
4. Remove rack stopper bolt C, then push in

rack pusher bolt (1) and move the rack.
* Tighten lightly until it touches the rack,
then tighten by hand until the rack does
not move any more. (approx. 14 - 15
turns)
I 423F302
561 FO3302
561 FO3303
20-A5-3
5. Turn the right No.1 cylinder back 35 - 40°
from the TOP position.
6. Operate the priming pump and rotate the

crankshaft slowly in the normal direction.
Checkthe point where the fuel stops flowing
7. Check that the injection timing line on the

vibration damper and the pointer are aligned
at the point where the fuel stops flowing.
Ir BEYOND injection timing line:
Timing RETARDED
* BEFORE injection timing line:
Timing ADVANCED
8. If the injection timing is correct, loosen rack

pusher bolt 0, and replace with stopper bolt
C.
Sr Do not forget to exchange the bolts.
Failure to install stopper bolt Cwill cause
the engine to overrun.
9. Assemble spring (6) and delivery valve (7)

8 again.
&
S
20-15-4
0
l Adjusting
1. Disconnect fuel injection pipe (4) from the
right No.1 cylinder.
2. Remove delivery valve holder (5).
3. Remove spring (6) and delivery valve (7)from
delivery valve holder (5). then install delivery
valve holder (5) again.
4. Remove rack stopper bolt C, then push in
rack pusher bolt @ and move the rack.
* Tighten lightly until it touches the rack,
then tighten by hand until the rack does
not move any more. (approx. 14 - 15 -- F5610302h
turns)
561 FO3302
/ 423F302 561 FO3303

5. Turn the right No.1 cylinder back 35 - 40°
from the TOP position.
6. Rotate the crankshaft slowly in the normal
direction and align the fuel injection line on
damper (1) correctly with pointer (2).
7. Loosen bolt (3) in the oblong hole of the
injection pump mounting flange, then
operate the priming pump and turn the
flange at the pump end a little at a time.
Stop at the point where fuel stops flowing
8. Tighten the bolt in the oblong hole of the
injection pump mounting flange.
* Check the fuel injection timing again to
confirm that the injection timing is
correct.
9. Replace rack pusher bolt @ and rack
stopper bolt C.
10. Assemble spring (6) and delivery valve (7)
again.
11. Align match mark “la ” with ” b” and make
a mark.
* Test and adjust the injection timing of the
left bank injection pump in the same way
as for the right bank injection pump.
F56103028
20-15-S
0
ADJUSTING ACCELERATOR
PEDAL
1. Adjust dimension a of low idling stopper bolt
(l), and adjust clearance b at low idling end.
Dimension a of stopper bolt: 19.3 mm

Clearance b: 0.8 f 0.1 mm
2. Adjust dimension c of high idling stopper

bolt (2). and adjust clearance d at high idling
end.
561 FO3305
Dimension c of stopper bolt: 25.5 mm
Clearance d: 2.5 & 0.1 mm
3. After adjusting, measure the output voltage

of the accelerator sensor.
Sensor output voltage: See Standard Value
Table
561 FO3306
’
* The following Steps 4 and 5 apply only to

engines with a mechanical governor.
4. Adjust with rod (5) at the bottom of the pedal
so that rod (4) of servo cylinder (3) is fully
retracted.
I 5. Depress the pedal fully to the end of its
travel, and check that the stroke of rod (6)
of servo cylinder (3) is dimension e.
j, If the stroke is too short,, reduce the
installed length of high idling stopper bolt
(2). and adjust so that the stroke of the F56103031-1
rod is dimension e.
Dimension e : 20 mm 6 f
F5610303iA
20-17
0
ADJUSTING OF AISS LINKAGE
. FOR ENGINES WITH MECHANICAL
GOVERNOR
1. Adjust AISS motor cable inner wire (1) to

an installed length @ of approx. 140 mm.
2. Push lever (3) at the peda1 end with adjust-

ment bolt A of lever (2) and adjust so that the
engine speed is 1000 rpm.
3. In this condition, tighten adjustment bolt B

until it contacts lever (3), then lock in posi-
tion.
F56103033
&DJUSTING__EillINE STOP
MOTOR CABLE
. FOR ENGINES WITH MECHANICAL
GOVERNOR
1. Adjust the clearance between stop lever (1)

and STOP stopper bolt (2) with nut (3) or
ball joint (4), then lock in position.
2. Turn the stop motor ON/OFF ten times, F56103034

then check the clearance @ again. If necessa-
ry, adjust clearance @) again with the nut.
+ Check that the engine stops.
Clearance @: 1 * 0.5 mm
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER
VALVE
A Raise the dump

the safety pin.
body and lock it with
A The
careful
oil is at high temperature,
not to get burned.
so be
Always remove and install the plugs and

A hydraulic pressure gauge with the
engine stopped.
* Measure the oil pressure at the specified oil

temperature.
l For details, see the Standard Values Table.
l Using the following table for reference, install
tool C or tool S to the measurement plug.
Measurement location Gauge
1 Main relief pressure 60 (C)

2 Torque converter inlet port pressure
W) JO(S)
3 Torque converter outlet port pressure 25 , o (C) (6)

(OUT) ’
4 Torque converter lock-up pressure (LU) 60 (Cl
8 1. Measuring main relief pressure

z Place the gearshift lever at N, and measure F56103036
8 the main relief pressure at low idling and
Connection diagram
high idling.
N
she&er
Mcd”l.ll0” cable
C0nnectmn
6
2. Measure the hydraulic pressure at the
torque converter inlet port (relief).
3. Measure the hydraulic pressure at the
torque converter outlet port (regulator).
Place the gearshift lever at N, and measure
the torque converter inlet port and outlet port
pressure at low idling and high idling.
4. Measuring torque converter lock-up

(7,
sable
Connectlo”
pressure F56103040
1) Disconnect the connector from the trans-
mission controller, and install tools N and
Connection diagram
0.
2) With the speed range of tool 0 at neutral,
turn the lock-up ON.
3) Measure the lock-up pressure at low
idling and high idling.
* For delails of the procedure for operating
the shift checker and modulation checker,
see PROCEDURE FOR OPERATING SHIFT
CHECKER + MODULATION CHECKER.
Connenlon cable (7,
F56103041
20-19
0
TESTING ECMV HYDRAULIC PRESSURE
(Using shift checker -t modulation checker)
A Stop the
block the tires.
machine on fiat ground and
Raise the dump body and lock it with

A
the safety pin.
A The
careful
oil is at high
not to get burned.
temperature, so be

A
hydraulic pressure gauge with the
engine stopped.
1. Transmission modulating pressure (clutch

circuit pressure)
* Measure the hydraulic pressure at the
specified oil temperature.
l For details, see the Standard Values
Table.
1) Measure the main relief pressure and
check that it is normal.
2) Using the following table for reference,
install tool C (all gauges are 60 kg/cm*)
to the ECMV of the clutch to be measured.
Plug No. Hydraulic circuit measured
(I) H clutch
F56103037
(2) L clutch
(3) 4th clutch
(4) 3rd clutch
(5) R clutch Combination of clutches
(6) 2nd clutch
(7) 1 st clutch
3) Install tools N and 0.

* For details, see PROCEDURE FOR
OPERATING SHIFT CHECKER + MOD-
ULATION CHECKER.
4) Operate checker 0 with the engine at low
idling, and shift to the speed range to be
measured.
5) Measrue the hydraulic pressure of the
circuit with the engine at low idling and
high idling.
Note: To protect the clutch, always run the
engine at low idling when operating
checker 0.
A In low speed ranges, the machine

move, so put blocks under the tires, apply
may
the parking brake, and also depress the

service brake.
TESTING ECMV OIL PRESSURE (Using fixed valve)
A Raise the dump body and lock it with the safety

pin.
A The oil is at high temperature, so be careful not
to get burned.
A Always remove and install the plugs, hydraulic
pressure gauge, and fixed valve with the engine
stopped.
A Block the wheels, apply the brake, and place the
shift lever at the N position.
A When measuring the oil pressure using a fixed
valve, never measure 2 places at the same time.
+ Before replacing the fixed valve assembly, clean the

area around the ECMV, and remove all mud and dirt.
1. Measuring transmission modulating pressure

(Clutch circuit pressure)
1) Raise the transmission oil temperature.
+ Oil temperature when measuring: 60 - 80°C
2) Check that there is no abnormality.
For details, see TESTING TORQUE CONVERTER
MAIN RELIEF PRESSURE.
3) Remove plugs (1) - (7) .from the pressure
measuring points, and install tool C (60 kg/cm2).
Plug No.
Circuit Plug No.
Circuit
measured measured
T: \ \\I 1’566F06139
(1) H clutch (5) R clutch
:
(2) L clutch (‘5) 2nd clutch
(3) 4th clutch (7) 1 st clutch
(4) 3rd clutch - -
4) Disconneci connectors (8) and (9).

+ Connector No.: CNTM3, TM4
5) Disconnect connectors (10) and (11) of the
proportional solenoid for the clutch where the
oil pressure is being tested.
6) Using tool T2, remove proportional solenoid (12)
for the clutch where the oil pressure is being
tested.
7) Assembly of fixed valve assembly (tool Tl)
i) Assemble spring (14) to cover (13).
ii) Refer to the table below and select necessary Tl __
spacer (15) for the clutch where the oil
pressure is being measured.
+ There are three types of spacer: each spacer
has a stamped mark showing the number
of the clutch for which it is used
Clutch measure- Spacer used when

ment location measuring
H clutch
Stamped
566FO6142
mark
3rd clutch
R clutch
Stamped
1 st clutch mark
2nd clutch
iii)Assemble valve (16).

iv) Assemble the O-ring at the matching surface
of the ECMV and proportional solenoid to the
fixed valve cover.
8) Using tool T2, install fixed valve assembly (17)
to the ECMV.
m Mounting bolt of fixed valve assembly:

1.35 + 0.15 kgm
9) Start the engine and measure the hydraulic pres-
sure with tool C.
* Note that the pressure measured using the
fixed valve .is different from the set pressure
for the hydraulic pressure when installed on
the machine.
10) After measuring, remove the fixed valve assem-
bly, then install the proportional solenoid valve.
* Always be sure to install the O-ring used with
the fixed valve to the proportional solenoid
valve.
566FO6144
w Mounting bolt of proportional sole-
noid valve: 1.35 f 0.15 kgm
2o-E-2
TESTING TRANSMISSION LUBRICATION PRESSURE
A
Raise the dump body and lock it with
the safety pin.
The oil is at high temperature, so be
A careful not to get burned.
A hydraulic pressure gauge with the
engine stopped.
* Measure the hydraulic pressure at the

specified oil temperature.
l For details, see the STANDARD VALUES 1
561 F03353
TABLE.
1. Remove plug (1) and install tool S (10 kg/
cm2).
2. With the gearshift lever at N, measure the

hydraulic pressure at high idling.
2o-2”1
TESTING TORQUE CONVERTER STALL SPEED
A Stop the machine on flat ground and block the

tires.
1. Remove rotation pickup port cover (1). and install

tool A2.
2. Raise the engine water temperature to the operating
range.
3. Measure the engine high idling and low idling
speeds.
* If the speed is too low, check the movement of
the linkage between the accelerator pedal and
fuel pump, and check that the accelerator lever
of the fuel pump contacts the FULL stopper.
4. Raise the temperature of the hydraulic oil and
transmission oil.
* Oil temperature when measuring: I A3
Hydraulic oil 50 - 80°C
Transmission 70 - 9o”c
5. Apply the parking brake and depress the brake pedal
fully, then place the gear shift lever at the D position
or use the checker and set to the F7 position.
* For details of the method of using the shift
checker, see “Procedure for operating shift
checker-t modulation checker”.
6. Depress the accelerator pedal gradually and stall
the torque converter with the engine at full throttle.
If the oil temperature exceeds 90°C (position A on
the green range of the torque converter oil
temperature gauge lights up), lower the engine
speed to low idling and return the gear shift lever
to the “N” position. Red
With the gear shift lever at “N”, run the engine
at a mid range speed and lower the oil temperature \ I
until position B on the green range of the torque
(90- 110°C )A
converter oil temperature gauge lights up.
Lower the engine speed to low idling, carry out the
above Steps 4) to 6) again to make the oil
(70-9O”c)B
temperature of the torque converter and transmis-
sion uniform, then measure the stall speed when
the oil temperature is approx.80% (position B on
the green range of the torque converter oil
561 F03355
temperature gauge lights up).
* Measure the stall speed two or three times.
A Do not operate the gear shift lever with the

accelerator pedal depressed.
This will cause a violent shock and will also reduce
the life of the machine.
2o-E-41
* The stall speed may very according to the following
conditions, so always measure the stall speed at
the time of delivery.
1) Variations according to the engine serial number
2) Variations in engine output due to atmospheric
pressure and temperature
3) Variations in consumption torque of accessories
4) Variations due to features of the torque converter
5) Variations according to the method of measuring
the stall
TESTING BRAKE PRESSURE
A Stop the machine on level ground, apply
the parking brake, and put blocks under
the tires.
1. Rear brake actuating pressure

1) Raise the air pressure to the specified
pressure.
2) Remove air bleed plug (l), and install tool
C (hydraulic pressure gauge: 60 kg/cm2).
3) Measure the hydraulic pressure when the
brake pedal and retarder lever are operated.
t After measuring the hydraulic pressure,
install the plug and bleed the air.
2. Front brake actuating pressure

1) Raise the air pressure to the specified
pressure.
2) Remove air bleed plug (2) or (3), and
install tool C (hydraulic pressure gauge:
400 kg/cm2 1.
3) Measure the hydraulic pressure when the
brake pedal is operated.
* After measuring the hydraulic pressure,
install the plug and bleed the air.
20622
BLEEDING AIR FROM BRAKE
CIRCUIT
+ Start the engine and wait for the gauge to

enter the green range, then bleed the air from
the circuit as follows.
1) Rear brake
+ Bleed the air at the slack adjuster end first.
i) Depress the brake pedal, then loosen air
bleed plugs (1) or (2) 3/4 turns. Tighten
the plug again, then release the pedal.
ii) Continue this procedure until no more
bubbles come out from the air bleed plug
hole, then bleed the air from the wheel end
(Pkl (3)).
+ After bleeding the air, close the plug and
fit the cap.
2) Front brake
* The oil tank is separately installed, so
always check the oil level while bleeding
the air.
l Loosen plug (41, and bleed the air in the
same way as for the rear brake.
8
z
z
TESTING WEAR OF FRONT BRAKE PAD
A Stop..the machine on level ground, apply
the tires.
Checking
Check visually, and if the pad has reached the
wear limit line, replace the pad.
1) If the stepped part of the gauge contacts
the mouth of the hole, the pad has reached
the wear limit, so replace it.
Replace the pads on the left and right sides at
the same time.
The pad wear is not the same for both left
and right sides, so check the wear of all pads.
TESTING WEAR OF REAR BRAKE DISC
A Stop the machine on level ground, apply

the tires.
A Install and remove plugs and gauges with
the brake lubricating oil temperature below
60°C and with the retarder brake lever at
the OFF position.
1. Remove air bleed plug (1) of the rear brake,
and install disc wear measurement gauge 0.
2. Raise the air pressure to the specified pressure.
3. Pull the retarder brake lever fully, push in
the rod until it contacts the piston, then
check the position of the stamped mark on
the rod.
Face of the case
* If the stamped mark on the rod goes in
beyond the end face of the case, the disc
has reached the wear limit.
4. After measuring the wear, install the air bleed
plug, and bleed the air.
For details, see BLEEDING AIR FROM
BRAKE CIRCUIT.
566F1210
ADJUSTING PARKING BRAKE
rl
A Stop the machine on level ground, and

put blocks under the tires.
1. Turn bolt (1) clockwise and bring both pads

(2) into close contact with disc (3).
* Push in bolt retainer 0 of slack adjuster

(4) until the bolt can turn, then turn bolt
(5) clockwise.
2. Turn bolt (1) back from this position coun-

terclockwise 360° + 15O.
* Standard clearance: Total for both clear- F56103043

antes = 1.88 + 0.08 mm.
2 r----
* After adjusting the clearance, actuating
stroke @ of the rod is approx. 50 mm.
* After adjusting, return bolt (1) to a position

where it stops bolt (5) from turning.
F56 103044
F56103045
20-25
co
TESTING BRAKE PERFORMANCE
Measurement conditions
Air pressure: 8.3 f 0.3 kg/cm2
Hydraulic oil temperature: 50 - 80°C
Engine water temperature: Within operating
range
Transmission oil temperature: 70 - 90°C
A Stop the machine on a horizontal road

surface, and check that there is no one
around the machine before carrying out
the check.
1. Measurement items
1) Parking brake
2) Service brake (front -t- rear brake)
3) Retarder brake (rear brake only)
4) Emergency brake (parking brake + service
brake)
2. Measurement procedure
1) Install the engine tachometer.
For details, see Measuring torque conver-
ter stall speed.
2) Measure Items 1) - 4).
0 Raise the air pressure to the maximum,
operate each brake in Items 1) - 4)
individually, and set the gear shift lever
at the “D” position.
ii) Gradually depress the accelerator
pedal to raise the engine speed, and
measure the engine speed at the point
where the machine starts to move.
20-25-l
co
TESTING AND ADJUSTING SUSPENSION CYLINDER
(With variable damping force selector valve)
+ Stop the machine empty on flat ground.
1. Testing length of cylinder

1) Check that the bottom of the cylinder
cover is within the range marked by
arrows for the cylinder level.
2) Before adjusting the oil level in the front
suspension cylinder, check the condition
of the variable damper valve.
t With the truck empty, starting switch [ ~ ] 569F104
ON, parking brake OFF, and hoist

control lever at the FLOAT position,
check that the air cylinder of the vari-
able damper valve is in the soft mode.
* If the air cylinder of the variable damper
I
valve is not in the soft mode when
checking, operate as follows to switch to
the soft mode. (Note 1)
i) Fill with air, use the retarder brake and
drive the machine several times re-
peatedly forward and in reverse to set to
the soft mode.
Note 1: If the foot brake pedal is used,
the automatic suspension is F56103046 cr)
automatically set to the medi- 0
z
um mode, and the resistance of
.8
the cylinder increases, so it
takes time to adjust.
2. Releasing nitrogen gas a
1) Front suspension cylinder
i) Set hydraulic jack @ (50ton) under the
main frame.
ii) Disconnect pressure sensor connector (2)
of oil level valve (l), then loosen the oil
level valve 2 - 3 turns.
* When releasing the nitrogen gas, there is
Front
danger that releasing the gas from the c
valve core of supply valve (3) will \\\\\\ \
damage the valve core, so remove the gas 569F105
561F106A-K
at the oil level valve.

Ir When loosening the oil level valve, loosen
only the valve itself. Do not loosen the
pressure sensor or nipple.
Ir When the oil level valve is loosened, and
oil and gas spurt out together, tighten
the valve slightly, and allow time for the
gas to escape slowly.
iii) Operate the hydraulic jack @ so that
dimension a of the cylinder is the spe-
cified dimension for the oil level.
Dimension a: 97 +_3 mm
F56103047
2) Rear suspension cylinder
i) Dieconnect pressure sensor connector
(2) of the oil level valve.
+ The precautions when handling the oil
level valve are the same as when releasing
the nitrogen gas from the front suspen-
sion cylinder.
ii)Set block @ between the stopper and
axle housing.
Thickness of block: 40 mm
iii)Loosen oil level valve (1) slowly 2 - 3
turns, and release the nitrogen gas from
inside the cylinder.
561F106A-K
3. Adjusting oil level

* Release the nitrogen gas before adjusting
T: the oil level.
z
s 1) Remove supply valve (3), and install
joint A,.
2) Install fitting A4 to joint AS, then con-
nect hose A2 and volume pump AI.
3) Loosen air bleed valve (4), then operate
volume pump A, until no more bubbles
come out with the oil from air bleed side
hole @ .
4) When no more bubbles come out with
the oil, tighten air bleed valve (4).
5) Remove oil level valve (l), then operate
volume pump A, until no more bubbles AI
come out with the oil from the oil level
Ld
valve mount.
6) When no more bubbles come out with
the oil, tighten the oil level valve. 561F106A-K
7) After completion of supplying the oil,

remove the volume pump, then install
supply valve (3).
4. Filling suspension cylinder with gas
11 Remove supply valve cap (5).
21 Set tool A as shown in the diagram.
* Before installing regulator AS, blow the
connector filter with nitrogen gas at 10
kg/cm* or more to blow out all dirt or
dust. (Dirt or dust in the system causes
failures.)
3) Open valve@of the gas cylinder, and 569F106
check the pressure reading of gauge A5 a

(internal pressure of gas cylinder).
* The pressure indicated must be at least
10 kg/cm* higher than the pressure
inside the suspension cylinder (max.
pressure inside suspension cylinder: 40
kg/cm* 1.
4) Turn handle@of regulator A5 slowly
clockwise, set the pressure reading of :vlinder
gauge A,b to 10 kg/cm* above the

internal pressure of the suspension cyl- As ‘I
inder, then operate valves A, and A4 to @chAZ
fill the suspension cylinder with nitrogen 569F107-K
gas. 0”
* Fill the left and right cylinders in the

z
8
same way.
5) When dimension a of the left and right
cylinders reaches the standard value,
turn handle@of regulator A5 counter-
clockwise to stop the flow of nitrogen
gas.
* Standard dimension a: See STANDARD
VALUE TABLE.
6) Turn handle@of A4 fully back coun-
terclockwise, loosen air bleed plug@,
release the gas inside the hose, then re-
Front 1 1 569F106
move tool A.
* Be careful not to lose the O-ring of the
supply valve.
569F109
5. Adjusting installed length of cylinder
* Carry out adjustment of the installed
length of the cylinder with the machine
empty and on level ground.
1) To remove the sliding resistance of the
cylinder (catching of bushing or pack-
ing), drive the machine forward approx.
15 m and stop suddenly, then drive in
reverse to the original position and stop
again suddenly. Repeat this cycle 3 - 4
times, and finally, allow the machine to
stop slowly without depressing the
brake. Then measure the installed
length.
* Do not use the foot brake when braking
the machine. Use the retarder control
lever to brake the machine, and check
that the suspension is in the soft mode.
2) If the result of the check shows that the
installed length is too long, release nitro-
gen gas to adjust the length.
* Loosen the oil level valve slightly to re-
lease the nitrogen gas. When doing this,
release only a small amount of gas; do
8 not make the cylinder move.
‘, * If too much nitrogen gas is released and
!s the cylinder moves, the installed length
may be below the specified length.
t Do not press the tip of the valve core. If
the tip of the valve core is pressed, the
valve core may be damaged.
31 After releasing nitrogen gas and adjusting
the installed length, repeat Step 1) to
check the installed length again.
4) Repeat the above Steps 1) - 3) to adjust
the cylinder to the specified length.
5) Finally, check that there is no leakage of
gas from the valve core, oil level valve,
and piston rod gland.
* Use soapy water to check for leakage of
gas.
* If there is any leakage of gas from the
valve core, use tool A, and remove the
valve core. 569FllO
Note: 1. Checking after changing oil and gas
After the oil and gas have been
changed, operation of the machine
causes the gas to dissolve in the new
oil inside the cylinder until it is
saturated, so the volume of gas is
reduced and the installed length of
the suspension goes below the speci-
fied limit. Therefore, 48 hours after
changing the oil and gas, check the
installed length of the suspension
and adjust the gas if the length is not
within the specified value.
2. Checking for changes in installed
length caused by variation in am-
bient temperature.
Depending on the ambient tempera-
ture when the machine is working,
the gas in the suspension may ex-
pand or contract, so the installed
length will also change. In territories
where there are big differences in
temperature throughout the year,
inspect daily and adjust to keep the
installed length within the specified
ranege.
TESTING AND ADJUSTING INVERTED TYPE REAR
SUSPENSION CYLINDER
* Stop the machine empty on flat ground.
1. Testing length of cylinder

Check that dimension “a” of the rear suspension
cylinder is within the specified value.
Specified value for dimension “a”: 239 f 10 mm
561 FO3401
2. Releasing nitrogen gas

1) Rear suspension cylinder
i) Set block @ between the stopper and axle
housing.
Thickness of block: 40 mm
[Dimension a: 149 5 3 mm (reference)]
56 1 FO3402
ii) Disconnect pressure sensor connector (2) of 1 4 5 2

Slit
oil level valve (l), then loosen the oil level
valve 2 - 3 turns.
* When releasing the nitrogen gas, there is
danger that releasing the gas from the valve
core of supply valve (3) will damage the valve
core, so remove the gas at the oil level valve.
* When loosening the oil level valve, loosen
only the valve itself. Do nto loosen the
561 FO3403
pressure sensor or nipple.
A When
gradually
loosening
loosen
the oil level
only valve (1) itself,
valve,
and
do not remove the valve until all the
nitrogen gas has been released from the
slit.
A If the
released,
nitrogen
pressure
gas has
sensor
not all
(5) and nipple
been
(4) are still underhigh pressure, so do not

loosen them under any circumstances.
When the oil level valve is loosened, and

oil and gas spurt out together, tighten the
valve slightly, and allow time for the gas
to escape slowly.
661 FO3404
20-30- 1
@B
3. Adjusting oil level
Ir Release the nitrogen gas before adjusting the
oil level
1) Remove supply valve (3). and install joint A5.
2) Install fitting A4 to joint A3, then connect hose
A2 and volume pump Al.
3) Loosen air bleed valve (4), then operate volume
pump Al until no more bubbles come out with
the oil from air bleed side hole 8.
4) When no more bubbles come out with the oil,
tighten air bleed valve (4).
5) Remove oil level valve (I), then operate volume
pump Al.
6) When no more bubbles come out with the oil,
tighten the oil level valve.
7) After adding oil, remove the volume pump, then
install supply valve (3).
561 FO3405
4. Filling suspension cylinder with gas
1) Remove supply valve cap (5).
2) Set tool A to the supply valve as shown in the
diagram.
* Before installing regulator A5, blow the filter 8
in the connector with nitrogen gas at 10 kg/ z
cm2 or more to blow out all dirt or dust. (Dirt 8
or dust in the system causes failures.)
561 FO3406
3) Open valve @ of the gas cylinder, and check

the pressure reading of gauge A5a (internal
pressure of gas cylinder).
+ The pressure indicated must be at least 10
kg/cm* higher than the pressure inside the
cylinder (max. pressure inside cylinder: 25
kg/cmz).
4) Turn handle @ of regulator A5 slowly clock-
wise, set the pressure reading of gauge A5b 0
to 10 kg/cm* above the internal pressure of itrogen gas cylinder
the cylinder, then operate valves Al and A4

to fill the cylinder with nitrogen gas.
* Fill the left and right cylinders in the same
way.
569F107.K
20-30-2
a@
5) When dimension “a” of the left and right
cylinders reaches the standard value, turn
handle @ of regulator A5 counterclockwise to
stop the flow of nitrogen gas.
* Standard dimension a: Rear 239 f 10 mm
6) Turn handle @ of A4 fully back counterclock-

wise, loosen air bleed plug 0, release the gas
inside the hose, then remove tool A
j, Be careful not to lose the O-ring of the intake
valve.
561 FO3401
5. Adjusting installed length of cylinder

Ir Carry out adjustment of the installed length of
the cylinder with the machine empty and on level
ground.
1) To remove the sliding resistance of the cylinder
(catching of bushing or packing), drive the
machine forward approx. 15m and stop sud-
denly, then drive the machine forward approx.
15m and stop suddenly, then drive in reverse
to the original position and stop again suddenly.
Repeat this cycle 3 - 4 times, and finally, allow
the machine to stop slowly without depressing
the brake. Then measure the installed length.
+ Do not use the foot brake when braking the
machine. Use the retarder control lever to
brake, the machine, then check that the
suspension is in the soft mode.
2) If the result of the check shows that the installed
length is too long, release nitrogen gas to adjust
the length.
* Loosen the oil level valve slightly to release
the nitrogen gas. When doing this, release
only a small amount of gas; do not make the
cylinder move.
+ If too much nitrogen gas is released and the
cylinder moves, the installed length may be
below the specified length.
* Do not press the tip of the valve core. If the
tip of the valve core is pressed, the valve
core may be damaged.
3) After releasing nitrogen gas and adjusting the
installed length, repeat Step 1) to check the
installed length again.
4) Repeat the above Steps 1) - 3) to adjust the
cylinder to the specified length.
20-F3 I
5) Finally, check that there is no leakage of gas
from the valve core, oil level valve, and piston
rod gland.
* Use soapy water to check for leakage of gas.
Ir If there is any leakage of gas from the valve
core, use tool A5 and remove the valve core.
QZEl Valve core: 1.7 - 3.5 kgcm
Valve core
561 FO3407
6. Testing and adjusting dust cover

* To protect the rear suspension from stones and
other objects thrown up by the tires when the
machine is traveling, carry out inspection of the
cover and repair or replace it as necessary.
1) Check visually that there are no cracks or breaks
in cover (1).
+ If the cover is damaged, replace it with a
new part.
2) Check that hooks (2) are not missing. (3 places)
+ If any hooks are missing, remove all mud
and dirt, then install hooks.
3) Check that band (3) is not loose or missing.
+ If the band is loose or missing, tighten to
the following torque.
m Band: 69 f 5 kgcm
561 FO3408
2o-F-4 1
TESTING AND ADJUSTING SUSPENSION AIR CYLINDER
* Fill the air tank completely with air.
1) Testing
i) Check that installed dimension a of the
air cylinder is within the standard value.
Standard dimension a: 34.6 f 1 mm
ii) With the starting switch ON, check that
lever (1) of the air cylinder is offset b
from horizontal when the work equip-
ment control lever is operated to any
position except FLOAT.
Air cylinder offset angle: 9” f 30’
2) Adjusting
i1 Loosen locknut (2) of the air cylinder,
and adjust rod end (3) to set to installed
standard dimension a, then tighten lock-
nut (2).
ii) With the starting switch ON, check that
lever (1) of the air cylinder is offset b
from horizontal when the work equip-
ment control lever is operated to any
position except FLOAT.
Air cylinder offset angle: 9” f 30’
iii) In the correctly installed condition, the a
8 slit of lever (1) must face in the same
Z direction as the hole in the bracket, and
8 the range limit must be within 3 mm.
‘I
b
14
F56 103048
ole
F56103049
20-3 1
@a
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT
Testing
Run the engine at full throttle and check that
the indicator of the panel gauge is in the green
range.
Adjusting
If the air pressure is not within the standard
value, adjust as follows.
l Remove the cap, then loosen the locknut
and turn adjustment screw (1) to adjust.
* Set pressure: 8.3 + 0.3 kg/cm2
* Adjust with the screw as follows.
To INCREASE pressure,
turn COUNTERCLOCKWISE
To DECREASE pressure,
turn CLOCKWISE
20-32
0
ADJUSTING HOIST LEVER LINKAGE
* Lock the control levers inside the cab in the

HOLD position with the lock plate on the
console box.
* Install and connect the push-pull cable so that
there is no twisting or slack.
1. Set hoist valve lever (1) in the HOLD position.
2. Disconnect push-pull cable (2) and hoist

valve lever (1). and adjust the length of the
cable at yoke (4). Then connect push-pull
cable (2) and hoist valve lever (l), check
standard dimension (A), and tighten the
locknut.
Standard dimension @ : 198.5 mm
F56103051-1
3. Adjust intermediate rod (3) to standard
dimension @.
Standard dimension @ : 509 mm
4. Connect push-pull cable (2) to intermediate

lever (5), adjust to standard dimension 0,
then tighten the locknut.
8
z Standard dimension @ : 203.5 mm
g
5. After adjusting, release the lock plate on the
consol box, and check that the travel from
HOLD to RAISE is the specified value @
when the control lever is operated to RAISE.
Standard dimension @I : 15 mm
F56103052
F56103053-1
20-33
co
ADJUSTING BODY POSITIONER
1. Set hoist value lever (3) in HOLD position
2. Adjust push cable (1) to the standard length.
Standard length @) : 180.25 mm
3. With the dump body raised to a point 50

mm before the end of the hoist cylinder
stroke, adjust plate (2) so that the hoist valve
lever is reieased from the detent.
Reference dimension @ : 147 mm

F56103054-1
F56103055
20-34
69
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
STEERING, HOIST CIRCUIT
A Stop the machine on level ground, apply the

parking brake, and put blocks under the tires.
Lower the body to the frame, stop the engine,
,A then loose the cap of the hydraulic tank and
release the pressure inside the cylinder
circuit.
A
hydraulic pressure gauge with the engine
stopped.
1. Measuring hydraulic pressure in steering circuit

1) Raise the hydraulic oil temperature.
* Oil temperature when measuring:
50 - 80°C
2) Remove plug (1) and install tool C (400 kg/
cm*).
3) Operate the steering wheel fully to the left or
right, and measure the hydraulic pressure with
the engine full throttle and low idling when
the circuit is relieved.
2. Adjusting hydraulic pressure in steering circuit

If the hydraulic pressure is not within the
standard value, adjust as follows.
l Steering pressure (adjust with demand valve)
1) Loosen locknut (2) and turn adjustment screw
g (3) to adjust.
z * To INCREASE pressure, turn CLOCKWISE
z To DECREASE pressure, turn COUNTER- F56103057
CLOCKWISE
* One turn of the adjustment screw adjusts
by 128 kg/cm*.
2) After adjusting, hold the adjustment screw
with a screwdriver to prevent it from turning,
then tighten the locknut and install the cap.
3) Check again so that the hydraulic pressure is
within the specified value.
l-
j, The pressure of crossover relief valve (4)
cannot be adjusted when it is installed on the
machine, so do not adjust the pressure.
<
3. Measuring steering valve discharge pressure
1) Remove plug (5) and install tool C (400 kg/
cm*). r
2) Measure in the same way as when measuring
the hydraulic pressure in the steering circuit.
4. Measuring hydraulic pressure in steering

cylinder
Remove pressure measurement plug (6) (when
turning the steering to the left) or pressure
measurement plug (7) (when turning the
steering to the right), and install tool C (400
kg/cm*).
Measure in the same way as when measuring
the hydraulic pressure in the steering circuit.
20-35
0
5. Measuring hydraulic pressure in hoist w I II
circuit
1) Raise the hydraulic oil temperature.
* Oil temperature when measuring:
50 - 80°C
2) Remove pressure measurement plug (1)
and install tool C (400 kg/cm).
3) Operate the hoist control lever, and move
the raise or lower position to relieve the
circuit, then measure the hydraulic
pressure with the engine at full throttle
and low idling.
* If the hoist lever is operated to the
RAISE position beyond the point where
the kick-out takes effect, the body will
rise and the hoist circuit will be
relieved.
6. Adjusting hydraulic pressure in hoist

circuit
If the hydraulic pressure is not within the
standard value, adjust as follows.
Hoist cylinder pressure (adjust with hoist
valve)
1) Loosen locknut (2) and turn adjustment
screw (3) to adjust.
Ir To INCREASE pressure, turn CLOCK-
WISE
To DECREASE pressure, turn COUN-
TERCLOCKWISE
* One turn of the adjustment screw
adjusts by 52.9 kg/cm*.
2) Adter adjusting, hold the adjustment
screw with a screwdriver to prevent it
from turning, then tighten the locknut and
install the cap.
3) Check again so that the hydraulic pres-
sure is within the specified value. F56i 03061
7. Measuring hoist cylinder pressure

1) Remove plug (4) and install tool C (400
kg/cm*).
2) Measure in the same way as when
measuring the hydraulic pressure in the
hoist circuit.
20-36
co
AIR BLEEDING FROM STEERING CYLINDER
t When removing or installing hydraulic cylin-
ders or pipings, bleed air as follows.
1. Start engine, run engine at low idling for

5 minutes.
2. Turn the steering wheel at 30 rpm (2 seconds

for one turn) to the left and right to a point
approx. 50 mm from the end of the steering
cylinder stroke.
Repeat this action ten times.
(This action is to prevent damage to the
piston seal caused by compression and com-
bustion of air in the steering cylinder.).
3. Turn the steering wheel at 30 rpm to the left

and right to the end of the steering cylinder
stroke.
Repeat this action four times.
4. Turn the steering wheel as quickly as possible

to the left and right to the end of the steering
cylinder stroke.
When reaching the end of the stroke at the
c) left and right, turn the steering wheel im-
0
G mediately in the opposite direction, and
g carry out this action continuously.
Repeat this action ten times in both direc-
tions.
20-37
0
ADJUSTING ENGINE SPEED SENSOR
1. Screw in sensor (1) by hand until the tip of
sensor (1) contacts gear (2).
* When putting the tip of the sensor in

contact with the gear, tighten lightly by
hand, and confirm that it is in contact.
Never tighten with a wrench or any other
tool.
2. Turn back 3/4 - 1 turn from the point where

sensor (1) contacts gear (2).
3. Tighten locknut (3).
w Locknut : 6 f 1 kgm
* Be careful to arrange the sensor wiring so

that there is no excessive force brought to
bear on the wire.
* Be careful not to damage the tip of the
sensor or get iron particles stuck to it.
Standard clearance: 1.38 + 0.13 mm
205FO5222
20-38
0
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN
REPLACING ENGINE CONTROLLER
Place to fill in
l FOR ENGINES WITH ELECTRONIC Q adjustment No.
GOVERNOR
1
+ When replacing the engine controller, adjust
the 0 adjustment switch and seal it.
1. Before replacing, check seal (1) on the

controller and name plate (2) on the engine
to confirm the engine controller Q
adjustment number.
2. Using a screwdriver, turn Q adjustment 3 561 F03307A

rotary switch (3) of the controller to be 2
replaced, and adjust the Q adjustment
\
number.
3. Write the adjusted number on the controller

seal.
* Use an oil-based ink pen or ball pen to
prevent the number from fading or
disappearing.
4. Remove the backing of the seal, and stick

the seal in position. 56 1 F03308A
8
;;
8
20-38-l
CD
ADJUSTING MACHINE MONITOR MODULE
(For speedometer and tachometer)
The module for speedometer and tachometer on the

machine monitor are the same for all machine
models, but the input signals for each machine model
are different, so these modules must be adjusted to
match the machine.
In addition, the tire diameter differs according to the
type of tire being used. This means that these
modules must also be adjusted to match the tire
diameter.
Rotatv switch
PROCEDURE FOR ADJUSTMENT
l Turn off the power source, then remove the
machine monitor and adjust with the switches at
the back of the speedometer.
For speedometer module: Switches 1 and 2
For tachometer module: Switch 3
1) Remove the rubber caps from the switches that

are to be adjusted at the back of the speedometer.
2) A rotary switch can be seen inside. Insert a flat-

bladed screwdriver into the rotary switch and turn
F41E01113
as shown in the diagram on the right to adjust
to the values in the table below.
Tire size Switch 1 Switch 2 Switch 3
27.00-49(OP) 1 9 1 c 1 0
24.00-49(STD) ) 9 ) D ) 0
3) After completing adjustment, fit the rubber caps

securely, and install the machine monitor.
Reference Compensation values for switch 2
Switch position 0 1 2 3 4 5 6 7
Suitab;;)setting +14 +12 +lO +8 +6 +4 $2 0
Switch position 8 9 A I3 C D E F
Suitab$$etting 0 -2 -4 -6 -8 -10 _1 2 -14
20-38-2
0
PROCEDURE FOR OPERATING SHIFT CHECKER AND
MODULATION CHECKER
PROCEDURE FOR OPERATING A-TYPE
SHIFT CHECKER + MODULATION CHECKER
1. General locations
A. Shift checker (Part No. 792-201-6105)
8) Transmission input/output speed selector switch

1) Speed pickup indicator (normally IN)
2) Speed sensor output check terminal 9) H clutch pilot lamp
3) Ground terminal 10) L clutch pilot lamp
4) Indicatorselector switch (OTHERS) 11) Manual shift switch (normally N)
5) Manual lockup switch (normally OFF) 12) Shift range pilot lamp
6) Lockup pilot lamp 13) Model selector switch (do not press)
7) F7/Rl,, F8/Rl selector switch (normally ON) 14) Output connector (connector to modulation
checker)
3 2.4 5 8 6 7 13 14
F56103065
B. Modulation checker (Part NO. 799-607-1001)
@ Modulation signal measurement terminal for H,

L clutch
@ Modulation signal measurement terminal for 4,

3, R, 2, 1 clutch
@ Fill switch signal lamps
F56603066-1 K
20-39
co
2. Procedure for connecting checker
1) Check that the starting switch is OFF.
2) Disconnect connectors (21, (31, (41, and

(5) of transmission control box (1).
3) Connect connection cable (6) to connec-

tors (21, (31, (41, and (51, and connect F5610306
the other end of the cable to modulation

checker N.
4)Connect shift checker 0 and modulation

checker N with connection cable (7).
Connection diagram
Modulation checker N Connection cable (6) I]

\
Shift checker 0 (A type)
5 ‘;’
t
\
.;ii Chassis wiring harness
s F-e_ (to modulation valve)
; 6 i, .-.
Connection (7)
F56103040-1 K
20-40
63
3. Procedure for operating manual shift
1) Put each switch in the following positions.
H M 6 5 4 c A
Switch Position
@ OFF
@ N
0 OFF
@ OFF
0 OTHERS
@ ON
0 IN
OFF
b\
@
2) Check that the parking brake is ON.

B J
3) Start the engine. F56103068
4) Run the engine at low idling and depress the
brake pedal.
5) Check that all the fill switch lamps on the
modulation checker are OFF.
1
If any fi,ll switch lamp is ON, there is a failure in Table 1
that valve system, so operate as shown in Table 1
on the right. If any fill switch lamp is ON, there is a failure in that
If any fill switch lamp is ON, do not operate the valve system, so operate the shift checker as follows
accelerator at the neutral position. according to the lamps that light up.
(There is danger of internal breakage in the trans- * [If the lamps for 2 and above light up]
mission.) The machine cannot be driven using the shift
6) Release the parking brake. checker, so carry out troubleshooting and repairs
7) Run the engine at low idling and set switch I3 to immediately. For details, see TROUBLESHOOT-
the desired speed position. ING TABLE.
* Check that pilot lamp J for the speed range * [When H clutch lamp lights up]
specified by switch B lights up. Travel is possible in forward only by specifying F3
* Do not carry out any shift operation when travel- with the shift checker.
ing or when depressing the accelerator. * [When L clutch lamp lights up]
8) Release the brake pedal and operate the machine. Travel is possible both forward and in reverse by
specifying R, Fl or F2 with the shift checker.
k [When 1st clutch lamp lights up]
Travel is possible in forward only by specifying Fl
with the shift checker.
k [When 2nd clutch lamp lights up]
Travel is possible in forward only by specifying F2
or F3 with the shift checker.
t [When 3rd clutch lamp lights up]
t [When 4th clutch lamp lights up]
t [When R clutch lamp lights up]
Travel is possible in reverse only by specifying RI
20-41
@
4. Procedure for manual operation of lockup
Switch Position
@ OFF
@ N
0 OFF
@ OFF
0 OTHERS
@ ON
0 IN
@ OFF

/
3) Start the engine.
fi 1 I3 J
41 Run the engine at low idling and depress the
brake pedal. F56103069
5) Check that all the fill switch lamps of the modu-
lation checker are OFF.
If any fill switch lamp is ON, there is a failure
in that valve system, so operate the machine
as shown in Table 1 given for Procedure for
operating manual shift. 1
If any fill switch lamp is ON, do not operate
the accelerator at the neutral position.
(There is danger of internal breakage in the
transmission.)
6) Turn switch M on.
20-42
0
5. Measuring transmission input shaft speed
Switch Position
8 OFF
@ N
0 OFF
@ OFF
0 OTHERS
@ ON
0 IN
@ OFF

1 k \
J
4) Run .the engine at low idling and depress the F56103670

brake pedal.
* If any fill switch lamp is ON, there is a failure
g
1 operating manual shift.
z
* If any fill switch lamp is ON, do not operate
g
transmission.)
6) Read the value shown by the meter.
20-43
@
6. Measuring transmission output shaft speed
1) Put each witch in the following positions.
Switch Position
G9 OFF
@ N
0 OFF
@ OFF
0 OTHERS
@ ON
0 OUT
@ OFF

brake pedal.
5) Check that all the fill switch lamps on the modu-
1
*
* If any fill switch lamp is ON, there is a fai-
lure in that valve system, so operate the
machine as shown in Table 1 given for Proce-
i dure for operating manual shift.
transmission.)
6) Release the parking brake.
7) Operate switch B and select the speed range.
8) Read the value shown by the meter.
20-44
60
7. Measuring clutch pressure Clutch pressure
1) Prepare to measure the clutch hydraulic pressure. pickup port Connector
For details, see TESTING HYDRAULIC PRE-
SSURE OF TRANSMISSION VALVE.
2) Operate switch B of shift checker.
For details, see Procedure for operating manual
shift.
* Operate with the engine running at low idling.
i) The settings of switch B and the clutch to be
measured are as shown in the table below.
R clutch valve
Rear of machine
F56103072
ii) Measure the clutch pressure with a hydraulic

pressure gauge.
If the measurement for the clutch pressure is
not within the standard value, put the tester
in contact with signal measurement terminals
@ and @ of the modulation checker and
measure. If the measurement is as shown in
the table below, there is no abnormality in
the checker; there is a failure in the ECMV or
transmission.
For details of the standard values and the

method of measuring the clutch pressure, see
TESTING AND ADJUSTING, and STAND-
ARD VALUES TABLE.
Note that the pressure measured using the
shift checker + modulation checker is differ-
ent from the hydraulic set pressure when
controled by transmission controller.
MODULATIONCHECKER
F56103078-1K
20-45
Go
PROCEDURE FOR OPERATING B-TYPE SHIFT
CHECKER + MODULATION CHECKER
SHIFT CHECKER II
CD-
n rm
1. General locations and functions

0’
A. Shift checker
@ Display
The model, type, speed, lockup, and
transmission input/output speed are
( displayed 3’
@ Power switch
This switches the power for the
( checker ON/OFF. > F56103074-1 K
@ Keyboard switches
The checker is operated with these
( keyboard switches. >
;\
\ Layout of keyboard switches
B. Modulation checker (Part No. 799-605-l 101)
@ Modulation signal measurement ter-

minal for H, Lclutch
@ Modulation signal measurement ter-
minal for 4,3, R, 2, 1, clutch
@ Fill switch signal lamps
MODULATION CHECKER
F56103066.1 K
20-46
0
2. Procedure for connecting checker
2) Disconnect connectors (2), (3), (4), and

(5) of transmission control box (1).
3) Connect connection cable (6) to connec-

tors (2), (3), (4) and (5), and connect the
other end of the cable to modulation
checker N.
4) Connect shift checker 0 and modulation

checker N with connection cable (7).
Connection diagram
Modulation checker N Connection cable (6)

Transmission
control box
Shift checker 0 (B type)

I
Disconnect
connector
I
Chassis wiring harness
(to modulation valve)
\
Connection cable (7)
F56103041-1K
20-47
co
3. Procedure for specifying model on shift checker
Method of securing checker
1) Use the band to secure the checker to your
right leg.
4) Turn the power switch of the shift checker
ON.
5) Check that the shift checker display is as
follows.
ii?121 1 1 1 ) 1 1
+ The number after the # mark differs

accorcing to the model of shift checker
(there is no display, or “1” is displayed). I
If this display (# mark) is not given, F56103075
there is a failure in the shift checker.
6) Press the keys on the keyboard as follows
to select the model.
B-type checker (Part No. 799-605-1010)
Press rLj
MoD +‘-l FNC + ~+~+~+~~+~+[-q
and H D 0 7 8 5 0 2 is displayed,
so check that the display is correct, and press NTE ,

Q
1st [ j 1 1 j 1 ( is displayed, and this
completes selection of the model.
If the selection is incorrect, an error message

is given, so carry out the selection process again.
B-type checker (Part No. 799-6051110 or 799-605-1001)
and H D 0, 7 8 5 0 3 is displayed,
I I
so check that the display is correct, and press
I I
/sI ( 1 ) 1 ) 1 1is displayed, and this
completes selection of the model.
If the selection is incorrect, an error message

is given, so carry out the selection process again.
20-48
@
4.. Procedure for operating manual siiift Table 1
1) Operate the shift checker to select the machine.
2) Check that the parking brake is ON. If any fill switch lamp is ON, there is a failure in that
3) Start the engine. valve system, so operate the shift checker as follows
4) Run the engine at low idling and depress the according to the lamps that light up.
brake pedal. If the lamps for 2 and above light up
5) Check that all the fill switch lamps of the modu- The machine cannot be driven using the shift
lation checker are OFF. checker, so carry out troubleshooting and repairs
1
* If any fill switch lamp is ON, there is a failure immediately. For details, see TROUBLESHOOT-
in that valve system, so operate the machine ING TABLE.
as shown in Table 1 on the right. When H clutch lamp lights up
* If any fill switch lamp is ON, do not operate with the shift checker.
the accelerator at the neutral position. When L clutch lamp lights up
(There is danger of internal breakage in the Travel is possible both forward and in reverse by
transmission.) specifying R, Fl or F2 with the shift checker.
6) Release the parking brake. When 1st clutch lamp lights up
7) Run the engine at low idling and select the speed Travel is possible in forward only by specifying Fl
range with the keyboard switches. with the shift checker.
For details of operating the keyboard switches When 2nd clutch lamp lights uo
to select the speed range, see Table 2. Travel is possible in forward only by specifying F2
* After operating the keyboard switches, check or F3 with the shift checker.
that the specified speed range is displayed. When 3rd clutch lamp lights up
8) Release the brake pedal and carry out the opera- Travel is possible in forward only by specifying F4
tion. or F5 with the shift checker.
9) Method of changing speed range When 4th clutch lamp lights up
8
z i) Press the CLEAR key on the keyboard.
8 cl
ii) Check that the drsplay shows
When R clutch lamp lights up
Travel is possible in reverse only by specifying Rl
then change the speed range.

* Do not carry out any shift operation when
traveling or when depressing the accelerator. Table 2
10) After completion of the operation, press the

Shift checker display
Selection Method of SeleCtiOn I
key on the keyboard.
20-49
co
1) Operate the shift checker to select the machine. b %
SHIFT CHECKER II
Display _
brake pedal.
---mDmxm
If any fill switch lamp is ON, there is a failure
1
operating manual shift.
transmission.)
6) Operate the keyboard as follows to select lockup.
Check thet the display is
*
After completion of the operation, press the
L-l AR key on the keyboad.
20-50
8
6. Measuring transmission input speed
3) Start the engine. SHIFT CHECKER II
4) Run the engine at low idling and depress the Display -
brake pedal.
; operating manual shift.
transmission.)
6) Operate the keyboard as follows.
7) Read the shift checker display. 569FO5128
Checker display
N ! 6 0 0
t t
Selected Measured value for
speed range rotating speed
LEAR key on the key board.

El
20-51
8
7. Mewing transmission output shaft speed Table 2
2) Start the engine. Selection Method of selection Shift checker display

brake pedal.
operating manual shift.
transmission.)
5) Release the parking brake.
6) Operate the keyboard to select the speed range.
7) For details of the keyboard operation for select-
ing the speed range, see Table 2.
8) After selecting the speed range, operate the key-
board as follows.
SHIFT CHECKER II
Display _
9) Operate the machine and carry out the measure- [F121! 1 1 1610101‘,,,,,
ment.
Read the shift checker display.
F 2 ! 6 0 0
t t
Selected speed range Measured value for
rotating speed
569FO5129
20-52
0
8. Measuring clutch pressure
1) Prepare to measure the clutch hydraulic pressure. Clutch pressure
For details, see TESTING HYDRAULIC PRE- pickup port Connector
SSURE OF TRANSMISSION VALVE.
2) Operate the shift checker keyboard according to
the clutch pressure to be measured.
For details, see Procedure for operating manual
shift.
* Operate with the engine running at low idling.
i) The settings of speed range and the clutch to
be measured are as shown in the table below.
Rear of machine
F56103072
ii) If the measurement for the clutch pressure i

not within the standard value, put the tester
in contact with signal measurement terminals
01 and 02 of the modulation checker and

measure. If the measurement is as shown in
the table below, there is no abnormality in
the checker; there is a failure in the ECMV or
transmission.
Clutch measured Measured value (V)
H, L, 3,4 0.62 f 0.02
1,2, R 0,895 f 0.02

MODULATION CHECKER
.I-
For details of the standard values and the
method of measuring the clutch pressure, see
TESTING AND ADJUSTING, and STAND-
ARD VALUES TABLE.
Note that the pressure measured using the F56103078:l K
shift checker + modulation checker is differ-
ent from the hydraulic set pressure when
controled by transmission controller.
q
MAR key on the keyboard.
20-52-l
8
PROCEDURE FOR OPERATING C-TYPE SHIFT
CHECKER
0
1. Names and funcions
1) Display
1No. 1 Function I Display
0 Measuring speed of transmission input shaft
Measuring speed of transmission intermediate

0
@.
shaft
101 Measuring speed of transmission output shaft
@ ) Fill signal display
1
Modulation signal output value display
Control panel
* When the pulse is set, the set value of the

pulse is automatically displayed.
569FO5152
2) Control panel (keyboard)
The keyboard consists of 16 control switches,
@\
l
and these switches are used to carry out the

i following operations. I
i) Speed range selector switch
l This is used to set or change the speed range.
Keyboard
Signal Function
switch
@ (1 Shifts up
@ /I Shifts down
0’ 569FO5153
0 (NJ Switches to neutral
@ I] Switches to reverse
ii) Lockup selector switch

l This switch is used to actuate the lockup.
Keyboard
No. Function
switch
@ I1 Selects lockup
569FO5154
20-52-2
03
iii) Clutch actuation switch
l This is used to actuate each clutch individually.
Keyboard
No. Function
switch
@ IHI Actuates H clutch
@ vi Actuates L clutch
@ [4thI Actuates 4th clutch
1 @ ( m 1 Actuates 3rd clutch 1
569FO5155
[Table l]
Set value of pulse
HD785
iv) Pulse set switch

l This switch is used to change the pulse
frequency for each rotation of the transmis- Output shaft 60
I I
sion input shaft, intermediate shaft, and
output shaft.
* The set value for the pulse on the HD785-

3 is already set, so do not change it. 1
569FO5156
/
v) Power source switch
No. Function
Used to switch the power source for the C-type

0 checker ON/OFF
vi) Connector
No. Function
I@I Used to connect the connection

(799-607-2020)
wiring harness
569FO5157
20-52-3
@
2. Procedure for connecting shift checker
2) Check that the checker power is OFF.
3) Disconnect connectors (2). (3). (4), and (5) from

transmission control box (1).
4) Connect the connectors (white) of connection

wiring harness (799-607-2020) to disconnected
connectors (2), (3), (4) and (5). \ 569FO5J 26
5) Connect the connector (black) of the connection

wiring harness to shift checker 0.
* Always check that the starting switch and

shift checker power source are OFF before
disconnecting the shift checker.
Shift checker 0
Transmission
control box
(White)
Disconnect connectors
. . . . . . . ,
Connection wiring harness
, J
Y
(Part No.: 799-607-2020)
Chassis wiring harness
(to modulation valve)
569FO5158
20-52-4
03
3. Procedure for operating manual shift
l Checking for disconnections, short circuits. If there is any abnormality, [B] will be
Connect the shift checker to the chassis wiring displayed above the name of the clutch, so
harness, start the engine, then turn the power carry out inspection and repair of the wiring
source switch for the shift checker ON. A harness and ECMV.
continuity check of the wiring harnesses If everything is normal, the screen will change
connected to each clutch will be carried out to the measurement screen.
automatically and the result will be displayed.
1) Turn the parking brake ON.

3) Turn the power source for the shift checker
ON.
* Check that all the fill switch lamps are + If any fill switch lamp is lighted up, there
OFF. is a failure in the system for that valve, so
4) Depress the brake pedal and select the speed refer to Item 4 “Procedure for emergency
range. operation”, and move the machine to a safe
i) Selecting forward speed range place for repair.
Press mUP(switch (9)once, and Fl will If any fill switch lamp is lighted up, do not
be selected. If km switch (9) is pres- operate the accelerator in neutral.
sed again within 1 - 3 seconds, the speed (There may be damage inside the trans-
range will change to F2; if ml switch mission.) J
(9) is pressed once more within 1 - 3
seconds, the speed range will change to F3.
j, Only Fl, F2, and F3 can be used for
forward travel. Do not shift gear while
traveling. 0
ii) Selecting reverse speed range \
With the machine stopped, press)switch
(12) to select reverse.
5) Turn the parking brake OFF.
@------
6) Release the brake pedal, and depress the
accelerator pedal to move the machine.
7) If the machine is stopped, press the aswitch
(11) to set to the neutral condition.
0’
569FO5159
20-52-5
43
4. Procedure for emergency operation
l Check the self-diagnostic display of the machine transmission controller, then refer to Table 2 below
and move the machine to a safe place for repair.
* Item 1 in Table 2 shows the conditions where the emergency escape can be carried out with
the equipment on the machine, Item 2 shows the’conditions where the emergency escape
can be carried out with the C-type shift controller, and Item 3 shows the conditions where
i the emergency escape must be carried out by towing the machine. I
Table 2
Condition of failure Operation using

Emergency operation
No. (self-diagnostic display on emergency operation
using shift checker
transmission controller) function of machine
[l. 31 Defective system for transmission out-

put shaft speed sensor
Remove and insert the
[2. [7] Slipping clutch or defective speed sen- emergency escape con_
sor system
nectars on the machine
14. [7] Defective pressure control valve (II)
1 to select the suitable -
[7. [7] Short circuit in solenoid output circuit (speed range R or F, F2)
I
[9.0] Disconnection in solenoid output
of the transmission
circuit
controller
13.01 Defective pressure control valve (I)
[5.0] Defective flow detector valve
[O. 61 Defective transmission cut relay

system
[B. W] Defective controller Operation is impossible Connect the chassis wir-
[O. 41 Data error using the emergency ing harness to the shift
2 [O. 71 Defective +12V output system operation function of the checker and carry out
[I. 41 Defective model selector signal system machine emergency operation
[l. 51 Defective lever signal system
[l. 61 Defective lever signal system
3 [O. 51 Detects for double meshing systems Impossible (tow with

another machine)
0 : Digits from 1 to 9 W : No number is displayed
20-52-6
@
A Check that the air pressure gauge on the machine

is in the green range.
1) Turn the parking brake-ON.

2) Check that the area around is safe, then start
the engine.
3) Turn the power for the shift checker ON.
4) Press 14thl switch (16) on the keyboard.
5) Press Illswitch (13) on the keyboard.
+ Run the engine at a mid-range speed. It is
possible to check by listening to changes in
the sound of the engine and the lighting up
of the lockup lamp.
6) After completing the operation, press m
switch (13) to turn the lockup OFF. 569FO5160
7) Press 14th switch (16) and check that the clutch
signal is N.
6) After completing the measurement, stop the
engine.
6. Measuring torque converter stall speed
g A Check that the air pressure gauge on the machine

is in the areen ranae.
z
0 1) Turn the parking brake ON.
2) Check that the area around is safe, then start
the engine.
3) Turn the power for the shift checker ON.
4) Depress the brake pedal to actuate the emer-
gency brake.
5) Press[w[switch @ on the keyboard
,three times to select F3.
[* When pressing -1 switch @for the 1
569FO5 161
2nd and 3rd times, always press within 1
to 3 seconds.
6) Depress the brake pedal with your left foot, and
depress the accelerator pedal slowly with your
right foot as far as it will go.
7) Measure the engine speed.
8) After completion of the measurement, run the
engine at low idling, then stop it.
20-52-7
@
7. Measuring clutch pressure
Clutch pressure
1) Prepare for measuring the clutch pressure. For pickup port Connector
details, see “Testing ECMV oil pressure”.
* Connect the oil pressure gauge directly to
the clutch pressure pickup port, without
using a hose.
Ir When measuring the modulating time, to
ensure accurate measurement, do not use
th clutch valve
an oil pressure gauge containing glycerin.
2) Measuring rd clutch valve
i) Turn the parking brake ON.

ii) Check that the area around is safe, then start
the engine.
iii) Turn the power for the shift checker ON.
iv) Press the keyboard switch for each clutch,
and measure the clutch pressure.
+ The measurement cannot be carried out
with the speed range specified, so set the
speed range first to neutral, then operate
the clutch switch. F56103072
Rear of machine
Keyboard switches for each clutch
63 0
8
‘@
Standard value for Standard value for Standard value
Clutch measured initial pressure clutch pressure for modulating
(kg/cmz)
\
(kg/cm*) time (set)
@
I- H 1 5+1 I 17+2 I 2 + 0.3
569FO5155
r---- 3 rd I 5fl I 17*2 I 2 It 0.3
I 4 th I 5+1 I 17f2 I 2 f 0.3
The modulating time is the time required to change from the initial pressure to the clutch pressure.
v) After completion of the measurement, stop the engine.
20-52-8
@
METHOD FOR EMERGENCY OPERATION OF TRUCK WHEN
THERE IS FAILURE IN ELECTRICAL SYSTEM OF TRANSMIS-
SION CONTROL SYSTEM OR ENGINE CONTROL SYSTEM
1. Need for emergency operation of truck
The following explanation gives the procedure to follow when it becomes impossible for the truck to
travel.
If the truck cannot travel, it means that a serious failure has occurred in the transmission control system
or the engine control system, and it must be repaired.
Use the procedure given in this section to move the truck to a safe place before carrying out repairs.
2. Self-diagnostic display and method of emergency operation
1) If the transmission suddenly shifts to neutral when the truck is traveling, and it becomes impossible
to start the machine again, decide the method of emergency operation according to the table below.
(If abnormality No. 2 occurs when the truck is traveling, do not stop the engine. Follow the instructions in
the table below to carry out the emergency escape.)
If the truck still does not start even when the procedure is carried out and the truck is operated, the truck
must be towed.
Key : q : 1 - 8 u : Blank
Transmission position for

Emergency Condition when Self display of
starting again after carrying out
escape method failure occurred transmission controller
emergency escape procedure
Return shift lever to l Transmission

neutral, then move shifted suddenly Normal travel is possible in R, Fl -
1
to travel position. to neutral while
0.3 Neutral safety
F7
(N - D, or N - R) traveling.
l After machine
stops, transmis- 1.3 Defective system for trans- Start in R, F2 (when shift lever is in
sion stays in neu- mission output shaft speed positions 5 - L, the machine starts
tral even when sensor in F2, and does not shift down to Fl)
shift lever is oper
ated,and machine 2.0 Slipping clutch or defective
Place shift lever at cannot start. speed sensor system [7. 2,4, 6, 7 :
Start in R, F2
N, then remove and 4. c] Defective pressure control (0 shows 2,4, 7, 9)
insert emergency valve (II) c]. 3 : Starts in E (equivalent to R,
escape connectors 7.0 Short circuit in solenoid out- F2)
Al and A2. (with put circuit cl. 5 Starts in R, Fl
the starting switch 9.0 Disconnection in solenoid Starts in F2 only
Ii. 8
ON) output circuit
After doing this,
place the shift lever 3. 2 Starts in E (equivalent to R,
in a drive position F2)
2 and start the 3.3 Starts in R, F2
machine again. 3. 0 Defective pressure control 3.4 Starts in Fl only
(N - D, or N - R) valve (I) 3. 5 Starts in F2 only
Note: When doing 3. 6 Starts in F4 only
this, do not 3. 7 Starts in F6 only
depress the 3.8 Starts in R only
accelerator
pedal when When starting agair
5.2 Starts in E (equivalent to R,
operating the when the transmis-
gear shift sion is fixed in one F2)
5.3 Starts in R, F2
lever. speed range, the
5.4 Starts in Fl only
speed range does 5. q Defective flow detector valve
5. 5 Starts in F2 only
not change from the
position it was in
when the machine
5. 8 Starts in R only
stopped.
Transmission
shifted suddenly
to neutral while
traveling.
After machine u.u Defective power source
If display returns to normal when
Check for blown stops, transmis- 0. 1 Drop in power voltage
3 fuse is replaced, normal travel is
fuse BTl No. 10 sion stays in neu- 0. 2 Drop in solenoid power
possible in R, Fl - F7
tral even when voltage
shift lever is oper
ated,and machine
cannot start.
20-53
09
Key:n: 1-8~: Blank
Transmission position for

Emergency Condition when Self display of
starting again after carrying out
escape method failure occurred &I transmission controller
emergency escape procedure
l Transmission If display returns to normal when

Replace transmis- shifted suddenly 0. 6 Defective transmission cut transmission cut relay is replaced
4 to neutral while relay system normal travel is possible in R, Fl -
sion cut relay R25
traveling. F7
l After machine
stops, transmis- If controller display returns to nor-
sion stays in neu- U. u Defective controller 1 mal when transmission cut relay is
5 Replace controller replaced normal travel is possible in
tral even when 0.4 Data error
shift lever is oper R, Fl - F7
0. 7 Defective + 12V output system

Possible to travel in any desired
Use shift checker 1. 4 Defective model selector sig-
speed range with shift checker
6 and modulation nal system
(However, auto lockup is not
checker 1. 5 Defective lever signal system
actuated.)
1. 6 Defective lever signal system
0. 5 Detects for double meshing -

7 Tow systems
I I
2) Engine control system (for engines with electronic governor)
a) If the engine stalls when the machine is traveling, and does not start again, decide the
emergency operation method according to the table below.
When the engine stalled, does ~0 Check fuel level. Failure in

any abnormality display for the c engine mechatronics
engine (mechatronics) appear portion.
on the monitor panel?
YES
+ I NOI
Is it possible to
Does self-diagnostic display of start machine Is it possible to start
YES ) again when BT2
NO YES
controller show abnormality in ) machine again when
power source (all lamps OFF)? No.10 fuse is breaker is reset?
replaced?
I
YES
NO
Make emergency escape in this
+ condition (with all except essential
*
power sources OFF), then investigate
cause.
Does self-diagnostic display of

controller show abnormality in YES lf no controller is available.
Replace controller
controller (both red and green tow. I
lamps light up)?
I I
I I
NO
t
Does self-diagnostic display of
controller show abnormality in
YES If no sensor is
engine speed sensor A (both
red and green lamps flash available, tow.
simultaneously)?
NO
Tow
I
b) When the starting switch is turned ON, if there is any abnormality, such as the automatic
transmission (mechatronics) abnormality display lighting up, or if the shipped position display
does not light up, and the engine does not start, take the following action, and it will
become possible to start the engine.
(With this action, the engine will start even if the gear shift lever is at a position other
than N, so be extremely careful when starting the engine.)
I I
Automatic transmission
(mechatronics) abnormality display Remove transmission neutral relay.
lights up, shift position display does ) Relay No.: R02
not light up.
20-54-l
0
TROUBLESHOOTING
Points to remember when troubleshooting .......................................................................................... 20- 56
Sequence of events in troubleshooting ................................................................................................. 20- 57
Precautions when carrying out maintenance ....................................................................................... 20- 58

Handling connectors ............................................................................................................................... 20- 65
Checks before troubleshooting .............................................................................................................. 20- 66

Method of using troubleshooting charts and tables.. .......................................................................... 20- 68
Method of using judgement table .......................................................................................................... 20- 72
Explanation of functions of electrical system (control mechanism) ................................................... 20- 75
Method of self-diagnostic display for monitor panel and each controller ......................................... 20- 77
Action by self-tester and machine symptoms (transmission controller system) .............................. 20- 81
Action by self-tester and machine symptoms (suspension controller system). ................................ 20- 87
Action by self-tester and machine symptoms (engine controller system) ........................................ 20-88-I
Type and location of connecotor, sensor (HD785-3) ............................................................................ 20- 89
Type and location of connecotor, sensor (HD985-3) ............................................................................. 92- 8
Connection table for connector .............................................................................................................. 20- 97
Troubleshooting of engine electrical system (for engines with mechanical governor). .................. .20-109
Troubleshooting of engine controller system
(for engines with electronic governor) (HD785-3) .................................................................... 20-I 14-1
(for engines with electronic governor) (HD985-3) ....................................................................... 92- 19
Troubleshooting of transmission controller system (HD785-3) .......................................................... 20-I 15
Troubleshooting of transmission controller system (HD985-3) .......................................................... 92- 45
Troubleshooting of suspension controller system ............................................................................... 20-I 53
Troubleshooting of payload meter system ........................................................................................ 20-I 66-l
Troubleshooting of pilot lamp system .................................................................................................. 20-I 67
Troubleshooting of monitor panel system (HD785-3). ......................................................................... 20-177
Troubleshooting of monitor panel system (HD985-3). ......................................................................... 92- 85

Troubleshooting of maintenance monitor system (HD785-3) .......................................................... 20-216-3
Troubleshooting of maintenance monitor system (HD985-3) ............................................................. 92-127
Troubleshooting of hydraulic and mechanical system ........................................................................ 20-217
This troubleshooting manual gives flowcharts for troubleshooting, including the electrical display
system, for the monitor system (abnormal display) and each controller system (self-diagnostic
display) according to the nature of the problem.
Therefore, before starting troubleshooting, it is necessary to read and fully understand the
testing, adjusting, and troubleshooting procedures given in this manual.
20-55
0
POINTS TO REMEMBER WHEN TROUBLESHOOTING
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake
are securely fitted.
When carrying out the operation with two or more workers, keep strickly to the agreed
signals, and do no allow any unauthorized person to come near.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
When removing the plug from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure
to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs
swiftly, and to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the
structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible cases of the failure that would produce
the reported symptoms.
1. When carrying out troubleshooting, do not 2) Check the CHECKS BEFORE STARTING
hurry to disassemble the components. items.
If components are disassembled imme- 3) Other inspection items.
diately any failure occurs: 4) Other maintenance items can be checked
l Parts that have no connection with the externally, so check any item that is
failure or other unnecessary parts will be considered to be necessary.
disassembled. 4. Confirming failure
l It will become impossible to find the cause l Confirm the extent of the failure yourself,
of the failure. and judge whether to handle it as a real
It will also cause a waste of manhours, parts, failure or as a problem with the method
or oil or grease, and at the same time, will of operation, etc.
also lose the confidence of the user or + When operating the machine to re-
operator. enact the troubleshooting symptoms,
For this reason, when carrying out trouble- do not carry out any investigation or
shooting, it is necessary to carry out measurement that may make the
thorough prior investigation and to carry out problem worse.
troubleshooting in accordance with the fixed 5. Troubleshooting
procedure. l Use the results of the investigation and
2. Points to ask user or operator inspection in Items 2 - 4 to narrow down
1) Have any other problems occured apart the causes of failure, then use the
from the problem that has been reported? troubleshooting tables (matrix) to locate
2) Was there anything strange about the the position of the failure exactly.
machine before the failure occurred? * The basic procedure for troubleshoot-
3) Did the failure occur suddenly, or were ing is as follows.
there problems with the machine condi- 1) Start from the simple points.
tion before this? 2) Start from the most likely points.
4) Under what conditions did the failure 3) Investigate other related parts or
occur? information.
5) Had any repairs been carried out before 6. Measures to remove root cause of failure.
the failure? l Even if the failure is repaired, if the root
When were these repairs carried out? cause of the failure is not repaired, the
6) Has the same kind of failure occurred same failure will occur again.
before? To prevent this, always investigate why
3. Check before troubleshooting the problem occurred. Then, remove the
1) Check for symptoms of any abnormality root cause.
in the machine.
SEtiUENCE OF EVENTS IN TROUBLESHOOTING
a Jobsite
Step 1
j Examination, confirmation of symptoms]
1I When a request for repairs is received,

Ring! Ring!
first ask the following points. __----
* Name of customer
------
* Type, serial number of machine
* Details of jobsite, etc.
2) Ask questions to gain an outline of the
problem.
* Condition of failure
’ Work being carried out at the time
of the failure
. Operating environment
. Past hIstory, details of maintenance,
etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes
Step 3
[Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools

in the shop manual and prepare the
necessary tools.
* T-adapter
. Hydraulic pressure gauge kit, etc.
troubleshooting)
2) Look in the parts book and prepare the
* Decide action to take
necessary replacement parts.
1) Before starting troubleshooting, locate and
repair simple failures.
* Check before starting items
. Other check items
2) See the Troubleshooting Section of the
shop manual, select a troubleshooting
flowchart that matches the symptoms, and
carry out troubleshooting.
Step 6
Re-enacting failure
’ Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
. Step 5
Ask operator questions to confirm details of
failure.
. Was there anything strange about the

machine before the failure occurred?
* Did the failure occur suddenly?
* Had any repairs been carried out before the
failure?
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine

over a long period, and to prevent failures or
other troubles before they occur, correct opera-
tion, maintenance and inspection, troubleshoot-
ing, and repairs must be carried out. This section
deals particularly with correct repair procedures
for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sec-
tions on “Handling elecric equipment” and
“Handling hydraulic equipment”.
1. PRECAUTIONS WHEN HANDLING

ELECTRIC EQUIPMENT
I) Handling wiring harnesses and

connectors
Wiring harnesses consist of wiring connect-
ing one component to another component,
connectors used for connecting and discon-
necting one wire from another wire, and
protector or tubes used for protecting the
wiring. Compared with other electrical
components fitted in boxes or cases, wiring
harnesses are more likely to be affected by
the direct effects of rain, water, heat, or vi-
bration. Furthermore, during inspection and
repair operations they are frequently re-
moved and installed again, so they are likely
to suffer deformation or damage. For this
reason, it is necessary to be extremely care-
ful when handling wiring harnesses. F20505201
Main failures occurring in wiring harness

(I) Defective contact of connectors
(defective contact between male and
female)
Problems with defective contact are Improper insertion
likely to occur because the male connec-
tor is not properly inserted into the
female connector, or because one or
]
both of the connectors is deformed or
the position is not correctly aligned, or
because there is corrosion or oxidization
of the contact surfaces. F20505202
(2) Defective compression or soldering of
connectors
The pins of the male and female Improper compression
connectors are in contact at the
compressed terminal or soldered
portion, but there is excessive force on
the wiring, and the plating peels to
cause improper correction or breakage. F56103079
(3) Disconnections in wiring

If the wiring is held and the connectors
are pulled apart, or components are
lifted with a crane with the wiring still
connected, or a heavy object hits the
wiring, the compression of the
connector may be lost, or the soldering
may be damaged, or the wiring may be
broken.
(4) High pressure water entering connector
F20505204
The connector is designed to make it
difficult for water to enter (drip-proof
structure), but if high-pressure water is
sprayed directly on the connector,
water may enter the connector depend-
ing on the direction of the water jet.
The connector is designed to prevent
8 water from entering, but at the same
z time, if the water does enter, it is diffi-
z cult for it to be drained. Therefore, if
water should get into the connector, the
pins will be short-circuited by the water,
so if any water gets in, immediately dry
F20505205
the connector or take other appropriate
action before passing electricity
through it.
(51 Oil or dirt stuck to connector
If oil or grease are stuck to the connec-
tor and an oil film is formed on the
mating surface between the male and
female pins, the oil will not let the elec-
tricity pass, so there will be defective
contact.
If there is oil, grease or dirt stuck to the
connector, wipe it off with a dry cloth
or blow dry with air, and spray it with F20505206
a contact restorer.
jl When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
* If any water or oil is in the compressed
air, it will result in contamination of
the points, so use only air that is
completely free of water and oil for
cleaning.
2) Removing, installing, and drying connec-
tors and wiring harnesses
Disconnecting connectors
(I) Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors and not the wires.
For connctors held by a screw, loosen
the screw fully, then hold the male and
female connectors in each hand and pull
apart. For connectors which have a lock
stopper, press down the stopper with
your thumb and pull the connectors
apart.
(2) Action to take after removing

connectors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
F20505208 T:
z
Connecting connectors %
(I 1 Check the connector visually.
a. Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
b. Check that there is no deformation,
defective contact, corrosion, or
damage to the connector pins.
c. Check that there is no damage or
breakage to the outside of the
connector.
* If there is any oil, water, or dirt stuck
to the connector, wipe it off with a
dry cloth. If any water has got inside
the connector, warm the inside of
the wiring with a dryer, but be care-
ful not to make it too hot as this will
cause short circuits.
* If there is any damage or breakage,
replace the connector.
(2) Fix the connector securely.
Align the position of the connector cor-
rectly, then insert it securely.
For connectors with lock stopper
Push in the connector until the stopper
clicks into position. Cliks into position
F20505209
(3) Correct any protrusion of the boot and

any misalignment of the wiring hanress
For connectors fitted with boots, correct
any protrusion or the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.
* If the connector cannot be corrected
smoothly, remove the clamp and
adjust the position.
F20505210,
Drying wiring harness
If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
(1) Disconnect the connector and wipe off
the water with a dry cloth.
* If the connector is blown dry with air,
F20505211
there is the risk that oil or water in
the air may cause defective contact,
so use only air that is completely free
of water and oil for cleaning.
(2) Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
* Hot air from the dryer can be used,
but be careful not to make the
connector or related parts too hot,
as this will cause deformation or
damage to the connector. F20505212
(3) Carry out a continuity test on the
connector.
After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits be-
tween pins caused by water.
+ After completely drying the connec-
T-adapter
tor, blow it with contact restorer
and reassemble.
F20505213
3) Handling control box

(I) The control box contains a micro-
computer and electronic control circuits.
These control all of the electronic cir-
cuits on the machine, so be extremely
careful when handling the control box.
(2) Do not open the cover of the control
box unless necessary.
(3) Do not place objects on top of the con-
trol box. . F20505214
(4) Cover the control connectors with tape
or a vinyl bag.
(5) During rainy weather, do not leave the
control box in a place where it is ex-
posed to rain.
(6) Do not place the control box on oil,
water, or soil, or in any hot place, even
for a short time. (Place it on a suitable
dry stand)
(7) Precautions when carrying out arc
welding
When carrying out arc welding on the
body, disconnect all wiring harness F20505215
connectors connected to the control
box. Fit an arc welding ground close to
the welding point.
F20505216
2. POINTS TO REMEMBER.WHEN
HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of

hydraulic equipment, the most common cause
of failure is dirt (foreign material) in the hydrau-
lic cirucit. When adding hydraulic oil, or when
disassembling or assembling hydraulic equip-
ment, it is necessary to be particularly careful.
I) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters,
or repairing the machine in rain or high
winds, or places where there is a lot of dust.
2) Disassembly and maintenance work in

the field
If disassembly or maintenance work is car-
ried out on hydraulic equipment in the field,
there is danger of dust entering the equip-
ment. It is also difficult to confirm the per-
formance after repairs, so it is desirable to
use unit exchange. Disassembly and mainte-
nance of hydraulic equipment should be car-
ried out in a specially prepared dustproof
8
z workshop, and the performance should be
8 confirmed with special test equipment.
F20505217
31 Sealing openings
After any piping or equipment is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left
open or is blocked with a rag, there is
danger of dirt entering or of the surrounding
area being made dirty by leaking oil so
never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose
of it, or take it back with you for disposal. F20505218
4) Do not let any dirt or dust get in during

refilling operations.
Be careful not to let any dirt or dust get in
when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil con-
tainers. If an oil cleaning device is used, it is
possible to filter out the dirt that has collect-
ed during storage, so this is an even more
effective method. F20505219
5) Change hydraulic oil when the tempera-
ture is high.
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can also
be drained out easily from the circuit togeth-
er with the oil, so it is best to change the oil
when it is still warm. When changing the oil,
as much as possible of the old hydraulic oil
must be drained out. (Do not drain the oil
from the hydraulic tank; also drain the oil
from the filter and from the drain plug in the
circuit.) If any old oil is left, the contaminants
and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the
equipment, or changing the oil, use flushing
oil to remove the contaminants, sludge, and
old oil from the hydraulic circuit.
Normally, flushing is carried out twice: pri-
mary flushing is carried out with flushing
oil, and secondary flushing is carried out
with the specified hydraulic oil.
F20505220
7) Cleaning operations
After repairing the hydraulic equipment
(pump, control valve, etc.) or when running
the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to
remove the ultrafine (about 3~) particles
that the filter built into the hydraulic equip-
ment cannot remove, so it is an extremely
effective device.
F20505221
HANDLING CONNECTORS
1. When removing the connectors from the

clips, pull the connector in a parallel direc-
tion to the clip.
* If the connector is twisted to the left
and right or up and down, the housing
may break.
205FO5609
8 205FO5610
z
8 male and female
2. When disconnecting
connectors, release the lock and pull in
parallel with both hands.
* Never try to pull out with one hand.
205FO5611
3. When the wiring harness clamp of the

connector has been removed, always return
it to its original condition and check that
there is no looseness of the clamp.
205FO5612
CHECKS BEFORE TROUBLESHOOTING
Item Standard value Remedy
1. Check fuel level Fuel gauge Add fuel

2. Check for dirt or water in fuel - Clean, drain
3. Check for water in air tank - Drain
4. Check transmission oil level Oil level gauge Add oil

5. Check hydraulic oil level Sight gauge Add oil
6. Check engine oil level (Level of oil in oil pan) Oil level gauge Add oil
7. Check cooling water level - Add water
8. Check condition of dust indicator Dust indicator Clean
9. Check front brake oil level (Level of in tank) Oil level gauge Add oil
10. Check for water in emergency brake air tank - Drain
11. Check play of steering wheel Max. 150mm -
12. Check operation of emergency steering - Repair
13. Check installation length of suspension Label Adjust

cylinder
14. Check tire inflation pressure and damage Charge air
g
Tightening - z
15. Check hub nuts
torque:
200 - 250 kgm 0”
16. Check efficacy of foot brake Adjust

17. Check efficacy of parking brake - Adjust or repair
18. Check efficacy of emergency brake - Adjust or repair
19. Check abnormality of steering - Adjust or repair
20. Check direction of rear and under view mirror - Adjust
21. Check exhaust gas color and abnormal noise - Adjust or repair
22. Check efficacy of retarder brake Adjust or repair
23. Check abnormality of body rubber mount Adjust or repair
24. Check air horn - Repair
25. Check function of lamps jepair or replace

26. Check function of gauges - Adjust or repair
27. Check function of electronic monitor panel - Adjust or repair
28. Check centralized warning lamp Adjust or repair
29. Check for loose or corroded battery terminals qetighten or clean
30. Check for loose or corroded alternator terminal - qetighten or clean
31. Check for loose or corroded starting motor - qetighten or clean
terminals
T Item Standard value Remedy
32. Check for abnormal noise or smell - Repair

33. Check for oil leakage - Repair
34. Bleed air from system - Bleed air
35. Check battery voltage (engine stopped) 20 - 3ov Replace

36. Check level of battery electrolyte - Add or replace
37. Check for discolored, burnt, or bare wiring - Replace
38. Check for missing wiring clamps, hanging - Repair
wires
39. Checks for water leaking onto wiring (check Disconnect

carefully water leakage at connectors and connector and
terminals) dry connection
40. Check for broken or corroded fuses - Replace
4.1. Check alternator voltage (engine running at 27.5 - 29.5V Replace
over half throttle)
42. Noise when battery relay is operated. - Replace
(Switch starting switch from on to off)
METHOD OF USING TROUBLESHOOTING CHARTS AND TABLES
1. Categories of troubleshooting code numbers
Troubleshooting Code No. Location of troubleshooting
G-00 Troubleshooting of engine electrical system/engine controller system
A-00 Troubleshooting of transmission controller system
s-00 Troubleshooting of suspension controller system
L-00 Troubleshooting of payload meter system
F-00 Troubleshooting of pilot lamp system
P-00 Troubleshooting of monitor panel system
H-00 Troubleshooting of hydraulic and mechanical system
M-00 Troubleshooting of maintenance monitor system
2. Method of using YES/NO troubleshooting charts

Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the
problem with the machine.
Distinguishing condition
Even with the same problem the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the troubleshooting chart is further divided into sections
marked with small letters (for example, a), so go to the appropriate section to carry out
troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item.
Method of following troubleshooting chart
Check or measure the item inside the box, and according to the answer follow either
the YES line or the NO line to go to the next box. (Note: The number written at the top
right corner of the box is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right.
Below the box there are methods for inspection or measurement, and the judgement values.
If the judgement values below the box are correct or the answer to the question inside
the box is YES, follow the YES line; if the judgement value is not correct, or the answer
to the question is NO, follow the NO line.
Below the box is given the preparatory work needed for inspection and measurement,
and judgement values. If this prepratory work is neglected, or the method of operation
or handing is mistaken, there is danger that it may cause mistaken judgement, or the
equipment may be damaged. Therefore, before starting inspection or measurement, always
read the instructions carefully, and start the work in order from Item 1).
General precautions
When using the troubleshooting chart, precautions that apply to all given at the top of the
page and marked with * . The precautions marked * are not given in the box, but must
always be followed when carrying out the check inside the box.
Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For
details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
@ Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection table, so when carrying out troubleshooting, see this chart for details
of the connector pin number and location for details of the connector pin number and locations
for inspection and measurement of wiring connector number 0 0 appearing in the
troubleshooting flow chart.
<Example>
Abnormality in transmission [cut relay] system
@ A-6 Abnormality in speed sensor system
Abnormality in engine speed sensor [B] system displayed
Abnormality in intermediate shaft speed sensor system displayed
Disconnection in travel speed sensor (transmission output shaft speed sensor)

displayed
Transmission controller
SC, (MICl3) Transmission input shah
I
TM2 (SWPl4)
F56103111
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
@
Ir Always connect any disconnected connectors before going on to the next step.
3. Method of using matrix troubleshooting tables
The troubleshooting tables use the same method as for other troubleshooting table (YES/NO
type) to locate the causes of failures in the machine. The troubleshooting tables are divided
broadly into categories for the main components, such as the steering system and work equipment
hydraulic system. Follow the procedure given below and carry out troubleshooting to locate
the problems accurately and swiftly.
Step 1. Questioning the operator 1. Steering does not work-Symptom [Example]

The questions to ask the operator are given
below the failure symptom. If the answers Ask the operator about the following points.
to the questions match the information given, * Did the steering suddenly stop working? +
follow the arrow to reach the probable cause Breakage in steering equipment
of the failure. * Had the steering gradually been becoming heavy?
Consider the contents of the questions and + Internal wear of steering equipment, defective
consult the table while proceeding to Steps seal
2 and 3 to grasp the true cause.
Step 2. Checks before troubleshooting Checks before staring [Example]

Before starting the main troubleshooting and
measuring the hydraulic pressure, first check * Is the oil level and type of oil in the hydraulic
the Checks before Starting items, and check
for oil leakage and loose bolts. These checks
may avoid time wasted on unnecessary
troubleshooting.
The items given under Checks before Starting
are items which must be considered partic-
ularly for that symptom before starting
troubleshooting.
[Example 1 ]
Step 3. Using cross-reference table

1) Operate the machine to carry out the Steering does not work to the left or right.
checks in the troubleshooting item column.
Mark the items where the results match
Steering can only be operated to one side.
the symptom.
* It is not necessary to follow the trou- 4 1 Steering wheel is heavy and cannot be turned.
bleshooting checks in order; follow an

order which is easiest to carry out
troubleshooting.
2) Find the appropriate cause from the cause
column. If the symptom appears, the 0
marks on that line indicate the possible
causes. (For item No. 2 in the table on the
right, the possible causes are c or e.)
If there is only one 0:
Carry out the other troubleshooting items
(where the same cause is marked with 0),
check if the symptom appears, then repair.
If there are two OS:
Go on to Step 3) to narrow down the
possible causes.
3)Operate the machine and check the Cause
troubleshooting items other than those in
1).
!.!,
Operate the machine and check the items
in the same way as in 1), and if the symptom
appears, mark that item. (In the chart on
the right, the symptom appears again for
item 5).
4) Find the appropriate cause from the cause
column. In the same way as in Step 2).
if the symptom appears, the 0 marks on
that line indicate the possible causes. (For
item No.5 in the table on the right, the Applicable troubleshooting item located in Step 3).
possible causes are b or e.)
- Applicable troubleshooting ite located in Step 1).
5) Narrow down the possible causes. Ignore these causes

There is one common cause among the A
causes located in Steps 2) and 4). (One
Common causes
cause marked 0 appears on the line for
both items.) This cause is common to both
the symptoms in troubleshooting Steps 1)
and 3).
* The causes which are not common to
T: both troubleshooting items (items which
z are not marked 0 for both symptoms)
8 are unlikely causes, so ignore them.
(In the example given on the right, the
causes for Troubleshooting Item 2 are
c or e, and the causes for Troubleshoot-
ing Item 5 are b or e, so cause e is
common to both.)
6) Repeat the operations in Steps 3). 4) and
5) until one cause (one common cause)
remains.
* If the causes cannot be narrowed down
to one cause, narrow the causes down Action to take
as far as possible.
7) Remedy
If the causes are narrowed down to one
common cause, take the action given in
the remedy column.
The symbols given in the remedy column
indicate the following:
X: Replace, A: Repair, A: Adjust, C: Clean
METHOD OF USING JUDGEMENT TABLE
This judgement table narrows down problems in the machine to abnormalities in the electrical
system or abnormalities in the hydraulic and mechanical system, and is a tool to proceed to the
troubleshooting table (G-00, A-00, S-00, L-00, F-00, H-00) that matches each problem.
The judgement table shows which troubleshooting table to go to according to the self-diagnostic
display.
* For abnormal display (warning) on the monitor panel and maintenance monitor panel, go directly
to troubleshooting (P-00, M-00) of the monitor panel or maintenance monitor system. (See
the list of contents for troubelshooting of the monitor system.)
1. Judgment table for transmission controller and transmission related parts
l If an abnormal display is given in the self-diagnostic display, go down ( 1 ) to the troubleshooting
code on the bottom line of the judgment table . .. go to A-00
(A 0 mark is given in the places where the failure mode and self-diagnostic display match.)
l If there is no abnormal display in the self-diagnostic display, but there is some problem,
check if there is any monitor panel and pilot lamp display (display at points marked 0) that
matches the failure mode in the judgment table, and
If the display is normal, go ( - ) io the troubleshooting code .. . go to H-00
If the display is abnormal, go down ( 1 ) to the troubleshooting code .. . go to F-00, P-00
Example: Failure mode [Machine does not start]

[Procedure] Check if any abnormal display is given in the self-diagnostic display, and
check the digit that is lighted up at the top of the controller.
[Judgment] If there is an abnormal display (m) in the self-diagnostic display ... go

to troubleshooting E-2 of electrical system
If there is no abnormal display given in the self-diagnostic display, but
the machine does not start,
l Check the monitor panel display or pilot display
go to troubleshooting H-l of hydraulic system
I go to troubleshooting of electrical system, either F-O or P-O
2. Judgment table for suspension controller and suspension related parts
l If an abnormal display is given in the self-diagnostic display, go down ( 1 ) to the trouble-
shooting code on the bottom line of the judgment table . . . go to S-00
(A 0 mark is given in the places where the failure mode and self-diagnostic display match.)
check if there is any monitor panel and pilot lamp display (display at points marked 0) that
matches the failure mode in the judgment table, and
If the display is normal, go (- ) to the troubleshooting code . .. go to TESTING AND ADJUSTING
OF SUSPENSION
If the display is abnormal, go down ( 1 ) to the troubleshooting code . .. go to P-00, F-00
ExampleFailure mode [Switching of suspension mode is abnormal]

[Procedure] Check if any abnormal display is given in the self-diagnostic display, and
check the digit that is lighted up on the top of the controller.
) in the self-diagnostic
display: go to troubleshooting S-2 of electrical system
If there is no abnormal display given in the self-diagnostic display, but

the suspension mode switches abnormally frequently,
l Check the pilot display - go to troubleshooting of electrical system,
either F-l or F-2
3. Judgement table for engine controller and engine related parts
1) Engine with mechanical governor
l Depending on the type of problem, go straight to this troubleshooting item.
2) Engine with electronic governor
l If an abnormal display is given in the self-diagnostic display, go down ( 4 ) to the
troubleshooting code on the bottom line of the judgement table . . . . . . . . . . . go to G-00
(A 0 mark is given in the places where the failure mode and self-diagnostic display come
together.)
check if there is any monitor panel and pilot lamp display (display at points marked 0)
that matches the failure mode in the judgement table.
If the display is normal, go to the troubleshooting code at the right side ( I) ) . . . . . . . . . . .
go to G-00, Engine Shop Manual.
If the display is abnormal, go down ( 4 ) to the troubleshooting code . . . . . . . go to F-00
<E xample> Failure mode [Engine does not start]
[Procedure] Check the two LEDs on the top of the controller to see if their ON/OFF
combination gives an abnormal display for the self-diagnostic display.
JUDGEMENTTAME FOR ENGINE CONTROUER AND ENGINE RELATED PARTS
[Judgement] If there is an abnormal display [ for example, Fij on the self-diag-
nostic display . . . . go to troubleshooting G-3 of the electrical system
If there is no abnormal display on the self-diagnostic display (but the

engine does not start):
Starting motor rotates . . . . . . . . . . . go to
troubelshooting of mechanical system (see
l Check that the starting Engine shop Manual)
motor rotates
Starting motor does not rotate . . . go to
troubleshooting G-l 2 of electrical system
20-74-l
0
EXPLANATION OF FUNCTIONS OF ELECTRICAL SYSTEM
(Control mechanism)
l FOR ENGINES WITH MECHANICAL GOVERNOR
This section gives as information that is necessary for troubleshooting of the electrical system
the function and details of confirmation of the transmission controller, suspension controller, and
monitor panel.
1) Explanation of functions
The control mechanism of the electrical system consists of the transmission controller and
suspension controller, and the monitor panel that displays failures in the mechatronics of each
system. lt controls the optimization (individual electronic modulation) of the transmission clutch
pressure, and the switching of the damping force of the suspension (auto suspension).
The monitor panel informs of any abnormality when there is a failure in the mechatronics
equipment in any system.
lnpUt/OUtput signal system for monitor panel and each controller (Fig. 1)
F56103080
Fig. 1
2) Explanation of self-diagnostic display functions
Each controller has self-diagnostic display functions, so it displays an abnormality if there is
any electrical abnormality (disconnection, contact with ground, internal short circuit, or short
circuit between wires, etc.) in the output signal system for No. 1 - 8 and input signal system
No. “1 - “11 in Fig. 1, or if the input/output does not match the action of the machine.
If the self-diagnostic display function is actuated, an abnormal display is output [Fig. 1 (a), (b)]
from each controller to the monitor panel, so it is possible to inform which mechatronics system
has the abnormality.
In addition, each controller has sensor signals, such-as the accelerator signal and transmission
output shaft speed signal, so if any abnormality occurs in that sensor signal, it is possible
that two failure displays with the same content may be given at the same time.
Even if there is an abnormality in input signal system B - G, no self-diagnostic display is
given, so in cases where no abnormal display is given in the display area, but there is an
abnormality in the movement of the machine, determine if the cause is in the electrical system
or hydraulic, pneumatic, or mechanical system. To do this, use the actuation confirmation method
for the electrical system in Item 3) to check if each signal is being input.
3) Checking actuation of electrical system
When carrying out the set of operations in the order given below, if the monitor panel, transmission
controller, and suspension controller act in the way described below, the input/output signals,
monitor panel, and each controller are normal.
Carry out this operating check with the machine unloaded.
(The operation for the suspension controller differs according to whether the machine is loaded
or unloaded, but it is possible to check all of the mode selections with the machine unloaded.)
8.8 is displayed for 3 seconds,

then seifdiagnosticdirplay goes
out for 0.5 seconds. After this, displays
part problems are displayed for Suspension mode is set
3 seconds each.
Following this, if the machine at
present is normal, 0.0 or 0.C
(in cold weather) is displayed.
. Shift p-asition display N
is below 10 C, 0.C is displayed.
8
z
8
. Shift position display R.

. Body caution lamp lights up. . When body is placed at FLOAT,
machine drives in revere.
nans, depress accelerator pedal.
gas out momentarily.

l FOR ENGINES WITH ELECTRONIC GOVERNOR
This section gives information about the function and details of confirmation of the transmission
controller, engine controller, suspension controller, and monitor panel that is necessary for
troubleshooting of the electrical system.
1. Explanation of functions
The control mechanism of the electrical system consists of the transmission controller, engine
controller, suspension controller, and the monitor panel that displays failures in the mechatronics
of each system. It carries out control by changing the output of the engine (power mode), providing
the optimum oil pressure for the transmission clutch (individual electronically controlled
modulation), and switching the damping force of the suspension (auto suspension).
The monitor panel informs the operator of any abnormality when there is a failure in the
mechatronics equipment in any system.
Input/output signal system for monitor panel and each controller (Fig. 1)
561 F3309
2. Explanation of self-diagnostic display functions
Each controller has self-diagnostic display functions, so it displays an abnormality if there is
any electrical abnormality (disconnection, contact with ground, internal short circuit, or short
circuit between wires, etc.) in the output signal system for No. 1 - 11 and input signal
system No.*1 - “17 in Fig. 1, or if the input/output does not match the action of the machine.
If the self-diagnostic display function is actuated, an abnormal display is output (Fig. 1 @, @,
@) from each controller to the monitor panel, so it is possible to know which mechatronics
system has the abnormality.
In addition, each controller has sensor signals, such as the accelerator signal and transmission
output shaft speed signal, so if any abnormality occurs in that sensor signal, it is possible
that two failure displays with the same content may be given at the same time.
Even if there is an abnormality in input signal system A - K, no self-diagnostic display is
given, so in cases where no abnormal display is given in the display area, but there is an
abnormality in the movement of the machine, determine if the cause is in the electrical system
or hydraulic, air or mechanical system. To do this, use the actuation confirmation method for
the electrical system in Item 3) to check if each signal is being input.
20-76- 1
a
3. Checking action of electrical system
When carrying out the set of operations in the order given below, if the monitor panel, engine
controller, transmission controller, and suspension controller act in the way described below,
the input/output signals, monitor panel, and each controller are normal.
Carry out this operating check with the machine unloaded. (The operation for the suspension
controller differs according to whether the machine is loaded or unloaded, but it is possible
to check all of the mode selections with the machine unloaded.)
20-76-2
0
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MO’NITOR
PANEL AND EACH CONTROLLER
1. Monitor panel
After the starting switch is turned ON, self testing is carried out on the monitor itself. After
this, the normal display is given.
The bulbs of the pilot lamps and caution lamps can be checked by pressing the switch at the
right edge of the panel.
2. Transmission controller
(1) Self-diagnostic display
The content of the self-diagnosis is displayed by LEDs (Light Emitting Diodes) in a 2-digit
code.
When the self-diagnosis detects an abnormality, the mechatronics abnormality display on
the monitor panel lights up, the warning lamp lights up, and the buzzer sounds.
Self-diagnostic display code table
Key:O- ,’ - 2: Adigit from ,’ to, 8 appears in the display pattern.

,I : Lock-up clutch related parts
L11: H clutch related parts
Tr: L clutch related parts
<f : 1st clutch related parts
5 : 2nd clutch related parts
6 : 3rd clutch related parts
7 : 4th clutch related parts
,_I
13.. R clutch related parts
,_’. Blank; no display
l Method of re-enacting failure display
It is possible to re-enact and investigate the abnormality display as follows.
0 system: Turn the starting switch OFF - ON.
q system: Turn the starting switch OFF - ON, and operate the lever slowly in turn
to N, R, N, D, 5, 4, 3, L. (Stop for at least 3 seconds at each position
before going to the next position.)
n system: Start the engine with the lever at N.
asystem: Using the clutch displayed in the failure display (at the speed range used),
carry out the travel test.
Cor;;“E;ding Speed range

Display
Lock-upclutch Lock-up
F3, F5, F7
Fl, F2, F4, F6
Fl
F2, F3
F4, F5
F6, F7
R
-1 -
:. 1:
(Intermediate
F2
shaft sensor)
l Operation of controller when abnormality is detected

When the transmission controller detects an abnormality, it displays the failure, and also
takes the following action.
A system: Transmission neutral, the transmission returns to neutral because of a

failure in the power source system or controller.
A system: Transmission neutral, there is danger of damage to the chassis electrial

system and controller, so the controller automatically turns the output OFF.
A system: Transmission neutral, there is possibility of failure in the hydraulic or

mechanical system, so to avoid fatal damage to the transmission itself,
the controller automatically turns the output OFF.
A system: Speed range held, but N held with lever at N

Because of the condition of the abnormality, the controller judges it to
be impossible to change gear, so the speed range is held.
A system: Travel is possible, but some functions have stopped

The controller automatically stops the functions of the system which is
abnormal.
(2) Operation mode display
The transmission controller always displays if it is controlling the transmission in the normal
temperature mode or in the low temperature mode.
Operating mode display
After ~.LI is displayed, abnormality

~1
After E. C is displayed, abnormality
(3) Recording self-diagnostic display

Once an abnormality is detected, even if the abnormality is removed, the self-diagnostic
display holds the display for 5 minutes.
(However, the monitor panel mechatronics abnormality display, warning lamp, and alarm
buzzer stop immediately the abnormality is removed.)
l If two failures occur at the same time, all the self-diagnostic displays are given.
Display method: The code display starts in the order that the abnormalities occurred,
and when all the abnormalities have been displayed, the display returns
to the original code.
This cycle is repeated.
(If the abnormality is repaired, the display returns to the normal display
5 minutes after it is repaired.)
(4) Recording failure codes
The transmission controller records the codes of the failure that have occurred (self-diagnostic
display codes.)
This data is kept even after the starting switch is turned OFF.
Because of this, when the starting switch is turned ON, and the transmission controller
power comes ON, it is possible to confirm the nature of the abnormalities that have occurred
so far.
Recording and display method of failure code [Key ,_,: Blank (no display)]
Occurrence of failure: Occurrence of failure:

F s?~$Q for example, disconnection for example, disconnection
5 in exhaust brake sysaem in accelerator signal *y*fem
‘D OFF - ON Faolure code 0.9 recorded. Fa~lura code 1.7 recorded
?
e
.‘o _, 5. c _ _ E. c E. ;I
- .........
2
Em.
,-
I E.I, 0:;s E.,_I : -,I c. I, I:- Y
2 Recording of
NO
t-l ,-I
II. J I:;. 9 : 7
22 failure code
EB se.2
Dtsplay time - 3 sec. os5ec 3
Recorded data
@ deleted
B
b
!
‘”
‘y Self-daagnost*c ,_, ,_,
;z display
g$ Recording of - - , -, NO
falurecode t: y ‘. ’
88
Dlsplsy tune - 3 sec. sec.
0.5 T sec.1 ;,,.
0.5
: ::t:hng
B OFF-ON
G
?
P
.Z
Ia Self-dtagnostic ,_, ,-,
,>,,~,
d? display
L’S
E- Recordnng of
N0
8% failure code
Display tune -3 sec.

In order to be able to make full use of this recording function to show clearly when a failure
occurred and which failures have been repaired, the following operation must be carried
out correctly.
l Method of deleting recorded data for failure codes
When carrying out troubleshooting, after completing repair of the failure, if the self-
diagnostic display has returned to the normal display, always delete the record of the
failure codes from the transmission controller by using the following procedure.
1) With the starting switch at the ON position, after all the past recorded data has been
- -
displayed, Z’.z or Cl:_ must be displayed.
2) Pull out connectors Cl and C2 (black 1 -pin) near the controller, then insert them again.
(When doing this, the starting switch must be at the ON position.)
3) After turning the starting switch OFF, turn it back to ON and check that the past data
has been deleted. (If the date has been deleted, 8.2 will be displayed for 3 seconds,
then the display will return to the normal display of ZZ or :I;; )
3. Suspension controller
(1) Self-diagnostic display
The abnormal display displays the category of abnormality(abnormal system) by a combination
of ON, flashing, and OFF of 2 LEDs (Light Emitting Diode). In addition, the monitor panel
mechatronics abnormal display and the warning lamp light up, and the buzzer sounds.
Normal display: Red 0 OFF, Green 0 ON
OFF/ON Flashing pattern
0 OFF c> Slow flashing

(2-second cycle) oyrmi’
1
561I=031
0.25sec
. ON oFRapid flashing ON
(0.5-second cycle) oFF
LED (Light Emitting Diode)

\lO. Abnormal system
Red Green
1 a a Defective controller system
2 0 OFF 0 OFF Defective power source system
3 0 Q Defective solenoid 3 system
4 a @ Defective solenoid 2 system
5 l ON 0 OFF Defective solenoid 1 system

Slow flashing
@ Slow flashing Defective pressure sensor (right) system
6 0 simultaneous
Raprd flashrng
7 @ @ Rapid flashing Defective pressure sensor (left) system
simultaneous
810 10 ON 1 Defective steering sensor system
9 Q 0 Defective travel speed sensor system
10 #I @ Defective machine selection signal system
(2) Recording self-diagnostic display

Once an abnormality is detected, even if the abnormality is removed, the self-diagnostic
display holds the display for 5 minutes.
(However, the monitor panel mechatronics abnormality display, warning lamp, and alarm
buzzer stop immediately the abnormality is removed.)
l If two failures occur at the same time, the upper one in the table is given priority and
is displayed.
4. Payload meter
(1) Self testing when power is switched ON
When the power is switched ON, self testing is carried out for the display panel and printer
of the payload meter.
If the system is found to be normal, the time display is given after the self test.
Passage of time 1 - I
Operation of starting switch 1 OFF C-ON 1
Flashes
Payload meter display 0000 ton ,1-;‘:-;‘88 ton ,_, :: ,22 ton L, ,_,,_,;;’ ton
panel WhenemmapFine is
All out - 3 seconds -_) - 7 seconds - ,(
i * G = Green GGGYR
GGGYR GGGYR
External display lamps Y = Yellow 00000
00000 0.0.. j
(both sides of machine) ;! R =Red All out
All on When machine is
All out - 10 seconds ; 4 empty >
Printer Operation stopped Paper fed 4 mm 1 Operation stopped
Note: The external display lamps give the display in the table only when the dump lever is at
FLOAT.
(2) Self-testing display

The content of the self test is given on the display panel (weight display) with a 2-digit
code.
the comparison between the content of the self test and failure code is given in the table
below.
l If two or more abnormalities occur at the same time, priority is given to display of the
lower number in the panel below. -
l If an abnormality is detected and a failure code is displayed, the failure code remains
displayed until the power is switched off or until the calibration switch is pressed.
Failure code chart * If the condition is normal, the weight display or time display is given.
-
Failure code
No. Abnormal system (including condition when normal) Symbol: ,_, = Blank (no display)
I- -,,
1 Defective sensor power source voltage (18V) system I L_ - 1, t
,- -, -1
2 Defective relay system (short circuit) I 11 - 3c
I-_ - 1 -1
3 Drop in voltage of backup battery (battery built into controller) L 11 3
,- _ r-1 I
Rear right wheel c I, t
Defective pressure sensor system I- _ r-1 11
Rear left wheel c ,-I L
4 (disconnection, contact with ground,
I- --,
internal defect in sensor) Front right wheel ,: -::I,
r-1 ,_;
Front left wheel ,‘-- - I ,
,-
Rear right wheel L_ - ; /
Rear left wheel ,‘-_ _ ; ,;I
Defective pressure sensor system
5
(short circuit in power source) I- ,7
1 Front right wheel 1 L_ - I _I
,- II,
Front left wheel L-- ,-,
Defective angle sensor system (disconnection, contact with ,-

ground, front-to-rear angle more than 1 O”) L_ _ ‘_; ;
6
Defective angle sensor system (short circuit in power source, I-- _ I_;,;
front-to-rear angle more than -loo) L
7 Paper jam ~~‘&‘,‘~‘~’ Display flashes

‘. ,:‘
;- , ‘I I I
8 Data overflow (storage of data in memory has reached 200) I- ,_Ic L, Display flashes
‘I-) I-,
,
9 Calibration demanded !_ r-, ,_ ,_,. Display flashes
-
20-80- 1
0
5. Engine controller
l ENGINES WITH ELECTRONIC GOVERNOR
1) Self-diagnostic display
The abnormal display displays the category of abnormality (abnormal system) by a combination
of ON, flashing, and OFF of 2 LEDs (Light Emitting Diodes) . . . . . . In addition,
the monitor panel
mechatronics abnormal display and the warning lamp light up, and the buzzer sounds.
Normal display: Red 0 ,OFF, Green e ON
Symbols OFF, ON Flashing pattern
0 OFF @ Slow flashing

(4-set cycle) ,“:,I-z-L_T-.
l ON @F Fast flashing rzFVm__.

(0.5-set cycle)
0.25sec
LED (Light Emitting Diode)

No. Abnormal system
Red Green
15 0 @ Defective left bank prestroke solenoid system
16 @I 0 Defective accelerator sensor system
17 c)F 0 Defective water temperature sensor system
2) Memory of self-diagnostic display

Once an abnormality is detected, even if the abnormality is removed, the self-diagnostic display
holds the display for 5 minutes.
(However, the monitor panel mechatronics abnormality display, warning lamp, and alarm buzzer
stop immediately the abnormality is removed.)
l If two failures occur at the same time, the order of the table is given priority and the first
failure is displayed.
20-80-2
0
ACTION BY SELF-TESTER AND MACHINE SYMPTOMS
hansmission controller system)
Details of abnormality Condition when normal Action of controller Symptoms that appear in machine
Display Abnormal system Check the wiring harnesses and equipment given below. when there is abnormality
2: Check with tester when abnormality
code *Judgment conditions &: Disconnection, short circuit in wiring harness Mechatronics abnormalitydisplay
Voltage (V), current (A), resistanee value S-7, is detected given, warning actuated.
(+): Positive, (-): Negative
L, !_I Iefective controller power source 1I. Battery (+) - circuit breaker& 1. SC3 (14) - (13) (V) : 20 - 3ov Cannot control Suddenly shifts to neutral when
rlnput voltage: Below 12V 2!. Circuit breaker - JO5 & 2. TMB(ll)-TMC(l)(V) 3: 20-30V (transmission returns traveling and cannot start again
Above 37V c $. JO5 - starting switch terminal B, ACC terminal -fuse BTI 3. JO5 - JO6 (V) 2 : 20 - 30V to neutral)
rvoltage of power source inside No.10 -TMB (ll)& 4. When starting switch is ON: ACC - chassis (V) 2: 20 - 30V
controller LI. (+) TMB (11) -SC3 (14)& 5. Fuse BTI No.iO is not blown.
Ei. SC3 (13) -TMC (1) - JO6 -battery relay terminal E
ci. Defective alternator regubtor &
7r. Defective power source circuit inside controller
L, ,_I Controller box system IDefective controller box Controller normal display: 0.0 or 0.C Cannot control Suddenly shifts to neutral when
(transmission returns
rWatch dog timer actuated traveling and cannot start again
to neutral)
0.1 Irop in controller voltage \iNhen controller power source has become weak. 1. SC3(14)-(13)(V)a: 20-30V Places in neutral Suddenly shifts to neutral when
rlnput voltage: Below 19.5V 1I. Defective charging by alternator 2.TMB(ll)-TMC(l)(V)z: 20-30V traveling and cannot start again
c
1 !. Battery tends to become discharged 3. JO5 - JO6 (V) 2 : 20 - 30V
3. Defective charging circuit 4. Check terminals alternator B, battery relay B, battery (+) for
r
.
1) Alternator terminal B -emergency steering relay terminal B - looseness

battery 4 (+) &
2) Alternator terminal E -chassis&
0.2 Irop in solenoid power source voltage t Defective solenoid power source circuit 1. SC3 (15) - chassis (V) 2 : 20 - 30V Places in neutral Suddenly shifts to neutral when
Golenoid power source input voltage: I. Defective transmission cut relay 2. TMC (2) - chassis (V) 2 : 20 - 30V traveling and cannot start again
!. SC3 (15) -TMC (2) - R25 (5), (3) (transmission cut relay) -
.
Below 19.5V 1 3. R25 (5) - chassis (V) 2 : 20 - 30V
fuse BTI No.10 & 4. R25 (3) - chassis (V) 2 : 20 - 30V
0.3 tieutral safety I. Defective handling of machine 1. Starting switch at ON and transmission shift lever at N Places in neutral Sometimes returns to neutral when
tWith starting switch ON
I
4 !. Defective controller power source system 2. No looseness at battery, circuit breaker, 505, JO6 starting switch traveling, but if transmission shift
Transmission shift lever at position 1) Check for looseness of battery (+), circuit breaker, JO5 terminals B and ACC, battery relay E lever is returned to N, it is possible to
other than N starting switch terminals B and ACC 3. Connectors TMB, TMC, SC3 are securely inserted start again.
(There may also be sudden cut in 2) Defective insertion of fuse BTI No.10
power source [when there is defec- 3) Defective contact of connectors TMB (1 l), SC3 (14)
tive contact of control power source 4) Looseness of battery relay terminal E, JO6 terminal
and power is momentarily cut and 5) Defective contact of connectors TMC (1), SC3 (13)
comes on again1 .)
0.4 Iata error IDefective controller box Controller normal display: 0.0 or 0.C Places in neutral Suddenly shifts to neutral when
Kontent of data has changed. traveling and cannot start again
0.5 Double meshing of clutch I. Defective control box Operate transmission Suddenly shifts to neutral when
kWith double meshing of clutch, input 2. Defective fill sensor switch cut relay and return traveling and cannot start again
I
of fill sensor signal was detected. 3. HSW - TM3 (3) - SC2 (20) & to neutral
mDouble meshing condition LSW - TM3 (6) - SC2 (11) c&
Actuated for 2.1 - 4.7 sec. RSW - TM3 (9) - SC2 (10) &
ISW - TM4 (3) - SC2 (8) &
2SW -TM4 (6) - SC2 (18) &
3SW - TM4 (9) - SC2 (9) &
4SW -TM4 (12) -SC2 (19)&
Display Abnormal system Check the wiring harnesses and equipment given below. 2 : Check with tester when abnormality when there is abnormality
code *Judgment conditions & : Disconnection, short circuit in wiring harness Voltage (V), current (A), resistance value a is detected Mechatronics abnormality display
(+): Positive, (-): Negative given, warning actuated.
0.6 Transmission cut relay disconnection, 1. Defective transmission cut relay Places in neutral Suddenly shifts to neutral when
short circuit, connection with ground 2. SC3 (7) - TMC (3) - R25 (2). (1) (transmission cut relay) - SC3 TMC R25 (V) zz? a z? traveling and cannot start again.
* Voltage at output terminal of fuse BTI No. 10 &
transmission cut relay (7) - (13) (1) - (3) (1) - chassis 20-30V -
- When actuated: Above 11 V
- When not actuated: Below 1 IV - - -
IOO-
Relay (1) - (2)
5ooa
0.7 12V output circuit in contact with 1. (+) SC2 (6) - TMB (1) 7 SF (1) & 1. SC2 (6) - chassis (V) a-: 12V 12V output circuit Suddenly shifts to neutral when
ground (transmission shift lever power 2. Defective voltage circuit inside controller 2. TMB (I) -chassis (V) 2 : 12V OFF (does not give traveling and cannot start again.
source) 3. SF (1) - (2) (V) 3 : 12V + 12V)
* 12V output terminal voltage: 4. SC2 (6). TMB (I), SF (I) -chassis: Over IMa
Below 6V
0.8 Rear brake solenoid disconnection, 1. (-) SC3 (3) -TMC (IO) - RH4 (6) -SL4 (2)& 1. SC3 (3), TMC (IO), RH4 (6). SL4 (2) - chassis: Over lM1;2 2 Operation of overrun Even when engine speed exceeds
short circuit, contact with ground 2. (+) SL4 (1) - RH4 (5) -fuse BTI No. 10 & 2. SL4 male (I) - (2): 20 - 6Oa 2 prevention function 2500 rpm and engine overruns,
* Rear brake 3. Defective rear brake solenoid 3. SL4 (1) - chassis: 20 - 30V 2 stopped brake to prevent overrun is not
When operated: Above 11 V 4. RH4 (5) - chassis: 20 - 3OVz actuated.
When not operated: Below 11 V
0.9 Exhaust brake solenoid disconnection, 1. (-) SC3 (12) - TMC (9) - RH4 (4) - SL5 (2) & 1. SC3 (12). TMC (9), RH4 (4), SL5 (2) -chassis: Over IMSI Operation of exhaust Even when accelerator pedal is
short circuit, contact with ground 2. (+) SL5 (1) - RH4 (5) -fuse BTI (No. 1) & 2. SL4 male (I) - (2): 2 20 - 6O!Z brake function released and retarder brake is
* Exhaust brake 3. Defective exhaust brake solenoid 3. SL5 (I). - chassis: 20 - 30V 2 stopped operated, exhaust brake is not
When operated: Above 11 V 4. RH4 (4) - chassis: 20 - 30V 3 actuated.
When not operated! Below 1 IV
1 .o Defective engine speed sensor output 1. Defective engine speed sensor system 1. Engine speed display on monitor panel is normal Considers engine to Engine speed display is not given on
* When engine speed is more than 350 1) E12(1) -E7 (4) -EGA(l) -TMA(14) -SC1 (7)& 2. SC1 (7) - (13): 500 - lOOO!Y22 be running and carries monitor panel.
rpm, transmission speed continues at 2) El2 (2) - E7 (5) - ECA (2) - TMA (15) - SC1 (13)& AC: Over 0.5Vz out control No problem with automatic gearshift
more than 500 rpm for 10 seconds. 3) ECA (1) - PO8 (3) & 3. SC1 (7), (13) -chassis:. Over IMa 2 function
4) ECA (2) - PO8 (4) & - However, part of self-diagnostic
2. Defective engine speed sensor system function stops working, so take
action quickly if abnormality
occurs.
1.2 Defective output of transmission 1. Intermediate shaft speed sensor system No problem with automatic gearshift
intermediate shaft speed sensor 1) N2(1)-TM2(3)-SC1 (6) &
t When the input shaft speed, inter- 2) N2 (2) - TM2 (4) - SC1 (12)&%
mediate shaft speed, output shaft 2. Defective intermediate shaft speed sensor
speed are converted and it is
recognized that there is an abnormal-
ity between the HL clutch and
speed clutch.
1.3 Defective output of transmission 1. Output shaft speed sensor system 1. When traveling, speedometer shows
output shaft speed sensor 1) N3 (I) -TM2 (5) -SC1 (3) & 0 km/h and transmission does not
* When disconnection detector is 2) N3 (2) -TM2 (6) -SC1 (IO)&
actuated and there is no sensor 2. Defective output shaft speed sensor 2. If transmission shift lever is returned
signal. to N, it is impossible to start again.
N3 (I) - TM2 (5) - SC1 (3) - chassis
1.4 Defective model selection signal 1. SC1 (2) - SC3 (4) & 1. SC1 female (2) - SC3 female (4) 52 $? : OSZ If there is abnormality When starting switch is turned ON,
* After starting switch ON, model 2. Defective contact of connector SC1 2. Connectors SC1 and SC3 are inserted securely when starting switch machine cannot be started.
selection signal from wiring harness is ON, transmission is
does not match. held at neutral
Details of abnormality Symptoms that appear in machine
Check the wiring harnesses and equipment given below.
Condition when normal Action of controller .
Display Abnormal system when there is abnormality
& : Disconnection, short circuit in wiring harness 2: Check with tester when abnormality
code *Judgment conditions Mechatronics abnormality display
(+): Positive, (-): Negative Voltage (V), current (A), resistance value 51 is detected
given. warning actuated.
Short circuit, connection with ground 1. R SC2 (1) -TMB (2) -SF (3)& Shift lever position SC2 TMB SF (VI 2 Set in order of prior- 1. Shifts to speed range higher than
1.5
in lever signal system N SC2 (2) - TMB (3) -SF (4)d R (1)- chassis (2) - (9) (3) - (2) ity: N>D>5>4>3>L position set by transmission shift
lever.
*When two or more lever signals are D SC2 (12) -TMB (4) -SF (5)& If it is together with
N (2) - chassis (3) - (9) (4) - (2) 2. Stays at neutral and machine canno
generated, and this continues for 3 5 SC2 (13) -TMB (5) -SF (6)& R, it is taken as N
D (12) - chassis (4) - (9) (5) - (2) start.
seconds. 4 SC2 (3) - TMB (6) -SF (7)& Position before signal 1. Shifts to speed range higher than
5 (13) -chassis (6) - (2) BelOw
(5) - (9)
3 SC2 (4) -TMB (7) -SF (8)& 1.5v stopped is held position set by transmission shift
1.6 Disconnection in lever signal system L SC2 (14) -TMB (8) -SF (9)& 4 (3) - chassis (6) - (9) (7) - (2) lever.
*When there is no lever signal for 3 GND SC3 (4) - TMB (9) -SF (2)& 3 (4) - chassis 2. Stays at neutral and machine canno
(7) - (9) (8) - (2)
start.
seconds. 2. Defective transmission shift lever L (14) - chassis (8) - (9) (9) - (2) 3. Impossible to shift between FOR-
When leveris not set to above positions Between above terminals Over 15V WARD and REVERSE.
1.7 Accelerator signal system 1. SC1 (4) -TMA (13) -SRI (2)& 1. Automatic gear- 1. Transmission shock becomes large.
1. SC1 TMA SRI (V)Z
Disconnection, defective adjustment 2. Defective adjustment and clearance at sensor mount shifting is carried 2. Suddenly shifts up when traveling
(4)-chassis (13)-chassis (2) - (3) 0.6 - 4.5V out with normal
of mount, link out of position 3. Accelerator pedal, link damaged downhill.
mode
*Voltage between SC1 (4) and chassis 4. Defective accelerator sensor 2. Adjustment of clearance of accelerator sensor mount.
2. Control of clutch
- Above 4.7 f O.lV 5. Defective power source circuit for engine controller, Clearance between sensor lever and sensor stopper bolt oil pressure is car-
- Below 0.6 f O.lV accelerator sensor * Low idling: 0.8 + 0.1 mm ried out as for
- High idling: 2.5 f 0.1 mm when accelerator
isfullydepressed.
1.9 Contact of transmission valve oil 1. (+) SC3 (17) -TM4 (13) -C/V.T (I)& _ Clutch oil pressure is Transmission shock becomes large.
temperature system with ground (-) SC3 (4) -TM4 (14) - C/V.T (2)&% SC3 female TM4 female C/V.T male &I 2 controlled at low
*When transmission oil temperature 2. Defective transmission valve oil temperature sensor (4) - (17) (13 - (14) (1) - (2) temperature mode
1 -1OOkQ
sensor signal is more than 150°C. (17)-chassis (13)-chassis (l&chassis
2.0 Clutch slipping or defective transmis- 1. Input shaft speed sensor 1. Suddenly shifts to neutral when
P sion speed sensor system 1) Nl (1) -TM2 (1) -SC1 (5)& traveling and cannot start again.
2 -8 2. Power is lost when traveling, and
*When the input shaft speed, inter- 2) Nl (2) -TM2 (2) -SC1 (1 I)&
transmission repeatedly shifts wher
mediate shaft speed, output shaft 2. Output shaft speed sensor I’ ~1 ‘laces in neutral tnr~;!li;guphill.
speed are converted and it is recog- 1) N3 (1) -TM2 (5) -SC1 (3)& 3. When speedometer display become!
nized that there is an abnormality 2) N3 (2) - TM2 (6) - SC1 (1 O)& 0 km/h, transmission returns to
with the Hi, Low clutch, speed 3. One of following clutches worn or damaged:
clutch, or between the Hi, Low Hi, Low, Ist, 2nd, 3rd, 4th, R 2. See TESTING AND ADJUSTING OF TRANSMISSION
clutch and speed clutch. 3. Transmission oil is not black enough to indicate abnormality
2.2 Defective Hi clutch or input shaft See display code 2.0 1. SC1 female (5) - (11) 2 : 500 - 100052 Places in neutral See display code 2 .U
Note: The problem in Item 3 does nc
speed sensor system 2. See TESTING AND ADJUSTING OF TRANSMISSION, Hi clutch
occur
Defective Low clutch or input shaft See display code 2.0 I. SC1 female (5) - (11) : 500 - lOOOn Places in neutral See display code 2.0
2.3
Note: The problem in Item 3 does nc
speed sensor system 2. See TESTING AND ADJUSTING OF TRANSMISSION, Low clutch occur
2.4 Defective 1st clutch or output shaft See display code 2.0 1. SC1 female (3) - (IO) 2 : 500 - lOOOn Places in neutral See display code 2.0
speed sensor system 2. See TESTING AND ADJUSTING OF TRANSMISSION, 1 st clutch
2.5 Defective 2nd clutch or output shaft See display code 2.0 1. SC1 female (3) - (IO) 2 : 500 - lOOOn Places in neutral See display code 2.0
speed sensor system 2. SeeTESTING AND ADJUSTING OF TRANSMISSION,2nd clutch1
2.6 Defective 3rd clutch or output shaft See display code 2.0 1. SC1 female (3) - (IO) 2 : 500 - lOOOn Places in neutral See display code 2.0
speed sensor system 2. SeeTESTING AND ADJUSTING OF TRANSMISSION, 3rd clutch
2.7 Defective 4th clutch or output shaft See display code 2.0 1. SC1 female (3) - (IO) a : 500 - 100052 Places in neutral See display code 2.0
speed sensor system 2. SeeTESTING AND ADJUSTING OF TRANSMISSION,4th clutch
2.8 Defective R clutch or output shaft See display code 2.0 1. SC1 female (3) - (10) 2 : 500 - lOOOs1 Places in neutral See display code 2.0
speed sensor system 2. See TESTING AND ADJUSTING OF TRANSMISSION, R clutch
Voltage (V), current (A), resistance value SI
t is tried to disengage the

the controller issues the
command, but the fill sensor signal
is still given (clutch engaged). 4) ISW - TM4 (3) - SC2 (8)
5) 2SW - TM4 (6) - SC2 (18)
6) 3SW - TM4 (9) - SC2 (9)&
7) 4SW - TM4 (12) - SC2 (19)&
3.2 Defective Hi clutch pressure control 1. Dirt or dust caught in Hi clutch pressure control spool Places in neutral Suddenly shifts to neutral when
chassis: Over 1 MB
valve system 2. HSW - TM3 (3) - SC2 (20)x&% traveling and cannot start again.
Between each terminal: Over 1 Ma
3.3 Defective Low clutch pressure control 1. Dirt or dust caught in Low clutch pressure control spool LSW male - chassis, TM3 male (6) - chassis, SC2 temale (11) - Places in neutral Suddenly shifts to neutral when
chassis: Over 1 Ma
valve system 2. LSW -TM3 (6) -SC2 (II),+ traveling and cannot start again
Between each terminal: Over 1 MG?
3.4 Defective 1st clutch pressure control 1. Dirt or dust caught in R clutch pressure control spool ISW male - chassis, TM4 female (3) - chassis, SC2 female (8) - Places in neutral Suddenly shifts to neutral when
chassis: Over 1 Ma
valve system 2. RSW - TM3 (9) - SC2 (IO)& traveling and cannot start again
Between each terminal: Over 1 MS2
3.5 Defective 2nd clutch pressure control 1. Dirt or dust caught in 1st clutch pressure control spool 2SW male - chassis, TM4 female (6) - chassis, SC2 female (18) - Places in neutral Suddenly shifts to neutral when
chassis: Over 1 MSZ
valve system 2. ISW - TM4 (3).- SC2 (8)& traveling and cannot start again
3.6 Defective 3rd clutch pressure control 1. Dirt or dust caught in 2nd clutch pressure control spool 3SW male - chassis, TM4 female (9) - chassis, SC2 female (9) - Places in neutral Suddenly shifts to neutral when
chassis: Over 1 Ma
valve system 2. 2SW - TM4 (6) - SC2 (18)& traveling and cannot start again
Between each terminal: Over 1 M$2
1. Dirt or dust caught in 3rd clutch pressure control spool GW.male - chassis, TM4 female (12) - chassis, SC2 female (19) - places in neutral Suddenly shifts to neutral when
3.7 Defective 4th clutch pressure control
chassis: Over 1 MSZ
valve system 2. 3SW - TM4 (9) - SC2 (9)& traveling and cannot start again
3.8 Defective R clutch pressure control 1. Dirt or dust caught in 4th clutch pressure control spool RSW male - chassis, TM3 male (9) - chassis, SC2 female (10) - Places in neutral Suddenly shifts to neutral when
chassis: Over 1 Ma
valve system 2. 4SW - TM4 (12) -SC2 (19)& traveling and cannot start again
Between each terminal: Over 1 MR
4.0 Defective pressure control valve Pressure control spool was stuck at side where clutch was Controller normal display: 0.0 or 0.C Places in neutral Suddenly shifts to neutral when
t system II disengaged. traveling and cannot start again
2 - 8’ *When it is tried to engage the clutch,
the controller issues the command,
but the fill sensor signal is not given,
and the clutch is not engaged.
4.2 Defective Hi clutch pressure control Pressure control spool was stuck at side where clutch was Controller normal display: 0.0 or 0.C Places in neutral Suddenly shifts to neutral when
valve disengaged. traveling and cannot start again
4.3 Defective Low clutch pressure control Pressure control spool was stuck at side where clutch was Controller normal display: 0.0 or 0.C Places in neutral Suddenly shifts to neutral when
4.4 Defective 1st clutch pressure control Pressure control spool was stuck at side where clutch was Places in neutral Suddenly shifts to neutral when
Controller normal display: 0.0 or 0.C
4.5 Defective 2nd clutch pressure control Pressure control spool was stuck at side where clutch was Places in neutral Suddenly shifts to neutral when
Controller normal display: 0.0 or 0.C
4.6 Defective 3rd clutch pressure control Pressure control spool was stuck at side where clutch was Controller normal display: 0.0 or 0.C Places in neutral Suddenly shifts to neutral when
4.7 Defective 4th clutch pressure control Pressure control spool was stuck at side where clutch was Controller normal display: 0.0 or 0.C Places in neutral Suddenly shifts to neutral when
4.8 Defective R clutch pressure control Pressure control spool was stuck at side where clutch was Controller normal display: 0.0 or 0.C Places in neutral Suddenly shifts to neutral when
code *Judgment conditions & : Disconnection, short circuit in wiring harness Mechatronics abnormality display
(+): Positive, (-): Negative Voltage (V), current (A), resistance value 0, is detected
given, warning actuated.
5.0 Disconnection in flow detection valve 1. Disconnection in fill sensor switch system When each speed range is engaged using the shift checker, the fill Holds the speed range 1. Transmission does not shift when
t, system 1) HSW - TM3 (3) - SC2 (20) & sensor signal is given with the combinations shown in the table below. beingusedfor travel. traveling.
2- 8 *When it is tried to engage the clutch, 2) LSW-TM3(6)-SC2(11)& When transmission 2. If transmission shift lever is
the controller issues the command, 3) RSW -TM3 (9) - SC2 (10) &, shift lever is at N, it returned to N, it is impossible to
but the fill sensor signal is not given. 4) ISW - TM4 (3) - SC2 (8) & holds transmission at start again.
However, the clutch is engaged. 5) 2SW -TM4 (6) -SC2 (18)& neutral
6) 3SW - TM4 (9) - SC2 (9)&
7) 4SW - TM4 (12) - SC2 (19)&
2. Defective fill sensor switch
5.2 Defective Hi clutch flow control valve 1. HSW - TM3 (3) - SC2 (20) & The same as above The same as above
system 2. Defective Hi clutch fill sensor switch
5.3 Defective Low clutch flow control valve 1. LSW - TM3 (6) - SC2 (11)& The same as above The same as above
system 2. Defective Low clutch fill sensor switch
5.4 Defective 1st clutch flow control valve 1. RSW - TM3 (9) - SC2 (IO)& Table 1 Relationship between speed range and fill The same as above The same as above
system 2. Defective R clutch fill sensor switch sensor signal
5.5 Defective 2nd clutch flow control 1. ISW - TM4 (3) - SC2 (8) ,& The same as above The same as above
valve system 2. Defective 1st clutch fill sensor switch
5.6 Defective 3rd clutch flow control 1. 2SW - TM4 (6) - SC2 (18)& When each speed range is engaged using the shift checker, the fill The same as above The same as above
valve system 2. Defective 2nd clutch fill sensor switch sensor signal is given with the combinations shown in Table 1.
5.7 Defective 4th clutch flow control 1. 3SW - TM4 (9) - SC2 (9) ,& When each speed range is engaged using the shift checker, the fill The same as above The same as above
valve system 2. Defective 3rd clutch fill sensor switch sensorsignal isgivenwith thecombinationsshown in Table 1.
5.8 Defective R clutch flow control valve 1. 4SW - TM4 (12) - SC2 (19)& When each speed range is engaged using the shift checker, the fill The same as above The same as above
system 2. Defective 4th clutch fill sensor switch sensor signal is given with the combinations shown in Table 1.
7.0 Short circuit in pressure control 1. 1) Lock-up (+) L/R.T (1) - SC3 (2) & Actuates transmission Suddenly shifts to neutral when
Table 2 Solenoid valve check
t solenoid system (-) L/U.T (2) -SC3 (ll),.& cut relay and returns traveling and cannot start again
l-8 *when it is tried to disengage the 2) Hi clutch (+) H.PS (1) -SC3 (I)& to N
clutch, (-) H.PS (2) - SC3 (lo)&
- The pressure control solenoid 3) Low clutch (+) L.PS (I) - SC4 (7) .&
output is turned OFF, but the (-) L.PS (2) - SC4 (13)&
solenoid current still flows, 4) 1st clutch (+) l.PS (I) -SC4 (l)&
or (-) 1 .PS (2) - SC4 (8) &
* Excessive solenoid current flows, 5) 2nd clutch (+) 2.PS (1) -SC4 (2) &
(-) 2.PS (2) - SC4 (9) &
6) 3rd clutch (+) 3.PS (1) - SC4 (3) &%
(-) 3.PS (2) - SC4 (IO)&
7) 4th clutch (+) 4.PS (I) - SC4 (5) 4
(-) 4.PS (2) -SC4 (ll)&
8) R clutch (+) R.PS (1) -SC4 (6) &
(-) R.PS (2) - SC4 (12)&
2. Defective pressure control solenoid
7.1 Short circuit in lock-up pressure See display code 7 .O The same as above The same as above The same as above
control solenoid system
7.2 Short circuit in Hi clutch pressure See display code 7.0 The same as above The same as above The same as above
7.3 Short circuit in Low clutch pressure See display code 7.0 The same as above The same as above The same as above
code *Judgment conditions &: Disconnection, short circuit in wiring harness Mechatronics abnormality display
Voltage (V), current (A), resistance value a is detected given, warning actuated.
7.4 Short circuit in 1st clutch pressure See display code 7.0 The same as above The same as above The same as above
7.5 Short circuit in 2nd clutch pressure See display code 7.0 The same as above The same as above The same as above
7.6 Short circuit in 3rd clutch pressure See display code 7 .U The same as above The same as above The same as above
7.7 Short circuit in 4th clutch pressure See display code 7.0 The same as above The same as above The same as above
7.8 Short circuit in R clutch pressure See display code 7.0 The same as above The same as above The same as above
9.0 Disconnection in pressure control 1. 1) Lock-up (+) L/U.T (1) -SC3 (2)& Even when a discon- 1. Power is lost when traveling, and
Table 2 Solenoid valve check
t solenoid system (-1 L/U.T (2) -SC3 (II)& nection is detected, when shifting up, transmission
1-8 *When it is tried to disengage the 2) Hi clutch (+) H. PS (I) - SC3 (I)& it tries to send cur- immediately shifts down again.
clutch, (-1 H. PS (2) - SC3 (10) .&X rent to the solenoid. * This frequently happens when
The pressure control solenoid output 3) Low clutch (+I L. PS (I) - SC4 (714 - This is because there traveling uphill loaded
is turned ON, but the solenoid (-) L. PS (2) - SC4 (13)& is no danger of 2. Shift indicator display shows “E”
current does not flow. 4) 1st cltuch (+) 1. PS (I) - SC4 (1 )&j damage to the con-
(-) 1. PS (2) - SC4 (814 troller even if there
5) 2nd clutch (+) 2. PS (I) - SC4 (2)& is a disconnection.
(-1 2. PS (2) - SC4 (914
‘.
6) 3rd clutch (+) 3. PS (1) - SC4 (3) G%
(-) 3. PS (2) - SC4 (IO)&
7) 4th clutch (+) 4. PS (I) - SC4 (5)&
(-) 4. PS (2) - SC4 (1 I,&
8) R clutch (+) R. PS (I) - SC4 (6)&
When each speed range is engaged using the shift checker, the
(-1 R. PS (2) - SC4 (12)&
fill sensor signal is given with the combinations shown in Table 1.
2. Defective pressure control solenoid
9.1 Disconnection in lock-up pressure See display code 9.0 Check using Table 2 See Item 9.0 See Item 9.0
9.2 Disconnection in Hi clutch pressure See display code 9.0 Check using Table 2 See Item 9.0 See Item 9.0
9.3 Disconnection in Low clutch pressure See display code 9.0 Check using Table 2 See Item 9.0 See item 9.0
9.4 Disconnection in 1st clutch pressure See display code 9.0 Check using Table 2 See Item 9.0 See Item 9.0
9.5 Disconnection in 2nd clutch pressure See display code 9.0 Check using Table 2 See Item 9.0 See Item 9.0
9.6 Disconnection in 3rd clutch pressure See display code 9.0 Check using Table 2 See Item 9.0 See Item 9.0
9.7 Disconnection in 4th clutch pressure See display code 9.0 Check using Table 2 See Item 9.0 See Item 9.0
9.8 Disconnection in R clutch pressure See display code 9.0 Check using Table 2 See Item 9.0 See Item 9.0
(Suspension controller system)
Details of abnormality Symptoms that appear in m.achrne
Condition when normal Action of controller when there IS abnormalrty
Display Abnormal system Check the wiring harnessesand equipment given below. when abnormality
3: Check with tester Mechatronics abnormality display
code *Judgment conditions &: Disconnection, short circuit in wiring harness
Voltage (V), current (A), resistance value a is detected given, warning actuated.
Red Green Defective controller power I. Battery (+) - circuit breaker - JO7 - starting switch B -terminal ACC - 1. SUl (16) -(17)(V) 2: 20-30V Cannot control Mode display goes out
0 0 source fuse BT2 No.5 -SU3 (1) -SUl (16)& 2. SUl (16)-chassis(V) 3: 20-30V - Suspension mode is * Suspension mode stays in same condi-
OFF OFF *Input voltage: Less than 2. (+) SUI (16) -SLl (l),SL2 (l),SL3 (I)& 3. SUI (17) -chassis (V) 2: On held in condition tion as before abnormality display
17V 3. SUl(17) - SU3(16) - JO3(8) - No.30 connecter(9) -battery relay terminal E 4. Fuse BT2 No.5 is not blown before power was cut appeared on monitor panel
Red Green Defective pressure sensor
(right) system
1. Payload meter PLl(10) JO4(1) No.31
INo.02 connector(l) - No.39 connector(l) -Fixed in medium 1. Mode is not switched.
Branch connector(l) - No.13 connector(l) To sensor mode ’ Remains in medium mode
@I @ *When internal pressure of I I RH2 (6) - PM3 (3)& 6% 2. Riding comfort may be poor
Slow Slow suspension is
Flash- flash- - Abnormally high 2. (-) SUS2 (10) - SU3 (7) - JO4 (3) - No.39 connector (2)& . The time taken to make judgment
Measure with machine stopped and unloaded
ing ing * Released 3. Defective sensor on detection of abnormalities is
*Disconnection, short circuit 4. If the sensor was not tightened sufficiently when it was installed to the 1. When sensor is installed (V) 2: 1.3 - 2.4V long, so if defective contact occurs,
jimultaneous in sensorsystem 2. When sensor is removed (V) 2: 0.98 - IV
suspension, it cannot detect the pressure. the mode may not switch.
1. Mode is not switched.
- Remains in medium mode
2. Riding comfort may be poor
- The time taken to make judgment
iimultaneous ly when it was installed to the
3. Disconnection in transmission output shaft speed sensor

ed in sensor system
ates between OV and
connector does not
nnection, short cir-
nnection, short cir-

etected in solenoid
2 system (solenoid 2
ylinder port B
- Remains fixed in one mode

2. Rolls excessively
3. Riding comfort becomes poor
(Engine controller system)
Details of abnormality Action of controller Symptoms that appear in machin
Condition when normal
3, : Check with tester
code *Judgment conditions & : Disconnection. short circuit in wiring harness when abnormality Mechatronics abnormality display
(+): Positive, (-): Negative Voltage (V), current (A), resistance value L2 is detected given, warning actuated.
Power source system Controller power source system 1. EC3 (I), (12) - (2), (13) 2 : 20 - 30V Stop engine 1. Engine stops during operation
Red Green *EC3 (1) - (2) (+) I) Battery (+) -circuit breaker & 2. EC3 (I), (12) -chassis 3 : 20 -30V 2. Engine cannot be started
0’ 0 - Over 42.4*6V and (+) 2) Circuit breaker - JO5 & 3. EC3 (2), (13) - chassis 2 : OS2 again.
OFF OFF abnormal voltage (+) 3) JO5 -starting switch terminal B - fuse BT2 No. IO &
(+) 4) Fuse - ECB (II) - EC3 (I), (12) &%
(-) 5) EC3 (2), (13) - ECB (12) - JO6 - battery relay E &
Controller Defective controller Normal display of controller Stop engine 1. Engine stops during operation
Red Green 2. Engine cannot be started
*Inside controller Normal Red OFF 0
0 0 - Watch dog again.
ON ON Timer actuated Green ON l
- Data abnormality
Red Green Disconnection, short 1. EC2 (II) - E8 (3) - El3 (3) (signal (+)) .& Stops right bank 1. It feels that there is loss of
circuit with ground in EC2 (5).- E8 (7) - El3 (4)(signal (-)) & engine power during operation.
0 (> right bank rack sensor $. (+) EC2 (1) - E8 (1) - El3 (I)& 2. The engine pick-up becomes
ON Slow *EC2 (5) - (11) 4:(-)EC2(8)-E8(2)-El3(2)& Normal control of poor.
flash- - Above 4.4kO.l V 5. Defective right bank rack sensor left bank 3. It becomes more difficult to
ing * Below O.l*O.O5V start the engine again.
Disconnection, short 1. EC2 (13) - E7 (3) - E9 (3) (signal (+)) & Stops left bank 1. It feels that there is loss of
Red Green
circuit with ground in EC2 (7) - E7 (7) - E9 (4) (signal (-)) & EC2 engine power during operation.
@ 0 left bank rack sensor :: (+) EC2 (2) - E7 (I) - E9 (I)& 2. The engine pick-up becomes
(7) - (13) (3) - (7) (3) - (4) 0.2 - 3.8 -
Slow OFF *EC2 (7) - (13) 4. (-) EC2 (9) - E7 (2) - E9 (2)&x Normal control of poor.
flash- - Above 4.4kO.l V 5. Defective left bank rack sensor (2) - (9) (I) - (2) (1) - (2) 5 - right bank 3. It becomes more difficult to
ing - Below O.l+O.O5V Each pin -chassis - Over 1 MSl
start the engine again.
Disconnection, short 1. (+) EC1 (I) - E8 (14) - El5 (2)& Stops right bank 1. It feels that there is loss of
Red Green
circuit with ground in 2. (-) EC1 (10) - E8 (13) - El5 (I)& engine power during operation.
l @F right bank governor 3. Defective right bank governor solenoid 2. The engine pick-up becomes
solenoid I) Defective resistance between El5 (2) and (I ) Normal control of poor.
ON 4Fast
flash- *EC1 (1) -(IO) 2) Short circuit between El5 (2) and chassis left bank 3. It becomes more difficult to
ing - Above 2.l+O.lA 4. (+) EC1 (16) - ECB (5) - R22 (6) - (right bank governor cut relay) start the engine again.
s Below O.lA (3) - fuse BT2 No. 10 &
Disconnection, short 1. (+) EC1 (3) - E7 (14) - El1 (2)& Stops left bank 1. It feels that there is loss of
Red Green
circuit with ground in 2. (-) EC1 (12) - E7 (13) - El1 (I)& engine power during operation.
left bank governor 3. Defective left bank governor solenoid 2. The engine pick-up becomes
OF @ solenoid 1) Defective resistance between El 1 (2) - (1) Normal control of poor.
Fast slow *EC1 (3) - (13) 2) Short circuit between El 1 (2) - chassis right bank 3. It becomes more difficult to
flash- flash-
ing ing
- Above 2.lkO.lA 4. (+) EC1 (8) - ECB (3) - R23 (6) - (left bank governor cut relay) start the engine again.
- Below 0.1 A (3) - fuse BT2 No. 10 &
Red Green Disconnection, short 1. Defective governor cut relay Normal control
EC1 ECB R22 az? V 2
circuit, short circuit with 2. EC1 (4) - ECB (2) - R22 (2). (I) (governor cut relay) - -
0 0 (4),(16)ch&sis (2).(5)chassis (1),(3)chassis - 20-30
ground in right bank fuse BT2 No. IO &
ON- OFF - (1) - (2) 200 - 900 -
governor cut relay 3. EC1 (16) - ECB (5) - R22 (6), (3) (governor cut relay) -
fuse BT2 NO. IO &
Red Green Disconnection, short 1. Defective governor cut relay 7 Normal control
EC1 ECB R23 azz? vz?
circuit, short circuit with 2. EC1 (13) -,ECB (I) - R23 (2), (I) (governor cut relay) -
@F ‘0 (13).(8Ichassis (1),(3)chassis (1),(3)chassis - 20-30 -
ground in left bank fuse BT2 No. IO &
Fast OFF - - 200 -900 -
governor cut relay 3. EC1 (8) - ECB (3) - R23 (6), (3) (governor cut relay) - (I) - (2)
flash-
ing fuse BT2 No. 10 &
Red Green Rack sensor power 1. Defective rack sensor Normal display of controller Stops engine 1. Engine stops during
2. Damage to rack sensor mount operation.
@ OF :‘;(I) -(8) Normal Red OFF 0
3. Defective injection pump 2. Engine cannot be started
Slow
flash-
Fast
flash-
EC2 (2) - (9)
Green ON l again .
Above 4.6+0.05V
ing ing
20-88-l
0
Details of abnormality Action of controller Symptoms that ap ear in machir
Display Abnormal system Condition when normal
Check the wiring harnesses and equipment given below. when there is a g normality
*Judgment conditions T+)i ~;;;~eec~_~n,;horo;cuit in wiring harness 2 : Check with tester when abnormality
code Mechatronics abnormality displa
I - Voltage (V), current (A), resistance value a is detected given, warning actuated.
Red ~~~~~ Right bank governor 1. + EC1 (16) - ECB (5) - R22 (6) - (right bank governor cut relay) 1. EC1 (16) - chassis: a 20 - 30V Stops right bank 1. It feels that there is loss of
servo system (3) -fuse BT2 No. 10 & 2. Same as right bank rack sensor system engine power during operation.
@F @F
*Rack command value 2. Defective right bank rack sensor system governor solenoid system 2. The engine pick-up becomes
Fast Fast and sensor input do governor solenoid system Normal control of poor.
flash- flash- not match 3. Defective right bank injection pump left bank 3. It becomes more difficult to
ng ing
Alternate
Red Green Left bank governor 1. + EC1 (8) - ECB (3) - R23 (6) .-- (left bank governor cut relay) (3) 1. EC1 (8) - chassis: 2 20 - 30V Stops left bank 1. It feels that there is loss of
servo system -fuse BT2 No. 10 & 2. Same as left bank rack sensor system engine power during operation.
OF @ F *Rack command value 2. Defective left bank rack sensor system governor solenoid system 2. The engine pick-up becomes
Fast Fast and sensor input do governor solenoid system
Normal operation poor.
Flash- flash- not match 3. Defective left bank injection pump
of right bank 3. It becomes more difficult to
ing ing
jimultaneous
Red Green Disconnection, drop in 1. Defective resistance between EC3 (7) and (17) Controls operation 1. It feels that there is loss of
output of engine speed 2. Defective AC voltage between EC3 (7) and (17)& EC3 E8 El6 ACV 2 to 50% of output power during operation.
az?
@ @ sensor A 3. EC3 (7) - E8 (4) - El6 (1) &%
(7) - (17) (4) - (5) (1) - (2) 0.5- lk&2 Over 0.5v 2. The engine pick-up becomes
Slow Slow *Does not match signal 4. EC3 (17) - E8 (5) - El6 (2) & poor.
Flash- flash- from speed sensor B 5. Defective engine speed sensor A Each pin -chassis Over lMn -
3. Engine stops during operation
ng ing and cannot be started again.
Note: Measure the voltage at an engine speed of at least 600 rpm.
iimultaneous
Red Green Disconnection, drop in 1. Defective resistance between EC3 (8) and (18) Controls operation 1. It feels that there is loss of
output of engine speed 2. Defective AC voltage between EC3 (8) and (18) to 50% of output power during operation.
@ @ sensor B 3. EC3 (8) - E7 (4) - El2 (I) & 2. The engine pick-up becomes
glow Slow *Does not match signal 4. EC3 (18) - E7 (5) - El2 (2)& poor.
flash- flash- from speed sensor A 5. Defective engine speed sensor B 3. Engine speed display does
ng ing
not appear on monitor panel.
Alternate Note: Measure the voltage at an engine speed of at least 600 rpm.
Disconnection, short 1. + EC1 (6)-E8(12)-El4(2)&

Red Green Controls right bank 1. It feels that there is loss of
circuit with ground in 2. - EC1 (14) - E8 (11) - El4 (I)&
output to 20% power during opetation.
0 @F right bank pre-stroke 3. Defective right bank pre-stroke solenoid
10 - 21sI 2. The engine pick-up becomes
,
OFF Fast solenoid 1) Defective resistance between El4 (2) and (1) (6) - (14) (11) - (12) (1) - (2)
Normal control of poor.
$sh- *EC1 (6) - (14) 2) Short circuit between El4 (2) and chassis (6)-chassis (12)-chassis (2)-chassis Over 1 MS2 left bank 3. More black smoke comes
* Above 2.1+0.1A Each pin -chassis Over 1 MS?, from exhaust.
- Below 0.1 A 4. Engine starting performance
is poor.
Disconnection, short 1. + EC1 (7) - E7 (12) - El0 (2) ,&
Red Green
2. - EC1 (15) - E7 (11) -El0 (I)&
Controls left bank 1. It feels that there is loss of
circuit with ground in power during operation.
output to 20%
0 @ left bank prestroke 3. Defective left bank prestroke solenoid
2. The engine pick-up becomes
DFF Slow solenoid 1) Defective resistance between El0 (2) - (I) Normal control of poor.
flash- *EC1 (7) - (15) 2) Short circuit between E 10 (2) - chassis right bank
ing -Above 2.1kO.lA 3. More black smoke comes
from exhaust.
* Below O.lA
4. Engine starting performance
IS Door.
Red Green Disconnection in acceler- 1. + EC3 (11) - ECA (14) -SRI (1) .& Lowers speed and 1. Engine speed does not rise.
ator sensor, defective 2. - EC3 (20) - ECA (16) -SRI (3) & keeps at low idling 2. Engine speed rises when
0 0 adjustment of mount, 3. EC3 (IO) - ECA (12) -SRI (2) & transmission is placed in
Slow OFF separated link 4. Defective adjustment of clearance at sensor mount neutral.
flash- *EC3 (IO) - (20) 5. Damaged accelerator pedal link
ng - Above 4.75fO.l V 6. Defective sensor
- Below 0.6*O.lV
Disconnection, short 1. EC2(4)-ECA(9)--02(l)-20(5)-26(l)&

Red Green Voltage between EC2 (4) and chassis: Above 1 .lV Automatic warming 1. Automatic warming up is
circuit in coolant 2. 26 (2) - 20 (9) - JO2 (3) - PO9 (8) &
Below 4.7V up is not carried out, not carried out.
@F . temperature sensor 3. Defective voltage between EC2 (4) and chassis
but other operations 2. No coolant temperature
Fast ON *EC2 (4) - chassis
are carried out as display is given,on monitor
flash- - Below l.l+O.lV normal panel.
‘ng - Above 4.750.1 V
20-88-2
0
TYPE AND LOCATION OF CONNECTOR, SENSOR
l For engines with mechanical governor
l For machines with electronic display panel, auto suspension and payload meter system
* The index column shows the index for the location of connectors.
Type of connector, sensor
ConNnoector- Location of device Index
Type No. of pins
Al (male),
Type M 1 Z-1
A2(female)
AS2 Type X 2 Parking brake sensor G-9
AS3 Type X 2 Retarder brake sensor H-9
AS4 Type X 2 Emergency brake sensor F-9
AS5 Type X 2 Service brake sensor G-9
BTl Terminal 20 Fuse box w-2
BT2 Terminal 20 Fuse box w-2
BT3 Type S 12 Fuse box w-2
BZ Type M 2 Buzzer R-4
Cl(female), For canceling failure mode

Type M 1 a-l
8 C2( male) memory
z
0
CM
I Type S I Combination switch
I T-8
Transmission oil temperature

CVT Type X 2 x-5
sensor
El2 Type X 2 Engine speed sensor (left bank) A-6
H.PS I Type X I 2 ECMV solenoid valve I W-8
H.SW
\I
Type X
I \
ECMV fill switch
I W-8
16 Cab inside-outside intermediate

JO1 Type S v-3
connector
16 Cab inside-outside intermediate

JO2 Type S v-3
connector
Cab inside-outside intermediate
JO3 Type S 16 v-4
connector
JO4 12 Cab inside-outside intermediate w-4

Type S
connector
JO5 Terminal 1 Cab inside-outside intermediate

v-3
connector
JO6 Terminal 1 v-3
connector
Terminal 1 Cab inside-outside intermediate

JO7 v-3
connector
JO9 Type S 12 Intermediate connector Y-l

Connector Type of connector, sensor
No. Location of device Index
Type 1 No. of pins
LCT
I Type X I Torque converter lock-up solenoid
valve
V-8
LS Type M 3 Rheostat u-7

I I I
L. PS
I Type X /
ECMV solenoid valve
L. SW
I Type X /
1 ECMV fill switch
I W-8
Nl
I Type X
/
Transmission input shaft speed
sensor I
V-8
N2 Type X Transmission intermediate shaft V-8

speed sensor
N3 Transmission output shaft speed

Type X z-9
sensor
PO1 Type 040 Electronic display panel Q-7
PO2 Type 040 8 Electronic display panel R-9
PO3 Type 040 2 Electronic display panel Q-7

g
G
PO4 Type 040 8 Electronic display panel R-9 %

I
PO7 Type 040 2 Electronic display panel s-9
PO8 Type 040 16 Electronic display panel s-9
PO9 Type 040 12 Electronic display panel S-8
PlO Type 040 2 Electronic display panel R-6
Pll Type 040 8 Electronic display panel T-8
P12 Type 040 16 Electronic display panel T-8
P13 Type 040 4 Electronic display panel S-6
P14 Type 040 2 Electronic display panel U-8
RE3 Socket 2 Resistor X-l
RE4 Socket 2 Resistor z-4
20690
CondEctor Type of connector, sensor
Location of device Index
Type 1 No. of pins
-I Types 10 Intermediate connector z-4

I
RH2 Type S 12 Intermediate connector Y-l

I I I
RH4 Type S 8 Intermediate connector z-4

I
RPS Type .X 2 ECMV solenoid valve Y-9

I I I
R.SW
1 Type X I ECMV fill switch
/
Y-9
ROl Relay 5 Engine start relay v-3
R02 Relay 5 Transmission neutral relay v-4
R03 5 Service brake relay

I w-4
R04 Relay 5 BCV control relay w-4
R05 Relay 5 Backup alarm relay x-4
R06 Relay 5 Head lamp (Hi) relay v-2
R07 Relay 5 Marker lamp relay v-2
i
Relay Head lamp (Lo) relay
I w-4
R09 I Relay I 6 1 Rear brake pilot relay I x-4
Charge caution relay x-5
R12 Relay 6 Parking body float relay v-2

I I I
Relay 5 Cooling water temperature v-2

R13
caution relay
R14 Relay 5 Transmission filter relay Y-5

I I I
R15 Relay 5 Battery hold relay Y-4

I I
R21 Relay 5 Parking brake relay x-2

I
R22 Relay 5 Engine stop relay x-2
R23 Relay 5 AISS relay X-l
R24 Relay 5 Lock-up display relay

No. Location of device Index
Type 1 No. of pins
R25
I Relay Transmission cut relay
I z-4
SC1 Type MIC 13 Transmission controller

I H-l
SC2 Type MIC 21 Transmission controller H-l
SC3 Type MIC 17 Transmission controller J-2
Type MIC 13 Transmission controller
SF Type S 12 Transmission shift lever P-l
SH Socket 7 Transmission shift limit swtch P-2
SLI 2 ;;l;yrion control solenoid

/ x-5
SL2 2 Suspension control solenoid Y-4

Type X
valve B
SL3 2 Suspension control solenoid z-4

Type X valve C
SL4 Type X 2 Auto retarder solenoid z-4
SRI Type X 3 Accelerator sensor D-l
Type X Steering sensor / F-l
SUI MIC 21 Suspension controller a-3,
su2 MIC 13 Suspension controller a-3
su3 Suspension controller intermediate

Type S 16 a-3
connector
su4 Type M 4 Model selection connector z-1
Torque converter oil temperature

TC.SE Type X 2 v-7
sensor
TMA Type S 16 X-l
I intermediate connector /
TMB 12 Transmission controller X-l
Type S
I intermediate connector /
TMC Type S 12 Y-l
intermediate connector
TM2 Type SWP 14 Transmission controller a-B

TM3 Type SWP 14 a-9
No. Type No. of pins
TM4 Type SWP 14 Transmission controller z-7

WL
I
I
Type M I
I
2
I
Caution lamp II Q-4
1.PS Type X 2 ECMV solenoid valve I z-9

II II I
/I
2. PS I Type X I 2 ECMV solenoid valve I Y-9
3. PS Type X 2 ECMV solenoid valve x-9
4. PS Type X 2 ECMV solenoid valve x-9
1.SW Type X 1 ECMV fill switch z-9
2. SW Type X 1 ECMV fill switch Y-9

I I I
3. SW Type X 1 ECMV fill switch x-9
4. SW Type X 1 ECMV fill switch x-9

B I I I
z Lighting intermediate connector
s 01 Type SWP 14 C-8
02 Type SWP 8 Platform harness intermediate D-8

connector
Front suspension (left) pressure
13 Type X 2 E-l
sensor
Engine left bank intermediate E-8
20 Type SWP 14
connector
26
I Type X I 2 Engine water temperature sensor
Platform harness intermediate 8-7

30 Type SWP 14
connector
2 Front suspension (right) pressure A-7

39 Type X sensor
52
1 Type X I 2 Transmission oil filter sensor
1
K-3
61 Type X 2 Fuel tank fuel gauge sensor I H-9

I I
64 Type X 2 Retarder oil temperature sensor N-4

I I
86 Type SWP 8 AISS motor connector
87 Type SWP 8 Stop motor connector

No. Type 1 No. of pins
PM1 1 Type MIC 1 21 1 Payload meter I P-7
PM2 Type M 4 Model selection l-l
PM3 Type X 3 Clinometer l-2
Rll Relay 6 Payload relay w-2
R16 Relay 5 External display lamp No. 5 w-2

I I I
R17 1 Relay I 5 1 External display lamp No. 4 II x-2

I I
I
I
R18 1 Relay I 5 I External display lamp No. 3 Y-4
R19 1 Relay I 5 I External displav lamp No. 2 I Y-4
R20 Relay 5 External display lamp No. 1 Y-4
62 Type X 2 Rear suspension left sensor L-8
63 Type X 2 Rear suspension right sensor J-Q
20-93-l
0
AS2
I
LOCATION OF CONNECTOR, SENSOR
\PM3
SC3
SC2 . ::
F56103081-1 ..:>.
>:...
13 SR2 SC1
.,.:.:
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.
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:o
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.:,::,,: ,,:;,:, +::..,
D F ..:.:. ...: H ,.,.,.,
.,.,..,.,../., ~. J L :.: .::.:
.... .................. N I’-
2PS
2sw 1sw
RPS \ I I 1PS
PO2
M-2
L/C,T
:.:.:.:
Nl ....I.
..
::‘:
..:...
./..
./..._
PM1 TC,SE .A...
./..
;z
.A..:
,.>:.
.::
j.j:;.
:::.:
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...._
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: .:
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C/VT :::.:.:
.:.,.
:..:.:
..........
:,::::
:.I.::
is.:.
:j:,:.
....\..
..:
..\..
R10 :.:::
:.....
BZ
4
Detail A
::..:.
:
::::
3
‘...>
,.:.::
...
:.::
.
::::
:.:
,...
.:.:
Detail B
F56103082-1 .:
Detail D ‘...
. :... .;.,y::;:
,.,.::.../. ..;. .,.:.
,.:.:.:.::::. ..:.,.:...A....
.. . .,:. . z [;,:,:;.::i;;::;:‘I
a p. ,;::.,.::I b I
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:,:::: ...:::.:S.sz;:s
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20-95
0
iYPE AND LOCATION OF CONNECTOR, SENSOR
l For engines with electronic governor and exhaust brake.
l For machines with electronic display panel, maintenance’ monitor, auto suspension and payload
meter.

No. Location of device INDEX
Type No. of pins
AS1 X type 2 Exhaust brake E-8
AS2 X type 2 Parking brake G-9
AS3 X type 2 Retarder brake G-9
AS4 X type 2 Emergency brake F-9
AS5 X type 2 Service brake F-9
BTI Terminal 20 Fuse box w-2
BT3 S type 12 Fuse box w-2

I I I
BZ I M type I 2 Buzzer I R-4
Cl I M type I 1 For canceling memory I a-2
CM S type 8 Combination switch T-8

I I I
CNS S type 12 Power set selector switch P-l
CVT X type 2 Transmission oil temperature sensor X-6
ECA S type 16 Engine controller intermediate X-l
ECB S type 12 Engine controller intermediate Y-l
EC1 MIC 17 Engine controller Y-l
Left bank engine controller

E7 SWP type 14 G-l
intermediate
Right bank engine controller
E8 SWP type 14 F-l
intermediate
E9 X type 4 Left bank rack sensor B-3
El0 X we 3 Left bank pre-stroke c-2

I I I
El1 X we 2 Left bank governor solenoid D-2

I I I
El2 I X type I 2 Engine speed sensor B II A-6

I I I
20-96-l
0
Location of device INDEX
No. No. of pins
Type
Right bank rack sensor A-5
Right bank pre-stroke A-4
El5 X ww 2 Right bank governor solenoid A-4

I I I
El6 X type 2 Right bank speed sensor A A-6

I I I
Transmission solenoid valve W-8
Transmission solenoid valve fill switch W-8

JO4 S We 12 w-4
I I connector I
Cab inside-outside intermediate g
JO5 I Terminal I 1 V-3
connector
z
Cab inside-outside intermediate S
JO6 Terminal 1 V-3
I I connector

JO7 Terminal 1 v-3
I I connector
LCT X type 2 Torque converter lockup solenoid valve V-8

I I
LS M we 3 Rheostat u-7
I I I
LPS X type 2 Transmission solenoid valve W-8

I I I
Transmission solenoid valve fill switch W-8
Maintenance monitor U-l
MM2 040 type 12 Maintenance monitor
MM3 040 type 8
MM4 040 type 8
MM5 040 type 2 Maintenance monitor u-2

I
MM6 040 type 2 Maintenance monitor T-2
Maintenance monitor intermediate

MM7 S type 16 P-2
connector
2o-F2
Connector Type oftonnector, sensor
Type No. of pins

MM8 S type 12 s-3
connector
MM9 X type 2 Engine oil level sensor c-2
MM10 Terminal Full-flow filter clogging sensor A-3

I I I I
I I I
MM11 I X we I 1 I Battery electrolyte sensor I B-7
MM12 X type 2 Brake oil level sensor C-8
MM13 X type 1 Air cleaner clogging sensor E-8
MM14 X type 1 Hydraulic oil level sensor K-3
MM15 1 X we 1 Retarder oil level sensor L-4

I I
MM16 X type 2 Transmission oil level sensor J-3

MM17 X type 3 K-9
connector
MM19 X type 2 Rear left brake wear sensor M-8
MM20 X type 2 Rear right brake wear sensor l-9
Nl X type 2 Transmission input speed sensor V-8
N2 X type 2 Transmission intermediate connector V-8
N3 X type 2 Transmission output shaft sensor z-9
PM1 MIC 21 Payload meter Q-7
PM2 M type 4 Model selection H-2
PM3 I X type I 3 I Inclinometer ) l-2
PW Socket 7 Power set selector switch I R-l

I I
PO1 040 type 5 Electronic display panel Q-7
PO2 040 type 8 Electronic display panel R-9

I
I
I
I
II II
2o-E3
Type No. of pins
PO7 040 type 2 Electronic display panel s-9

I I I I
PO8 040 type 16 Electronic display panel S-8

I I I

I I I
PI0 040 type 2 Electronic display panel R-6
PI1 040 type 8 Electronic display panel S-8
PI2 040 type 16 Electronic display panel T-8
RPS X type 2 Transmission solenoid valve x-9

I I I
RSW X type 1 Transmission solenoid valve fill switch x-9 g

z
RE3 Socket 2 Resistor x-2 z
RE4 Socket 2 Resistor 2-4
RHI S type IO Intermediate connector 2-4
RH2 S type 12 Intermediate connector z-1

I I I

I I I
ROI Relay 5 Engine start relay V-3
I I I
R02 Relay 5 Transmission neutral relay V-4
I I
R03 Relay 1 5 1Service brake relay w-4

I I
R04 Relay 5 B.C.V control relay w-4
R05 Relay 5 Backup alarm relay w-5
R06 Relay 5 Head lamp relay Hi v-2
R08 Relay 5 Head lamp relay Lo v-4

No.
Type No. of pins
R09 Relay 6 Rear brake pilot relay W-4
RIO Relay 5 Charge level caution relay x-5
Rll Relay Payload relay w-2
RI2 Relay 6 Parking body FLOAT relay V-2
RI3 Relay 5 Coolant temperature caution relay V-2
RI4 Relay 5 Transmission filter relay x-5
RI5 Relay 5 Fog lamp relay x-5

I I I
RI6 I Relay I External display lamp relay No. 5 I w-2
RI7 Relay External display lamp relay No. 4 w-2
RI8 Relay External display lamp relay No, 3 w-2
8
RI9 Relay External display lamp relay No. 2 Y-4
TT
R20 I Relay I External display lamp relay No. 1 I Y-4
R21
I
Relay
I
Parking brake relay
I w-2
R22 Relay R. governor cut relay w-2

I I I
R23 Relay L. governor cut relay x-2
R24 Relay Lock-up display relay Y-4
R25 Relay Transmission cut relay 2-4
SC1 MIC 13 Transmission controller G-l
SC2 MIC 21 Transmission controller H-l
SC3 MIC 17 Transmission controller l-2

I I I
SC4 MIC 13 Transmission controller J-2

I I I
SF I S type I 12 Transmission shift lever I P-l
SH I Socket 1 7 1Shift limit switch I P-2
SLl X type 2 Suspension control solenoid valve A x-5

I
1
I
I I
I
I
2o-F5
Type No. of pins
SL2 X type 2 Suspension control solenoid valve B Y-4
SL3 X type 2 Suspension control solenoid valve C Y-4
SL4 X type 2 Auto retarder Y-4
2 Y-4
SL5
I X We I. I Exhaust brake I
SL6 X type 2 F. brake cut x-5
SRI X type 3 Accelerator sensor D-l
SR2 X type 3 Steering sensor E-l
SUI MIC 21 Suspension controller z-3
su2 MIC 13 Suspension controller z-3
su3 16 Intermediate controller z-3 8

S type
z
3
su4 M type 4 Model selection z-1
TC, SE X type 2 Transmission oil temperature sensor v-7
TMA S type 16 Transmission controller intermediate x-2
TMB S type 12 Transmission controller intermediate x-2
TMC S type 12 Transmission controller intermediate X-l
TM2 JWP type 14 Transmission controller intermediate a-9
TM3 SWP type 14 Transmission controller intermediate z-9

I I I I
WL I M We I 2 Caution lamp I Q-4
1PS X type 2 Transmission solenoid valve Y-9

I I I
3PS X type 2 Transmission solenoid valve x-9

ISW I Xww I 1 Transmission solenoid valve fill switch Y-9
2sw Xtwe 1 Transmission solenoid valve fill switch Y-9

I I
3sw I X type I 1 Transmission solenoid valve fill switch x-9
4sw X type 1 Transmission solenoid valve fill switch w-9

I I
01 I SWP type I 14 Lighting intermediate connector I C-8
Platform wiring harness intermediate

02 SWP type 8 D-8
I I connector
13 X type 2 Front suspension (left) E-l

I
20 SWP type 14 Intermediate connector E-8
I I I
26 I X We I 2 Water temperature sensor I B-3

30 SWP type 14 B-7
connector
39 X type 2 Front suspension (right) A-7
52 X type 2 Transmission filter sensor K-3

I I I
53 X type 2 Retarder filter sensor M-4

I I I
54 I X ww I 2 Hydraulic filter sensor I L-3
61 X type 2 Fuel sensor H-9
62 X type 2 Rear suspension left sensor L-8
63 X type 2 Rear suspension right sensor l-9
64 X type 2 Retarder oil temperature sensor M-4
I I I I
20-r7
LOCATION OF CONNECTOR
62
8
::
.:j:
.:>.:
:
...I..
.../
..I..
....
:g:
..I..
.....
........
:::.
;..:
:.
:::.:.:
...
.I....
.,I.,.
....
.,.
.,::. :
..j..j
.A:
,.:::,
:.:::.
.I...
3
::..:.
..I:.
.a...
..I.
..A...
...I
.A..
......
....:
:.>:.
.A.’
:...
.A.,
2
2PS .
2sw 1sw
RPS 1 I I IPS
,
PO2
M-2
:j
,
LCT
TC
CVT
Detail C
RlO
14
R15
Detail A
JO1
ROl
JO7
JO5
JO6
Cl
ECB
tiM3 MM1
Detail B Detail D
561 F03312
20-96-9
0
CONNECTION TABLE FOR CONNECTOR
No. cIf
pins
1 ‘X TYPE CONNECTOR
Male connector Female cdnnector
205FO53OC 205FO5310
8
z
8 205FO5311 205F053 12
1 3
ml
205FO5313 205FO5314
1 3
bli
2 4.
205FO5315 205FO5316
20697
No. o fl M TYPE CONNECTOR
pins
Male connector Female connector
1
Ela
205FO5317 iO5FO5318
205FO5319 205FO5320
205FO5322
205FO5323
No. o fl M TYPE CONNECTOR
pins Male connector Female connector
3 6 6 3
205FO5325 205FO5326
8
z
8
No. oIf
pin:
l- AMP040 type connector
Male connector (terminal insertion portion) Female connector (terminal insertion portion)
4 8
8 4
1 5
F56 103083 F56103084
12
z
1’ ‘7 7 1
;3
F56103085 F56103086
8 16 16 8
16
205FO5335 205FO5336
20-ioo
No. (>f1 S TYPE CONNECTOR
pin:
Male connector Female connector
6 4
205FO5327 205FO5328
16
10
5 1'0 10 5
205FO5329 205FO5330
12 5 6 1
12
d ‘I 205FO5331
Ii ‘s 205FO5332
16 7 6 1
16
8 i 16 7
205FO5333 205FO5334
20-101
0
No. 0’ fl SWP TYPE CONNECTOR
pins Male connector Female connector
H E@
4 1
6 I I 0
i ’ 6 6. 3
205FO5339 205FO5340
1 5
8
z
8
205FO5341 205FO5342
I 4 8
11 8 4 1
F56103087 F56103088
20-Ao2
MIC CONNECTOR
No.of
pins Male terminal (Contact fi )
Female terminal (Contact m )
142F410
J 142F411
1 7
a 13
1 1
13
I ,
142F412 142F413
17
- 142F415
142F414
11
1
21 12
21
1 J
142F416 142F417
20-Ao3
T
No. o f N-SLC CONNECTOR
pins Female connector Male connector
F56103090
F56103089
423F349 423F350
B
1 1
2 3 3 2
423F351 423F352
1 2
B
3 4
423F353 423F354
20-104
0
No.{ Relay connector
pin
Female connector (terminal insertion portion) Male connector (terminal insertion portion)
2
\
5
E
423F346
F56103091
6 4 3
F56103093 F56103094
20-105
0
No. a Fuse box
pins :emale connector (terminal insertion portion) Male connector (terminal insertion portion)
12 6 lade type fuse 5A

10A
20A
F56103095
1 19
/ \
F56103096
(Seen from direction of inserting fuse)

No. c PA connector
pins
7 4
\ /
3 1 7 4
F56103097 F56103098
g -
z
Ei -
No.0 If
pins
T PA connector (Maker: Yazaki)
F56103099 F56103100
20-l 07
0
TROUBLESHOOTING OF ENGINE
ELECTRICAL SYSTEM
(FOR ENGINES WITH MECHANICAL GOVERNOR)
G-l Engine does not start

(Fuel injection pump stop lever stays at STOP position) ..................... 20-l 10
G-2 Engine does not stop

(Fuel injection pump stop lever stays at FULL position) ...................... 20-l 11
G-3 Defective operation of AISS

a) Stays at low idling (high speed) when AISS switch is ON ( 1 ) ............ 20-l 12
b) Stays at low idling (low speed) when AISS switch is OFF ( 1 ) ............ 20-l 12
c) Stays at low idling (high speed) when AISS switch is OFF ( 1) ........... 20-l 13
Electrical circuit diagram for engine start and stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I 14

T:
z
g AISS electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 14
20-109
0
G-l Engine does not start
(Fuel injection pump stop lever stays at STOP position)
check that all the related connectors are properly inserted.

* Before carrying out troubleshooting,
* Always connect any disconnected connectors before going on to the next step.
* When fuse BT2 No.2 (3 - 4) BT3 No.6 (11 - 12) are not blown.
* When power source system is normal with starting switch ON (when battery is normal).
CalIS Remedy
YES R22 (relay) Replace

Defective
Defective engine stop motor, Repair or

or defective contact, or dis- replace
connection in wiring harness
between 87 (male) (7) -
Replace R22 (r&y). motor (+) I-) - 87 (male) (8).
Does it become or defective ground
connection
1)20-30V
2) Turn startmg
.svvitch ON. I l I” case of abnormality Repair or
NO between (4) and (8) reDlaCe
Defective contact. or discon-
nection in wiring’harness
between BT3 (male) (12) -
JO9 (7) - 87 (female) (4)
8 In case of abnormalitY
1) Turn starting between (5) and (8)
switch OFF - Defective contact, or discon-
ON. nection in wiring harness
between 87 (male) (4) -
engine stop motor(B) (D) -
87 (male) (5)
) In case of abnormalitv
between (7) and (8) .
Defective contact, or discon-
nection in wiring harness
between 87 (female) (5) -
JO9 (6) - R22 (5). (3) - JO9
(5) - 87 (female) (7)
Defective contact, or discon- Repair or

nection in wiring harness replace
between ET2 No.2 (4) - R22
I1 l(2) -ground cOnnection
G-2 Engine does not stop
(Fuel injection pump stop lever stays at FULL position)
* Disconnect the stop motor cable and injection pump stop lever, then operate the injection pump
stop lever by hand, and stop the engine.
-)r Always connect any disconnected connectors before going on to the next step.
* When engine starts normally (G-l is normal).
CaUSe Remedy
YES Replace
Defective R22 (relay)
Defective R15 (relay) Replace
Replace R22 (relay).

Does it become
Y Replace R15 (relay).
Does it become
normal?
n
El Does R22 (relay)

make switching
sound?
1) Turn starting
switch ON -
OFF.
between 8T3 (male) (12) -
R15 (female) (3).(5) -JO1
(male) (10)
YES
between 87 (female) (3) -
JO9 (8) - R22 (8).(3) - R15
(l).(2) - chassis ground
Defective engine stop motor Repair or

(Defective contact, or discon- replace
nection between terminal (8).
(C) - 87 (male) (3))
Contact with other wiring har-

1)20-3DV NO ne.ss of wiring harness
2) Turn starting between starting switch Act
,‘;yh ON - - 8T2 No. 2 (3) (4) - R22
,
[female) (1). or defective start-
ing switch.
20-l 11
0
c) Stays at low idling (high speed) when AISS switch is OFF ( 1 )
l Problem happens when engine water temperature is high and brake is applied (brake normal).
Remedy

between R23 Ifemale 121-
JO9 (9) - 92 (i,. 93 (2) - JO9
YES
(lOI- DO7 (female) (2).D13 Repair or
2 (female) (2). replace
or defective contact, or dis-
Is resistance value
connection in wiring harness
YES between water
betwaen RH4 (female) 12) and
- temperature sensor -
chassis ground, or b&&&n
switch 92 (1) and
1 R21 (female) (6) and chassis
m 93 (2) normal?
ground
Turn AISS switch 1) When engine
Defective water temperature Replace
ON. Does it become _ water tempera- *NO
sensor switch
low idling (low ture is high.
speed)? 2) Disconnect 92
and 93.
1) Start engine. 3) Max. 1 n
2) Turn AISS See G-3, a)
switch ON. NO
T:
z l Problem happens when either parking brake or retarder brake
z is applied. Does not become low idling (low speed) only
l
when parking brake is applied.

nection in wirins harness replace
between JO9 (m&) (10) -
DO7 (2).(l) - R21 (female)
(3).(S) - chassis ground,
or defective parking brake
relay
l Does not become low idling (low speed) only
I when retarder brake is aDalied.
Defective contact. or discon- 7epair or
nection in wiring harness .eplace
between JO9 (male) (10) -
D13 (2).(l) -RHl (4) - AS3
(1 I.(2) - RH4 (2) - chassis
ground,
or defective retarder air
switch
Electrical circuit diagram for engine start and stop
(For battery relay hold)
Engine stop motor _- (OFF
I-
i -
L. ‘-4
Starting
switch
r----
c .-
(ON
(For engine
stop motor]
111I
Braker Battery
Alternator
BZtery reR;ay F56103101
AISS electrical circuit diagram
Parking brake relay AISS relay
_ I
Engine water
temperature switch
i--I-
L-L-
861581
& AISS %tor
JO7
I_- Battery + terminal
2 ER
d
Inner cab
ground
f-
AISS switch
ii F56103102
Retarder air switch
TROUBLESHOOTING. OF ENGINE
CONTROLLER SYSTEM
(FOR ENGINES WITH ELECTRONIC GOVERNOR)
Judgement table for engine controller and engine related parts . . . . . . . . . . . . . . . . . . . . . 20-I 14-3
Red Green
0 0
G-l OFF OFF Abnormality in power source system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I 14-5
Red Green
0 0
G-2 ON ON Abnormality in controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I 14-6
Red Green
e(>
G-3 ON Slow a. Abnormality in right bank rack sensor system . . . . . . . . . . . . . . . . . . 20-l 14-7
flash-
Ing
Red Green
@O
Slow OFF b. Abnormality in left bank rack sensor system ................... 20-l 14-8
flash-
ing
Red Green
0 OF
G-4 ON Fast a. Abnormality in right bank governor solenoid system ............. 20-I 14-9
flash-
ing
Red Green
OF 0
Fast Slow
b. Abnormality in left bank governor solenoid system ............. 20-l 14-10
flash- flash-
ing ‘“g
Red Green
0 0
G-5 ON OFF
a. Abnormality in right bank governor cut relay system ............ 20-I 14-l 1
Red Green
OF 0
b. Abnormality in left bank governor cut relay system . . . . . . . . . . . . . 20-I 14-l 2
;z;;. OFF
ing
Red Green
0 Of
G-6 a. Abnormality in right bank pre-stroke solenoid system . . . . . . . . . . . 20-I 14-13
OFF Fast
flash.
ing
Red Green
0 (>
b. Abnormality in left bank pre-stroke solenoid system . . . . . . . . . . . . 20-I 14-l 4
OFF Slow
flash-
ing
20-l 14-l
0
Red Green
@ Or
G-7 Abnormality in rack sensor power source system ................. 20-214-I 5
Slow Fast
flash- flash
ing ing
Red Green
0 Q
G-8 Slow Slow a. Abnormality in engine speed sensor A system ................. 20-214-I 6
flash- flash.
ing ing
Simultaneou:
Red Green
@I CD
Slow Slow b. Abnormality in engine speed sensor 8 system ................. 20-214-I 7
flash- flash-
ing mg
Alternate
Red Green
G-9 @ 0
Abnormality in accelerator sensor system ....................... 20-214-I 8
Slow ON
flash-
ing
Red Green
G-10 OF l Abnormality in water temperature sensor system . . . . . . . . . . . . . . . . 20-214-20

Fast ON
flash-
ing
Red Green
G-l 1 OF
Fast
QF
Fast
a. Abnormality in right bank governor servo system . . . . . . . . . . . . . . . 20-214-21
flash- flash-
ing ing
Alternate
Red Green
OF OF
b. Abnormality in left bank governor servo system . . . . . . . . . . . . . . . . 20-214-21 8
Fast Fast
flash- flash-
ing ing
Simultaneous _I
G-l 2 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I 14-22
Electrical circuit diagram for engine controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-225
* Re-enacting failures in electrical system

Of the failures in the electrical system, such failures such as defective contact of the wiring
harness or connector occurs particularly in the initial stages, but may occur only under certain
conditions.
For example, problems may occur when the engine is running at high speed, or when the machine
is traveling at high speed on a rough road.
Therefore, always check the resistance value, voltage, etc. of the place giving the failure display,
and even if no abnormality is found, it is necessary to investigate the conditions at the time
that the problem occurred, and try to re-enact the failure conditions when carrying out
troubleshooting.
20-114-2
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS
Self diagnostic display (abnormal display) Pilot lamps
Troubleshoot-
E
_m ing code when
_c
there is no
r" abnormal
z r”
n display
II
Category Failure mode

I /
See Engine
1 Engine does not start 0 0 0 0 a---.---* 0
Either of these Shop Manual
Starting perform- .l Exhaust smoke comes out but engine +_____* l _______@ *__.___a
does not start or is difficult to start 0 See Engine
ante is poor, no Either of these Either of these Either of these
2 Shop Manual
exhaust smoke
comes out 2 No exhaust smoke comes out
1 Engine stalls when machine is stopped

l _______*
0
Engine stops Either of these See Engine
3
when running 2 Engine stalls when turning while *______* *__.___* Shop Manual
stationarv or when braking suddenlv Either of these Either of these 9%; of-t%
l _______* l __.___* l ___.___*
Engine lacks out- 1 Running on one bank
Either of there Either of these Either of there
4 put power,
acceleration is *__, ___* *_______a
See Engine
poor
2 Running on both banks
Either of theSe Either of these
0 0 Shop Manual
Engine stays at Exhaust smoke is normal
’ (in operator’s judgement) 0 G-9
low idling and
5
does not follow @________@
2 Exhaust smoke is extremely black -
accelerator Either of these
, Engine speed increased at same time l ___.___* -

Engine speed as abnormal display was given Either of these
6 increases to l ______*
Engine speed increased during abnormal
high idling 0 -
2 display Either of there
Low idling is not 1 Engine speed does not change to

high-speed low idling a 0 0 0 G-9
actuated accord-
7
ing to operation 2 Engine speed does not change to low-
speed low idling 0 0 0 0 G-9
Exhaust smoke is normal See Engine

Fuel consumption ’ (in operator’s judgement) Shop Manual
Q
” 1 is excessive l __ ___* See Engine
2 Exhaust smoke is extremely black
Either of these / z;p NTanual
I cnglne
r--.
speeo
,
does 1 Does not rise to high idling 0 0 0
9 not increase to
2 Rises to high idling but returns to
high idling
low idling l
10 Defective automatic warming-up operation 0
l __..__*
1 Engine speed stays accelerated
Engine does Either of these
11
not stop 2 Even when starting switch is turned OFF, *_______@
engine continues to run at low idling Either of these
1 Rotation at low idling is unstable

There is hunting See Engine
12
from engine Shop Manual
2 Rotation at high idling is unstable
13 Oil consumption is excessive or exhaust gas is blue See Engine

Shop Manual
14 Oil soon becomes dirty See Engine
Shop Manual
15 Oil in cooling water See Engine
Shop Manual
16 Oil pressure lamp lights up See Engine

Shop Manual
17 Oil level has risen See Engine
Shop Manual
18 Water temperature rises too high See Engine

Shop Manual
19 Abnormal noise is made See Engine

Shop Manual
20 Excessive vibration See Engine

Shop Manual
Troubleshooting code when there is abnormal display G-l G-2 G-3 G-3 G-4 G4 G-5 G-5 G6 G-6 G-7 G-8 G-8 G-9 G-10 G-II G-l 1 G-12 F-4 F-5 F-3 F-l P-26
20-l 14-3
0
G-1 m
I I
Ab normality in power source system
* When fuse BT2 (10) (19-20) is not blown.

If the fuse is blown, check for any short circuiting with the ground by any part inside the controller
or the wiring harness between the fuse and controller.
* When the battery is normal.
Remedy
(ES
Defective controller Replace

between EC3 (female) (13) - Repair or
YES
ECB Ifemale) (12).(111- EC3 replace
I (female) (12i, br &.&en EC3
2 I (female) (2) - ECB (female)
(12),(11) - EC3 (female) (1).
l)ZO-3ov
2) Turn starting
switch ON.
I Defective Contact, or discon- Repair or
reDlace
between ECB (male) (12) -
JO6 - battery relay.

I I L nection in wiring harness Repair or
NO between ECB (male) (11) - replace
1)20-3ov
2) Turn starting BT2 (No.10) - starting switch
switch ON. terminal B - JO5 -circuit
breaker - battery terminal
(+).
Engine controller.
ET2 Starfing switch
EC3(MICZl) ECB (Sl2)
Circuit breaker
JO5
n To battery
-
terminal (+)
6OA
JO6
v
Battery relay
561 FO3316-1
20-‘A4-5
G-2 El Ab normality in controller system
Ir When the battery is normal.

1 Defective contact, or discon-

Is voltage between between EC3 (female) (13) - Repair or
YES
EC3 (1) - (2). and - ECB (female) (12),(11) - EC3 V3plXZ
(12)-_(13)normal? (female) (12). or between EC3

2 (female) (2) - ECB (female)
(12).(11)- EC3 (female)(l)
1) 20-30V
2) Turn starting Is voltage between
switch ON. No ECB(ll)a”d(lZ) *
normal?
3 YES Repair or
1) 20-30V -7 between ECB (male) (12) -
2) Turn starting JO6 - batter+ relay
switch ON.
1) 20-30V NO between ECB (male) (11) -
2) Turn starting BT2 (No.10) - starting switch
switch ON. terminal B - JO5 - circuit
breaker - battery terminal (+)
Engine controller
Circuit breaker
To battery
terminal (+)
U
Battery relay
561FO3316-1
G-3 (a) Abnormality in right bank.rack sensor system ~
* Engine output will change if thickness of shims for rack sensor were changed, so assemble
the same number and thickness of shims that was removed during disassembly.
C3lE.e Remedy
YES
4 YE! Defective right bank rack

Sensor
Is resistance
between El 3
(female) (2) - (4).
and between (2) -
(3) normal? Wiring harness between EC2
1) Engine stopped H (female) (11) - E8(3) - El 3 Repair or
(Starting switch
1150KR-1 MO NC
(female) (3),(4) - E&7) - EC2 reolece
Is voltage between 2j Turn starting (female) (5) short circuiting
0.25-0.45V.
switch ON. with chassis ground
3) Disconnect El3
0.25-3.5V
1) 4.6-5.4V Defective contact, or discon-

2) Turn starting nection in wiring harness Repair or
switch ON. between EC2 (female) (1) - replace
ES(l) - El3 (female) (l).(2) -
E8(2) --EC2 (female) (8)
See G-7
Engine controller
EC2(MIC 13)
k (Innercontroller)
561 FO3409
G-3 (b) 1‘cd Grn/ Ab normality in left bank rack sensor system
Sr Always connect any disconnected connectors before going on to the next step.
Defective controller
4 Defective left bank rack

Replace
sensor wtput Is resistance *e”SDr
Y
voltage) between between E9 (female)
EC2 (10) and (9) YES
(2) - (4). and
between (2) - (3) Wiring harness between EC2
Repair or
normal? (female) (13) - E7(3) -
1) Engine stopped replace
E9(31.(4) - E7(7) - EC2
(Starting switch (female) (7) short circuiting
1) 50kfL1 MQ
1 ON) Is voltage between with chassis ground
2) Turn starting
0.25-0.45V. . switch OFF.
Is voltage between 2) Engine running
3) Disconnect E9
EC2 (2) and (9) 0.25-3.5V
normal?
1) 4.6--5.4V Defective contact, or discon-
nection in wiring harness Repair or
2) Turn starting
switch ON. between EC2 (female) (2) -
1) 4.6-5.4V
E7(1) - E9 (female) (l),(2) -
2) Turn starting
E7l2) - EC2 (female) (9)
switch ON.
See G-7
0
Engine controller
ECP(MiCl3)
Left rack sensor
I (Inner controller)
561 FO3410
2o-1&4-8
G-4 (a) ( ‘id GzFnl Abnormality in right bank. governor solenoid system
C.?JUSZ Remedy
1
ES - Defective controller ‘lep1ac.s
3
YES between EC1 Wiring harness between EC1
fizgii$K
(female)(l)- ES(14) -
E15(2).(1)- E8(13)-EC1
(female) (10) short circuiting
with chassis ground
1) Min. 1 MQ
2) Turn starting
: switch OFF.
3) Disconnect EC1 Defective right bank governor
1) Min. 1 MCI NO , solenoid
2) Turn starting
(female)(l) and (10) switch OFF.
3) Disconnect El5
1) lo-21R
2) Turn starting
switch OFF.
3) Disconnect EC1
between EC1 (female) (1) - replace
ES(14) - E15(2).(1) -
ES(13)
Isvoltage between - EC1 (female) (10)
EC1 (4) -chassis.
and between EC1
(16) -chassis Defetiive right bank governor
Redace
normal? NO solenoid
1) lo-21Q
z
0
1)20-30V
2) Turn starting
switch ON.
2) Turn starting
switch OFF.
3) Disconnect El 5.
See G-5 (a)

0
Engine controller
To governor cut relay
, ,
EC8 (S.12) 561 FO3320
20-‘A4-9
G-4 (b) )R;;G;n) Abnormality in left bank governor solenoid system
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
YES
Defective controller Zeplwx
3
Is resistance
Yl between EC1 Wiring harness between EC1
’ (female)(3)and - 4 YES
(female) (3) - E7(14) - El 1
tepair or
chassis normal? (female) (2),(l) - E7(13) -
ep1ace
- EC1 (female) (12) short cir-
Is resistance
cuiting with chassis ground
1) Min. 1MR between El 1 (male)
2) Turn starting NO (1) and chassis
switch OFF. normal?
r 3) Disconnect ECl. Defective left bank governor
Replace
NO solenoid
11 Min. 1MR
2j Turn starting
switch OFF.
3) Disconnect El 1.
1) lo-21R Defective contact, or discon-

2) Turn starting nection in wiring harness
switch OFF. 5 YES between EC1 (female) (3) - Repair or
1
3) Disconnect ECl. E7(14) - El 1 (female) (2),(l) replace
Isvoltage between Is resistance - E7 (14) - El 1 (female)
-
(2).(l) E7(13) - EC1
I
EC1 (8) -chassis, between El 1 (male)
and between EC1 c (1) and (2) normal? (female) (12)
(13) -chassis
Defective left bank governor
normal?
NO solenoid
1) 10-2157
1)20-30V 2) Turn starting
2) Turn starting switch OFF.
switch ON. 3) Disconnect El 1
See G-5(b)
E7(SWPl41
Left bank governor
ECB (S 12)
561 FO3321-1
G-5 (a) Abnormality in right bank. governor relay system
* When fuse BT2 (10) (19 - 20) is not blown.

CaUSe Remedy
I
ES
Yl Defective contact, or discon-
3 YES
ECB(2) - R22 (2),(l) - ET2
(20)
1) 20-30V l-$$j&jHP
2) Turn starting I
switch ON.
Defective right bank governor
Replace
NO cut relay
Is voltagebetween 1) 2DO-99000
EC1 (16) and chas- 2) Turn starting
switch OFF.
3) Disconnect R22.
1) zo-3ov
nection in wirina harness
2) Turn starting Repair or
between EC1 (female) (16) -
switch ON. 4 YES ECS(51 - R22 (6),(1 L(3)- ET2
replace
r II (No.10) - starting switch ter-
minal 6 - JO5 -circuit
breaker -battery terminal (i-1
NO
Defective right bank governor
ReDlace
- 1)Max. 157 ‘NO C”t r&v
2) Turn starting
switch OFF.
3) Disconnect R22.
Right bank governor

cut relay
Engine controller
EC I(MIC 171
To battery
terminal (+)
561 FO3322-1
20-l 14-l 1
0
Abnormality in left bank governor cut relay system
* When fuse BT2 (10) (19 - 20) isnot blown.

CatJSe Remedy
YES
2
” ES Is voltage between Defective contact, or discon-

l- EC1 (13) and chas- - nection in wiring harness
sis normal? 3 YES Repair or
replace
ECB (1) - R23 (2),(l) -
P Is resistance 8T2(20)
1) 20-30V - between R23 (male) -
2) Turn starting
NO (1) and (2) normal?
switch ON.
Is voltage between 1) 2DD-9DDR NO cur relay
EC1 (8) and chassis 2) Turn startina
normal? switch OFF.”
3) Disconnect R23
1)20-30V Defective contact, or discon-

switch ON. 4 YES between EC1 (female) (8) -
EC8 (3) - R23 (6),(l),(3) - Repair or
I II
H
BT2 (No.10) - starting switch W?Pl63Cl2
Is resistance terminal 8 - JO5 -circuit
between R23 (male) breaker-battery terminal (+)
JO (3) and (6) normal?

C”f relay Replace
1) Max. 1 n NO
2) Turn starting
switch OFF.
3) Disconnect R23.
Left bank
governor cut relay
power sourc
To battery
‘terminal (+I
561 FO3323-1
20-l 14-12
0
G-6 (a) 1R6d Gzni Ab normality in right bank pre-stroke solenoid system
CaK% Remedy
YES Replace
*< I
YES’ Wiring ha&s between EC1

(female)(14)- E8(11)- El4 Repair or
(female) (l),(2) - E8 (12) - reDlaCe
EC1 (female) (6) short circuit-
ing with chassis ground
1) Min. 1MQ L
2) Turn starting NO
switch OFF. Defective right bank pre-
3) Disconnect ECl. II stroke solenoid
Replace
1) Min. 1MQ NO
2) Turn starting
(female) (6) and (14) switch OFF.
3) Disconnect E14.
1) lo--210 Defective contact. or discon-

2) Turn starting nection in wirina harness
switch OFF. 4 YES between EC1 (fe;nalel(14) -
Repair or
3) Disconnect EC1
I I I E8 (11) - El4 (female) (l).(2)
I H
Is resistance - E8 (12) - EC1 (female) (6)
I between El4 (male)
I I I Defective right bank pre-

stroke solenoid
NO
1) lo-21Q
2) Turn starting
switch OFF.
3) Disconnect E14.
E8 (SWPl4)
Engine controller Right bank pre-stroke
EC I (MIC 17) E 14 (X3) solenoid
II 0
I2 @
561 F03324
20-l 14-13
0
G-6 (b) )I Ab normality in left bank pre-stroke solenoid system
CatEZ Remedy
YES Replace
0 I
Is resistance
between EC1 Wiring harness between EC1
(female) (7) and (female)(l5)-E7(11)-El0 Repair or
YES
(female) (l),(2) - E7 (12) -
Is resistance EC1 (female) (7) short circuit-
between El0 (male) ing with chassis ground
1) Min. IMR
2) Turn starting (2) and chassis
switch OFF. normal?
Defective left pre-stroke
3) Disconnect ECl. J
NO solenoid
1) Min. 1MR
between EC1
2) Turn starting
(female) (7) and (15)
switch OFF.
3) Disconnect ElO.
1) lo--21n
r-i
2j Turn starting nection in wiring harness
Repair or
switch OFF. between EC1 (female) (15) -
3) Disconnect ECl. E7 (11) - El 0 (female) (1 L(2)
1 between ElO(male)
’ (1) and (2) normal?
Defective left bank pre-stroke Replace
NO solenoid
1) lo--210
2) Turn starting
switch OFF.
3) DisconnectElO.
E7 (SWP 14)
Engine controller Left bank prestoke
EC I (MIC 17) El0 (X3) solenoid
0 0
@ @
561 F03325
4
20-1A4-1
G-7 El Ab normality in rack sensor power source system
I I
* Before carrying out troubleshooting, checkthat all the related

connectors are properly inserted.
* Always connect any disconnected connectors before going
on to the next step. YES
I
Wiring harness between EC2

3 YE: (female) (1) - E8 (1) - El3 Repair or
(female) (l),(2) - E8 (2) - replace
YEI EC2 (female) (8) short circuit-
r
HUH
1 ,
Defective right bank rack
) Min. 1 MR Se”SOr ReplaCe
NC
!) Turn starting sis, or between EC2 1) Min. 1MR
switch OFF. (female) (8) and 2) Turn starting
I) Disconnect EC2. chassis. switch OFF.
IJ 3) Disconnect E13.
NI

4 YE: (female) (2) - E7 (1) - ES Repair or
(female) (l),(2) - E; (2) - replace
~~~
between EC2
Defective leh bank rack
(female) (1)-(8).
NC sensor
7eplace
and between (2) - sis, or between EC2 1) Min. 1MR
(female) (9) and 2) Turn starting
chassis. switch OFF.
1) Min. 500 kR 3) Disconnect ES.
2) Turn starting Contact of wiring harness
3) Disconnect EC2. E8 (1) - El3 (female) (1) with
5 YES Gpair or
wiring harness between EC2 .ep1ace
(female) (8) - E8 (2) - EC13
(female) (2) (short circuit
KH/
between wires)
k If there is defect
between EC2
(female) (1) and (8). Defective right bank rack wace
)
1 Min. 5ODkR NO sensw
2) Turn starting
switch OFF.
3) Disconnect E13.
Contact of wiring harness

6 YES E7 I1 I- ES (female) (1) with fepair or
wiring harness between EC2 eplace
III
Is resistance (female) (9) - E7 (2) - ES
between ES (male) - (female) (2) (short circuit
* If there is defect (1) and (2) normal? between wires)
between EC2
(female) (2) and (9). ..- Defective left bank rack
NO leplace
1) Min. 5COkQ Se”SOr
2) Turn starting
switch OFF.
3) Disconnect ES.
Engine controller
EC 2 (MIC 13)
E8 (SWP 14) El3 (X4)
0 0 Right
bank
@ @ sensor
0 Left
bank
@
sensor
E9 (X4)
E?(SWPl4)
561 F03326
20-l 14-l 5
0
Abnormality in engine speed sensor A system
Simultaneous
*If engine is cranking more than 1 second at too low speed (less than 20 rpm) when engine
starting, the self-diagnostic display displays abnormality and holds the display for 5 minutes
even if engine is normaly started. That is normal.
C.3U.S Remedy
3 YES Defective adjustment of speed

sensor A
-
$I%k&ZH-
l-4
* For details, see NO
between EC3 TESTING AND
(female) (7) and ADJUSTING.
chassis normal? Wiring harness between EC3
(female) (7) - ES (4) - El 6 Repair or
(female) (l),(2) - ES (5) - replaCe
1) Min. 1MQ EC3 (female) (17) short cir-
2) Turn starting cuiting with chassis ground
switch OFF.
3) Disconnect EC3.
Defective speed sensor A Replace

between EC3 NO
1) Min. 1MQ
2) Turn starting
switch OFF.
3) Disconnect E16.
115DD- lOOOR
2j Turn starting Defective contact, or discon-
switch OFF. nection in wiring harness
3) Disconnect EC3
5 YES Repair or
ES (4) - El 6 (female) (l).(2)
Is resistance - ES (5) - EC3 (female) (17)
betweefi El 6 (male)
(1) and (2) normal?
Defective speed sensor A ReplaCe

1~5cO-lDDDn
2j Turn starting
switch OFF.
3) Disconnect E16.
E8 (SWP14)
Engine controller
Speed sensor A
EC3 (MIC21) El6 (X2)
@ a
@ @
561 F03327
20-l 14-l 6
@
Red Green
G-8 (W 1 aI Q Abnormality in engine speed sensor B system
Alternate

senspr B
B return to normal
NO
f For details, see
TESTING AND
ADJUSTING.
Disconnection in wiring har-
ness between EC3 (female) (8)
- E7 (4) - El2 (female)
(l),(2) - E7 (5) - EC3
(female) (18). or short circuit Repair or
YES
with chassis ground, or wiring rePlaCe
harness between E7 (female)
(4) - ECA (1) -transmission
1)5cx-l@JoR controller - ECA (2) - E7
Y
2) Turn starting (female) (5) short circuiting
switch OFF. F[_
with chassis ground
3) Disconnect EC3. 4
Defective speed sensor B Replace

between El 2 (male) 2) T&n starting NO
(1) and (2) normal? switch OFF.
3) Disconnect E12.
1)5cO-lDDDn
2) Turn starting Defective speed sensor 6 RePlace
3
switch OFF.
3) Disconnect E12.
E7 (SWP 141
Engine controller 1 I , Speed sensor B
El2 (X2)
@ 0
@ @
- ECAIS 16) Transmission controller

SC I (MIC 13)
PO8 (04016) TMA (S 16)
@
Monitor panel
@
561 F03328
20-1A4-1
7
G-9 ElRed Green
aI 0 Abnormality in accelerator sensor
* Use this flow chart also if the Judgement Table for engine related parts shows that there may
be an abnormality in the accelerator system.
cause Remedy,
Defective controller :epkice

Does voltage
between EC3 (10)
and (20) change
Y
according to accel- idjust
erator pedal angle 3 YES Defective adjustment of accel- For details, see
as shown in Dia-
gram I? In test in Item 2,
17 erator sensor ‘ESTING AND
\DJUSTING)
l-l_
does voltage
1 NO change. bu tis out-
1) Turn starting side specified value?
switch ON.
Is voltage between 2) operate acceler- To(4
NO
EC3 (11) and (20) ator pedal.
1) 4.6 - 5.4V Defective controller wace

2) Turn starting
switch ON.
(female) (11) - ECA (14) -
SRI (female) (1 L(3) - ECA
(16) - EC3 (female) (20) short 2epair or
circuiting with chassis eplace
ground, or contact with other
wiring harness
Ieplace
2) Turn starting 1) Between (1) and NO
switch OFF (3): 4.6 - 5.4kQ
3) Disconnect EC3. Between (1) and
chassis: Min. 1MQ
2) Turn starting
switch OFF.
3) Disconnect SRl

between EC3 (female) (10) - qepair or
ECA (12) - SRl (female) (2). .eplace
or between ECA (male) (12) -
TMA (13) - SC1 (female) (4)
5
Does voltage
(female)(lO)-ECA(lZ)-
between SRl (2)
I
SRI (female) (2). or between
YES
and (3) change 7 YE!
ECA (male) (12) - TMA (13)
according to accel- Sepair or
- SC1 (female) (4) short cir- ‘eplace
erator pedal angle
between SRl (male) cuiting with chassis ground,
as shown in Oia-
gram 1? YE:
(2) and (3) change or contact with other wiring
1
harness
7 r according to accel-
1
erator pedal angle
) Turn starting as shown in Dia-
switch ON.
2) operate acceier Accelerator sensor linkage Repair or
Is resistance
afor pedal. out of position, or defective :eplWe
Is voltage between between SRl (male) NC
1) Turn starting Se”*Or
switch OFF.
2) Disconnect SRl.
1) 4.6 - 5.4kQ
2) Turn starting Rep&X
2) Turn starting switch OFF. NO
switch ON. 3) Disconnect SRl
between EC3 (female) (11) - Repair or
ECA(14) - SRl (female) replace
(l).(3) - ECA (16) - EC3
(female) (20)
20-l 14-l 8
Engine controller
EC3fMIC21)
TMA(Sl6)
SC I (MIC 13)
Transmission
controller 561 F03329
Fig. 1 Fig. 2
Accelerator signal voltage (Kfi) Sensor resistance value

(VI
Approx.4.3- Approx. 4.3 -
Approx. 1 .O - Approx. l.O-

I
I
I
,
Low idling C Full Low idling Full
c
Accelerator pedal position

561 F03331
561 FO3330
G-10 pi Ab normality in water temperature sensor system
CalIS% Remedy
2 YES
I Defective controller Replace
YES Is voltage between

- EC2 (4) and chassis -
1 normal? Defective contact. or discon-
IS water tempera-
~NO between EC2 (female) (4) - replace
ture gauge on moni- 1) 1.1 -4.7v ECA (9) - JO2 (female) (1)
tar panel actuated - 2) Turn starting
normally? switch ON.
. SeeP-22 -
NO
Monitor panel
PO9 (040)
Water temperature
JO2(Sl6) 2OcSWP 14) 26 (X2) sensor
0. @ 0
@ @ @
ECA (S 16)
EC2 (MIC 131

561 F03332
Engine cmtroller
20-l 14-20
a
G-l? (a) Abnormality in right bank governor servo system
Alternate
cause Remedy
2 YES
Defective fuel injection pump RePlaCe
I I I (see engine shop manual)
ISvoltage between
EC2 (111 and (5) l-l
1 Defective contact. or discon- Repair wiring

nection in wiring harness harness or
1) 0.1 - 4.5v NO between EC2 (female) Ill L (5) repi.Xe
Is voltagebetween 2) Turn starting, ES (3). (7) - El3 (female)
EC1 (16) and chas- switch ON. (31. (4)
sis normal?
t
1)20-30v
2) Turn starting Defective contact. or discon- Repair wiring
switch ON. nection in wiring harness harness or
between EC1 (female) (16) reDlaCe
and R22 (6)
m
0
z G-II (b) Abnormality in left bank governor servo system
g
CaLIS Remedy
2 YES
Defective fuel injection pump Replace
(see engine shop manual)
- EC2(13)and(7) -
normal?
Defective contact, or discon Repair wiring
1
nection III wrina harness harness or
1) 0.1 - 4.5v NO between EC2 (f&ale) (13). (7) replace
Is voltage between 2) Turn starting ES (3). (7) - E9 (female)
EC1 (8) and chassis - switch ON. n. (4)
normal?
L
1) 20-30V
2) Turn starting
switch ON. Defective contact. or discon- Repair wiring
NO nection in wiring harness harness or
between EC1 (8) and R23 (6)
20-l 14-21
@
G-12 Engine does not start
* When starting motor does not turn.

* Check that the circuit breaker is not OFF before starting the troubleshooting.
4 YES
Is voltage between
starting motor ter-
minal B and chas-
sis normal?
NO
1) Approx. 24V
YES Is there sound of

- starting motor pin-
ion moving in?
1) Turn starting
switch to START
YES
7r
transmission
Is resistance
Y
between ROl (male)
* Abnormality in
(3) and (6) normal?
transmission
neutral relay 6
system 1) Max. 1 R L
Is voltage between 2) Turn starting NO
starting switch ter- switch OFF.
minal C and chas- 3) Disconnect 1701
sis normal?
(relay). 8
1) Turn starting
switch to START
2) Approx. 20 - 30V
switch is turned
NIO
OFF, is sound
heard from batwrY
1) Turn starting 11 YES

switch ON -
OFF. between battery
YES
terminal (-_) and
battery relay (b-_)
10
l-l
Is resistance 1) Max. 1R NO
Y between starting
switch BR and bat-
tery relay BR
normal?
9 I
1 Between startino
Is voltage and spe- switch BR and _
Is resistance I
cific gravity of bat- batten, r&v BR:
N
tery normal?
YES between starting Max. in
switch terminals B 2) Between wiring
and BR normal? harness and
1) Min. 24V 8- chassis: Min.
2) Specific gravity: - l)Max.ln 1MR
Min. 1.26. 2) Turn starting 3) Disconnect both starting switch
IS voltage of start-
and battery relay ends.
ing switch terminal - switch ON.
B normal’ 3) Remove terminal B.
1) Connect (-) end

of tester to bat-
2o-1A4-22
CalES Remedy
) Defective starting motor Replace

between starting switch ter- Repair or
minal C - ROl (female) (3) &?pkX
-(6)-JO1 (4)-24(1)or
25 (1) - starting motor ter-
minal C
Defective engine starting

Rf@EW
relay [between (3) and (611
Defective starting switch

Replace
[between B and Cl
,-I Defective battery relay
Repair or

between Starting switch ter- replace
minal BR - JO1 (10) - 30
(10) - battery relay terminal
BR
Defective starting switch ReplaCe

between starting motor ter- Repair or
minal B - JO5 - circuit reDlaCe
breaker - battery terminal
(+)
Repair or
Defective battery
replace
2o-1A4-23
3OEWPl4)
IO
Circuit breaker +
JO5
+
r
A
I
FF
Starting B
M E M E
/ Engine starting relay
I Starting C Starting C
motor 8 motor 6
RO Ro
-&& ROI
IReM
I JOI (Sl6)
v
IO -
To transmission
neutral relay
561 F03333
20-1k4-24
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM
-_ ------Ill
--
b I II I I III I
561FO3106-1
20-114-25
0
TROUBLESHOOTING OF
TRANSMISSION CONTROLLER SYSTEM
Points to remember when carrying out troubleshooting of controller system . . . . . . . . . . . . 20-I 17
Judgement table for transmission controller, transmission related parts . . . . . . . . . . . . . . . . 20-I 19
Abnormality in power source
a. (OFF) Self testing display of controller does not light up . . . . . . . . . . . . 20-I 21
b. Drop in voltage of controller power source displayed ............... 20-I 22
c. Abnormality in transmission cut relay power source displayed ....... 20-I 23
Abnormality in neutral safety system displayed ..................... 20-I 24
Abnormality in controller system
(only dot lights up) or

m:
J
a. Only dot lights up or abnormality in controller
displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I 25
Double system for clutch displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I 26
Abnormality in transmission [out relay] system displayed ............. 20-I 27
Abnormality in auto-retarder brake solenoid system displayed ......... 20-I 28
Abnormality in speed sensor system
Abnormality in engine speed sensor system displayed . . . . . . . . . . . . . 20-I 29
Abnormality in intermediate shaft speed sensor system

displayed ‘. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 30
Disconnection in travel speed sensor (transmission output shaft

speed sensor) displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I 31
Speed sensor system, clutch slipping
Input shaft sensor or H.L clutch system displayed ......... 20-I 32
Travel speed sensor or speed clutch (I ,2,3,4,R) system

displayed ......................................... 20-I 33
Abnormality in model selection displayed .......................... 20-I 34

Abnormality in transmission shift lever system
Short circuit in transmission shift lever assembly power source

displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 35
Transmission shift lever position signal displayes 2-system

abnormal input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 36
Transmission shift lever position signal is not input . . . . . . . . . . . . . . . 20-l 38
Abnormality in accelerator signal displayed . . . . . . . . . . . . . . . . . . . . . . . . 20- 140
Abnormality in transmission oil temperature sensor displayed . . . . . . . . . 20-l 42
Abnormality in pressure control valve system
a. Fill signal displayes ON regardless of command . . . . . . . . . . 20-l 43
not input and clutch slipping
m . ~‘~~di;b;aved:::::::::::::::::::::::::: ~~~~~~
2) When R., . . . . . . . . . . . . . . . . . . . . . . 20- 146
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 47
18 Short circuit in pressure control valve solenoid system

m-m displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 48
A-14
‘2 0 Disconnection in pressure control valve solenoid system
a’m displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 48
Electrical circuit diagram for transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 51

With failures in the electrical system, there are cases where failures, such as defective contact
of wiring harnesses and connectors, occur only under special conditions particularly at the
initial stage of the occurrence of the failure.
(For example, when the engine is running at high speed or the truck is traveling at high speed
on rough road surfaces.)
Therefore, investigate the values for the resistance and voltage at the locations indicated by the
abnormal display. Even if no abnormality is found, it is necessary to investigate the conditions
under which the failure occurred, and to try to re-enact the failure condition to carry out
troubleshooting.
20-116
0
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-
SHOOTING OF TRANSMISSION CONTROLLER SYSTEM
1. Connection between troublestooting of electrical system and mechanical system

If the failure display shows ,?.[7, 3.0, ‘-:.a 5.0, there are some cases where there is a failure
in the electrical system (sensors, wiring harnesses), and other cases where the failure is in
the mechanical or hydraulic system (ECMV or clutch).
Therefore, if troubleshooting is carried out on the electrical circuit and no failure is found,
go to troubleshooting of the mechanical and hydraulic system; on the other hand, if no abnormality
is found during troubleshooting of the mechanical and hydraulic system, go to troubleshooting
of the electrical system.
(For details if the display is ~20, 3.u L[n, 5.0, see the action taken by the self-tester on
page 20-81 and the section on :‘Transmission controller system” dealing’with the chassis.)
* : One of 0 - IZ,~Y,S,&,q,)
2. Recording failure code

The transmission controller records failures that have occurred in the past, and when the starting
switch is turned OFF - ON, the recorded codes are displayed as shown in Fig. 1.
Therefore, by seeing these recorded failure codes, it is possible to obtain information about
problems that have occurred in the past.
- -- -
-+I-+’
3sec 0.5sec 3sec
8.::; IJ.lJ ;_!.;:! lJ.lJ !.‘I U.U l.6 &
g;ttiyswitch
Recorded fatlure codes are displayed

(all recorded codes are displayed)
A-;;Pr
;n;code isdisplayed
F56103103
Note:
When investigating failures, if the starting switch is turned ON/OFF with the connector
disconnected, the controller may judge that there is an abnormality, and the failure code may
be recorded.
Therefore, after carrying out troubleshooting, always delete the recorded data and check that
the failure code has been deleted. (Disconnect and reconnect connectors Cl and C2 to reset
the memory. For details, see page 20-77.)
When carrying out an investigation of any other controller or monitor system, check that the
transmission controller is not recording the failure codes even when the connector is disconnected.
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS
Self-tester display (abnormal display) Monitor panel display Pilot lamp
F”u’vz; Neutral Control- Tram Rear Exhaust Speed CA$ch Mode) T.rans- Accel- Tranrmis- Pressure Flow pcbensg$!
safety ler box mrssron brake brake sensor selector mIssron erator $~$$~_ control detector valve
signal shift
system system cut ra)aY solenoidsolenoid system zg,@r signal rature valve Valve solenoid Engine Troubleshootin
Check system SyStem system lever system system Shift
system system system system system system con- Mode Shift Shift Body Exhaust code when no
item Brake
U. 8-1 0.3 LCC’ 0.6 0.8 1.0 1 .o 2.0 troller selector hz$:,“d; position limiter float brake abnormal dis-
1.4 0.7 1.7 1.9 3.0 5.0 7.0
1.2 f 1.5 4.0 f 9.0 display played is given.
0.1 0.4
0.2 0.5 1.3 2-8 1.6 t 2-8 f
2-8 l-8
Engine does not, 1 Engine does not start a 0 # 0 0 0 See

engine
start shop manual
Machine does not 1 Does not start in any speed range 0 0 0 0 0 a 0 0
start
2 Cannot start in R or D - L
0 *% 0 0 0 H-l
After stopping and placing in N, it is
3 impossible to start again a 0
Movement of
machine is
1 Travels forward even when lever is at N
0 0 -
abnormal when
starting
2 Travel forward when lever is in R 0 0
3 Starting shock is abnormally large H-4
\ 0 0 a
4
Starts in above F3 (startingwhen
machine is stopped) l
Movement of 1
Transmission enters R, Fl, F2, but does
l 0 / 0 -
machine is not enter F3 or above I
abnormal during
-
travel 2 Suddenly shifts down l 0 I
Repeatedly shifts between certain speed
3
ranges a 1 0 0 0 H-2
Will not shift from a certain speed range -
4
when traveling 0
I 0 1 0
5 Engine stalls 0 0 H-3
6 Transmission shock is abnormally large /o 0 H-4

0
7 Brake is applied when traveling 0 0

I
Even whenshift limiterswitch isON
8 transmission shiftsup to F7 when le\;eris
at D and to F2 when lever is at L
0
-
9 Abnormal display given when overrun
speed is reached 0
1o Retarder is being operated, but trans- I

mission immediately shifts up 0
-
Transmission shifts to neutral when
5 Suddenly returns t traveling, but it is possible to start again 0
to neutral when with transmission shift lever at N
traveling -
Shifts to neutral when.traveling, but
2 impossible to start again 0 0 l 0 0 ls l
-
3 Shifts to N when about to lock up l
6 Long time taken 1 Shift up speed is too high 0
to shift up H-5
-
2 Long time taken to lock up l
7 No power 1 Lack of power at all speed ranges l
H-6
2 Lack of power at certain speed range l l
-
3 Does not lock up l H-5
8 Excessive time lag 1 Time lag is excessive when starting l

H-7
2 Takes time to shift gear l l
pEk;;i;; to shift from FORWARD to
-
3 l
9 Defective shift 1
y;;;hifting is normal, but E display is 0
-
indicator display
2
Gearshifting
wrong
is normal, but display is
0
-
IO Defective actua- 1 Exhaust brake does not work l 0 H-8
tion of exhaust
Method of operation of exhaust brake
brake 2
does not match operation of machine l 0 0 -
-
‘orqueconverteroil
I1
Pmperature is high ’ Torque converter oil temperature is high l H-8
-
Troubleshooting code when abnormal display is given A-l A-2 A-3 A-4 A-5 A-5A A-6 A-7 A-8 A-9 A-10 A-l 1 A-12 A-13 A-14 P-26 P-l 1 P-6 P-7 F-l F-2 F-4
display (A-l 1 b)) only measure the oil pressure of the clutch first, and if the oil pressure is normal,
Troubleshooting
carry out troubleshoo;ing of the electrical system. (The probability of the clutch slipping is high.) by displayed code
20-l 19
0
A-l Abnormality in power source
a) I==7
\& 1-i [OFF] Self testing display of controller does not light up
* When fuse BTl (10) is not blown.

If it is blown, check for contact with ground of wiring harness between fuse and controller.
* When battery is normal.
a For engines with mechanical governor
2 YES
ReDlXe

- SC3(14)and(13) -
normal? Defective starting switch, or
defective contact, or
1 disconnection in wirina Repair or
NO harness between fuse-BTl replace wiring
Isvoltage
between 1) 20-30V
(101-TMB111)-SC3 harness
starting switch 2) Turn starting
switch ON. ife&le) (14); or.defective
terminal and
contact, or disconnection in
chassis normal?
wiring harness between SC3
(female) (14) - TMC (l)-
1 j Turn starting JO6 - battery terminal E
switch ON. 1
Defective contact, or Repair or
2) 20 - 3ov
NO disconnection in wiring replace wiring
harness between battery harness
terminal (+)-circuit breaker
- JO5 - starting switch
terminal B
Circuit braker
TMB(SI2)
To battery JO5 Transmission
terminal (+) -
I II controller
BOA I >+ SC3 (MIC 17)
~ 0I4 Power
source
-0 GND
TMC LSl2)
To battery
terminal E -
F56103104
20-A21
l For engines with electronic governor and exhaust brake
Cal&e Remedy :
2 YES Defective controller

I I RfXhX
YES Is voltage
between
SC3 (14) and (13) -
normal?
nection in wiring harness Repair wiring
NO between fuse ST1 (No.10) - harness or
1)20-30V
2) Turn starting TM6 (11) - SC3 (female) (14) Whe
switch ON.
Defective starting switch ReplaCe

1) Turn starting IS voltage between
Switch ON. starting switch ter-
I
N minal 6 and chassis
nOrmal? Defective contact, or discon-
between battery terminal (+) Repair wiring
1) Turn starting NO harness or
- circuit breaker - JO5 -
switch ON. starting switch terminal B
2) 20 - 3ov
Starting switch
BT I Fircuit Freaker
I
To enginecontro,,er_ ~@?P-$--~~~~mTo (+)
termina’
battery
l-e] Shift limit switch
-_-
--a-” ’
TMCISII)
To battery JO6
termial E
Transmission
cut relay
561 F03334
-’
2o-1o2’
Drop in voltage of controller power source displayed
Cause Remedy
1 YES Disconnection in wiring

harness between alternator Repair or
Is voltage between terminal 6 - emergency replaCe
alternator terminal steering relay terminal 6 -

R and chassis battery terminal (+I, or
normal? looseness of terminal
Defective generation of Repair or

NO electricity by alternator
1)20-3ov
2) Start engine.
Emergency steering relay

Battery
F56103105
Abnormality in transmission cut relay power source displayed
Ir When battery and charging voltage are normal.

* When fuse BTl (10) is normal.
I CaUSe I Remedy I
YES -
See A-4
11
__._..-..-.
Ddactivs __~cut
transmission ~_
ReDl.3C.Z
I --.-
relav I transmission I
Defective contact. or ~_
Reoair or
_^_l^^i.._
4, AL__ NO I di;c&nection in wiring I replace wiring I
harness between SC3 harness
(female) (15) - TMC (2) -
star&g switch R25 (female) (5)
ON.
Transmission cut relay
25
SC3 IMICl7)
Transmission TMC(SI2)
I I
- To fuse BTl(10)
F56103106
20-ik23
A-2
m
F
F’,;
.-
l-l _7
zj
-.
Abnormality in neutral safety system
Jr When the starting switch is turned to ON with the transmission

than N, or when the power source is momentarily cut when traveling.
displayed
shift lever at a position other
set
YES transmission
Mistaken operation
l See Operation Manual shift lever to N,
and turn
starting switch
Defective starting switch, or ON.
defective contsct, or
disconnection in wiring Repair or
harness between starting replace wiring
switch terminal ACC - BTl harness
(lo)-TMB(ll)-SC3
(female) (14)

1) zo-3ov harness between battery harness
2) Turn starting terminal (+) - circuit breaker
switch ON. - JO5 - starting switch
ITransmission controller
SC3 (MIC’17)
- To battery relay terminal E
Circuit breaker
JO5 To battery
terminal (+)
F56103107
20-l 24
0
A-3 Abnormality in controller system
a) abnormality in controller displayed
abnormality in controller displayed

(only dot lights up)
cause Remedy
3 YES
Does problem occur

Y
even when wireless
. and electronic
equipment are
2 removed? \
Wireless: Check method of
NO’ installation
Is wireless or
Electronic equipment: Install
YES electronic
surge absorber
equipment
installed?
4 YE!
Check wiring harness of
1- problem circuit
Does problem occur (Surge absorber diode has
’ when a certain come out, etc.)
Isvoltage between 0 switch is operated?
SC3(14)and(13) -
normal? Defective controller Replace
NC
1) Turn starting
switch ON.
2) 20 - 3ov I See A-l, a) -
Double system for clutch is displayed
+ Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES -
See A-l 2, a).
IS ,T - -,
J. cl
(No.2 - 8)
displayed at same
time?
I Failure in controller ReplZ.Ce
NO
1) Turn starting
switch ON.
A-4 Abnormality in transmission [cut relay] system displayed
* Displays disconnection, short circuit, or contact with ground in transmission cut relay system.
Call.% Remedy
Defective relay Replace
Defective contact. or Repair or

1) loo-5DDn disconnection in wiring replace wiring
2) Turn starting harness between SC3 harness
switch OFF. (female) (7) - TMC (31- R25
3) Disconnect SC3. (21, or between SC3 (female)
(14)-TMB(ll)--2511)
Transmission,
cut relay
9
6 3 5 2(
SC3 (MIC 17) TMC(SI21
I
Transmission @
Transmission
TM6 (512)
F56103108
Abnormality in auto-retarder brake solenoid system
I Cause Remedy
2 YES
Is resistance value disconnection in wiring replace wiring
YES between SL4 (male) harness between SL4 (female) harness
, - (1)-(2),and(l)or - (2) - TMC (10) - SC3
(2) - chassis as (female) (3)
- shown in Table l?
n Defective solenoid Replace
Is voltage between NO
1) Turn starting
SL4(1) and chassis -
switch OFF.
normal?
2) Disconnect SL4.
1)20-30V
2) awitCh ON.
Turn starting
Table 1
Measurement Normal
location value
Between SL4(male)
20 - 6OQ
(1) and (2)
Between SL4 pin
Min. 1 MC!
(I) - chassis
Between SL4 pin Min. 1Mfi

(2) - chassis
SC3 ( MICii’)
oid
t
Transmission cut relay resistor
F56103109
Displays abnormality in exhaust brake solenoid system
cause Remedy

YES nection in wiring harness Repair wiring
5
Is resistance
between SL5 (male) between SL5 (female)(2) - harness or
(1) and (2). between TMC (9) - SC3 (female)(12) ~~Pl.?C~.
YES SLY (male) (I) and _

1 chassis, and
4 between SL5 (male)
(2) and chassis as Defective solenoid Replace
IS voltage between
shown in Table l?
SL5 (1) and chassis -
normal? 1) Turn starting
switch OFF.
- 2) Disconnect SL5.
1) 20-30V See A-l (Power swrce -
2) Turn starting NO system)
switch ON.
Table 1
Places for measurement 1 Normal value
Between SL5 (male) (1)
and 12)
SC3 (MICl7)
\ I
TMC (Sl2)
Exhaust brake
- GND SL5 (X2) solenoid
0 I I I I 1
@ @
I a
Fuse B T 1
TM8 IS121
IO
Transmission
cut relay resistor
561 F03335K
20-l 28-l
0
A-6 Abnormality in speed sensor system
Abnormality in engine speed sensor system displayed
out troubleshooting, check that all the related connectors are properly inserted.
4 YES Defective adjustment of speed Adjust

se”sOr
Adjust speed
2
YES
_ sensor. Does it _
become normal?
After measuring
Defective controller ReDbSCe
YES Item 1, return NO
r cOnnectOr tcl
orig$l position. Is
( I: displayed?
1 .
1) Start engine. Is reset
Is resistance value NO
between SC1
(female) (7) and (13) - Disconnection in wiring
normal? harness between SC1
3 YES (female)(7)(13)- TMA(14)
1,500- 1DDDn
(15,-JO3(15)(16)-Zl (13) Repair or .
Is resistance value (14) - El2 (female) (1) (2). or replace wiring
2) Turn starting between El 2 (male) wiring harness between SC1 harness
switch ON.
(female) (7) - TMA (14) -
3) Disconnect SCl.
JO3(15,-Zl (13,-El2
chassis as shown in (female) (1) in contact with
ground
1) Turn starting I Defective engine speed

switch OFF. NO
sensor
2) Disconnect El 2.
Table 1
Between (I) and

Min. IMS?,
chassis
SC I 1 MIC 13)
I \ I Engine speed sensor
TMALSIG) JO9tSl2) El2tX2,
I5 @-
@ 0
F56103110
20-‘z8-2
CalBe Remedy
YES
See G-8 b) (Speed sensor 8 -
system)
1
Repair or
Defective controller replace.
I
Does engine con-
troller also display YI
abnormality?
t
Already reset
1) Turn starting
switch ON. 1) Delete abnormal
display memory.
between SC1 2) Turn starting switch OFF - ON, then start the
(female) (7) and (13) engine.
3) Wait for 20 seconds.
1)5Dc-lccOn
2) Turn starting
Defective contact, or discon
switch ON.
3) Disconnect SCl.
between SC1 (female) (7). (13) harness or
-TMA (14). (15) - ECA replace.
(male) (1 L(2)
TMAIS 16)
SC I (MICl3) Monitor panel
PO8(04016.l
Engine controller
EC3 (MIC21) ECA (S 16 1
0
@
0
.A sensor 6
E7(SWPl4) El2(X2)
@ @
@
0
561 F03336
20-A29
* Check that the mounting bolts of the intermediate shaft speed sensor are not loose.
CW.lse Remedy
2 YES
-
Return to Item 1 and start
troubleshooting again
1 displayed? ] 1 NO
Is reset -
Is resistance value 1) Delete abnormal display memory.
between SC1 2) Turn starting switch OFF-ON.
(female) (6) - (12). 3) Start engine and travel.
and between (6) -
chassis as shown in 3 YES
Table l? Defective contact, or Repair or
I Is resistance value I disconnection in wiring replace wiring
1 I Disconnect SCl. between N2 (male) harness between N2 (female) harness
(1) - (2). and (1) (2) -TM (3) (4) - SC1
cJO between(l)- (female) (6) (12)
chassis es shown in
Table 1 ? Defective intermediate shaft Replace
- NO speed sensor
1) Disconnect N2
Table 1
Resistance
SLl (female) N2 (male) value
SCI (MICl3) Transmission input shah
Intermediate TM2 LSWPl4) N (X2) speed sensor
@ @
Intermediate
@ 0
F56103111
Disconnection in travel speed sensor (transmission output shaft speed sensor)
displayed
Check that the mounting bolts of the travel speed sensor are not loose.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
Remedy
2 YES
troubleshootingagain
Is reset
Defectivecontact.or Repairor
disconnectionin wiring replacewiring
harness between N3 (female) harness
(1). (2) - TM2 (5). (6) - SC1
(female)(3). (10)
Defectivetravel speedsenam Replace
1) DisconnectN3.
Table 1
Resistance
SC1 (female) N3 (male)
value
Between(3) and (10) Between (, 1and

Between (3) and 500 - 100052
(2)
chassis
- Between (I) and

Min. 1 Ma
chassis
Monitor panel
TMA(Sl6) POE3(04016)
Transmission controller ’
SCI (MICl3) Transmission output shaft
speed sensor
TM26WPl4) N3 (X2)
Transmission
@
F56103112
A-7 Speed sensor system, clutch slipping
I- I I__, 8 ,--I
Input shaft sensor or H.L. clutch system displayed
* Check that the mounting bolts of the speed sensor are not loose.
YES
See H-6, c).
11 I (Oil pressure of H.L. clutch)
Is resistancevalue *If the oil pressure is normal,
between SC1 return to Item 1 and start
(female) (5) - (11). - troubleshooting again
and between (5) - 2 YES Repair or
Defective contact, or
chassis as shown in Is resistance value disconnection in wiring replace wiring
Table 1 ? _ between Nl (male) harness between SC1 harness
1) Turn starting - (I)-_(2),s”d (female)(5) (11) - TM2 (1) (2)
switch OFF. No between (1) and - Nl (female) (1) (2)
2) Disconnect SCl. chassis as shown in
Table l? Defective transmission input
- NO shaft speed sensor
1) Turn starting
switch OFF.
2) Disconnect Nl.
Table 1
SCI (MICl31
Transmission input shaft
TM2(SWPl4) NI (X2) sensor speed
Transmission
@
Transmission I
F56103113
Travel speed sensor or speed clutch (1.2.3.4.R) system displayed
* Check that the mounting bolts of the travel speed sensor are not loose.
Cause Remedy
See H-6, C).

(Oil pressure of speed clutch
YES 1,2,3.4.R)
*If the oil pressure is normal,
1 return to.ltem 1 and start
troubleshooting again.
Is resistance value
between SC1 Disconnection in wirina
(female) (3) - (10). - harness between N3 (fimale)
2 YES
and between (3) - (1 I(2) - TM2 15) (6) - SC1 Repair or
chassis as shown in Is resistance value (female) (l)(ld),‘dr’cantact replace wiring
Table l? between N3 (male) with ground, or wiring harness
1) Turn starting
- - (1)- (2). and harness beween TM2
ND between (1) and (female) (5) - TMA (1) - SU3
switch OFF. chassis as shown in (2) - su2 (female) (1). or
2) Disconnect SCI. Table 1 ? between TMA (male) (1) -
PO8 (female) (1) in contact
1) Turn starting with ground
switch OFF.
2) Disconnect N3. NO Defective travel speed sensor
m Table 1
0
z Resistance
z value
tput shaft
F56103114
20-A33
A-8 Abnormality in model selection displayed
* When controller power source is normal.

1
Remedy
2 YES Replace
Defective transmission
I” same conditions controller
YES as when measuring
1- lteml,is :L;
a displayed?
Is voltage between
Is reset
SC1 (2)-_(131.(1) NO
- (13). and (8) - -
(13) as shown in
Table 1?
1) Turn starting
switch ON. NO disconnection in wiring replace wiring
Note:
Connect pin (13)
(female) (2) and SC3 (female)
to the ground
(4) - TM3 (12) - chassis
connection inside
ground
the controller box.
Table 1
SCI (MIC13)
SC3(MICl7) TM3[SWPl4)
F56103115
20-A34
A-9 Abnormality in transmission shift lever system
Short circuit in transmission shift lever assembly power source displayed
* When controller power source is normal.

Remedy
2 YES
. Return c0nnectc.r t0
Y
L original position. Is
,c. 7 displaYed? IIN0
1
El
Is reset
1) Delete abnormal display memory.
Is resistance value
2) Turn starting switch OFF - ON.
between SC2
4
(female) (6) and
chassis normal?
3
If resistance value YES
Defective transmission shift Replace
1) Min. 1MSI in Item 1 is
lever a&y
abnormal, keep
2) Turn starting
switch OFF. same meas”rement _
conditions, and
3) Disconnect SC~. NO
disconnect SF. Does
Wiring harness between SC2 Repair or
I. ‘female) (6) - TM6 (1) - SF replace wiring
female)(l) in contact with harness
2) Turn starting switch OFF. around
3) Disconnect SF.
sc3 (MIC17)
Transmission
shift lever
F56103116
Transmission shift lever position signal displays 2-system abnormal input.
l For machines without payload meter
CdlJse Remedy

Return connectorto
YES original position.
disappear with
operation in Item l?
IS reset
Are all monitor

panel displays - Defective transmission shift
normal? lever ass’y
Wiring harness for position Repair or

shown in Table in contact replace wiring
with ground harness
display on
monitor panel Defective transmission ReplaCe
only N? neutral relay (internal short

(If position other circuit)
than N lights up,
that position
indicates the
(fern&)-transmission Repair or
failed system.) neutral r&v - SF (female) (4) replace wiring
4) Set lever to D
1) Turn starting - TMB (3) 1 SC2 (iemale) (i) harness
position. in contact with ground
5) Is lever position switch ON.
5 * See Table.
display on
monitor panel Defective back-up alarm relay
onlv D? meas”reme”t
(If dosition other conditions as in
than D lights up, - Abnormal system(R) Item 3. and remwe Defective wiring
that position harness or
indicates the relay. Does display connectclr
failed system.) Wiring harness between SF between lever
6) If no failure is (female) (3) - R05 (2). or assembly SF-(3)
indicated by between SF (female) (3) - - tran&ission
above procedure, TMB (2) - SC2 (female) (1) in cOntrOller sc2-
switch ON. ”
all systems are contact with ground (1) - monitor
normal. panel PO8-(9) -
*For details of the back-up alarm
abnormal pwtion relay (Short
and the related circuit with
wiring harness, GND wire or
see Table 1. chassis)
Table A-10-3.
20-l 36
0
Table 1
~1
R SF-(3)-SC2-(l)-Back-
alarm relav-PO8191
SF-(9)-SC2-(14)-
L
PO8(15)
SC3 (MICl7)
I In-lTMB (Sl2)
Transmission
ransmission neutral
relav
I ’ R02
I 5 )@j
I
J
I Back-up alarm relay

R05
F56103117
20-137
0
Shift lever position signal displays two or more systems.
2 YES
When connector is
returned to original
Y ES
position, does dis- _
play disappear with
NO
1) Deleteabnormal
display memory.
2) carry O”t opera-
tion in Item 1.
YES
1 I
*Order of operation
1) Turn starting
switch ON. - ’ Abnormal system (D, 5,4,3. L)
2) Place lever at N 3
position.
3) Check if lever
position display not disappear in
on monitor panel Item 1, does display YES
go cut if system is r
indicates only N.
If any Dosition NO left in condition for
othe; ihan N measurement and _ Does display disap-4’
lights up. this SF is disconnected? pear when system
shows ihe failed . Abnormal system (NI is left in measure-
system. ment condition for
*Same order of
4) Place lever at D operation as Item 1. Item 3 and neutral
position. relay is removed? Does display disap-
5) Check if lever pear when system
position display 1) Turn starting is left in measure-
on monitor panel switch ON. NO ment condition for -
indicates only D. Item 4 and pavload
If any position 1 relay is r&&d? 11
othe; ihan D
lights up, this 1) Turn starting
shows ihe failed switch ON.
system.
6) If this operation
does not show
any failure. all
systems are
normal.
*The relationship between the position display-
ing the abnormality and the related wiring har-
ness is shown in Table 1. YES
Does panel display

disappear when
system is left in
L . Abnormal system (R) measureme”t con-
dition for Item 3 and
backup alarm relay
is removed?
L
1)Turn starting
switch ON.
20-A38
I Cause I Remedy
Already reset
Defective shift lever assembly Replace
Repair wiring
harness or
replace
Replace
Defective payload relay (inter-

+/ nal short circuit) Replace
trans&ssian neutral relay

R02 (female) (2) - SF
(female) (4) - TMS (3) - SC2 Repair wiring
(female) (2). or between pay- harness or
load relay Roll (female) (2) - replace
PO8 (female) (10) - MM7 (5)
- MM2 (female) (2) short cir-
* See Table 1.
21 Defective backup alarm relay
Wiring harness between SF

(female) (3) and backup alarm
relay R05 (female) 12). or Repair wiring
between SF (female) (3) - harness or
TM6 (2) - SC2 (female) (1)
short circuiting with chassis
ground
20-138-l
0
Table 1
Place lighting up System for wiring harnes

on monitor panel at failure location
SF-(4)-SC2-(2)-PO8-(1Of
N -MM2-(2bTransmission
neutral relay-Payload rela
R SF-(3)--SC2-(1 )-Back-
alarm relay-P08(9)
I 5
Transmission
ft lever
Transmission
neutral relay
~~
Backup alarm relay
Yfl Pavload relav
561 F03337
20-138-2
a
Transmission shift lever position signal is not input
Remedy
See A-9, a)
YE
Is reset
2) Turn starting switch OFF -ON.
3) Operate transmission shift lever in
order shown in Table 1.
shown in Table l?
1) Turn starting Repair or

Defective contact. or
switch ON. replace wiring
disconnection in wiring
2) Operate lever N - harness
harness between problem
R-D-5-4-
SC2 (female) and SF (female)
3- Land check h
signal input.
See Table 1 to Defective transmission shift Replace
judge. 1) Turn starting PJ” lever ass’y
switch ON.
2) Set lever tcl
Dosition where
&lure occurred,
and measure
+24V power
source and
signal from
position of
failure. See Table
1 to judge.
Table 1
I \
L
5 Transmission
D shift lever
N
0 -++12v
F56103116
20- 139
0
A-10
R-R
t-_
t .I
1.
_I Abnormality
1. I
in accelerator
signal displayed
j, Always connect any disconnected connectors before going on to the next step.
YES
l For engines with

mechanical governor
SC1 (4) and (2) as

/ES
shown in Fig.1
when accelerator
oedal is ooerated?
YES
1) Turn starting
switch ON.
2) operate
accelerator 4
pedal. Does voltage
between SRl (2)
YI
and (3) change
according to angle
of accelerator pedal
es in Fig. l? 5
1) Turn starting
siwtch ON. Is resistance value
2) Operate - betweenSR1 (male) -
Isvoltage between accelerator NO (1) and (3) normal?
pedal.
I I
1) 4.6 - 5.4 kf-J
2) Turn starting
1) 4.6 - 6.4V 1) 4.6 - 5.4V switch OFF.
2) Turn starting 2) Turn starting 3) Disconnect SRI
switch ON. witch ON.
NO
Is res.iStance value
between SC3
(female) (8) - SC1
(female) (2). and
between SC3 0 YES
(female) (8) -
chassis as shown in Is resistance value
Table 1 ? between SRl (male)
U-_(3).and(l)- -
1) Turn starting chassis as shown in
switch OFF. Table l?
2) Disconnect SC1
1) Turn starting NO
and SC3.
switch OFF.
2) Disconnect SRl. Table 1
Resistance
Connector
value
Between SC3 Between SR 1
(female)(8) and (female)(l) and 4.6 - 5.4 Ka
SC1 (female)(2)
Between SC3
(female)(8) and
chassis
(V) Accelerator signal voltage (KQ) Sensor resistance value
Approx. 4.3 Approx. 4.3
‘I\‘\
Low idling - Full Low idling - Full
Accelerator pedal position Accelerator pedal position
F56103119 Fig. 2 F56103120
2oi7:40
Fig. 1
Remedy
Defective transmission Replace

controller
Defective adjustment of Adjust

accelerator sensor
harnass between SC1 Repair or
(female) (4) - TMA (13) - replace wiring
SRl (female) (2). or between hanress
SC1 (female) (2) - TMB (9) -
SRI (female) (3)
6 YES
(female) (8) - TMA (16) - replace wiring
SRl (female) (1) in contact hanress
with ground, or contact with
according to angle other wiring harness
of accelerator pedbl
Accelerator sensor linkage correct or
has come out, or defective replace
1) Turn starting accelerator sensor
switch OFF.
2) Disconnect SRl.
Replace

disconnection in wiring replace wiring
(female) (8) - TMA (16) -
SRl (female)(l)

cO”trOller
Wiring harness between SC3

(female) (8) - TMA (16) -
SRl (female) (1). or between Repair or
SC1 (female) (2) - TM8 (9) - replace wiring
SRl (female) (3) in contact harness
with ground, or in contact
with other wiring harness
Defective accelerator sensor Replace
SC3 (MIC 171 TMA(SI6)
@
SRI (X3)
@
I
0
@
SCI (MIC 13) TMB ISIZ)
0
F56103121A
20-141
a8
l For engines with electronic governor
CSJse Remedy
See G-9 (Accelerator se”&

system)
Does engine co”- Defective controller

troller also display
abnormality? Yf
t
1) Turn starting
switch ON. Already reset
1) Delete abnormal
display mem0rY.
2) Turn starting
switch OFF - ON.
1) 0.6 - 4.75V
2) Turn Starting Defective contact. or discon-
switch ON.
between SC1 (female) (4) - harness or
3) operate acceler-
TMA (13) - SRl (female) (2) replaCe
ator pedal
slow -full.
Engine controller Accelerator

ECA (S 16)
Power source
TMA.(S 161
SC1 (MIC13)
Transmission
controller
561 F03329
20-141-l
Cc
I Case Remedy
I
YES With Item 1 normal,
is 1 .S displayed?
2
IS reset
Isresistance value
1) Delete
abnormal NO
display memory.
YES between sc3
- (female) (4) and (19) - 2, T”r” narti”g
switch OFF -
normal?
ON. 4 YES
Defective contact, or disconnec- Repair or
1 1) Turn starting tion in wiring harness between replace
switch OFF. Is resistance value CVT (female) (1) (2) - TM4 (13) wiring
2) 1 -5ODkn - between Cvr(“l&) - (14) - SC3 (female)(lsJ(4), or harness
Is transmission oil 3) Disconnect SC~. NO (1) and (2) normal? contact with ground
temperature normal? -
Defective transmission oil Replace
l)l-5ODkn NO temperature sensor
2) Disconnect CVT.
1) Check with moni-
tw panel display.
I I
See H-8
SC3 (MICl7) TM4 (SWP 14) CVT(X2)
IP @
F56103122
20-&42
A-l 2 Abnormality in pressure control valve system
Fill signal displays ON regardless of command
CalXSZ Remedy
YES
See H-6, C)
1 1 *If the hydraulic pressure is
normal, return to Item 1 and
start troubleshooting again
YES
Wiring harness in problem Repair or
circuit in contact with ground replace
I *See Table 1. wiring
1
harness
Defective fill switch in problem Replace

2) When measuring *See Table 1. NO circuit
resistance, turn 1) The measurement *See Table 1.
starting switch conditions are the
OFF. same as for Item
3) Disconnect con- 1
nectars to be
measured.
ransmission
connector and
X2-(18) - PO5-(5) - 2.SW
E. -36 3 clutch sc2-(9) - PO5-(4) - 3. SW Max. IV Max. 1L-J 15-25V Min. IMfi
E. -3; 4 clutch sc2-(19) - PO5-(3) - 4.sw Max. IV Max. In 15-25V Min. lMS2
E. -3.6 R clutch SC2-(IO) - PO5-(7) - R.SW Max. IV Max. l!FJ 15-25V Min. lMS2
b) ~-J+p--JpJ Fill signal is not input and clutch slipping is displayed
* Measure the clutih oil pressure of the system where the abnormality is displayed. If the oil
pressure is normal, carry out the troubleshooting below.
b-l) Inspection of fill signal system
-
Remedy
YES
See H-6. c)
1 (Clutch oil pressure)
Are resistance value
between SC2 ,
(female) and chassis, _
and voltage between
SC2 and chassis as
2 YES
Repair or
Defective SW (fill switch)
shown in Table l? *See Table 1. replace
- Is voltage beween
wiring
1) When measuring _ 0 SW (fill switch)
harness
resistance. discon- NO (female) and
nact sc2. chassis normal?
*See Table 1. Defective wiring harness in Replace
*See Table 1. NO problem circuit
1) Same as Item 1. *See Table 1.
Connection of connector and fill switch 1 Fill switch
When connected 1 When released
pin number ’ Voltage Resistance Voltage Resistance
1: Ill
_. - -1.1: Hi clutch SC2-(20) - PO5-(I) - H. SW Max. IV Max. Ia 15-25V Min. IMa
1: II-l
Max. Ifi 15-25V Min. IMa
_. - -1.7 Low clutch SC2-(11) - PO5-(2) - L. SW Max. 1V
- r-1’-; 1 clutch SC2 -(8) - PO5-(6) - 1. SW Max. IV Max. Is1 15-25V Min. lMS2
t.
_ u 2 clutch SC2-(18) - PO5-(5) - 2.SW Max. IV Max. Ia 15-25V Min. lMS2

t. l.S
k. - ‘-l.6 3 clutch sc2-(9) - PO5-(4) - 3. SW Max. IV Max. Ia 15-25V Min. IMfi
II-l
- 7. I 4 clutch sc2-(19) - PO5-(3) - 4. SW Max. IV Max. 152 15-25V Min. lMS1
t.
11 I I Cl
R clutch sc2-(IO) - PO5-(7) - R.SW Max. IV Max. IR 15-25V Min. IMa
_. - -1.1-1
20-144
0
PO5 IO40121 TMA(SI61 TM3 tSWPl41 RSW
HSW
\
\
I
SC3 (Ml~l7) TM3lSWPl4)
GND
F56103123
b-2) Transmission input shaft revolution signal system, check of Hi-Lo clutch system.
When E/--q . E/q is displayed
* Carry out diagnosis of A-8 a).
b-3) Transmission output shaft revolution signal system, check of F, R clutch.
When FHq -E-$# is displayed
I Carry out diagnosis of A-8 b).

A-1 3~~$$~~~syst.m; When fill. signal is not input (flow detector valve
Carry out diagnosis of A-12 b-l) Fill signal system.
Correspondences of indications are as follows.
-
I-_ _I_1 I -1
J.l- I-
-1-_
_-
I- _Ic) 1-I3
-I._I L-1
I
I-- I__qq
_I. I
1:: c )-c l-l I_

-1.1 I. _I
c c lll-
J.U - 3.0
1:1 -'$]
J. I
I-- I-l
_._q~
J.U
20-l 47
@
170 Disconnection in pressure control valve solenoid
~&~-&&stern displayed

YI
1 displayed?
I
Is reset
1) Delete abnormal
display memory.
2) Turn starting
switch OFF -
ON. 3 YES
Defective contact, or disconnec- Repair or
I I
*Measure pi” no. Is resista”cepvSa;e tion in wiring harness between replace wiring
where abnormal between problem SC3 or SC4 - TM3 or harness
display is given. 9
LK.T. (ma e) (1) - TM4 - /-J PS or L/CT.
1) Turn starting NO and (2) as shown in (female)
switch OFF. Table 1 and Table 2?
2) Disconnect SC3 Defective solenoid in problem ReplaCe
1) Turn starting NO
or sc4. circuit problem
switch OFF. *See Table 1. solenoid
2) ;~“ect 0
Disconnect L/CT
20-148
0
Table 2
Measurement location
Display Measured item Normal value
Step (I) Step (2)
:: Between SC3 (1) Resistance

LCT (I), (2)
57 (2) and (11) betweeen 30 - 80R
pins
(2) Resistance
between pin
and chassis Min. 1 MR
ground (2
places)
L/CT
TM3ISWPl4)
ECMV 4(-_)
ECMV 3(-_)
ECMV 2(-_)
ECMV l(-_)
ECMV L(+)
ECMV R(+)
ECMV 4(+)
ECMV 3(f)
k56103124
056103
8
u
t!fQ
Starting
d
motor
3
4
Battery
relay
Engine speed
Batt sensor
CNEIP
I
5
I
6 ,
Starting
motor
Battery
relay
8
d
2
Engine speed T
056103
TROUBLESHOOTING OF SUSPENSION
CONTROLLER SYSTEM
Judgement table for suspension controller, suspension related parts . . . . . . . . . . . . . . . . . . 20-I 54
Red Green
S-l OFF
0 0
OFF
Abnormality in power source system ............. i ............... 20-l 55
Red Green
0 (>
Slow slow
s-2 flash- flash- Abnormality in pressure sensor [right] system ...................... 20-l 56
ing ing
Simultaneous
Red Green
0 c,
Rapid Rapid
s-3 flash- flarh- Abnormality in pressure sensor [left] system ....................... 20-l 57
ing ing
Simultaneous
Red Green
0 0
s-4 Rapid OFF
flarh- Abnormality in travel speed sensor system ......................... 20-l 58
ing
Red Grew
0 0
s-5 ;:;. ON
Abnormality in steering sensor system ............................ 20-l 59
ing
Red Green
c, c,
S-6 Rapid Slow
flash- flash-
Abnormality in model selector system ....... i .................... 20-I 60
ing ing
8
z Red Grew
z 0 0
s-7 ON OFF Abnormality in solenoid [I] system ............................... 20-l 61
Red Greer
0 a
S-8 ON slow
flash-
Abnormality in solenoid [II] system ............................... 20-l 62
ing
Red Greer
0 0
s-9 ON Rapid
flash-
Abnormality in solenoid [Ill] system .............................. 20-l 63
ing
Red Greel
0 0
S-IO ON ON
Abnormality in controller system ................................ 20-l 64
Electrical circuit diagram for suspension control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-I 65
Re-enacting failures in electrical system

of wiring harnesses and connectors, occur only under special conditions particularly at the initial
stage of the occurrence of the failure.
Therefore, investigate the values for the resistance and voltage at the locations indicated by
the abnormal display, Even if no abnormality is found, it is necessary to investigate the conditions
troubleshooting.
20-&53
JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS
Self-tester display (abnormal display) Pilot display
Pressure Pressure Travel
Check item Power Steering Model Monitor
sensor sensor speed Solenoid Solenoid Solenoid Controller Body
source sensor selector panel mode Brake
(right) (left) sensor [II system [Ill system [Ill1 system system float Troubleshooting
system system system display
system system system code when no
Red Green Red Green Red Green Red Green Red Green Red Green Red Green Red Green Red Green Red Green abnormal display is
0 0@(>@4l@00. given.
OFF OFF Flashes Flashes Flashes Flashes Flashes OFF Flashes ON 2hes 2, 0: &i- 0: Fl% 0: @
Flashes .
ON .
ON
slowly slowly rapidly rapidly rapidly slowly rapidly slowly slowly rapidly
VO. Failure mode Simultaneous Simultaneous
1 Abnormal noise comes from suspension See “Testing and

adjusting suspension”
2 Suspension mode switches abnormally frequently a a a a 00 -
3 Suspension mode 1 When traveling loaded, sus- See “Testing and

does not switch pension stays in medium l 0 0 l a a 0 l adjusting suspension”
*Operator judges mode
h to be abnormal 2 When traveling unloaded, See “Testing and
from mode dis-
suspension stays in medium l 0 l adjusting suspension”
play on monitor
mode
panel
3 Suspension stays in hard
mode 0 l a -
4 Suspension stays in soft

a a a 0 -
mode
5 Mode dipslay is not given -
(all lamps OFF) l a 0.
6 Abnormal display -
(all lamps light up)
4 Chassis rolls
excessively See “Testing and
1 Always rolls excessively
*Operator judges adjusting suspension”
it to be abnormal
from mode dis- See “Testing and
2 Sometimes rolls excessively
play on monitor a a adjusting suspension”
panel
I
5 Riding comfort for
operator drops 1 Riding comfort is always See “Testing and
*Operator judges poor adjusting suspension”
it to be abnormal
from mode dis- 2 Riding comfort is sometimes See “Testing and
play on monitor poor l 0 adjusting suspension”
panel
6 Chassis bounces See “Testing and
*Operator judges it to be abnormal from mode adjusting suspension”
display on monitor panel
7 Operation of ma- 1 Defective operation of
chine and suspen- antidive function [when
sion mode do not service brake is applied,
0 -
match suspension does not switch
S + M (unloaded), M + H
(loaded)]
2 Defective operation of anti- See “Testing and
lift function[Suspension adjusting suspension”
does not enter hard mode 0
except at body float]
Troubleshooting code when abnormal display is given S-l s-2 s-3 s-4 s-5 S-6 s-7 S-8 s-9 s-10 Carry out trou- F-l F-2
bleshooting for
item displayed
by monitor panel
Troubleshooting code when lamps
do not light up for operation of
applicable item
2oi154
s_, =I
Abnormality in power source system
* When fuse BT2 (3) (5 - 6) is not blown.

If the fuse is blown, check for contact with ground of wiring harness between fuse and controller,
and inside controller.
* When lamp goes out only in suspension mode.
2 YES
Replace
Under same
YES conditions as when
- measuring Item 1, -
do both LEDs go
1 out? -
Is reset
1) Turn starting NO
Is voltage between switch ON.
SUl (16)and817) -
normal?
1 YES
1)20-30V disconnection in wiring replace
2) Turn starting Is voltage between harness between SU3
switch ON. Nz W&Wl6) - (female) (1) -SUl (female)
(16)(17) - SU3 (female) (16)
Iefective contact, or discon- Repair or

NO wction in wiring harness replace
1) 20-30V
Detween ET2 No. 3 - SU3
2) Turn starting male) (1)(16)- JO3 (8) - 30
switch ON. 9) - battery relay
SUI IMIC21) SU3 (S16) JO3(Sl6) 3O(SWPl4)
1
battery relay
BT2
-m- To banery terminal (+)

5A
F56103126
20-ik55
Abnormality in pressure sensor [right] system
1 Simultaneous 1
Remedy
2 YES Defective suspension

Under same controller
conditions as when
measuring Item 1, _
do both LEDs flash
slowly after 5
minutes? Is reset
- NO
1) Turn starting
Is voltage
between switch ON.
SU2 (9) and (10) Defective contact, or
harness between SU2 Repair or
(female) (10) - SU3 (7) - Jo4 replace wiring
1) 1 -4v [3) - 31 (7) - 39 (female) (2). harness
2) Turn starting or defective pressure SensOr
switch ON.
Isvoltage between 11
harness between SUl replace wiring
(female) 815) - SU3 (15) - harness
SU6-PWR-JD4(1)-31
(6) - 39 (female) (1)
Defective suspension Replace

1) 16-19V NO controller
2) Turn starting
switch ON.
sion,
pressure sensor
(right)
SUI (MIC21) F56103127
20-156
0
l For machines with payload meter
Remedy
1
Defective suspension
controller
Alreadv reset
1) Turn starting
switch ON.
1 5 YEE
Defective sensor Replace
Is voltage between between SU2

SU2 (9) and (10) (female)(lO)and
normal? chassis normal? Defective contact, or discon-
4 nection in wiring harness Repair or
NO between SU2 (female) (10) - replace
1) 1-4v 1) 100-4DD400R
Is resistance SU3 (7) - PM1 [female) (14)
2) Turn starting 2) Disconnect SU2
YES between 39 (female) _
switch ON. and 39.
(2) and chassis
31 Turn starting
normal?
3 switch OFF.
1) lDD-4DDQ Defective contact. or discon-

Is voltage between 2) Disconnect 39 nection in wiring harness
Repair or
39 (1) and chassis - .+“d SU2. between 39 (female) (2) - 31
normal? 3) Turn starting (7l- JD4 (3) - PM1 (female)
switch OFF. 114)
See L-8
NO
SU2 (MICl3) SU3 IS I61 F.R suspension
JO4El2) 31 (SWP81 39 (X2)
pressure
sensor
0, 0 @
0 @ a
ipr!i2iq PM I (MIC21)
561 F03338
20456-l
0
r-l
Red Green
S-3 @ @ Abnormality in pressure sensor [left] system
Simultaneous
Remedy
Replace
Isvoltage
beween
SU2 (9) and (11) Defective contact. or
normal? disconnection in wiring
harness between SU2 Repair or
(female) (11) - SU3 (8) - JD4 replace wiring
1) 1-4v (2) - 02 (7) - 13 (female) (2). harness
2) Turn starting Is voltage between or defective pressure sensor
switch ON. 13 (1) and chassis -
h ,B normal? 4 YES
harness bewee” SUl replace wiring
Is voltage between (female) (15) - SU3 (15) - harness
1) 16-19V
2) Turn starting SU6-PWR-JD4(1)-02
switch ON. (6) - 13 (female) 11)
Defective suspension Replace

1) 16-19V NO controller
2) Turn starting 8
switch ON. z
8
Front suspension
uspemon pressure sensor,

ower source selector connector)
F56103128
20- 156-2
0
l For machines with payload meter
Cause Remedy
Defective suspension
cOntrOller
AlreadY reset
1) Turn starting
switch ON.
5
, I P Defective senear Replace
Is resistance
Is voltage between
YES between su2
SK? (9)and (11)
(female) (11) and -
normal?
chassis normal? Defective contact, or discon-
t 4 nection in wiring harness Repair or
1) l -4v N( between SU2 (female) (11) - replace
Is resistance 1) loo-4ODQ SU3 (8) - PM1 (female) (15)
2) Turn starting 2) y(lleti su2
YES between 13 (female)
switch ON.
(2) and chassis
normal? 3) Turn starting
3 switch OFF.
1) lDD-4cO4oon Defective contact, or discon-

Is voltage between 2) Disconnect 13 nection in wiring harness
13 (1) and chassis - and SU2, Repair or
between 13 (female) (2) - 02
normal? NO replace
3) Turn starting (7) - JD4 (2) - PM1 (female)
switch OFF. (151
1)16-19V I
2j Turn starting
See L-8 -
switch ON.
-
SU3tS 16)
F. L suspension
JO4El2) pressure sensor
92CSWPS) 13(X2)
@ @
a 0
-I PMI(MIC21)
561 F03339A
*
See A-6, c)
I
Does transmission II
controller displaY
show abnormalitY in -
transmission output _ 2 YES
~ Defective controller Replace
speed system?
- Is resistance value
between SU2
~5 (female) (1) and (8) -
normal?
I Defective contact, or Repair or
1)5oc-1000n NO disconnection in wiring
2) Turn starting harness between SU2
switch OFF. Ifemale) I1 b- SU3 12)- TMA
3) Disconnect SU2. il) - Tti2’(5) (6) -‘TMA (2)
- SU3 (3) - SU2 (8)
SU2 fMICl3) SU3fSl6) TMA fSl6) TM2fSWPl41 Transmission output shaft
0 @ f.~3 (~2Ispeed seti<or-
(7 @ -0
Transmission
0 @ 0
3
I
monitor panel
Transmission
oontroller
F56103129
20-158
0
* Before carrying out troubleshooting,check that all the related connectors are properly inserted.
* Always connect any disconriected connectors before going on to the next step.
Cause
3 YES
Replace
FHP
IS reset -
NO

SU2 (9) and (12) as 5 YE! Defective contact, or
shown in Table l? disconnection in wiriw Repair or
I harness between SR2-
I I YES Is voltage between
(female) (2) - SR3 (5) - SU2
1) Turn starting - SRZ(l)and(B)as -
(12)
switch ON. 4 shown in Table l?
2) Turn steerin
wheel slowly. Is voltage between - -NC Defective steering sensor
1) Turn starting
SK? (1) and (3)
switch ON.
normal?
Is voltage between 2) Turn steering
SUl (14)and(17) wheel slowly.
I-lOrmal? Defective contact, or
1) 11-13v
2) Turn starting NO harness between SUl replacs
h ON.
1)11-13v (female) (14) - SU3 (4) -
2) Turn starting SR2 (female) (1) (3) - SU3 (6)
switch ON. - SU2 (female) (9)
6 YES
Defective steering sensor
In test 1, does
voltage become
normal if SR2 is
disconnected?
, 1 I
Wiring harness between SUl Repair or
NO (female) (14) - SU3 (4) - replace
SR2 (female) (1) (3) - SU3 (6)
- SU2 (female) (9) in contact
with ground
Steering Sensor
F56103130
Table 1
SUI (MIC21)
-
Operation of steering wheel
F56103131
S-61: G;n(Ab normality in model selection system
Remedy
2 YES
Defective controller. or Replace
Under same condi- controller for different model
tions as when maas-
FS installed
wing Item 1, does _
red LED flash ra
Is reset -
NO
Isvoltage of each
pin of SUl and SU2
as shown in Table
l? t
1) When No.1 is abnormal
Wiring harness between
1) Turn starting
SUl (female) (12) and SU4
switch ON.
($$Jl) in contact with
2) Disconnect SUl
and SU2.
2) When No.2 is abnormal Repair or
J
Wiring harness between replace
SU2 (female) (2) and SU4
Fz;;J2) in contact with
3) When No.3 is abnormal

harness between SU2
(female) (3) - SU4 (3) -
SU4 (4) - SUl (female)
(17)
Table 1
Measurement
No. Normal value
location
1 SUl(12) - (17) 17 -3OV
2 SU2(2) - (9) 17 -3QV
3 SU2(3) - (9) o-1v
Model selection 1
F56103132
S-7=1 Abnormality in solenoid [I] system
Sr When repairing or troubleshooting, check the direction of the solenoid diode.

* Before carrying out troubleshooting, check that ail the related connectors are properly inserted.
Defectivecontroller ReplaCe
YES ISvoltagebetween
SUl (16)and(17)
2 IWrllW?
A--
See S-l.
Defectivecontact,or Repair or
disconnectionin wiring replace
harness between SLl (female)
(2) - SUl (female) (1) (16) -
SLl (female)(1)
1) Turn starting
switch OFF. I Defectivesolenoid IWhX?
2) DisconnectSll. NO
(3) SLl(mle)(2)-chassis Min. lMS2
SU3 (S16)
To battery relay
49
S UI (MIC21)
1
nln\
F56103133
2o-2
S-8 m)Q normality in solenoid [II] system
* When repairing or troubleshooting, check the direction of the solenoid diode.

CalBe Remedy
3 YES

2 - SlJ1(16)and(17) -
normal?
-
Is resistance value See S-l
1) 20-30V NO
YES between Sul
@;;$j (2)and(16) - 2) Turn starting
1 switch ON.
Is resistance valve 1)20-5On Defective contact, or Repair or

of each pin of SL2 _ 2) Turn starting NO disconnection in wiring rl3plaCe
as shown in Table switch OFF. harness between Sl2 (female)
l? 3) Disconnect SM. (2) - SUl (female) (2) (16) -
SL2 (female) (1)
1) Turn starting
switch ON. Defective solenoid Replace
2) Disconnect SL2. NO
No. Measurement location Normal value
(1) SL2 (male) (I) - (2) 20 - 5052
(2) 1SL2(male)(l)-chassis.1 Min. lM!CZ

I I
(3) 1SL2(male)(2)-chassis 1 Min. lMS2
SU3(Sl6)
9 - To battery relay
Suspension controller - To battery terminal (+I

I
SUI (MIC21)
solenoid valve B
F56103134
S-9mlAb normality in solenoid [Ill] system
* When repairing or troubleshooting, check the direction of the solenoid diode.

CaUSe Remedy
3 YES
Defective controller ’ RePlace
2 - SUl(16)and(17) -
normal?
Isresistance value -
See S-l
YES between SUl 1) 20-30V NO
- (female) (3) and (16) - 2) Turn starting
1 normal? switch ON.
Is resistance value 1) 20-5OQ

of each pin of SL3 _ 2) Turn starting
1 Defective contact, or disconnec- i Repair or
NO tion in wiring harness between replace
as shown in Table switch OFF.
l? 3) Disconnect SUl. ‘SL3(female) (2) - SUl (female)
(3)(16) - SL3 (female) (1)
1) Turn starting
switch OFF. Defective solenoid / Replace
2) Disconnect SL3. NO
Measurement location Normal value
1 (1) 1 SL3 (male) (1) - (2) ) 20 - 5OQ I

(2) SL3(male)(l)-chassis Min. IMQ
(3) SL3(male)(2)-chassis Min. 1Ma
SU3(Sl6)
E- To battery relay
-@
( ,-b \ 1-w To battery terminal (+)
1 I
WI (MIC21)
;Suspension controller
SL3IX2) solenoid valve C
0
4
-----@
F56103135
20-&63
S-1 o/“.” “;s’“iAbnormality in controller

Remedy
3 YES
$,,[I
Wireless: Install
Defectivemethodof correctlY
Is wireless or installationof wireless and Electronic
l_+gjiFq
elsctronicequipment equipment:
Installsurge
absorber
Surge absorberdiode has Repair 0,
c0me c.“t replace
Is voltage
between
Defectivecontroller
N(
2) Turn starting
switch ON.
See s-1
Battery relay
SUI (MIC21) SU3ISl61 JO3 (Sl6) 30 (SWPl4)
- To battery terminal (+)
F56103136
20-&64
056103
Transmission output shaft.

speed sensor
31
Battery relay 0
Front suspension
I pressure sensor (R.H.)
# II
v LJV
Front suspension TM2

1' 1.L pressure sensor (L.H.)
1
From air tank -
Starting switch
/r
Payloa
5 meter
ectronic 4E!F
Brake lamp solav panel Es2 (3)
t
Steering nsor
t
TMA
Electronic display
panel
Limit switch
(body float)
TROUBLESHOOTING OF PAYLOAD
METER SYSTEM
L- 1 When the starting switch is turned ON, no display appears ...................... 20-l 66- 3
L- 2 After the starting switch is turned ON, the demand for calibration
(CAL flashes) continues to be given ........................................... 20-I 66- 3
L- 3 Calibration cannot be carried out .............................................. 20-I 16- 4
L- 4 After the starting switch is turned ON, the external display lamps
do not all light up ............................................................ 20-I 16- 6
L- 5 External display lamps light up even when it is not the condition
for lighting up ............................................................... 20-l 66- 6
L- 6 The level of lighting up of the external display lamps is not correct ............... 20-I 66- 7
L- 7 There is abnormality in the display logic
a) Even when the dump body is operated, the display does not
becomeoton ............................................................ ..20-166 - 8
b) The display stays at 0 ton and does not change .............................. 20-I 66- 8
c) When the transmission lever is at neutral, the weight display
is not given (time display is given) .......................................... 20-l 66-l 0
d) When the transmission lever is at a position other than neutral, the time
display is not given ....................................................... 20-l 66-l 2
L- 8 EOl - E04 is displayed ....................................................... 20-l 66-l 3
g
z L- 9 El 1 - El4 is displayed ....................................................... 20-I 66-14
g L-IO E21 - E28 is displayed by sensor check ....................................... 20-l 66-14
L-l 1 E31 is displayed .............................................................. 20-l 66-l 6
L-l 2 E32 is displayed .............................................................. 20-l 66-l 8
L-l 3 E41 is displayed .............................................................. 20-I 66-l 8
L-14 E42 is displayed .............................................................. 20-I 66-l 9
L-l 5 The printer does not print anything (only blank paper comes out) ................ 20-l 66-l 9
L-l 6 The printer only prints NO DATA .............................................. 20-l 66-20
L-l 7 Even when the [PRT] switch is pressed, nothing is printed out .................. 20-I 66-20
L-18 PAPEflashes ................................................................. 20-166-21
L-l 9 The time is wrong ............................................................ 20-I 66-21
L-20 E33 is displayed .............................................................. 20-I 66-21
Related electrical circuit diagrams ................................................... 20-I 66-22
Electrical circuit diagrams for payload meter system .................................. 20-I 66-25
* Re-enacting failures of the electrical system

Of the failures of the electrical system, defective contact of the wiring harness and connectors
often occurs only under special conditions, particularly when such problems first start to appear.
For example, they may appear when the engine is running at high speed or when the machine
is traveling at high speed on rough roads.
Therefore, even no abnormality is found when investigating the resistance and voltage at the
locations indicated by the failure display, always be sure to check thoroughly the conditions
when the problem occurred and try to re-enact the conditions of the failure when carrying
out troubleshooting.
20-l 66-I
0
L-l When the starting switch is turned ON, no display appears
Jr Always connect any disconnected connectors before going on the next step.
CalBe Remedy
YES
Defective PLM controller Replace
Short circuit between (16) an After

:17) in wiring harness inspection,
knvaen controller fuse and repair
‘Ml, or contact between I1 61
kfective PLM controller Replace
Disconnection in wiring har- After

“ass starting switch ACC ant inspection.
PM1 (16). or batween PM1 repair
I1 7) and battery relay (E).
L-2 After the starting switch is turned ON, the demand for calibration
g
(CAL flashes) continues to be given z
-5
* Always connect any discconected connectors before going on the next step.
Cause Remedy
(ES
c Normal -
NO

1) Max. 1V “ass between PM1 (11) - inspection,
2) Turn starting RH2 (3) - PM2 (3) - PM2 (4)
IS voltage between repair
switch ON. - RH2 (4) - PM1 (17).
Wiring harness between PM1 After

(5) - RH2 (2) - PM2 (2) shor inspection,
circuiting with chassis repair
1 I ground.
1)4-6V
2) Turn starting Wiring harness between PM1 After
switch ON. (l)-RH2(1)-PM2(1)shor inspection,
NO circuiting with chassis repair
ground.
20-l 66-2
0
L-3 Calibration cannot be carried out
* Always connect any disconnected connectors before going on the next step.
CAL display flash-

YE ing. If CAL switch is
pressed when
2 machine is travel-
ing, does CAL dis-
YI ES pressed with trans- play light up ?
mission lever at N, NO
FS
r ‘FS
YE
1
Is transmission N
relay fuse blown?
and (17) as shown
I
4
in Table 1 when
1
transmission lever Does transmission 0 YES
N relay make oper-
ating sound when
1) Turn starting
transmission lever YE
switch ON.
NO is switched
between N -
other position ? is at N ?
IL
I
1) Turn starting
IJ
1 Max. 1.W NO
switch ON
:!) Turnstarting g
switch ON.
z
4 NO g
r
YES
l)Max.20-27V.
L
normal when the
VOtransmission lever 2) Turn starting
switch ON.
Is there continuity I1
1) Max. 1.5V between SF (4) and
2) Turn starting N
swttch ON.
1) Remove trans-
mission N relay. NO
YES
11
,
Does transmission
ating sound when 13 YES

transmission lever II
between
1)Turn
N e
starting
dd
switch ON. mal both when the 1) Remove trans- NO
NO transmission lever mission N relay.
is at N and at a I
1 r?on other than
JO
1)Max. 1.5V
2) Turn starting
Table 1 switch ON.
20- 166-4
0
I Remedy
I
Blown fuse Replace

(20) and R02 (6) short circuit- inspection.
ing with chassis ground repair
Defective transmission neu- Replace

tral relay
Defective transmission lever Replace
8
z
8 10 YES Defective transmission relay Replace
IS voltage between
- PO2 (2) and chassis -
ground normal ?
ness between R02 (1) and inspection,
1)20-27v NO BTl (10) repair
2) Remove trans-
mission N relay.
ness between SF (4) and R02 inspection,
repair
(21

ness between PM1 (20) and
R02 (6). or between R02 (3) re&r
and chassis ground
Wiring harness between R02

I (2) and SF (4) short circuiting
with chassis ground r&air
cr transmission new Replace
20-166-5
0
L-4 After the starting switch is turned ON, the external display lamps do
not all light up
Sr Always connect any disconnected connectors before going on the next step.
Cause
Wiring harness between laml: After

Fuse and display lamp short inspection,
1 circuiting with chassis repair
Qround.
IS fuse of external
display lamp blown? - Wiring harness with conti- After
2 nuity short circuiting with
repair
P Isthere continuity
chassis ground.
between each lamp
/!ZJggH
NO r+ay (2) and chas-
SIS ground? ToA
N After
Disconneciton in wiring har-
ness between each lamp relal inspection,
16) and each display lamp, or repair or
1) Max. 20R
lamp bulb blown. replace
Replace

each lamp relay (31 ness between Rl 1 (2).(4) and After
From A 5 YES
and chassis ground each lamp relay (3). or inspection.
between T62 (12) and Rl 1 repair
131.(l).
2) Remove lamp
relay. NO Defective payload relay Replace
~~
3) Turn starting
switch ON.

1) Max. 1.5V NO
L-5 External display lamps light up even when it is nclt the condition for
lighting up
* Before carrvina out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
Contact of +24V line with

wiring harness between Rl
1 After
YES (2).(4) and each lamp relay (3 inspection,
J or with wiring harness repair
I
between each lamp relay (61
Does lamp remain and display lamp
lighted up eve”
when Rl 1 is 2 YES
Defective payload relay Replace
removed ? Is voltage between
- SF (4) and (2) nor-
1) Turn starting
-..
swtch ON.
- mal when transmis-
NO sion lever is at posi-
,tion other than N ? llDefectk transmission lever ReDlace
1)20-27V
2) Turn starting
switch ON.
20-166-6
0
L-6 The level of lighting up of the external display lamps is not correct
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause
YES
Normal
1 After replacing,
ISrelationship
carry ollt
between level of YE is calibration
lighting up of the -
external display
lamps and number
Disconnection in applicable After
of tons displayed as
wiring harness
shown in Table 1 ? 2 inspection,
repair
1) Turn starting Does display lamp
switch ON. _ light up even when
~0 panel display is 0 Defective controller After replacing,
ton ? carry out
calibration
1) Turn starting
switch ON.
2) Place transmis-
Normal -
sion lever at N.
Defective wiring harness of lfter

‘Ml (1).(5).(11) spection. repair
:arry out
:alibration
Table 1
Display lamp 1 2 3 4 5
Color Green Green Green Yellow Red
Display level 1 47 1 62 1 78 1 86 1 94 1
Table 3
20-l 66-7
0
L-7 There is abnormality in the display logic
a) Even when the dump body is operated, the display does not become 0 ton.
cause Remedy
‘ES
Defective controllel Replace
Defective wiring harness After

and(17)asshown
between body float switch inspection,
in Table 1 when
and PM1 (19) - repair
1) Turn starting 1
switch ON. NO Defective body float detection Replace
pressure switch
light up when dump
body is in float con-
I) Pull out wiring
ness between PH2 (7) and inspection,
NO chassis ground repair
2) fsae dump
Defective air pressure system After

inspection.
repair
Table 1 Table 2
b) The display stays at 0 ton and does not change
Remedy
YES
.c Befective controller Replace
2
ISValue for voltage
YES between PM1 (19) After
I
and (17) es shown - 3 YEIS CDefective wiring harness
etween body float switch am inspection,
in Table 1 when
dump body is oper-
Is value for resist-
ante between bady
F‘Ml (19) repair
ated ?
1 float switch and
)Turn starting - chassis ground es -
switch ON. NO shown in Table 2
when dump body is
light up when dump ooerated 7 .o lefectivebody float detection Replace
body is in float con-
1) Pull out wiring hIO Pressure switch
harness of body
float switch.
2) Operate dump
body
After
-c kfective air pressure System inspection.
Table 1
20-l 66-8
0
cl When the transmission lever is at neutral, the weight display is not given
(time display is given)
IS
iS
YES
1 Is transmission N
relay fuse blow” ?
between PM1 (20)

and (17) as shown Does transmission 6 YES
in Table 1 when N relay make oper-
transmission lever ating sound when
transmission lever
F[
1) Turn starting
between Nv
switch ON.
1) Max. 1.5V
2) Turn starting
Is voltage between
switch ON.
SF (4) and (2) nor-
mal when transmis-
NO sion lever is at posi-
IfionotherthanN? 1
YES
1)20-27V 7r
2; Turn starting
N
switch ON.
Is there continuity
1)Ma.x. 1.5V between SF (4) and
2) Turn starting
switch ON.
YES
N relay make oper.

ating sound when I 11 YES g
fii$jFJH-
transmission lever
between N -
I) Turn starting
switch ON. I) Remove tram- NO
N 0” transmission lever mission N relay.
is at N and at a
position other than
NO
1) Max. 1.5V
Table 1 2) Turn starting
switch ON.
20-166-10
0
Defective eOntroller Replace
1)
Replace
After
inspection,
repair
Replace
Replace
After
mission N relay.
ness between SF (4) and R02 inspection,
repair
B
z
0
ness between PM1 (20) and
After
inspection,
R02 (6). or between R02 (3) repair
and chassis ground

(2) and SF (4) short circuiting
with chassis ground repair
. Defective transmission lever Replace
cr transmission “eu-
20-166-11
0
d) When the transmission lever is at a position other than neutral, the time display is not given
YES
Defective controller RepI&%
H
I I
1
IS value for voltage After
_... .^^,
beti Yveen I-M I (L”, inspection,
and (17) as shown repair
in Table 1 when
Afler
inspection,
reDair
between N w
Defective transmission relay Replace
1) Turn starting
switch ON. I
Table 1
20-166-12
0
L-8 EOI - E04 is displayed
cause
Wiring harness between se” m.?r

3 sor (2) and PM1 short circuit- nspection,
Is resistance ing with chassis ground epair
YE: between sensor (2) _
2 and chassis ground
normal ?
YES Is voltage normal - - To A
_ between sensor _ 1) Max. 1Dn
PM1 input pin and 2) Disconnect PMl.
(17)?
1 -
1) Max. 0.4V
IS voltage normal >efective controller %eplace
2) Turn starting
between chassis NO
ground and termi- - switCh ON.
1
“al I1 of sensor
Disconnection in wiring har- uter
ness between PM1 (10) and Inspection.
Sensor repair
I I I Disconnection controller Replace

1)17-19v NO
2) Turn starting
switch ON.
Disconnetiion in wiring har- Mer

ness between sensor (2) and inspection.
PM1 repair
From After
inspection,
Defective sensor circuit
replace
if defective
2) Connect PMl.
lefective controller
1)245zt 1on NO
I I I
3 FR 39 14
4 FL 13 15
‘20-l 66-l 3
@
L-9 El1 - El 4 is displayed
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Short circuit between signal wer

line and power source line nspection,
between PM1 and sensor epair
3) Disconnect PM1
I 4fter
1 ) Max. 5V Defective sensor circuit nspection,
‘ !) Pull out connec- NO ‘eplace
tor of sensor f defective
indicated in
Table 1.
3) Turn starting
switch ON.
Table 1
Mounting PM1 Input

Sensor No. Connector No. terrnina, No,
position
I I I
1 1 RR 1 63 1 12
2 1 RL 1 62 1 13
3 FR 39 14
4 FL 13 15
L-IO E21 - E28 is displayed by sensor check
Offset of calibration weight 3arry out cali-

wation again
20-l 66-l 4
@
L-l 1 E31 is displayed
YE
1) Remove J04. NO
2) Disconnect PMl.
,
IS same error mes-

sager given when
YE
JO4 is removed and 6
YES
Is same error mes- -
sage given when 62
1) Turn starting YES is recconected. 63
switch ON. 5’ is removed, and
power source is
Is same error mes- reset ?
sage given when NO
_ JO4 is reconnected, _ 1) Remove 63.
NI 62 is removed, and 2) Turn starting
YE.S
is removed and power source is switch ON.
reset 7
1) Remove 62.
1) Remove 31.
2) Turn starting NO
2) Turn starting
switch ON.
switch ON.
8
YES
Ismm error
mes-
sage given when 02
is reconnected, 13
is removed, and
power source is
reset ?
NO
1) Remove 02.
1) Remove 13.
2) Turn starting
2) Turn starting
switch ON.
switch ON.
Is same error me*-’

YES
sage given when 31
is reconnected, 39
NO is removed, and
power source is
reset ?
NO
1) Remove 39.
2) Turn starting
switch ON.
CaUSe Remedy

I (10)and JO4 short circuiting inspection,
Wiring harness between JO4 After

(1) and each sensor connector inspection,
(1) short circuiting with chas- repair
sis ground
Defective RR sensor Replace
Defective RL sensm Replace
1 ;rify hays batyen

and pressure sensor FR short
Aftey
inspection.
cmmtmg wth chasm ground repalr
Replace
ground
. Defective FL sensor Replace
20-166-17
0
Cause Remedy
Line where resistance is After

2 YES below 1 Q short circuiting inspection,
YES repair
Isresistance with +24V line
1 between PM1 (16)
and (2). (3). (4). (8).
(9) normal 7
IS Same error mes- Defective controller Replace
sage given when all
lamp relays are - 1) Max. ‘*
removed and power
source is reset ? Measure resist-
Defective relay ance of relay
coil according
1) Remove I71 6 - 20. NO to Table 1, and
2) Turn starting replace defec-
switch ON. tive pan
Table 1
case Remedy.
YES
Normal
Wiring harness between PM1

1 4 YE
(18) and PM3 (2) in contact
Is machine traveling
or parked on an _
uphill slope of more
than loo ? After checking
YES installation,
replace

Is voltage between ness between PM1 (10) and inspection,
‘-PM1 (18)and(l7) - PM3 (3) repair
NO Norman? switch ON.
1) Max. 1.6V
2) Turn starting Defective controller Replace
switch ON. NO
20-I 66-18
0
lormal
lefective wiring harness after

etween PM1 (16) and PM3 nspectio”.
9 epair
efective clinometer ?eplace
NO normal ?
I’
I
1) Max. 3.6V
2) Turn etarting
I
1NO iefective controller Replace
switch ON.
L-l 5 The printer does not print anything

(only blank paper comes out)
1 YES
>efective setting of printer Set printer
I II saper paper properlV
Has printer paper
been set back to -
front ?
Iefective controller Replace
NO
‘20-I 66-19
0
L-l 6 The printer only prints NO DATA
Cause Remedy
L-l 7 Even when the [PRT] switch is pressed,

nothing is printed out
I Defective contrdler Rl?place
20-l 66-20
0
L-l 8 PAPE flashes
Callse Remedy
1 YES
Paper jam Clean paper
jam
Does PAPE flash
again immediately _
afier error message
is canceled 7
Normal -
1) Press CAL switch NO
to cancel error
message.
L-l 9 The time is wrong
1 YES
Defective controller ReplaCe
Does time deviate

more than 10 min a
month ?
Normal Reset time
L-20 E33 is displayed
kop in voltage of backup bat-

cry (battery built into eplace battery
:ontroller)
20-166-21
0
RELATED ELECTRICAL CIRCUIT DIAGRAMS
1. Power source
PMI (040)
t24V 16 -
GND 17 To battery relay E
561 FO3340
2. N signal
PM I
I I
Transmission
Power source neutral relay
inside cab 561 F03341
3. Dump body (body float switch)
RH2
Body float 19 @
Body float
@ switch
ml
561 F03342
20- 166-22
0
4. Model selection
PM1 RH2 PM2
561 F03343
5. Pressure sensor
JO4 02 13
PMI
0 @ 0
FL
@ -0 @
RR sensor 12 @
@ 31 39
8 FR sensor 14 - I @-I 0 @ o/- 1

FR
z FL sensor I5
I I I, I
0 @
8
62
0 0 RL
@
63
RR
561 F03344
6. Clinometer
RH2 PM3
PM1
Clinometer
Clinometer 18
561 F03345
20-166-23
0
7. Lamp
PM1 (MIC 21)
Lamp3 4
I
R16 R17 R18 R19 R20

External display relay External display relay External display relay External display relay External display relay
No. 5 No. 4 No. 3 No. 2 No. 1
m
SF
EDCBA
5631 24
JO4
Starting switch
To power source
inside cab
561 F03346
20-166-24
0
ELECTRICAL CIRCUIT DIAGRAMS FOR PAYLOAD METER SYSTEM
Rear (right)
suspension cylinder
di$plaY lamps
* External display lamp colors

1, 2,3. Green
4. YellOW
5. Red
561FO3137
20-166-25
0
TROUBLESHOOTING OF PILOT LAMP
SYSTEM
F-l Abnormality in lighting up of rear brake lamp

a) Brake is not being applied, but pilot lamp lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 168
b) Pilot lamp does not light up even when brake is applied . . . . . . . . . . . . . . . . . . . . . . . 20-l 69
F-2 Abnormality in lighting up of body float pilot lamp

a) Hoist lever is at FLOAT position, but pilot lamp lights up . . . . . . . . . . . . . . . . . . . . . . . 20-l 71
b) Pilot lamp does not light up even when hoist lever is operated . . . . . . . . . . . . . . . . . 20-172
F-3 Abnormality in lighting up of parking brake pilot lamp

a) Parking brake is not being applied, but pilot lamp lights up . . . . . . . . . . . . . . . . . . . . . 20-173
b) Pilot lamp does not light up even when parking brake is applied . . . . . . . . . . . . . . . 20-l 74
F-4 Abnormal lighting up of exhaust brake pilot lamp

a) Pilot lamp lights up even when exhaust brake is not being operated . . . . . . . . . . . 20- 175
b) Pilot lamp does not light up even when exhaust brake is being
operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 76
8
z
z F-5 Abnormal action of AISS
a) When AISS switch is ON, it does not become low idling
(low speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 76-l
b) When AISS switch is ON, it does not become low idling
(high speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 76-l
Electrical circuit diagram for pilot lamp system . . . . . ..I............................... 20-l 76-3

of wiring harnesses and connectors, occur only under special conditions particularly at the initial
stage of the occurrence of the failure.
Therefore, investigate the values for the resistance and voltage at the locations indicated by
the abnormal display. Even if no abnormality is found, it is necessary to investigate the conditions
troubleshooting.
20-l 67
0
F-l Abnormality in lighting up of rear brake lamp
a) Brake is not being applied, but pilot lamp lights up.
Cause Remedy
Defective brake valve
YES
Defective relay ROg
1
YES between AS3
Is there any braking *Service brake 2 (male) (1) and (2)
Is resistance value Wiring harness between ROg Repair or

between AS5 1) Min. 1Mn NO (female) (3) - TMC (7) - SC2 replace wiring
(male) (1) and (2) 2) Turn starting (female) (5) in contact with harness
normal? switch OFF. ground
3) Disconnect AS3.
Hi
1) Min. 1 MO Replace
Defective AS5 (pressure
2) Turn starting
switch)
switch OFF. Ytl
3) Disconnect AS5.
*Retarder brake 4
I
Interchange ROg
with Rll (R12). -
Does lamp go out?
Defective AS3 (preSSUrC! Replace

switch)
20-28
b) Pilot lamp does not light up even when brake is applied.
* When the brake is working normally.

* When the power source to R09 (relay) is normal.
2 YES
Defective relay R09 Replace
Interchange R09
- Both service brake - with Rll (R12). -
and retarder brake Does lamp light up?

1) Turn starting NO disconnection in wiring replace wiring
switch OFF. harness between R09 harness
2) Operate brake. (female) (3) - TMC (7) - SC2
(female) (5)
1 3 YES
Which brake is Is resistance value disconnatiion in Wiring replace wiring
being applied when between AS5 harness between AS5 harness
lamp does not light - - When operating I - (female) 81)- RHl (1) -
‘,“,;:;/;‘I and (2)
service brake TMC (7) - SC2 (female) (5)
UP?
Defective AS5 (pressure
1) Min. 1MCJ NO switch)
2) Turn starting
switch OFF.
3) Disconnect AS5.
4 YES
8 Is resistance value
harness between AS3 harness
z -When operating
retarder brake
between AS3
(,mo;;;/;) and (2) - (female) 81) - RHl (4) -
8 TMC (7) - SC2 (female) (5)
Defective AS3 (pressure Replace

1) Min. 1Mn NC switch)
2) Turn starting
switch OFF.
3) Disconnect AS3.
20-&69
(+24V) Marker lamp relay
DM3 Rear brake lamp
PLISIO)
-lw w
AS5 (X2)
--
Service Draw
\ SC2 (MIC211
-p/q%q
AS3 IX21
Retarder brake
F56103138
20-270
F-2 Abnormality in lighting up of body float .pilot lamp
a) Hoist lever is at FLOAT position, but pilot lamp lights up.
Remedy
YES
Wiring harness between PL
1 (female) (8) - DM2 (4) -
DM2 (9) - RH2 (9) -body
Isresistance value float switch in contact with
between terminals _ ground
of body float witch 2 YES
Defective adjustment of float Adjust
normal?
Adjust float switch. switch
p
1) Min. ln _ Does resistance _
2) Turn starting NO value become
switch OFF. normal?
3) Disconnect Defective float switch
wiring harness *Same conditions NO
of switch. as Item 1
4) Place hoist
lever at FLOAT.
Body float lamp
PL DN2
v (SIO)
9@
2
7 9
RH2 (Sl2)
Body float switch
I I
F56103139
20-A71
b) Pilot lamp does not light up even when hoist lever is operated.
* When the power source is normal.
CaUSe Remedy
YES Defective contact, or

harness between 8T2 (4) - replace wiring
PL (female) (9) - PL (female) harness
(8) - DM2 (4) - DM2 (9) -
RH2 (9) -float switch
Defective adjustment of float Adjust

switch
Defective float switch Replace

wiring harness of *fame conditions NO
switch. as Item 1
4) Place hoist lever
at FLOAT.
Body float lamp
PL DN2
v (SIO)
9 8
2
7 9
RH2 (Sl2)
(t24v)
Body float switch
F56103139
F-3 Abnormality in lighting up of parking brake pilot lamp
a) Parking brake is not being applied. but pilot lamp lights up.
2 YES
(female) (3) and DM2 (female)
(6) in contact with ground
YES retrace 1721 way).
1 - Doeslampgoout? -
Defective R21 (relay) Replace

Is resistance value
1) Turn starting NO
between AS2
(male) (1) and (2) - switch ON.
normal?
1) When parking Defective AS2 (pressure

brake is ON NO switch)
(,a$ied): Min.
2) When parking
brake is OFF
(,y$aleased): Max.
3) Turn starting
switch OFF.
4) Disconnect AS2.
Parking brake lamp
PL DM2
- (SIO)
2 6
Pressure switch AS2 Ix2 1 RHI (SIO)
@ 0
0
@ @
Parking brake relay
F56103141
20-i73
b) Pilot lamp does not light up even when parking brake is applied
* When the power source for RHl (female) (6) is normal.
CaUSe RC?“tedy
3 YES harness between AS2
Repair or
(female) (1) - RHl (female)
Is resistance value (6). between RHl (female) (6) replace wiring
YES between ~21 - PL (female) (9). between harness
2 - (female)(l)- DM2 (female) (6) - R21
4 chassis normal? (female) (3)

YES retrace ~21 (relay). NO disconnection in wiring replace wiring
r Does lamp light up? - harness between AS2- harness
1 (female) (2) - RHl (5) - R21
(femalej il j
Is resistance value
between AS2 Defective R21 (relay)
NO
(male)(l)and(2) -
normal?
1) When parking
brake is ON Defective AS2 (pressure
(applied): Min. NO switch)
1MfI
2) When parking
brake is OFF
(released): Max.
lfl
3) Turn starting
switch OFF.
4) Disconnect
AS2.
Parking brake lamp
Pressure switch As2 (x2j RHI (SIOI
Parking brake relay
F56103141
20-&74
F-4 Abnormal lighting up of exhaust brake pilot lamp

* Always connect any disconnected connectors beforeming on to the next step.
a) Pilot lamp lights up even when exhaust brake is not being operated
C.%E.E! Remedy
YES
Defective exhaust brake valve -
1
Isexhaust brake _ Contact of +24V wiring har-

shutter down? 2 YES ness with wiring harness Repair wiring
between AS1 (female) (2) - harness or
, RHl (7) - DM3 (female) (6) replace
’ Is resistance
_ between AS1 (male) _
Defective AS1 (Pressure

Replace
NO switch)
1) Min. 1MQ
2) Turn starting
switch OFF.
3) Disconnect ASl,
Exhaust brake lamp
PL(SI0) v w DM3
RHI(SIO)
Pressure switch II
ASI (X2)
0
@ Marker lamp
relay
Exhaust brake
Rhreostat
561 F03371
b) Pilot lamp does not light up even when exhaust brake is being operated
* When R07 (relay) and rheostat are normal.
Defective contact, or discon.

YES nection in wiring harness Repair wiring
between AS1 (female) (2) - harness or
4r RHl (7) - DM3 (6) - PL (3) reDlaCe
- PL (1) - chassis
Is voltage between
Y
AS1 (1) and chassis
n

IS voltage between 1) 20-30V nection in wiring harness Repair wiring
Y between AS1 (female) (1) - harness or
AS1 (1) and chassis 2) Turn starting NO
normal? switch ON. RHl (9) - LS (female) (2) replace
2
1)20-3ov
YE 2) Turn starting
between AS1 (male) between AS1 (female) (1) - harness or
switch ON.
(1) and (2) normal? RHl (81 - R07 (female) (6) replace
1
1) Min. 1MD
Is exhaust brake 2) Turn starting Defective AS1 (Pressure
shutter down? switch OFF. switch)
3) Disconnect AS1
Repair or
Defective exhaust brake valve
8
z
8
Exhaust brake lamp
w ,... Marker lamp

relay
Exhaust brake / I
LS(M3)
,111
(G4V)
t
Rhreostat
561 F03371
F-5 Abnormal actuation of AISS
k Always connect any disconnected connectors before going on to the next step.
* When fuse BT2 No.1 0 (10 - 20) is not blown.
a) When AISS switch is ON, it does not become low idling (low speed)
Remedy
2 YES
seplace
Is resistance
between ES3
’ (female) (16)and - Defective contact, or discon-
chassis normal? nection in wiring harness 7epair or
between AL (female) (2) - ,eplace
NO DO1 (l,,(2)-ECA(lO)-EC3
1) Max. 1R
(16)
2) Turn AISS switch
OFF.
1) Turn starting
Does pilot lamp light switch ON.
2) Disconnect EC3.
1) Turn starting Defective contact, or discon-

switch ON. 3 YES nection in wiring harness Sepair or
I
2) Turn AISS switch between AL (female) (4) and .epalce
ON. ER ground connection
h
Is resistance
between AL (male)
(2) end (4) normal?
I I I Defective AISS switch Replace

1)Max. 1R NO
2) Turn AISS switch
ON.
3) Turn starting
switch OFF.
4) Disconnect AL.
b) When AISS switch is ON, it does not become low idling

(high speed)
* When brake is released, and water temperature is normal.
YES
Defective AISS switch Replace
11
Does pilot lamp light _

up? 2 YES
Is resistance
1) Turn starting _ between EC3
switch ON. NO (female) (16) and
chassis normal? Wiring harness between AL
2) Turn AISS switch Repair or
(female) (2) - DDl (1 j,(2) -
OFF. replace
NO ECA (10) - EC3 (16) short cir-
1) Min. 1MQ cuiting with chassis ground
2) Turn starting
switch OFF.
3) Disconnect EC3.
Engine controller
EC3 (MIC21) ECA(S 16)

ET2
I I
To battery
terminal (+I
ER
To parking relay
brake pilot lamp
561 F03375
20-‘r2
ELCTRICAL CIRCUIT DIAGRAM FOR PILOT LAMP CIRCUIT
Parking brake
LOW - AUTO
F56103143
20-‘F3
TROUBLESHOOTING OF MONITOR
PANEL SYSTEM
P-l Monitor panel does not work at all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 179
P-2 Part of monitor panel does not work

a) Speedometer display does not work .................................... 20- 180
b) Speedometer display works, but other parts do not work .................... 20-l 80
c) Suspension display does not work ..................................... 20- 180
d) (Mechatronics) caution, fuel gauge displays do not work .................... 20-l 81
P-3 Automatic shift display (mechatronics) flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 82
P-4 Suspension (mechatronics) display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 82
P-5 Abnormality in suspension display

a) Hard display does not light up ......................................... 20- 183
b) Medium display does not light up ...................................... 20- 183
c) Soft display does not light up ......................................... 20- 184
d) Suspension mode displays all light up .................................. 20-l 84
P-6 Abnormality in shift position display

a) R display does not light up ............................................ 20- 185
b) N display does not light up ........................................... 20- 185
T: 20-l 86
c) D display does not light up ...........................................
z
d) 5 display does not light up ............................................ 20-186
3
e) 4 display does not light up ............................................ 20- 187
f) 3 display does not light up ............................................ 20- 187
g) L display does not light up ............................................ 20-188
P-7 Shift limiter display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 189
P-8 Lock-up display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 89
P-9 Hi beam display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 190
P-l 0 Abnormality in turn signal

a) Right turn signal lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 91
b) Left turn signal lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-191
P-l 1 Abnormality in shift indicator display

a) When 1, 2,4, 6, R is displayed, display changes to E ....................... 20-l 92
b) When 3,5,7 is displayed, display changes to E ........................... 20-l 92
c) When 1 is displayed, display changes to E ............................... 20-l 93
d) When 2,3 is displayed, display changes to E ............................. 20-193
e) When 4,5 is displayed, display changes to E ............................. 20-l 94
f) When 6,7 is displayed, display changes to E ............................. 20-l 94
g) When R is displayed, display changes to E ............................... 20-l 95
P-12 Speedometer does not work normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 96
P-13 Tachometer does not work normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 96
P-14 Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 97
P-15 Odometer does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 97
P-16 Abnormality in alarm buzzer

a) Caution display is flashing (lighted up), but alarm buzzer does not sound . . . . . . . 20-l 98
b) Alarm buzzer continues to sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 198
P-17 Abnormality in warning lamp

a) Caution display is flashing (lighted up), but warning lamp does not flash . . . . . . . 20- 199
b) Warning lamp stays ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 99
P-18 Caution display does not flash (does not light up), but warning lamp flashes and
alarm buzzer sounds.
a) Warning lamp flashes and alarm buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200
b) Warning lamp flashes when engine stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200
c) Warning lamp flashes when engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200
P-19 Abnormality in pressure gauge

a) No display given in display area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
b) Display shows highest level and does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
P-20 Abnormality in coolant temperature gauge

b) Display shows lowest level and does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202
P-21 Abnormality in torque converter oil temperature gauge

P-22 Abnormality in retarder oil temperature gauge

P-23 Abnormality in fuel gauge

b) Display shows FULL and does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-205
P-24 Abnormality in night lighting

a) None of panel lamps light up .......................................... 20-206
b) Service meter and odometer light up, but other parts do not light up ........... 20-207
c) Service meter and odometer do not light up .............................. 20-207
P-25 Engine (mechatronics) display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-208
P-26 Abnormality in power mode display

a) High power display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-208-l
b) Economy display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-208-l
Electrical circuit diagram for monitor panel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-208-2

Related electrical circuit diagrams . . . . . . . . . . . . . . .‘. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-209
20-l 78
0
P-l Monitor panel does not work at all
Cause
Defective module (7631-31. Replace

6100) of monitor panel
Isvoltage between YES

PO9(female)(l)and - Defective contact. or After
(2) normal? disconnection in wiring inspection,
harness between PO9 (female) clean or replace
2
(1)- BT2 (4). or between BT2
1)20-30V Is there continuity (3) - starting switch ACC
2) Turn starting between PO9
switch ON. - (female)(2) and -
3) Disconnect PO9. No chassis ground?
1) Turn starting
switch OFF.
2) Disconnect pO9. NO Defective contact, or After
disconnection in wiring inspection,
(2) - JO3 (8) - 30 (9) -
battery relay terminal E
20-A79

a) Speedometer display does not work.
2 YES
Defenive module (7831-31- Replace
I II 5100) of monitor panel
Defective contact, or After

harness between Pl 1 cfamale) clean or replace
1;; (8) and Pw (female) (1L
1) 14-20V
Defective module (7831-31- Replace

b) Speedometer display works, but other parts do not ‘work.

c) Suspension display does not work.

1 YES
Is there continuity 7100) of monitor panel
between each pin
as shown in table
below?
1) Turn starting disconnection in wiring inspection,
switch OFF. harness in table below clean or replace
2) Disconnect Pl 1.
1 PI 1 (female) (I 1 - PO2 (female) (I 1

I Pll (female) (3) - PO2 (female) (3)
PI 1 (female) (4) - PO2 (female) (4)
Pll (female) (6) - PO2 (female) (6)
Pll (female) (7) - PO2 (female) (7)
I PI 1 (female) (8) - PO2 (female) (8)

d) (Mechatronics) caution, fuel gauge displays do not work.
CalIS Remedy
2 YES Defective module (7831-31-

1 I I 5100) of monitor panel
Is there continuity
Y between PD2
’ (female) (2) and PO4 -
(female) (4))
c Defective contact, or After
1 11 Turn startino NO disconnection in wiring inspection,
switch OFF.-
Is there continuity 2) Connect socket (2) and PD4 (female) (4)
between each pin adaoter to F’O4
as shown in table (fenLie).
3) Disconnect P02.
1) Turn starting
switch OFF.
2) Connect socket
adapter to PO4 Defective contact, or After
(female) NO disconnection in wiring inspection,
3) Disconnect Pl 1. harness in table below clean or replace
Pl 1 (female) (4) - PO4 (female) (5)
Pl 1 (female) (7) - PO4 (female) (7)

P-3 Automatic shift display (mechatronics) flashes
Cause RMlWdy
Defective module (7831-31- qeplace
L-t
Isvoltage between
P12 (2) and chassis
ground normal? 2 YES
I II See Troubleshooting of shift
controller
l)O-3v
2) Turn starting P
switch ON.
I I I Defective contact, or After
1112-2ov NO disconnection in wiring inspaction,
2j T&n skting harness between P12 (female) clean or replace
switch ON. 12) - TMC (11) - SC3
3) Disconnect SC3. [female) (3)
P-4 Suspension (mechatronics) display flashes
Sr Before carrying out troubleshooting, check that all the

related connectors are properly inserted.
* Always connect any disconnected connectors before
going on to the next step.
YES
1 . 8100) of monitor panel
Is voltage between
P12 (3) and chassis -
See Troubleshooting of
- Is voltage between suspension controller
l)O-3v _ SUl (female)(4) _
2) Turn starting NO and chassis ground
switch ON. normal?
1) 12-2ov NO disconnection in wiring inspaction,
2) Turn startina harness between P12 (female) clean or replace
switch ON. ” (3) - SU3 (9) - SUl (female)
31 Disconnect SUl (4)
2o-A82
a) Hard display does not light up.
Cause
Defective module (7831.31. Replace

2 YES See Troubleshooting of

I II
I J suspension controller
l)O-3v
2) Turn starting p
switch ON.
L I I Defective contact. or After
1) 12-2ov NO disconnection in wiring inspection,
2j Turn starting harness between P12 (female) clean or replace
switch ON. (7) - su3 (12) - SUl
3) Disconnect SUl (female) (18)
b) Medium display does not light up.

YES
Defective module (7831-31- ~ Replace
1 I 6100) of monitor panel
Is voltage between
ground normal?
2 YES
suspension controller
p Is voltage between
l)O-3v _ SU1 (fernale) _
switch ON. normal?
After
- 1) 12-2ov Lo Defective contact, or
disconnection in wirina
harness between P12 {female)
inspection,
clean or replace
2) Turn starting
switch ON. (8)- SU3 (13)-SUl
3) Disconnect SUl, (female) (19)
20-283
c) Soft display does not light up.
YES
Defective module (7831-3l- Replace
II 6100) of monitor panel
Isvoltage between
P12 (9) and chassis
II
Is voltage between suspension controller
SUl (female) (20)
2) Turn starting
switch ON.
2) Turn starting harness between P12 (female) clean or replace
3) Disconnect SU 1. (female) (20)
d) Suspension mode displays all light up.
See S-1 0 Trobleshooting of

20-i84
P-6 Abnormality in shift position display .
a) R display does not light up.
Cause Remedy
YES
1 5100) of monitor panel
*
Is voltage between
PO8 (9) and chassis -
- Is voltage between harness between PO8 (female) clean or replace
l)O-1v
- SF(3)andchassis - (9) and SF (female) (31
2) Turn starting
NO ground normal?
switch ON.
1)4-3ov NO disconnection in wiring inspection,
2) Turn starting harness between SF (male) (3) clean or replace
switch ON. and transmission shift lever,
or defective transmission shift
IWar
b) N display does not light up.

YES
1 . 5100) of monitor panel
Is voltage between
PD8 (10) and
chassis ground 2 YES
normal? Defetive contact. or After
l)O-1v - SF(4)andchassis -
2) Turn starting [lo) and SF (female) (4)
NO ground normal?
switch ON.
)efective contact, or After
1)4-3ov NO jisconnenion in wiring inspection,
2) Turn starting ?arness between SF (male) (4) clean or replace
switch ON. rnd transmission shift lever,
x defective transmission shift
ever
c) D display does not light up.
I Cause I Remedy
Defective module (7831-31-

Is voltage between
PDB(ll)and
normal? Defective contact, Or After
disconnection in Wiring inspection,
l)O-1v - SF(5)andchassis - (11) and SF (female) (5)
2) Turn starting NO ground Norman?
switch ON.
2j Turn starting harness between SF (male) (5) clean or replace
IWW
d) 5 display does not light up.

YES
1r 5100) of monitor panel
Is voltage between
PO8 (12) and
“Ormal?
l)O--1v
- SF(6)andchassis - (12) and SF (female) (6)
2) Turn starting
No ground normal?
switch ON.
I I I After
21 Turq starting harness between SF (male) (6) clean or replace
p;v$fenive transmission shift
2o-&86
e) 4 display does not light up.
Remedy
YES
(13) and SF (female) (7)

switch ON. and transmission shift lever.
lever
z
s f) 3 display does not light up.
YES
1; 5100) of monitor panel
Is voltage between
PO8 (14) and
normal? Defective contact, or After
l)O-1v
_ SF(8)andchassis - (14) and SF (female) (8)
2) Turn nafling NO ground
norma,)
switch ON.
I I I
2) Turn starting harness between SF (male) (8) :lean or replace
lever
g) L display does not light up.
YES
r
Isvoltage between
PO8 (15) and
normal?
Is voltage between harness between PO8 (female1 clean or replace
l)O-1v
2) Turn starting
No ground normal?
switch ON.
1)4-3ov disconnection in wiring inspection,
yrv$fective transmission shift
P-7 Shift limiter display does not light up

ES
(female) (16) and

YES
Defective contact, or Afiar
1) Turn starting harness between PO8 (female) clean 0, replace
switch ON. (16) - CNS (5) - SH (female)
2) Disconnect POE. (4). or between SH (female) (2)
h j and chassis ground
Defective shift limit switch

NO
2) Disconnect SH.
P-8 Lock-up display does not light up

8
z
* Before carrying out troubleshooting, check that all the
g related connectors are properly inserted.
* Always connect any disconnected connectors before YE! Defective contact. or
disconnection in wiring After
going on to the next step. harness between R24 inspection,
(female) (1) - TMC (4) - SC3 clean or replace
(female) (2). or defective lock-
up relay, or sea
Troubleshooting of shift
cOntrOller

Yl disconnection in wiring inspection,
harness between R24 clean or replace
(female) (2) - JO6 - battery
relay E
2 1) Remove lock-up
Is voltage between 2) Turn starting

R24 (female) (3) and Defective contact, or After
chassis ground 3) Disconnect R24. disconnection in wiring inspection,
normal? harness between R24 clean or replace
(female) 85) - TM6 (9) -
SC3 (4). or sea
1)4-5v
Troubleshooting of shift
2) Turn starting
controller
switch ON.
3) Remove RE3,
RE4 and R24. DSefective contact, or After
display light up? 4) Remove lock-up ) disconnection in wiring inspection.
ralsy. aharness between PD5 clean or replace
(female) (8) and R24 (female)
1) connect PO5 (3)
(male) (8) to
INO
chassis ground.
2) Turn starting
switch ON. Replace
20-i89
P-9 Hi beam display does not light up
Cause Remedy

ES
Is voltage between
PO8 (6) and chassis
ground normal?
I
(8) and R06 (female) (5)
1) 20-30V
2) Turn starting
switch ON. Does Hi beam of left
and right head
lamps light up? YES
r. ToA
1) Turn Hi beam
1~~~~~
switch ON.
2) Turn starting
switch ON.
b
:3) and CM (female) (2)

1)20-30V NO disconnection in wiring Inspection,
2) Turn starting harness between CM (male) lIea” or replace
switch ON. [2) and combination switch, or
3) Disconnect CM. defective combination switch
Defective head lamp (Hi) relay, After

or defective contact, or inspection,
Y disconnection in wiring clean or replace
harness between PO8 (female)
(6) and R06 (female) (5)
1
Defective contact. or AfW*
1) Remove head NO disconnection in wiring inspection,
Isvoltage between lamp (Hi) relay. harness between PO6 (female) clean or replace
‘From A -c R06 (female) (1) and 2) Turn starting (2) and chassis ground
chassis ground switch OFF.
normal? I 3) Disconnect R06. 3 .,Fs
Defectwe contact, or After
1)20-30V disconnection in wiring inspection,
2) Turn starting harness between PO6 (female) clean or replace
switch ON. (1) and CM (female) (8)
3) Remove head
lamp (Hi) relay.
4) Disconnect R06. Defective contact, or After
1)20-30V NO disconnection in wiring inspection,
2) Turn starting harness between CM &male) clean or replace
switch ON. (6) and combination switch, or
3) Disconnect CM. defective combination switch
20-A90
a) Right turn signal lamp does not light up.
1 YES
Defective module (7831-31.
Is resistance value 5100) of monitor panel
between PO8
1 ;$ssss;ground 11
Defective contact. or AhW
1) Max. 5l-1 NO disconnection in wiring inspection.
Do front and rear 2) Turn starting harness between PO8 (female) clean or replace
turn signal lamps switch OFF. (8) and JO3 (male) (5)
work normally? 3) Disconnect PD8.
1) operate
turn
signal.
2) Turn starting See Troubleshooting of turn
switch ON. signal
g b) Left turn signal lamp does not light up.
1 YES
YES between PO8
- (femaW(7) and -
chassis ground
1 ll0Ullal?
1) Max. 5l7 NO disconnect in wiring harness inspection,
Do front and rear 2) Turn starting between PO8 (female) (7) and clean or replace
turn signal lamps - switch OFF. JO3 (male) (3)
work normally? 3) Disconnect POS.
1) operate turn
signal.
I See Troubleshooting of turn
2) Turn starting
switch ON. NO signal
20-A91
a) When 1, 2.4. 6. R is displayed, display changes to E.
CC3USf2 Remedy
2 YES
See Troubleshooting of shift
cOntrOller
Is shift controller
YES; abnormal display as
shown in table
below?
I I
1) Turn starting Nc
switch ON.

disconnection in wirina inspection,
switch ON. Does shift indicator harness between PD5 ifemale) clean or replace
I (2) - TMA (8) - TM3
NO .’ 1 “? (female) (6)

Shift controller abnormal display L------lk------
1 3.2 1 4.2 1 5.2 1 9.2 1 1) contact PD5 5100) of monitor panel
(male)(2) and (6)
-1 3)t!!;05
2) Turn startrng
b) When 3, 5, 7 is displayed, display changes to E.
2 YES See Troubleshooting of shift

Is shift controller controller
YES abnormal display as _
shown in table
below?
1 i
1) Turn starting NO
Does automatic
switch ON.
3 YES
Defective contact. or &fter
1) Turn starting disconnection in wiring Inspection,
switch ON. 1 1 harness between PO5 (female) :lean or replace
‘FH_ (l)--MA(g)-TM3
NO (female) (3)
Shift controller abnormal display Defective module (7831-31.

1) contact PO5 NO 5100) of monitor panel
( 9.2 (male) (1) and (5)
3.2 1 4.2 1 5.2 with chassis
ground.
2) Turn starting
switch ON.
3) Disconnect P05.
20-292
c) When 1 is displayed, display changes to E.

Is shift controller co”trOller
YES abnormal display as _
;:p,w,; in table
1
11 Turn starting NO
Does automatic
switch ON.
3 YES
Defective contact, or discon- After
1) Turn starting inspection,
Doershiftindicatorr----- between PO5 (female) (6) -
switch ON. 1 1 clean or replacs
H
TMA (4) - TM4 (male) (3)
display become
NO “1 “7

Shift controller abnormal display 1) Connect PD5 NO 5100) of monitor panel
(male) (2) and (6)
to chassis
ground.
2) Turn starting
switch ON.
3) Disconnect W5.
d) When 2, 3 is displayed, display changes to E.

2 YES
gee Troubleshooting of shift
Is shift controller :o”troller
YES abnormal display as
shown in table
below?
1
1) Turn starting NO
Does automatic
switch ON.
shift display
~rn$atranics) -
3 YES kfective contact, or discon- 4fter

section in wiring harness
1) Turn starting nspection,
Does shift indicator v.w9een PO5 (female) (5) -
switch ON. ‘MA (5) - TM5 (male) (6) :lean or replace
’ display become -
NO “2”?
kfetiive module (7831-31- +&ace

Shift controller abnormal display NO
1)Connecl
PO5 5100) of monitor panel
(male) (2) and (5)
to chassis
ground.
2) Turn starting
switch ON.
3) Disconnect P05.
20-193
@
e) When 4, 5 is displayed, display changes to E.
2 YES
jee Troubleshooting of shift
I
:ontroller
Is shift controller
YEE abnormal display as _
;iwoww;in table
H
I) Turn starting NO
Does automatic
switch ON.
shift display
(mechatronics)
flash?
3 YES Defective contact, or discon- Mer
Inspection.
between PO5 (female) (4) -
TMA (6) - TM4 (male) (9) DIean or replace
Defective module (7831-31- ReplaCe

switch ON. -
3) Disconnect PO5
f) When 6,7 is displayed, display changes to E.
2 YES
controller
YES
/$%Jj/!
1
Does a<tomatic
shift display
(mechatronics) -
flash?
3 YES
After
1) Turn starting nection in wiring harness inspection,
switch ON. ,, Does shift indicator between PO5 (female) (3) - clean or repk
display become - TMA (7) - TM4 (male) (12)
NO “6”)
1 I L
Defective module (7831-31- ReplaCe
1) connect PO5 NO 5100) of monitor panel
(male) (2) and (3)
to chassis
Shift controller abnormal display ground.
2) Turn starting
switch ON.
3) Disconnect PD5.
20-l 94
0
g) When R is displayed, display changes to E.
1 YES
controller
YES Is shift controller
_ abnormal display as
shown in table
below?
1
1) Turn starting NO
Does automatic
switch ON.
shift display
(mechatronics)
flash? YES
3
1) Turn starting
Does shift indicator harness between PD5 (female) clean or reDlace
switch ON.
‘_ display
become - (7) - TMA (3) - TM3
NO “,q”? (female) (9)

NO 5100) of monitor panel
1) Connect PD5
(male) (2) and (7)
to chassis
ground.
2) Turn starting
Shift controller abnormal display switch ON.
3) Disconnect P05.
20-A95
P-l 2 Speedometer display does not work normally

CatX.e Remedy
Defective module (7831-31. ?eplace

lefective contact, or vther

lisconnection in wiring nspection,
mrness between PO8 (female) :lean or replace
1). (2) - TMA (1). (2) - TM2
5), (6) - N3 (female) (1). (2)
lefetiive speed sensor
P-l 3 Tachometer display does not work

normally

on to the next step.
3 YES lefective module (7831-31 Ieplace

ilOO) of monitor panel
)efective mounting of engine 4djust

peedsensor 8
Is resistance value sensor, and turn

YES between PO8
c (female) (3) and (4) - wise. If it contacts
normal?
1+1/6 turns, it is
l- kfl
within 1.75 mm.
P 1)5oOn--1
2) Turn starting
Is resistance value switch OFF.
Defective contact. or After
between El2 (male) - 3) Disconnect P08.
disconnection in wiring inspection.
(1) and (2) normal? NO clean or repkxc
(3). (4) - ECA (1). (2) - E7
1)50%-I-1 kSI (4). (5) - El 2 (female) (1). (2)
2) Turn starting
switch OFF. Defective engine speed
3) Disconnect E12. NO sensor 8
20-l 96
@
P-l 4 Service meter does not work

Cause RemedY
YES
kfective service meter Replace
2
Y Isvoltage between
- PO1 (female)(l)and -
(4) normal?
3 YES
After
)efective contact, or
lisconnection in wiring inspection,
IS there continuity
wness between PO1 (female) clean or replace
1) 20-30V _ between PO1
2) Start engine. NO (female) (4) and
1)- JO1 (1) - alternator
erminal R
alternator terminal 3) Disconnect PO1 chassis ground?
kfective contact. or After
ground normal? 1) Turn starting NO lisconnection in wiring inspection,
switch OFF. harness between PO1 (female) clean or replace
1)20-3ov 2) Disconnect pot. 1) and chassis ground
2) Start engine.
Replace
0
8
G P-l 5 Odometer does not work
g
* Before carrying out troubleshooting, check that all the related
2 YES Defective odometer module Replace

I I I (7831-31-9100)
Is voltage between
YES P13 (female) (1). (3) -
)efectivev contact, or discon- After

-.’
11 Between (1) and NO rection in wiring harness inspection,
Is voltage between (2): 7 - 9v petween PO4 (female) (2), (3). (8 Ck” Or reDkf
PO4 (2). (3) - (6) Between 13) and md P13 (female) (1). (3). (2)
normal? (2): 4 - 6i !/
2) Turn start ing
switch ON
1) Between (2) and 3) Disconnect ~73
18k7-9V
ho Defective module (7831-31-
ktween (3) and
181:4 - 6V
2) T&n starting
switch ON.
20-197
0
P-l 6 Abnormality in alarm buzzer
a) Caution display is flashing (lighted up), but alarm buzzer does not sound.
YES
Defective module (7631-31- R@3Ce
1 I I
Does buzzer sound? - YES

2 disconnection in wiring inspection.
1) connect PO9 (12) and BZ (female) (2)
(female) 112) to - Does buzzer sound? -
chassis ground. NO 3 YES
p Defective buzzer ~ Replace
2) Turn starting
switch ON. p Is voltage between
3) Disconnect PO9. 1) connect
BZ (2) to _ BZ (female) (1) and _ I
chassis ground. NO chassis ground
2) Turn starting normal? ..
switch ON. After
.._ Defective contact,
1)20-30V N” disconnection in wiring inspection,
2) Turn starting harness between BZ [female) clean or replace
switch ON. (1) and +24V
3) Disconnect BZ.
b) Alarm buzzer continues to sound
Contact of chassis ground AftW

with wiring harness between inspection,
PO9 (female) (12) and BZ repair or
(female) (2) replace
Contact of chassis ground After

repair or
1) Remove PO9.
2) Turn starting
switch ON. Defective module (7631-31. Replace
20-298
P-l 7 Abnormality in warning lamp
a) Caution display is flashing (lighted up), but warning lamp does not flash.
Remedy

YES
I 1 Defective contact, or After
1) Connect PO9 (11) and WL (female) (2)
(female) (11) to
chassis ground. NO Replace
2) Turn starting
switchoN.PO9.
3) Disconnect ~~~~~ ~..,~~ 1
chassis ground l-l

switch ON. , ~~
1120-XIV NO disconnection in wiring inspection,
2) Turn s&in9 harness between WI (female) clean or replace
3) Disconnect WL.
b) Warning lamp stays ON

Is there continuity
YES between WL PO9 (female) (11) and WL repair or
(female) (2) replace
- (female)(2) and -
chassis ground?
1 After
Contact of chassis ground
1) Remove PO9. NO with warning lamp-body. or inspection.
2) Turn starting contact of chassis ground repair or
Does lamp light up? - switch OFF. with wiring harness between replaCe
3) Disconnect WL. warning lamp and WL (male)
(2)
1) Remove PO9.
2) Turn starting
switch ON. Defective module (7831-31-
2o-&99
P-l 8 Caution display does not flash (does not light up), but warning lamp
flashes and alarm buzzer sounds
a) Warning lamp flashes and alarm buzzer sounds
Cause Remedy
Defective module (7631-31- iepkace

$100) of monitor panel
Is voltage between
ground normal?
see Troubleshooting of
1) 15-3ov NO nachine caution monitor
2) Turn starting
switch ON.
b) Warning lamp flashes when engine stops.
Defective module (7831-31- tepk4ce

Is there continuity
YES between P12
- (fernale) and -
chassis ground?
1
Iefective contact, or uter
Is there continuity 1) Turn starting NO jisconnection in wiring nspection,
between 20 (male) switch OFF. wness between P12 (female) :1ean or replace
(6) and chassis - 2) Disconnect P12. 10) - JO2 (2) - 20 (female)
ground? 6)
1) Turn starting
switch OFF.
2) Disconnect 20. lefective contact, or vter
NO disconnection in wiring nspection,
wness between 20 (male) (6) :lean or replace
and engine oil preswre
;ensor, or defective engine oil
Dres?.“re sensCr
c) Warning lamp flashes when engine is running.

YES
IS voltage between
PO9 (female) (9) and _
normal? Defective Contact, or After
- Is voltage between
1) 20-30V L Alternator terminal
2) Start engine. NO R and chassis (9) - JO1 (1) - alternator
3) Disconnect PU9. ground normal? terminal R
Defective alternator
1)20-30V NO
2) Start engine.
P-l 9 Abnormality in air pressure gauge
j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a) No display given in display area
Defective air pressure sensor Replace
1
Does air pressure
gauge display YES
Defective module (7831~31- Replace
FULL? 2 - 6100) of monitor panel
1) Connect short Is there continuity

connector to DL _ between PO9
(female). No (female) (3) and (S)? 3 YES
Aftt?r
2) Turn starting Defective contact, or
Is there continuity disconnection in wiring inspection,
switch ON.
1) Connect short between DL harness between PO9 (female) clean or replace
connector to DL Ng (female) (2) and - (3) - RH4 (1) - DL (female)
(female). chassis ground? (1)
2) Turn starting Defective contact, or After
switch OFF. NO disconnection in wiring inspection,
1) Turn starting
3) Disconnect PO9. switch OFF. harness between PO9 (female) clean or replace
2) Disconnect DL I;; - RHl (lo)- DL(female)
8
z
8 b) Display shows highest level and does not move.
YES
Defective air pressure sensor
1
Is whole display
area of air pressure -
gauge off? 2 YES
- Is there continuity
PO9 (female) (3) - RH4 (1) - repair or
1) Remove DL. _ between PO9
DL (female) (1) replace
2) Turn starting NO (female) (3) and
switch ON. chassis ground?
1) Remove DL. NO 6100) of monitor panel
2) Turn starting
switch OFF.
3) Disconnect PO9.
Defective engine water

temperature sensor
temperature gauge
1 YES Mer
Contact of chassis ground with
wiring harness between PO9 Inspection.
Is there continuity clean or replace
1) Remove 26. between PO9 :female) (4) - JO2 (1)- 20 (5)
; - 26 (female) (1)
2) Turn starting INtl (female)(4) and -
I I I
1) Remove 26. NO 6100) of monitor panel
2j Turn starting
switch OFF.
3) Disconnect PO9.
b) Display shows lowest level and does not move.
II
temperat”re sensor
1
Is whole display
area of coolant I I YES
Defective module (7831.31. ReplaCe
zziiiz?
NON Defective contact, or

(4) - JO2 (1) - 20 (5) - 26
(female) (1)
After
inspection,
clean or replace

1) Turn starting NO disconnection in wiring inspection,
3) Disconnect PO9.
switch OFF. harness between PO9 (female) repair or
2) Disconnect 26. (8) - JO2 (3) - 20 (9) - 26 replace
(female) (2)
jr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Remedy
‘FS
Defective torque convwter oil
temperature sensor
2 YES After
H
I I I Defective of chassis ground
Is there continuity
PO9 (female) (5) - TMC (8) - repair or
1) Remove TCSE. between PO9
TM2 (7) - TC.SE (female) (1) replace
2) Turn starting p (female) (5) and
L I I
1) Remove TC.SE. NO 61 CID) of monitor panel
2) Turn starting
switch OFF.
3) Disconnect PD9.
x
0 b) Display shows lowest level and does not move.
ES
Defective torque wnverter oil Replace
temperature sensor
YES
temperature gauge

3
1
cO”“ector to between PO9
TCSE (female). b (female) (5) and (S)? 3 YES
2) Turn starting
switch ON.
1) Connect short
cO”nector
to L harness between PO9 (female)
(5) - TMC (8) - TM2 (7) -
clean or replace
NC WH_
TCSE (female). TC.SE (female) (1)
2) Turn starting
switch OFF. NO
31 Disconnect PO9.
1)Turn starting disconnection in wiring inspection,
switch OFF. harness between TC.SE repair or
2) Disconnect (female) (2) - TM2 (8) - TMC replace
TCSE. (5) - PO9 (female) (8)
20-203
a) No display given in display area.
Defective retarder oil Replace

temperature sensor
Does retarder oil

temperature gauge
display lowest
level? Contact of chassis ground
Nith wiring harness between inspection,
‘Do9 (female) (6) - JO2 (10) - repair or
1) Remove
64. replace
2) Turn starting 64 (female) (1)
switch ON.
Defective module (7831.31- Replace
2) Turn starting
switch OFF.
3) Disconnect PO9.

.

temperature sensor
YES
Defective module (7831-31. RF@.%

connector to 64 . between PO9
(female). P ’ (female) (6) and (6)) 3 YES
2) Turn starting
switch ON. Is there continuity
between 64 harness between PO9 (female) clean or reDlace
1) Connect short
connector to 64 NT (female) (2)and - (6) - JO2 (10) - 64 (female)
2) Turn starting Defective contact, or AftW
switch OFF. 1) Turn starting NO disconnection in wiring inspection,
3) Disconnect PO9. switch OFF. harness between PO9 (female) repair or
2) Disconnect 64. I;; - JO2 (9) - 64 (femalel
(It takes 30 seconds for the fuel gauge to change one level, so remember this point when carrying
out troubleshooting.)
Remedy
YES leplace
Defective fuel sensor
1 I
Defective module (7831-31- kplace

J 1 Defective contact, Or tfter

switch ON. 134-1DDs-l NO disconnection in wiring nspection.
2) Turn starting harness between PO9 (female) :1ean or replace
switch OFF. (7) - JO2 (15) - 61 (female)
3) Disconnect PD9.
b) Display shows FULL and does not move.
YES
Defective fuel Sensor Replace
1
Is whole display
area of fuel gauge -
off? 2 YES
, Isthere continuity with wiring harness between inspection.
between PO9 PO9 (female) (7) - JO2 (15) - repair or
1) Remove 61. replace
- (female)(7) and - 61 (female)
2, Tur” starti”g NO chassis gro,,nd
switch ON.
normal?
2) Turn starting
switch OFF.
9 Disconnect PO9.
P-24 Abnormality in night lighting (abnormality only in night lighting of
monitor panel)

a) None of panel lamps light up.
-cause Remedy
YES
1 harness between PO1 (female) clean or replace
(3). PO3 (female) (2). PO6
(female) (2). PO7 (female) (2).
h
Isvoltage between PlO (female) (2). P14 (female)
each pin in table (2) -chassis ground
below normal?
I 1
1) 20-30V
2) Turn starting
switch ON. Defective contact, or After
3) Turn light switch ND disconnection in wiring inspection,
_...
f-m harness between LS (female) clean or replace
4) Disconnect POl, (1). PO1 (female)(2), P14
P14. and LS. (female) (1)
Note: If the night lighting for other devices (transmission shift

lever, etc.) does not light up, go to troubleshooting of
chassis (marker lamp relay system).
b) Service meter and odometer light up, but other parts do not light up.
Cause RemedY
‘ES
harness between LS (female) clean or replace
(2) - PO3 (female) (1). PO6
[female) (1). PO7 (female) (1).
1 PlO(female)(l)
Is voltage
between
3
LS (2) and chassis Defective rheostat Replace
Isthere continuity
YES between LS
- (femalej(3) and -
1) lo-3ov
chassis ground?
2) Turn starting
switch ON.
1
3) Turn light switch Is voltage between 1) Turn starting disconnection in wiring inspection,
ON. LS (female) 81) and switch OFF. harness between LS (female) clean or replace
chassis ground - 2) Disconnect LS. (3) and chassis ground
normal?
1)20-30V
2) Turn starting
switch ON. Defective contact, or After
3) Turn light switch ND disconnection in wiring inspection.
ON. harness between LS (female) clean or replace
4) Disconnect LS. (1) and R07 (female) (5)
c) Service meter and odometer do not light up.

disconnection in wiring Inspection,
12). P14 (female) (1) - R07
[female) (5)
P-25 Engine (mechatronics) display flashes
CalIS? Remedy
YES Defective module (7831-31.

ReplaCe
Isvoltagebetween
PlZ(1) and chassis -
ground normal? 2 YES See troubleshooting of engine
controller
- IS voltage between
1) o-3v _ EC1 (female) (5) and _
2) Turn starting NO chassis ground
IVXltlal? Defective contact. or discon-
switch ON. After inspec-
tion. clean or
NO between P12 (female) (1) -
1) 12-2ov replace
ECA (4) - EC1 (female) (5)
2) Turn starting
switch ON.
3) Disconnect ECl.
a) High power display does not light up.
CalSe Remedy
YES _ Ikfective module (?831-31- Replace

I3100) of monitor panel
Is voltage between
P12 (4). (5) and YES Defective power mode switch Replace
chassis ground
normal?
2
1) 12-3ov Is voltage between
2) Turn starting P12 (4), (5) and _
switch ON. NO chassis ground
1
Niring harness between P12
normal?
female) (4),(5) - CNS (10) -
‘W (female) (2) short circuit-
1) 12-30V I ng with chassis ground, or
After inspec-
2) Turn starting wiring harness between EC3
tion, repair or
switch ON. female) (10) - ECA (6) -
NO replace
3) Remove PW. i :NS (female) (10). of between
‘
X2 (female) (17) - TMA (12)
- CNS (female) (10) short cir-
‘ :uiting with chassis ground
b) Economy display does not light up.
YE Defective module (7831.31.

Replace
Is there continuity
between P12 Defective contact, or discon-
nection in wiring harness 4fter inspec-
(female) (4). (5) and
chassis ground? YES xtween P12 (female) (4). (5) tion, clean or
n I - CNS (10) - PW (female) replace
(2). or between PW (female)
1) Turn starting (4) and chassis ground
H
switch OFF. IS there continuity
2) Disconnect P12. between PW (male)
(2) and (4)?
1) Turn starting Defective dower mode switch Replace

switch OFF. s
2) Disconnect PW.
2o-%8-1
ELCTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL
SYSTEM
F56103144-1
IOd ZOd Od VOd SOd 90d LOd 80d 60d Old Zld
Jaiatuopg
aww 00I~-zE~IE8L alwow awow
OOIL-I&.IE8L 0016.IE-IE8L
1008-IE-IF8L
1 I
OOOZ-ZE-IE8L laued Aqds!p yuomal3
561FO3350-1
RELATED ELECTRICAL CIRCUIT DIAGRAMS
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Battery relay
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PO9 (04012) JO3 (Sl6) (SWPl4)
F56103145
P-2
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PO2 (0406)
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F56103146
P-3
Pi2 (04016) MC (512) SC3 LMIC21)
Shift controller
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P-4
Pl2(04016) SU3 lSl6) SUItMICEI)

Suspension
controller
F56103148
20-;09
P-5
Pl2(040161 SU3 tSl6) SUI(MIC21)
@-
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P-6
PO8 (04016) SFISl2)
Transmission
lever
Monitor
8
z
i3
F56103150
P-7
Shift limit switch
PO6[04016)
Monitor panel
F56103151
P-8
Lock-up relav
(relay)
R24
TMC (Sl2) SC3
Transmission
controller
RE3 RE4
(resistor) (resistor)
Battery relay
F56103152
P-9
Head lamp relay (Hi)
Monitor panel
To head lamp
F561031
P-10
PO8 (04016) CM (S8) Combination switch
JO3 (Sl6)
@ - To turn signal lamp (right)

@ - To turn signal lamp (left)
F56103154
P-l 1
PO5(04012) TMA(SI6) TM3 (SWP 14)
F56103155-1
20-212
0
P-12
Output shaft
PO8(04016) TMA (Sl61 TM2 (SWPl4) N3IX2) speed sensor
@ @ @
o- @ 0
F56103156
P-13
Speed sensor B
PO8(04016) ECA(Sl6) E7tSWP14) El2(X2)
0 @ 0
Monitor panel
@ @ @
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P-14
Alternator
4,
ER
F56103158A
P-15
Pl3(04041 PO4(0408)
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Modul’e
F56103159
P-16
+24V
BZ (M2) Buzzer
PO9 104012) t
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P-17
WL(M2) Lamp
PO9(04012) 0
@
Resistor
RE2
F56103161
P-l 8
Pl2(04016) JO2 (Sl6) 2OCSWP20)

Engine oil
t pressure
sensor
F56103162
Alternator
JOI IS161
F56103163
P-19
PO9(04012) RHI(SI0) PL (X2)
F56103164
P-20
Water
PO9 (04012) JO2 IS161 20 (SWP20) 26 (X2)
@ @ @
o-0 0
F56103165
P-21
PO9(04012) TMC (Sl2) TM2 (SWP14) TC,SE(XP)
@ @
Torque
@
converter oil
B-0 0 temperature
sensor
F56103166
P-22
PO9(04012) JO2 (Sl6) 64(X21
@ @ Retarder oil
temperature
@-_o sensor
F56103167
P-23
PO9(04012) JO2 (Sl6) 61 (XII
Fuel sensor
F56103168
P-24
Marker lamp relay
Combination switch
CM (SE)
PO I (0405)
PO3 (0402)
I , LS(ry3), ,Rheostat (
I
A I \ , 1 I
777
PO6(0402) ER
PO7 10402)
PlO(O402)
Pl4(0402)
I=
ER
r
F56103169-1
P-25
Pl2(04016) ECA (S 16) EC I(MIC 17)
Engine
controller
561 F03347
P-26
Engine controller
EC30KPI~ ECA,S16)
~+JJ-j_
Transmission controller,
SC2lMlc21) TMNS161
Monitor panel
P 12IO40161
r \ 1
561 FO3348-1
TO batten/ terminal (+)

TROUBLESHOOTING OF MAINTE-
NANCE MONITOR SYSTEM
M-l Maintenance monitor does not work .......................................... 20-216- 4

a) When nothing works ..................................................... 20-216- 4
b) When CHECK display does not work ...................................... 20-216- 4
M-2 When engine is stopped, engine oil level display flashes ...................... 20-216- 5
M-3 When engine is stopped, transmission oil level display flashes ................ 20-216- 6
M-4 When engine is stopped, hydraulic oil level display flashes .................... 20-216- 7
M-5 When engine is stopped, retarder oil level display flashes ..................... 20-216- 8
M-6 When engine is stopped, brake oil level display flashes ....................... 20-216- 9
M-7 When engine is stopped, battery electrolyte level display flashes .............. 20-216- 10
M-8 At neutral, retarder wear display flashes ..................................... 20-216- 11
M-9 When engine is running, air cleaner clogging display flashes ................. 20-216-12
M-10 When engine is running, full-flow filter clogging display flashes ............... 20-216-l 3
M-l 1 When engine is running, transmission filter clogging display flashes .......... 20-216-14
M-12 When engine is running, hydraulic filter clogging display flashes .............. 20-216-I 5
M-13 When engine is running, retarder filter clogging display flashes ............... 20-216-l 6
M-14 Maintenance timer does not work .... ........................................ 20-216-l 7
8 M-15 Maintenance timer is not Oh or below, but maintenance item
z lights up ..................................................................... 20-216-18
8
M-l 6 Abnormality in switch ........................................................ 20-216-l 8
a) Confirmation switch for oil or filter replacement time
does not work ............................................................ 20-216-l 8
b) Replacement switch, misoperation cancel switch do not work ............. 20-216-l 8
M-17 Night lighting does not light up ............................................... 20-216-l 9
Electrical circuit diagram of maintenance monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-216-20

conditions.
Threrefore, always check the resistance value, voltage, etc. of the place giving the failure display,
that the problem occurred, and try to re-enact the failure conditioins when carrying out
troubleshooting.
20-216-3
a
M-l Maintenance monitor does not work

on to the next step. CCNKSe RemedY
a) When nothing works
ES
5100) of maintenance monitor
Is voltage
between Defective contact. or discon-
MM1 (1) and (2) nection in wiring-harness
between MM1 (female)(l) - Repair wiring
YES
MM7 (1) - 8T2 (8). or harness or
! 1 between 8T2 (7) and starting reDlaCe
1) 20-30V switch ACC, or blown fuse
2) Turn starting Is there continuity
switch ON. between MM1
F Ifemale) (2) and

1) Turn starting between MM1 &male) (2) - harness or
switch OFF. NO MM7 (2) - JO3 18) - battq replace
21 Disconnect MMl. relay terminal E
MM I (04016) MM7(Sl6)
BT2
Starting
0 switch
8 7
@
JO3(S 16)
@
Battery relay
561 F03351
Remedy
b) When CHECK display does not work
1 YES Defective module (7831-41- Replace

7100) of maintenance
Is there continuin/ monitor
between the pins in -
the table below?
Defective contact, or discon- Repair wiring
..-
1) Turn starting
between the pins given replaCe
switch OFF.
2) Disconnect MM3
and MM4.
MM3(0408) MM4 (0408)
Table 1
MM3 (female) (1) - MM4 (female) (1)

Maintenance monitor
Maintenance monito
MM3 (female) (4) - MM4 (female) (4) module
module
(7831-41-7100)
MM3 (female) (5) - MM4 (female) (5) (7831-41-5100)
561 F03352
M-2 When engine is stopped, engine oil level display flashes
* Check the engine oil level again before starting troubleshooting.

cause
YES.
Is there continuity
between MM1
(female) (4) and (2)?

switch OFF. between MM1 (female) (4) - replace
between MM9 2) Disconnect MMl. MM8 (1 J - MM9 (female) (1)
(female) (2) and
1) Turn starting
IS there continuity ’ switchOFF.
between MM9 2) Disconnect MM9.
(male)(l) and (2)? NO between MM1 (female) (2) - replace
MM8 (12) - MM9 (female) (2)
1) Turn starting
.,= Defective engine oil level

NO sensor
MM I(O4016) MM8CSl2) MM9IX2)
0 Engine oil level

sensor
@
561 F03353
M-3 When engine is stopped, transmission oil level display flashes
* Check the transmission oil level again before starting troubleshooting.

x
CaUSe Remedy
YES
3 5100) of maintenance monitor
YES Isthere continuity

- between MM1
2 Defective contact, or discon- lepair wiring

1)Turn starting nection in wiring harness tarnas or
Is there continuity switch OFF. NO between MM1 (female) (5) - epklce
YES between MM 16 2) Disconnect MMl. MM8 (2) - MM16 (female)(l)
- (female)(2)and -
chassis ground?
1 1) Turn starting
switch OFF. Ddfective contact, or discon- lepair wiring
2) Disconnect nection in wiring harness ,arness or
Is there continuity
NO between MM1 (female) (2) - l?phX
betweenMM16 - MM16.
(male)(l) and (2)? MM8 (12)- MM16 (female)
(2)
1) Turn starting
switch OFF.
2) Disconnect
MM16. Defective transmission oil k?place
level sensor
Transmission
oil level sensor
MM I (04016) MMBLSl2) MM 16(X2)
561 F03354
20-2A6-6
M-4 When engine is stopped, hydraulic oil level display flashes
* Check the hydraulic oil level again before starting troubleshooting.

CaUSe Remedy
YES
2 51001 of maintenance monitor
Isthere continuity
YES between MM1
- (female) and chassis
1 ground?

Is there continuity
1) Turn starting nection in wiring harness harness or
between MM1 4 _ NO
switch OFF. between MM1 (female) (6) - replace
(male) and chassis
2) Disconnect MMl. MM8 (3) - MM14 (female)
ground?
1) Turn starting
switch OFF. Defective hydraulic oil level Replace
2) Disconnect NO sensor
MM14.
8
z
8
MMI (04016) MMS(Sl2)
MM 14
Hydraulic oil level

sensor
561 F03355
20-2A6-7
M-5 When engine is stopped, retarder oil level display flashes
Sr Check the retarder oil level again before starting troubleshooting.

YES
Defective contact. or discon- ?epair wiring

1) Turn starting
nection in wiring harness wrness or
Switch OFF. NO
between MM2 (female) (6) - Y&S2
2) Disconnect MM2.
MM8 (10) - MM15 (female)
1) Turn starting
switch OFF. Defective retarder oil level
2) Disconnect *enSOr
MM15.
MM2(04012) MMB(Sl2)
MM15
Reterder oil level

1
sensor
561 F03356
M-7 When engine is stopped, battery electrolyte level display flashes
* Check the battery electrolyte level again before starting troubleshooting.

Remedy
YES
I
Isvoltage between
Y ES MM1 (male) (11) I
and chassis ground *
normal?

1) Min. 4V nection in wiring harness harness or
2) Turn starting NO between MM1 (female) (11) WAXe
switch ON. - MM8 (8) - MM1 1 (female)
3) Disconnect MMl.
1) Min. 4V
2) Turn starting
switch ON.
Defective ba&ry electrolyte ReplaW
3) Disconnect Nl level sensor
MMll.
MMI (04016) MM8(Sl2)
MM II
Battery electrolyte
level sensor
561 F03358
O
2o-2&6-1
M-8 At neutral, retarder wear display flashes
* Check again that the retarder brake is not worn before starting troubleshooting.
CC3lFX Remedy
YES
Defective module (7831.41- ?eplace
I 5100) of maintenance monitor
YES
r
Is there continuity Defective brake wear (rear ReplaCe

between MM20 switch OFF. NO left) sen?.or
(male) (1) and (2)?
1) Turn startring
switch OFF. Defective brake wear (r&r Replace
2) Disconnect NO right) sensor
MM20.
disconnection in wiring Repair wiring
YES
harness between MM1 harness or
(female) (9) - MM8 (6) - replace
I
MM1 7 (2) - MM20 (female)
(1)

Y
1
(female) (2) and MM19 replace
1) Turn startring (female) (2)
switch OFF.
2) Disconnect between MM19
MM20.
Defective cont&t. or
disconnection m wiring Repair wiring
1) Turn startring i harness between MM1 harness or
switch OFF. n (female) (2) - MM8 (12) - replace
2) Disconnect
MM17(3)- MM19 (female)
MM19.
(1)
MMI (04016) MM8(Sl2) MM I7 (X3) MM20(X2)
@ @
Rear left
@ @
Brake wear sensor

MM 19(X2)
Rear right
561 F03359
2o-2F
’
M-9 When engine is running, air cleaner clogging display flashes
* Check clogging of air cleaner again before starting troubleshooting.

Cause Remedy
YES
Is there continuitv
Defective contact, Or : Repair wiring

lisconnetiio” in wiring harness of
harness between MM1 replaCe
[female) (10) - MM8 (7) -
I I MM13 (female)
1) Turn starting
switch OFF. Defective air cleaner clogging
2) Disconnect NO
sensor
MM13.
MMI (04016) MMB El21
MM 13
Maintenance
monitor Air cleaner
clogging sensor
561 FO3350
20-2F12
M-l 0 When engine is running, full-flow filter clogging display flashes
* Replace the full-flow filter before starting troubleshooting.

CalIS Remedy
2 YES
Yf
:jWHH
Defective contact. or discon- iepair wiring
nection in wiring.harness 1arness or
1) Turn starting between MM1 (female) (12) ‘eDlaCe
switch OFF. -MM8(9)-MM10
2) Disconnect MM1
1) Turn starting
switch OFF.
2) Disconnect Defective full-flow filter ciog-
3
MMlO. ging sensor
8
z
8
MM I (04016) MM8cSl2)
MM IO
Full-flow filter
sensor
561 F03361
20-2&6-l
3
M-l 1 When engine is running, transmission filter clogging display
flashes
* Check clogging of transmission filter again before starting troubleshooting.

YES
2ijyizJ-
YI
2 Defective contact. or discon- Repair wiring

Isthere continuity switch OFF. NO between MM1 (female) (13) replace
YES between 52 (female) 2) Disconnect MMl. MM7(11)-JO2(13)-52
- (2) and chassis (female) (1)
ground?
1
7
1) Turn starting
Is there continuity swifch OFF.
between 52 (male) - 2) Disconnect 52. nection in wiring harness harness or
(1) and (Z)? between 52 (female) (2) and replace
JO3 (female)(8)
1) Turn starting I
switch OFF.
2) Disconnect 52. 1 Defective transmission filter
NO
clogging sensor
MM I(O4016) MM7(S 16) JO2
@
Transmission filter
clogging sensor
JO3CSl61
@. 2 - To battery relay E
561 F03362
20-216-l 4
0
M-l 2 When engine is running, hydraulic filter clogging display flashes
* Check clogging of hydraulic filter again before starting troubleshooting.

Remedy

\I
2 Defective contact, or discon- Repair wiring

, 1 1) Turn starting nection in wiring harness harness or
Is there continuity switch OFF. NO between MM1 (female)(14) replace
YES between 54 (female) 2) Disconnect MM1 -MM7(12)-JO2(12)-54
- (2) and chassis
(female) (1)
ground?
1
1) Turn starting
Is there continuity switch OFF.
Repair wiring
between 54 (male) - 2) Disconnect 54. nection in wiring harness harness or
(1) and (2)? 3 between 54 (female) (2) and replace
~03 (female) (81
1) Turn starting
switch OFF.
_.
2) Disconnect 54. I Defective hydraulic filter clog-
NO ging sensor
T:
2
0
MM I(O4016) MM7(Sl6) JO2(S 16) 54(X2)
0 Hydraulic filter
clogging sensor
@
561 F03363
20-216-15
0
M-l 3 When engine is running, retarder filter clogging display flashes
* Check clogging of retarder filter again before starting troubleshooting.

I Call93 Remedy

51001 of maintenance monitor
Defective contact. or discon- Repair wiring

Is there continuity switch OFF. between MM2 (female) (7) - replace
2) Disconnect MM2. MM7(13)-JO2(14)-53
(female) (1)

between 53 (female) (2) and replace
JO3 (female) (8)
1) Turn starting
switch OFF.
2) Disconnect 53. I Defective retarder filter clog. RC?plaCe
NO ging sensor
MM2(04012) MM7C316) JO2E.16) 53(X2)
a Reterder filter
clogging sensor
@
I
561 F03364
M-l 4 Maintenance timer does not work (time does not advance)
j, Before carrying out troubleshooting,

CalSe Remedy
YES Defective module (7831-41- Replace

1
Isvoltage between
MM2 (female) (5)
and chassis ground
“Ormal? Defective contact, “r discon- Repair wiring
2 YES
1) 20-30V between MM2 (female) (5) - replace
Is voltage between
2) MM7 (8) - JO1 (1) - alterna-
3, Start engine.MM2.
Disconnect L alternator terminal _
tor terminal R
NO R and chassis
ground normal?
NO
1) 20-30V
2) Start engine.
MM2(04012) MM7CSl6)
Altenator
561 F03365
M-l 5 Maintenance timer is not Oh or below, but maintenance item

lights up

connectors are properly inserted. C-SUSe Remedy
I Defective module (7831-41-

20-2F’7
M-l 6 Abnormality in switch
Sr Before carrying out troubleshooting,


Cause Remedy
does not work

b) Replacement switch, misoperation cancel switch

do not work
YES
Defective module (7831-41- ?eplace
monitor
1 I
Is voltage between
MM2 (female) (5)
and chassis ground
Contact of +24V with wiring &pair wiring
“Ormal? YES
harness between JO1 (female) 1arnas.s or
2 (1) and alternator terminal R. xplace
1) Max. 16V or defective alternator
switch ON. JO1 (male) (1) and
3) Disconnect MM2. NO ~~~~~,gro”“d
Contact of +24V with wiring iepair wiring

1) Max. 16V I harness between MM2 lames* or
2) Turn starting NO (female) (5) - MM7 (8) - JO1
switch ON. (male) (1)
3) Disconnect JOl.
MM2(04012) MM7Sl6) JOIE 16)
Alternator
561 F03365
20-216-l 8
M-17 Night lighting does not light up
(only lighting of maintenance monitor does not light up)
CaLE.e Remedy

between MM5 (female) (1). Repair wiring
MM6 (female) (1) - MM7 harness or
(male) (9). or between MM5 replace
(female) (2). MM6 (female) (2)
- MM7 (male) (10). or blow”
bulb
4 YES Defective contact, or discon- Repair wiring

1) lo-3ov
2) Turn starting
, 1I nection in wiring harness
between MM7 (female) (9)
harness or
replace
switch ON. and LS (male) (2)
2 3) Turn light switch
ON.
4) Disconnect MM7 Defective contact, or discon- Repair wiring
NO between MM7 (female) (10) W$hX
: 1) Tur” starting
switch OFF. and chassis ground
82) Disconnect MM7.
1) lo-3ov
2) Turn starting
switch ON.
3) Turn light switch
ON. Defective rheostat Replace
between LS (male)
(3) and chassis
1) 20-30V nection in wiring harness harness or
2) Turn starting between LS (male) (3) and replace
1) Turn starting
switch ON. chassis ground
switch OFF.
2) Disconnect LS
ON.
4) Di.sc0”“ect LS.
k nection in wiring harness
I
between LS (male) (1 and
harness or
replace
R07 (female) (5)
Note: If the lighting of other equipment (monitor panel,
shift lever, etc.) does also not light up, see
troubleshooting for the chassis (marker lamp relay
system).
Marker lamp relay
+24V
MM5 MM7 (Sl6) 1

o-
@
Maintenance
monitor
561 F03366
20-2A4-‘9
Electronic display panel
Rhreostat
CNBT2
Charging level
caution relay
Transmission neutral
CNMM7
Shift controller
Shift lever N signal
starting signal
ter
Transmission oil
sensor
: level
electrolyte
level
Reterder oil
level sensor Air cleaner clogging
sensor
MM15
J
,“:: $2
mm mm
66 dd
MM19 MM20
Rear brake (L.H.)’ Rear brake fR.H.1

wear sensor wear sensor
056103
TROUBLESHOOTING OF HYDRAULIC
AND MECHANICAL SYSTEM
H-l : Machine does not move ............................................... 20-218

H-2: Machine does not travel smoothly ....................................... 20-220
H-3: Lock-up clutch cannot be disengaged ..................................... 20-220
H-4: Large shock when starting or shifting ..................................... 20-221
H-5: Transmission does not shift up .......................................... 20-221
H-6: Machine lacks power or speed when traveling .............................. 20-222
H-7: Time lag is excessive when starting or shifting gear ......................... 20-228
H-8: Torque converter oil temperature is hgh ................................... 20-230
H-9: Torque converter oil pressure is low ...................................... 20-23 1
H-10: Front brake is ineffective or effective one side .............................. 20-232
H-l 1: Rear brake is ineffective or effective one side ............................... 20-233
H-l 2: Steering wheel is heavy ............................................... 20-234
B H-l 3: Steering wheel does not function ........................................ 20-235
z H-14: Steering wheel vibrates ................................................ 20-235
8 H-l 5: Hoist cylinder lacks lifting force (lifting speed) .............................. 20-236
H-l 6: Hoist cylinder does not work ............................................ 20-237
H-l 7: Excessive hydrualic drift of dump body .................................... 20-238
H-l 8: Air pressure does not rise .............................................. 20-239
H-l: MACHINE DOES NOT MOVE.
Ask the operator the following points.

- Did the machine suddenly stop moving?
Yes = Component seized or damaged.
- Was there any abnormal noise when the machines
stopped moving?
Yes = Component broken.
Checks before troubleshooting

* Is oil level in transmission case correct?
- Is drive shaft broken?
- Are input shaft of torque converter or transmis-
sion broken? (Check with transmission input
speed sensor)
- Does not brake drag?
No.
Problems
1 Abnormal noise between pump and filter.
Machine does not move in any speed range.

* (Item 1 normal)
31 M ac h’me moves normally in certain speed ranges.

I I I I I lbl
41 M ac h’me will not move when T/C oil temperature rises.
I I lol I I
w ololol IO1
E
5
- ~;;y~,s.ion
6 set pressure 0
7 Indicator fluctuates violently. 0 0
Oil does not flow out when remove pressure measuring
8 0
plug and crank engine.
9 Insufficiency of modulating pressures 0

10 insufficiency of pump outlet pressure I I I lol
The following symbols are used to indicate the
action to be taken when a cause of failure is
located.
X: Replace A : Repair
A: Adjust C: Clean
Combination of clutches
H-2: MACHINE DOES NOT TRAVEL SMOOTHLY
- Hunting of engine
- Flash lock-up lamp
Cause Remedy
- Insufficiency of main relief pressure

Go to H-6
* Wear of clutch seal ring
H-3: LOCK-UP CLUTCH CANNOT BE DISENGAGED

Check before troubleshooting located.
+ Is oil level in transmission case correct? X: Replace A : Repair
A: Adjust C: Clean
H-4: LARGE SHOCK WHEN STARTING OF SHIFTING
Criteria
A shock is judged to be excessive in the following cases:
- The magnitude of shocks is suddenly larger than before.
- Shocks are much larger than in other machines of the same class.
Cause
Defective operation because of dirt caught in the ECMV pressure control valve spool and flow detector valve
spool, or defective operation of the ECMV proportional solenoid.
H-5: TRANSMISSION DOES NOT SHIFT UP

a) Does not shift up
* Shifts up on downhill slopes
Causes Remedy
. Slipping or damage of torque converter lock-up clutch AX
b) Does not shift up
Causes Remedy
. Defective operation of selector valve of clutch not

CAX
shifted-up
I * Defective seal ring of clutch not shifted-up I X

I
I - Insufficiency of main relief pressure I ACAX I
v
sNo.1 No.2 No.3 No.4 No.5 No.6 No.7
F2 lOI lOI
H-6: MACHINE LACKS POWER OR The following symbols are used to indicate
SPEED WHEN TRAVELING action to be taken when a cause of failure
located.
is
A: Adjust C: Clean
I
a) Abnormality at all speed ranges

l Is the oil level in the transmission case correct?
l Is there any external oil leakage from the piping
or valve joints?
l Is there any dragging of the parking brake,
service brake, or retarder?
Check the following

l Engine high idling speed
l Torque converter stall speed
l Machine travel speed
l Transmission clutch oil pressure
l Torque converter lock-up oil pressure
l Main relief pressure
T
No.
Problems
b) Torque converter does not engage lock-up clutch. action to be taken when a cause of failure is
Ask the operator about the following:

- Did the trouble occur suddenly? + Internal parts
are seized or damaged.
* Did an abnormal sound occur at the same time?.+
Broken parts.

- Is the oil level in transmission case correct?
* Is there any external oil leakage from piping or
valve joints?
’ Does electric circuit to lock-up solenoid valve
(with checker)?
Check the following

- Main relief pressure
- Torque converter lock-up oil pressure
* Machine travel speeds
Insufficiency of main relief oil pressure
Same as item (2) but solenoid is abnormal.

4
(No continuity, short circuit) 0
Items (1) to (4) are normal but lock-up oil pressure
5 0 0
is low.
6 Same as item (5) but lock-up oil pressure is normal. 0

Lockup oil pressure is low and main relief oil
7
pressure is low. 0
8 It takes long time to engage lock-up clutch. I I lolol I

C)-1 Abnormality at some speed ranges
[Troubleshooting without using shift checker]

l Is there any dragging of the parking brake,
service brake, or retarder?
Check the following

F6 0 0
1=7 0 0
4
No. Problems
* Remove all the mud and dirt from around the ECMV. and clean it before replacing.
*After replacing, tighten the ECMV mounting bolts to the specified tightening torque.
w ECMV mounting bolt: 3.15tO.35 kgm
056103
+
I I I ,
’
R I 0
h?D
0 0
00
v-0 -
I
w I ;
I I
00
Cl-2 Abnormality at some speed ranges
[Troubleshooting using shift checker]

l Is the oil level in the transmission case proper?
l Is there gragging in the service brake, parking
brake or retarder?
l Does not plug of manual travel loosen?
Check the following

l Transmission clutch oil pressure
l Torque converter lock-up clutch oil pressure
l Check that each solenoid valve functions
normally by using checker.
F6 0 0
F7 0 0
No. Problems
transmission controller
@ Fl is normal, but F2 is defective 2.5 3.5 4.5 5.5
1
@ 2nd clutch oil pressure is normal
@ F2 is normal, but Fl is defective, or only Fl is defective 2.4 3.4 4.4 5.4

2
@ 1st clutch oil pressure is normal
@ Fl and F2 are normal, but F3 is defective 2.2 3.2 4.2 5.2
3 02 H clutch oil pressure is normal
@ Fl, F2, and F3 are normal, but F4 is defective 2.6 3.6 4.6 5.6
4
@ 3rd clutch oil pressure is normal
@ Fl - F5 are normal, but F6 is defective 2.7 3.7 4.7 5.7
5 02 4th clutch oil pressure is normal
@ F3, F5, and F7 are normal, but others are defective 2.3 3.3 4.3 5.3
6
@ L clutch oil pressure is normal
@ Only R is defective 2.8 3.8 4.8 5.8
7 @ R clutch oil pressure is normal
l For details of the oil pressure for each clutch, see the STANDARD VALUES TABLE.
* Remove all the mud and dirt from around the ECMV, and clean it before replacing.
l After replacing, tighten the ECMV mounting bolts to the specified tightening torque.
m ECMV mounting bolt: 3.15 * 0.35 kgm
H-7: TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR

l Is there any external oil leakage from the piping
or valve joints?
Check the following

l See the standard value table to check if the
time lag is actually excessive.
No.
Problems
shiftina to F3
Fl, F2, and F3 are normal, but there is time lag

6
when shifting to F4
Fl - F5 are normal, but there is time lag when

7
shifting to F6
0 0’ 0
F3, F5, and F7 are normal, but there is time lag

8 0
when in other speed ranges
9 There is time lag in R
10
Transmission modulation pressure is low when
placed in any speed range 101010/ ~ I loi I / I
Torque converter oil temperature goes above
11 000
operating range
056103
I I loI I 1
‘+t-f-t--.
I.
1.
0 X
0 X
I I I 1
-----
0 I X
-
H-8: TORQUE CONVERTER OIL TEMPERATURE IS HIGH

- Does the oil temperature rise when the torque con-
verter stalls and drop when the torque converter
does not stall? + Normal (Improper selection of action to be taken when a cause of failure is
speed range) located.
A: Adjust C: Clean
Check before troubleshooting
- Is the oil levels in the transmission case correct?
Check the following

- Confirm that the actual oil temperature is.
higher than that specified in the maintenance
standard.
t If the actual oil temperature is normal but
the indication of the oil temperature gauge
on the machine exceeds the operating range.
-+ The oil temperature gauge is defective.
I From tank to pump / ~~$~er /
4 Torque converter inlet oil pressure is too low. 0
5 Transmission modulation pressure is too low. 0 0 0
6 Torque converter internal oil leak is excessive. 0
L If all other items of the problems

pass inspection, this is the cause.
20-;30
H-9: TORQUE CONVERTER OIL PRESSURE IS LOW.

- Is oil level in the transmission case correct?
- Is there any external oil leakage from the piping or
valve joints? The following symbols are used to indicate the
Check the following

- Pump outlet pressure
Problems
1 Abnormal noise from pump. 0
2 Oil pressure is low between pump and relief valve. 0
3 Torque converter inlet pressure is low. 0 0
Transmission oil pressure and lock-up oil pressure are

4
normal but torque converter inlet pressure is low. 0
When raise set pressure of torque converter relief valve,

5
relief pressure raises. 0
20831
H-10: FRONT BRAKE IS INEFFECTIVE OR ONE SIDE.

- Is oil level in the brake tank correct?
* Does not air mix in brake oil?
- Is there any external oil leakage between brake The following symbols are used to indicate the
chamber and wheel cylinder?
- Is air pressure inside operating range?
Check the following

- Air pressure
- Brake chamber outlet pressure
No.
Problems
Master cylinder outlet pressure is low (disconnect

A
x
A
x x
A x
X
A
I
I
X
1 0 0 0 0 0
outlet hose).
2 Brake chamber inlet air pressure is normal. 0 0
a3
316k ra e chamber inlet air pressure is insufficiency. 0 0 0
Air leaks from brake chamber. 0
Items 1 to 4 are normal. Insufficiency oil pressure at

5
wheel cylinder.
0
Items 1 to 5are normal. But front brake is ineffective
6
or not very effective.
20-;32
H-l 1: REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE.

* Does not air mix in brake oil circuit?
- Is oil level in transmission case correct?
* Is there any external oil leakage between brake The following symbols are used to indicate the
chamber and rear brake? located.
* Is air pressure inside operating range? X: Replace A : Repair
A: Adjust C: Clean
Check the following

* Air pressure
* Brake chamber outlet pressure
Problems
0 0 0 0 0
2 Brake chamber inlet pressure is normal.

I I I 10101 I I I I
3 Brake chamber inlet pressure is insufficiency. 0 0 0
4 Air leaks from brake chamber. 0

Items 1 to 4 are normal. Slack adjuster outlet pressure
5
is low. I I I I I loI I I I
6
Items 1 to 5 are normal.
low.
Brake piston oil pressure is
I I I I I I lol II
7 Deterioration of cooling oil is strong. 0
8 Oil in final drive case increases. 0
9 Same as item 7 but brake piston pressure is normal. C
Items 1 to 5 are normal, but rear brake is ineffective

10
or not very effective.
H-12: STEERING WHEEL IS HEAVY.
Checks before troubleshooting The following symbols are used to indicate the
* Is the oil level of the hydraulic tank correct? action to be taken when a cause of failure is
- Is there any external oil leakage between the
demand valve and steering valve?
* Is the play of the steering wheel proper?
Check the following

- Steering wheel operating force
- Time required to turn the steering wheel lock to
lock.
* Steering circuit relief oil pressure.
No.
Problems
Circuit pressure is too high at low engine speeds or

1
rises uo to the relief oressure.
2 Steering circuit relief oil pressure is too low.
3 Hoist cylinder also lacks power.
Item 3 is abnormal and the relief valve makes oil-

4
spurting sounds.
Relief pressure at cylinder stroke ends is insufficient.

5
(When items 1 through 4 are normal.)
6 Abnormal noise between the pump and filter.
Oil flows out continuously when the steering wheel is

7 turned clockwise (or counterclockwise) with the hose
on the opposite side removed.
81 Steering wheel does not drag at engine low idling
9 Pump delivery flow is too small.
10 Hoist develops normal power but moves slowly.
11 Play of steering wheel is too much

H-13: STEERING WHEEL DOES The following symbols are used to indicate the
NOT FUNCTION located.
Checks before troubleshooting A: Adjust C: Clean
* Is the oil level of the hydraulic tank correct?
- Is there any external oil leakage between the
pump and steering valve?
- Is the play of the steering wheel proper?
Check the following

* Relief pressure
, , , , , , ,
Circuit pressure is too high at low engine speeds or rises
3
up to the relief pressure. (When item 2 is normal.) 0
4 Hoist cylinder operates normally. 0 0 0.0
No relief pressure arises at the cylinder stroke ends.

5 (When item 4 is normal.) 0 0 0
Item 5 is abnormal, and the relief valve makes oil-
the hose on the opposite side removed.
10 Pump delivery flow is too small. 0 0
11 Play of steering wheel is too much 0

,
H-l 4: STEERING WHEEL VIBRATES.

Cause Remedy
Air in hydraulic oil AC
Oil leakage in steering cylinder LIX

H-15: HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED).

* Is the oil level in the hydraulic tank correct? action to be taken when a cause of failure is
- Does the dump body control lever operate normal-
ly?
- Are there bends or distortion of the control link-
age?
- Does the control valve lever move normally when
the linkage is disconnected from the hoist valve?
* Is there any external oil leakage between the
pump and cylinder?
Check the following

- Relief oil pressure
- Dump body lifting speed
l /iii a b c
ACAXXAL~L~AA
No. C x x
1 Problems X
! /
1 Steering wheel also drags. 000000
2 Steering wheel functions normally. 0000000
Item 1 is abnormal and the hoist circuit relief oil
3
pressure is too low.

4
spurting sounds.
Hoist circuit pressure is too high at engine high idling

5
speed. (When items 1 to 4 are normal.)
6 Only the hoist circuit relief pressure is low.

7
spurting sounds.
8 Dump body raises unevenly.
9 Pump delivery is too little. __I

I I I I I I I I I I I I
10 Excessive hydraulic drift of the hoist cylinder. I lolol lo
External oil leakage from the valve is found when
11
the tank cover is removed. I I 1 I I I I I IPIOI I
Items 1 to 9 are normal, but the dump body lifting
12
speed is low.
13 Abnormal noise between the pump and filter.

H-16: HOIST CYLINDER DOES NOT WORK,

. Did the trouble occur suddenly? + Seized or dam- located.
aged equipment. X: Replace A : Repair
- Were there any faulty symptoms such as a decrease A: Adjust C: Clean
in the lifting speed?+ Worn parts, fatigued springs,

etc.

* ISthe oil level of the hydraulic tank correct?
* Does the dump body control lever operate
normally?
* Does the control valve lever work normally
when the linkage is disconnected from the hoist
valve?
Check the following

- Relief oil pressure
when the hole is un
, oil comes out even
I I I I I I I I I I I I I 1
H-17: EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY.
Check before troubleshooting The following symbols are used to indicate the
- See if the hydraulic.drift falls into the standard action to be taken when a cause of failure is
range when the air cylinder rod is disconnected

from the valve side. + Bent or distorted rod
Check the following

* Hydraulic drift of the hoist cylinder
No.
Hydraulic drift increases when the control switch is

1 pushed on RAISE position with the engine stopped. 0
(Starting switch ON)
H-18: AIR PRESSURE DOES NOT RISE.
(The lowpressure buzzer does not stop sounding and the air gauge pointer does not deflect into
the green range.)
Checks before troubleshooting The following symbols are used to indicate the
* Does the air gauge function normally? action to be taken when a cause of failure is
* Is there any leakage from the air pipes?
4 Compressor overheats. 0
Buzzer does not stop sounding even after the air
5 0
pressure gauge indicates the green range.
The safety valve blows air even though the air pressure
6 0
does not rise.
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL.. ........................... 30- 3 TORQUE CONVERTER CONTROL VALVE

PRECAUTIONS WHEN CARRYING OUT Removal.. ............................................................. 30-42
OPERATION ......................................................... 30- 4 Installation ........................................................... 30-42
SPECIAL TOOL LIST.. ............................................ 30- 6 Disassembly ........................................................ 30-44
TIGHTENING TORQUES AND Assembly ............................................................. 30-44
STANDARD VALUES TABLE ............................... 30- 8 TORQUE CONVERTER AND TRANSMISSION
WEIGHT TABLE ...................................................... 30-12 Disconnection ...................................................... 30-46
LUBRICANT AND COOLANT TABLE.. .................. 30-13 Connection .......................................................... 30-46
STARTING MOTOR TORQUE CONVERTER, PTO
Removal ...............................................................30-14 Disassembly ........................................................ 30-48
Installation ........................................................... 30-14 Assembly ............................................................. 30-54
ALTERNATOR PTO
Removal ............................................................... 30-14 Disassembly ........................................................ 30-60
ENGINE OIL COOLER TRANSMISSION
Removal.. ............................................................. 30-14 Disassembly ........................................................ 30-62
FUEL INJECTION PUMP (LEFT AND RIGHT) TRANSMISSION CONTROL VALVE (ECMV)
Removal ............................................................... 30-16 Removal ............................................................... 30-94
Installation ........................................................... 30-16 Installation ........................................................... 30-94
AIR COMPRESSOR TRANSMISSION PUMP
Removal ............................................................... 30-16 Removal ............................................................... 30-94
WATER PUMP ECMV
Removal ............................................................... 30-18 Disassembly ..................................................... 30-95-I
Installation ........................................................... 30-18 Assembly .......................................................... 30-95-I
AFTER-COOLER DIFFERENTIAL (For standard)
Removal.. ............................................................. 30-18 Removal ............................................................... 30-96
TURBOCHARGER Disassembly ........................................................ 30-98
Removal ............................................................... 30-20 Assembly ........................................................... 30-I 02
Installation ........................................................... 30-20 DIFFERENTIAL (For with differential lock)
NOZZLE HOLDER Removal.. ........................................................ 30-I 1 I-l
Removal ............................................................... 30-20 Installation ...................................................... 30-I 1 l-l
Installation ........................................................... 30-20 Disassembly ................................................... 30-I 1 I-3
CYLINDER HEAD Assembly ........................................................ 30-I 1 l-7
Removal ............................................................... 30-22 CARRIER
Installation ........................................................... 30-24 Removal.. ........................................................... 30-I 12
ENGINE Installation ......................................................... 30-I 12
Removal ............................................................... 30-26 Disassembly ...................................................... 30-I 12
Installation ........................................................... 30-30 Assembly ........................................................... 30-I 12
RADIATOR, TORQUE CONVERTER OIL COOLER FINAL DRIVE
OUTPUT SHAFT REAR WHEEL BRAKE
Removal ............................................................... 30-34 Removal. ............................................................ 30-I 18
Installation ........................................................... 30-34 Installation ......................................................... 30-I 18
Disassembly ........................................................ 30-36 Disassembly ...................................................... 30-I 18
Assembly ............................................................. 30-36 Assembly ........................................................... 30-I 20
TORQUE CONVERTER, TRANSMISSION
Removal ............................................................... 30-38
Installation ........................................................... 30-40
30-l
0
PARKING BRAKE CALIPER FRONT BRAKE CHAMBER
Removal.. ........................................................... 30-122 Removal ............................................................. 30-174
Installation ......................................................... 30-122 Installation ......................................................... 30-174
Disassembly ...................................................... 30-122 Disassembly ...................................................... 30-176
Assembly ........................................................... 30-I 22 Assembly ........................................................... 30-I 80
PAKING BRAKE PAD REAR BRAKE CHAMBER
Removal ............................................................. 30-124 Removal ............................................................. 30-174
FRONT BRAKE CALIPER Disassembly ...................................................... 30-184
Removal ............................................................. 30-124 Assembly ........................................................... 30-188
Installation ......................................................... 30-124 AIR GOVERNOR
Disassembly ...................................................... 30-126 Removal ............................................................. 30-192
Assembly ........................................................... 30-126 Installation ......................................................... 30-192
FRONT FBRAKE CALIPER PAD Disassembly ...................................................... 30-I 92
Installation ......................................................... 30-126 SLACK ADJUSTER
STEERING VALVE Removal.. ........................................................... 30-194
Removal (HD785-3) ........................................... 30-128 Installation ......................................................... 30-194
Removal (HD9853) ........................................... 93- 2 Disassembly ...................................................... 30-194
Installation (HD785-3) ....................................... 30-128 Assembly ........................................................... 30-194
Installation (HD985-3) ....................................... 93- 2 BRAKE COOLING PUMP
FRONT WHEEL STEERING, HOIST PUMP
Removal ............................................................. 30-146 Removal ............................................................. 30-196
REAR WHEEL BRAKE COOLER
Removal.. ........................................................... 30-148 Removal ............................................................. 30-196
FRONT WHEEL HUB DEMAND VALVE g
Disassembly ...................................................... 30-150 Removal ............................................................. 30-198 z
Assembly ........................................................... 30-152 Installation ......................................................... 30-198 z
FRONT SUSPENSION Disassembly ...................................................... 30-200
Installation ......................................................... 30-156 RELIEF VALVE
VARIABLE DAMPER VALVE Disassembly ...................................................... 30-200
Removal .......................................................... 30-157-I Assembly ........................................................... 30-200
Installation ...................................................... 30-157-l EMERGENCY STEERING MOTOR PUMP
VARIABLE DAMPER SELECTOR VALVE Removal ............................................................. 30-202
Disassembly ................................................... 30-157-3 Installation ......................................................... 30-202
Assembly ........................................................ 30-157-3 STEERING CYLINDER
FIXED ATTENUATION VALVE Removal ............................................................. 30-202
Disassembly ................................................... 30-I 57-5 Installation ......................................................... 30-202
Assembly ........................................................ 30-157-5 Disassembly ...................................................... 30-204
FRONT SUSPENSION CYLINDER Assembly ........................................................... 30-206
Disassembly ...................................................... 30-I 58 HOIST VALVE
Assembly ........................................................... 30-I 58 Removal ............................................................. 30-210
REAR SUSPENSION CYLINDER Installation ......................................................... 30-210
Removal ............................................................. 30-160 Disassembly ...................................................... 30-212
Installation ......................................................... 30-160 Assembly ........................................................... 30-212
Disassembly ...................................................... 30-162 HOIST CYLINDER
Assembly ..................... .._................................... 30-I 62 Removal ............................................................. 30-214
PARKING BRAKE SPRING CYLINDER Installation ......................................................... 30-214
Removal ............................................................. 30-I 64 Disassembly ...................................................... 30-216
Installation ......................................................... 30-164 Assembly ........................................................... 30-218
Disassembly ...................................................... 30-166 BODY
Assembly ........................................................... 30-166 Removal ............................................................. 30-220
BRAKE VALVE Installation ......................................................... 30-220
Removal ............................................................. 30-168 TRANSMISSION CONTROLLER
Installation ......................................................... 30-168 Removal ............................................................. 30-222
Disassembly ...................................................... 30-170 Installation ......................................................... 30-222
Assembly ........................................................... 30-172
30-2
0
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked=, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 0 0 0 ASSEMBLY. . . . . . . . . Tilte of operation
A . . . . . _. . . . . _. . . . . . . . . . . . . . . . . . . . . . Precautions related to safety when carrying out the
operation
1. xxxx (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in operation
* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when
removing XXXX (1).
2. AAA(2): ._....................... m Indicates that a technique is listed for use
during installation
3. Cl Cl 0 Cl assembly (31
u : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Lubricant and Coolant Table
INSTALLATION OF 0 0 OASSEMBLY . . . . Title of operation

. Carry out installation in the reverse order to removal.
m . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique used during installation
* _............................ Technique or important point to remember when in-
stalling A A A (2).
. Adding water, oil . . . . . . . . . . . . . . . Step in operation
* _............................ Point to remember when adding water or oil
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools
(I) For details of the description, part number, and quantity of any tools (A,, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
4. Listing of tightening torque, weight, refill amount for oil and water
(1) If symbols such as w , &,orli8 appear in the operation procedure, See TIGHTENING
TORQUES AND STANDARD VALUES TABLE, MAINTENANCE STANDARD TABLE, WEIGHT
TABLE, and LUBRICANT AND COOLANT TABLE for details of the values.
30-3
Co
PRECAUTIONS WHEN CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.1
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.

. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws alternately.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
sr Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end)
Plug (nut end)
number Use the two items below as a set
07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
07376-51034 07221-21034 (Nut), 07222-01018 (Plus)
12 07376-51234 07221-21234 (Nut). 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal Sleeve head
Flange (hose end) Split flange
number (tube end)
04 07379-00400 07378-10400 07371-30400
05 1 07379-00500 07378-l 0500 1 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
A
A
Taper l/8
4D 4d
22 07049-02228 22 18.5 28 202F2001

24 107049-024301 24 1 20 1 30
27 07049-02734 27 22.5 34
30-4
0
2. Precautions for installation operations
l Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
l Install the hoses without twisting or interference.
l Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
l Bend the cotter pin or lock plate securely.
l When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
l When coating with gasket sealant, clean the surface and remove all oil and grease, check that
there is no dirt or damage, then coat uniformly with gasket sealant.
l Clean all parts, and correct any damage, dents, burrs, or rust.
l Coat rotating parts and sliding parts with engine oil.
l When press fitting parts, coat the surface with antifriction compound (LM-PI.
l After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
l When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then con-
nect securely.
l When using eyebolts, check that there is no deformation or deterioration, screw them fully, and
align the direction of the hook.
l When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3. Precautions when completing the operations
. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
* . If the hydraulic equipment has been removed and installed again, add engine oil to the specified
%
level. Run the engine to circulate the oil through the system. Then check the oil level again.
: . If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been re-
moved for repair, always bleed the air from the system after reassembling the parts.
* For details, see TESTING AND ADJUSTING, Bleeding air.
. Add the specified amount of grease (molybdenum disulphide grease) to the work equpment related
parts.
30-5
0
SPECIAL TOOL LIST
I
Nature of work ymbo I Part No. Part Name
Removal, installa-
tion of engine Centering engine
assembly, torque A 790-413-I 100 Centering tool 1 and torque
converter, transmis- converter
I
sion assembly
790-501-2000 Engine repair stand 1
1 790-901-2110 Bracket 1
_=/
790-901-2181 Plate 1 I
Disassembly,
assembly of torque Removal, installa-
3
converter, PTO 1 tion of stator shaft
2 790-413-l 130 Wrench
assembly round nut
Removal, installa-
3 791-346-I 400 Wrench tion of PTO pump
Disassembly, Checking operation

assembly of trans- C 799-301-1600 Oil leak tester kit (A)
of clutch, piston
mission assembly
- -
__I
790-501-2000 Engine repair stand 1
1
790-901-5110 Bracket 1
-
2 790-425-l 660 Wrench
-
Disassembly, Adjusting preload of
3 790-425-I 670 Adapter
assembly of differ- 3 - side bearing
ential assembly
4 792-525-3000 Micrometer
-
5 09003-07280 Wrench
- -
1 790-438-l 150 Fixture
-
2 792- 104-4501 Push tool

-
Disassembly, 1 Installation of rear
791-585-l 510 Installer
assembly of final wheel brake floating
drive, rear wheel E seal (for large
792-530-l 700 Push tool -i 1 diameter)
brake assembly
3
792-520-2110 lntaller 3 I Installation
of rear
wheel brake floating
seal (for small
792-530-I 600 Push tool 1 1diameter)
- -
Centering steering
Disassembly, 1 790-452-1200 Pilot ring tool 1
valve upper cover
assembly of steer- F - 1
ing valve assembly
- -
2 790-452-l 100 Installer set 1 I
Disassembly,
assembly of front 2
G 790-450-l 120 Plate
suspension cylinder
assembly
30-6
0
Model, q’ty
Nature of work symbol Part No. Part Name Remarks
HD785-3
, 790-502-1003 or
Cylinder repair stand
790-502-2000
790-102-3802 or Removal, installa-

Wrench assembly tion of cylinder
2
790-I 02-3791
head nut
Disassembly,
I
assembly of steer- Socket (width across
H 3 790-302-I 340 Removal, installa-
ing cylinder flats: 80 mm)
I tion of piston nut
assembly I I
4 790-720- 1000 Expander Expansion of piston

ring
5 790-720-I 660 Ring Compression of pis-

ton ring
-
, 790-502-1003 or
Disassembly, Cylinder repair stand
790-502-2000
assembly of hoist I
cylinder assembly Expansion of piston
2 1 790-720-10~ 1 Expander
ring
-
Removal, installa-
tion of body J 790-441-I 320 Hook Lifting tool for body
assembly assembly
I I
30-7
0
TIGHTENING TORQUES AND STANDARD VALUES TABLE
Corn Machine model

PO- Item Unit
nen HD785-3
1 Fuel injection tube sleeve nut 2.4fO.l

-
2 Fuel injection pump coupling lock bolt 9.oZto.5
-
3 Turbocharger mounting bolt 5.0f0.5
-
4 Nozzle holder connection 3.8kO.3
-
5 Nozzle holder connection locknut 4.OkO.5
-
6 Nozzle holder mounting bolt 6.75+0.75
-
kgm
7 Rocker arm mounting bolt
-
8 Crosshead screw locknut
.-iti -
t? 9 Rocker arm screw locknut
w -
IO Cylinder head mounting bolt
-
\kf *~:Mo~
F56103201
II Engine mount mounting bolt (front, rear) 1 kgm 1 56f6.0 (

-
1 Misalignment of drive shaft (front)
1) Left-right direction of shaft center Within 3.0
2) Out-of-parallel of shaft center in up-down mm

Within 3.0
direction
3) If not parallel, at place where it is farthest

Within 3.0
apart
-
.-s 2 Output shaft
5
t 1) Bearing cover mounting bolt I 11.5*1 .o I
I
3
2 2) Output shaft assembly mounting bolt I 11.5+1 .o I
-
3) Flange mounting bolt I 18+2.0 I
II
3 Transmlission mount mounting bolt (front, rear) kgm
4
2) Pump retainer mounting bolt I 1 6.75kO.75 1
30-8
@
Con Machine model
PO- Item Unit
nen HD785-3 I
4 3) Torque converter pump drain plug 1.15*0.15
4) Pump ring nut 0 22.5f2.5 I
0 47.5f2.5 I
F56103202
5) Stator, race mounting bolt bm 6.75f0.75 1
6) Housing mounting bolt
7) Pump mounting bolt
8) Pilot shaft mounting bolt
9) PTO gear mounting ring nut
10) Input coupling mounting bolt
11) Torque converter control valve assemblly

mounting bolt
5 Transmission assembly
1) Mounting bolt for plate for No. 2 clutch torque

converter output shaft speed detection
2) No. 2 clutch cylinder mounting bolt 6.5fl .O I

3) No. 2 clutch housing mounting bolt 11+1.0
4) No. 1 clutch ring gear mounting bolt 6.75kO.75
5) No. 1 clutch housing mounting bolt 18k2.0
6) Output shaft bearing holder plate mounting

6.75k0.75
bolt km
7) Output shaft cage mounting bolt 18k2.0
8) Tie bolt 26.51tl.5 I

9) No. 3 clutch ring gear mounting bolt 181t2.0 I
10) No. 3 clutch housing mounting bolt
11) ECMV mounting bolt +-j----
12) Drive shaft mounting

-
6 Differential assembly
1) Differential assembly mounting bolt kgm 94.5ItlO.O
2) Pinion, cage assembly mounting bolt 56t6.0 1
30-9
0
COIT Machine model
PO- Item Unit
nen HD785-3
6 3) Bevel gear mounting bolt I 94.5+10 I

4) Pinion gear bearing adjustment nut I I 67.5+8 I
5) Differential case mounting bolt
I 94.5510 I
6) Side bearing cap mounting bolt 175f20
kgm
7) Bevel pinion gear center bearing holder
11.5+1 .o
bolt
8) Coupling mounting bolt 225f25
9) Parking brake support mounting bolt I I 56f6.0 I

10) Parking brake caliper plate mounting bolt I I 561t6.0 I
+%-I-
.-C
2 7 -inal drive, rear brake assembly

b
3 1) Carrier planetary gear plate mounting bolt
a”
2) Rear brake wheel hub nut
3) Wheel hub retainer mounting bolt

13.oIto.5
(when adjusting preload) I
94.5*10
(when tightening fully) km
5) Carrier assembly mounting bolt
6) Floating seal retainer mounting bolt
7) Rear brake cylinder mounting bolt
8) Rear brake cylinder and outer gear

mounting bolt 56+6.0 I
1 ‘arking brake
1) Disc plate mounting bolt 56zt6.0
2) Caliper plate mounting bolt
3) Spring cylinder assembly mounting nut
4) Spring cylinder support mounting bolt
5) Spring cylinder piston adjustment nut
2 =ront brake
1) Caliper mounting bolt kgm

2) Caliper pad mounting pin set bolt
1 Steering valve
1) Upper cover mounting bolt kgm 2.75f0.25
2) End cover mounting bolt 6.950.7 I

2 Wheel clamp nut
-
Conn- Machine model

PO Item Unit
ner1t HD785-3
3 Front wheel hub
1) Brake disc mounting bolt

(when adjusting preload) km

(when tightening fully) 94.5 * 10
. -
J 4 Suspension cylinder
1) Air bleed valve 4.5 + 0.5

,
2) Feed valve 4.5 f 0.5
km
3) Oil level valve 4.5 + 0.5
4) Damping force selector valve mounting

bolt 28.25 + 3.25
1 Brake valve tube sleeve nut
Brake chamber assembly (front, rear)
1) Cover plug km
2) Cover and air cylinder mounting bolt
3) Oil cylinder mounting bolt 3.85 f 0.35 1
Steering cylinder assembly
1) Piston nut km 405 f 40.5
2) Cylinder head nut 95 * 9.5
2 -foist valve assembly
1) Detent mounting bolt 11 fl.O
2) Main relief valve assembly km 32.5 f 4.75 1
3) Main relief valve holder locknut 15.5 zt 2.5 I
4) Main relief valve screw locknut 7.0 f 1 .o I
..”
3 Hoist cylinder assembly
1) Piston mounting nut km

2) Cylinder head mounting bolt
30-11
0
WEIGHT TABLE
Unit: kg
Machine model HD785-3
Serial No. I 2001 - ~I
Fuel Injection pump assembly (right) (left) I I

Intake manifold assembly 50
.-?
Exhaust manifold assembly 30
p
Lu
Engine, output shaft assembly 3,370
Radiator assembly 410
I Torque converter, transmission assembly 1,960
I Torque converter assembly I 582 7
I Transmission control valve assembly (ECMV) I 80 I

C
._
m
1 Drive shaft assembly (front) I 47 I
z
t Drive shaft assembly (rear) 118
3
n” Differential assembly 1,500
Differential case (with differential lock) 55
I Carrier assembly I 390
I Ring gear 240 I

I Parking brake caliper assembly I 30 I
Front suspension cylinder assembly
s Front wheel hub assembly

5
zi Front brake caliper assembly
.-c” Rear wheel brake assembly
z
aY
6 Front, rear wheel assembly
I Steering valve assembly I 23 I

Rear suspension cylinder assembly 240
Steering cylinder assembly 75
Hoist, steering pump assembly 44

5
Iii Brake cooling pump assembly 51
$
.o Demand valve assembly 66
5 _
h
u Hoist valve assembly 37
I”
Hoist cylinder assembly 330
Brake oil cooler 247
-p” Dump body assembly 14,250

mo
30-l 2
@
LUBRICANT AND COOLANT TABLE .
Unit: &
Machine mode HD785-3

Remarks
Serial No. 2001 -
Engine cooling water 228
Engine oil pan 56
Transmission oil pan 102
132 ( ) is for machines

Differential case
(120) with differential lock
Final drive gear case 64 (Each side)

I
Steering, hoist: 153
Hydraulic tank
Brake cooling: 246
Front suspension cylinder 20.2

I I
Rear suspension cylinder 17.2
30-l 3
@
REMOVAL OF STARTING MOTOR REMOVAL OF ENGINE OIL
ASSEMBLY COOLER ASSEMBLY
A Disconnect the cable from the negative 1. Remove fuel injection pump assembly(right)
(-) terminal of the battery. For details, see REMOVAL OF FUEL INJEC-
TION PUMP ASSEMBLY (RIGHT).
1. Disconnect wiring (1). (See Fl)
2. Drain cooling water
2. Disconnect connector (2) and remove
bracket (3). (See Fl) & For details, see Lubricant and Coo-
3. Remove bottom starting motor (4). (See Fl) lant Table
4. Remove top starting motor (5). (See Fl)
3. Disconnect cooling water bypass tube (1).
(See F3)
4. Remove oil cooler assembly (front) (2).
INSTALLATION OF STARTING
(See F3)
MOTOR ASSEMBLY
5. Remove manifold (3). (See F3)
6. Remove oil cooler assembly (rear) (4).
l Carry out installation in the reverse order
(See F3)
to removal.
REMOVAL OF ALTERNATOR INSTALLATION OF ENGINE OIL

ASSEMBLY COOLER ASSEMBLY
A Disconnect the cable from the negative l Carry out installation in the reverse order
(-) terminal of the battery. to removal.
l Install fuel injection pump assembly
1. Disconnect wiring (1). (See F2)
(right).
2. Remove adjustment nuts (2). (See F2)
For details, see INSTALLATION OF FUEL
3. Remove mounting bolts (3). (See F2) m
INJECTION PUMP ASSEMBLY (RIGHT).
4. Remove belt (4). (See F2)
5. Remove alternator assembly (5). (See F2)
INSTALLATION OF ALTERNATOR
ASSEMBLY

to removal.
* Dimension of belt tension: For details, see

Standard Value Table for Engine Related
Parts
F3
I
f- \ \ ,
r
3
2
.4 1 F56103203 u u F56703205
J
f-2
F56103204
REMOVAL OF FUEL INJECTION REMOVAL OF AIR COMPRESSOR
PUMP ASSEMBLY (LEFT AND ASSEMBLY
RIGHT)
l Drain cooling water.
A Disconnect the cable from the negative

(-) terminal of the battery.
& For details, see Lubricant and Coolant
Table.
1. Remove injection pump coupling cover.
1. Air tube
2. Disconnect injection pump control wiring
1) Disconnect inlet tubes (1) and (2).
connectors (1). (See Fl )
(See F3)
3. Disconnect emergency stop solenoid con-
2) Disconnect outlet tubes (3) and (4).
nector (2). (See Fl)
(See F3)
4. Disconnect lubrication tubes (3). (See F2)
3) Disconnect unload tubes (5). (6), and (7).
5. Disconnect feed pump hoses (4). (See F2)
(See F3, F4)
6. Disconnect tubes (5) and (6). (See F2)
2. Disconnect cooling water tubes (8). (9), and
7. Disconnect fuel hoses (7). (See F2)
(10). (See F3, F4)
8. Disconnect fuel injection tubes (8). (See F2)
3. Disconnect lubrication tubes (11) and (12).
m
(See F3, F4)
9. Remove injection pump mounting bolts (9).
4. Remove oil filler (13). (See F4)
(See F2)
5. Remove front air compressor (14).
10. Remove coupling lock bolt (10). (See F2) m
(See F4, F5) m
11. Remove fuel injection pump assembly (11).
* Part has a spline shaft (15). (See F5)
(See F2) m
6. Remove rear compressor (16). (See F4, F5)
* Keep the coupling key in a safe place and
m
be careful not to lose it.
* Part has a gear (17). (See F5)
Injection pump assembly: For details,
6 kg see Weight Table.
INSTALLATION OF FUEL INSTALLATION OF AIR

INJECTION PUMP ASSEMBLY COMPRESSOR ASSEMBLY
(LEFT AND RIGHT)
l Carry out installation in the reverse order to removal.
to removal.
* When installing compressors (14) and

Sleeve nut: For details, see Tightening (16), align the missing tooth for position-
Torques and Standard Values Table. ing spline shaft (15) and gear (17).
(See F4, F5)
l Refilling with water
Coupling lock bolt: For details, see * Refill water to the specified level and run
Tightening Torques and StandardValues the engine to circulate the water through
Table. the system. Then check the water level
again.
Adjust the injection timing.

For details, see TESTING AND ADJUST-
ING.
F3
I 6 ‘2 F56103208 1
F2 F4
14
12 / ‘\
F56103209
F5
Missing
(for positioning)
F56103210
REMOVAL OF WATER PUMP REMOVAL OF AFTER-COOLER
ASSEMBLY CORE ASSEMBLY
1. Drain cooling water A Raise the dump body and lock with the
safety pin.
A For details, see Lubricant and Coo-
lant Table. A Disconnect the cable from the negative
2. Remove corrosion resistor (1). (See Fl )
3. Piping 1. Drain cooling water
1) Disconnect bypass tube (2). (See Fl )
& For details, see Lubricant and Coo-
2) Disconnect after-cooler inlet tube (3).
lant Table.
(See Fl)
3) Remove brake cooler outlet tube (4). 2. Remove intake pipes (1). (See F3) (31cll
(See Fl) 3. Disconnect electrical intake air heater wiring
4) Remove engine inlet tube (5). (See Fl) (2). (See F2)
5) Disconnect by-pass tube (6). (See Fl) 4. Remove intake connector (3). (See F3)
6) Remove water pump inlet tube (7). 5. Disconnect cooling water tubes (4), (5), (6).
(See Fl) and (7). (See F4, F5, F6)
4. Remove water pump assembly (8). (See Fl) 6. Remove connector (8). (See F6)
7. Remove cover (9). (See F6)
8. Remove core assembly (10). (See F6)
INSTALLATION OF WATER PUMP INSTALLATION OF AFTER-

ASSEMBLY COOLER CORE ASSEMBLY
l Carry out installation in the reverse order, l Carry out installation in the reverse order
to removal. to removal.
* Refill water to the specified level and run
the engine to circulate the water through Only when removing the left bank core assembly
the system. Then check the water level
again. Refilling with water
* Refill water to the specified level and run
the engine to circulate the water through
again.
Fl F2
‘1
F56103211 F56103212 F56103213
F4 F5
F6
@h ‘8 F5610321E
REMOVAL OF TURBOCHARGER REMOVAL OF NOZZLE HOLDER
ASSEMBLY ASSEMBLY
1. Remove exhaust pipes (1) and (2). (See Fl) 1. Remove intake pipe (1). (See F4) 13Ebll
2. Remove intake pipes (3) and (4). (See Fl) 2. Remove cover (2). (See F5)
3. Remove intake connector (5) and (6). 3. Disconnect fuel injection pipe (3). (See F5)
(See Fl, F2) 1#21
4. Disconnect oil supply tube (7). (See F3) 4. Remove connection (4). (See F6) 113)
5. Disconnect drain tube (8). (See F3) 5. Remove holder (5). (See F6) m
6. Remove turbocharger assembly (left) (9) and 6. Remove nozzle holder assembly (6). (See F7)
(right) (10). (See F3) m 13#5)
+ Screw in the bolt and use a lever to pull
out the assembly.
* Check that there is a gasket fitted at the
tip of the nozzle holder.
j, Mark the cylinder number, be careful not
to damage the tip, and keep in a safe place.
INSTALLATION OF INSTALLATION OF NOZZLE

TURBOCHARGER ASSEMBLY HOLDER ASSEMBLY
l Carry out installation in the reverse order l Carry out installation in the reverse order
w Turbocharger mounting bolt: For details, No. 4, 5, 6 cylinders on the left bank only
see Tightening Torques and Standard
Values Table.
Qa Sleeve nut: For details, see Tightening
Torques and Standard Values Table.
m
m Connection: For details, see Tightening
w Locknut: For details, see Tightening

* Fit a spherical washer to the bolt, then

install.
w Holder mounting bolt: For details, see

Tightening TorquesandStandardVaIues
Table.
m
* When installing the nozzle holder assembly,
check the nozzle mount and clean it, then
install.
30-20
0
Fl F4
F56103217 \’ F56103220
F2 F5
F56103218 II
F56103221
F------
F3
4 F56103222
F7
30621
REMOVAL OF CYLINDER HEAD
ASSEMBLY
A Raise the dump body and lock with the 9. Intake manifold assembly (for right bank)
safety pin. 1) Disconnect electrical intake air heater

wiring (13). (See F5)
2) Disconnect after-cooler tubes (14) and
(15). (See F5)
1. Drain cooling water 3) Remove intake manifold assembly (right
2. Remove intake pipes (1). (See FI ) bank) (16). (See F5)
3. Remove exhaust pipes (2). (See Fl ) 4) Remove electrical intake air heater (12).
(See F5)
* For details, see the procedure for the
left bank.
4. Disconnect lubrication hoses (3). (See F2)
5. Remove drain tubes (4). (See F2)
10. Disconnect fuel injection pipe (17). (See F6)
6. Remove intake connector (5). (See F2)
Il. Disconnect spill tube (18). (See F6)

12. Disconnect air vent tubes (19). (See F6)
13. Remove head cover (20). (See F6)
T:
7. Remove exhaust manifold and turbocharger 14. Remove rocker arm (21). (See F7) m Z
assemblies (6). (See F3) 15. Remove push rod (22). (See F8) m .Z
16. Remove crosshead (23).(See F8) m
17. Nozzle holder assembly.
* For details, see REMOVAL OF NOZZLE
HOLDER ASSEMBLY.
8. Intake manifold assembly (for left bank) 18. Remove rocker arm housing (24). (See F9)
1) Disconnect air compressor tubes (7) and m
(8). (See F4) 19. Remove cylinder head assembly (25).
2) Disconnect after-cooler tube (9). (See F4) (See FlO)m
3) Disconnect 2 heater relay wires (10).
(See F4)
4) Remove intake manifold assembly (left
bank) (11). (See F4)
5) Remove electrical intake air heater (12).
(See F4)
Fl F5
I’ F56103224
F2
I
,8mbv 17
I I F56103225 F56103229
F7 F8
F3
v F56103226
F4 F9 FlO
F56103227
INSTALLATION OF CYLINDER
HEAD ASSEMBLY

to removal. j, Check that there is no dirt or dust on the
mounting surface of the cylinder head or
inside the cylinder, then set the cylinder
Sleeve nut: For details, see Tightening head gasket in position.
Torques and Standard Values Table * When installing the gasket, check that the
grommets have not come out.
Qa Cylinder head mounting bolt: For details,

j, Check that the ball of the adjustment screw see Tightening Torques and Standard
is fitted securely in the socket of the push Values Table
rod.
w Rocker arm mounting bolt: For details, Refill water to the specified level and run
see Tightening Torques and Standard the engine to circulate the water through
Values Table the system. Then check the water level
again.
* Check that the push rod is fitted securely

in the cam follower.
peJ
* Adjust the crosshead as follows.
0 Loosen the locknut, and turn back the
adjustment screw.
8
ii) Hold the top surface of the crosshead
lightly, and screw in the adjustment
z
8
screw.
iii) After the adjustment screw contacts,
screw it in a further 20’.
iv) Tighten the locknut to hold it at this
position.
Qa Locknut: For details, see Tightening

Torques and Standard Values Table
m
* Adjust the valve clearance.
For details, see TESTING AND ADJUSTING,
Adjusting valve clearance.
w Rocker arm screw locknut: For details,

Values Table
30-24
Co
REMOVAL OF ENGINE
ASSEMBLY
A Stop the machine on level ground, and 8) Disconnect engine oil pressure switch
put blocks under the wheels. wires (10). (See F8)
9) Disconnect engine oil level sensorwiring
A Raise the dump body and lock with the
(11). (See F9)
safety pin.

* Close the fuel supply valve.

1. Remove radiator assembly.
For derails, see REMOVAL OF RADIATOR
ASSEMBLY. 10) Disconnect engine ground connection
2. Wiring wiring (12). (See Fl 0)
1) Remove alternator (1). (See Fl)
2) Remove air compressor wiring connector
(2).(See Fl )
3) Disconnect electrical intake air heater
relay wiring (left bank) (3). (See F2); (right
bank) (4). (See F3)
4) Disconnect engine water temperature 3. Remove intake pipes (13). (See Fl 1)

sensor connector (5). (See F4) 4. Remove exhaust pipe (14). (See Fl 1)
5) Disconnect 2 starting motor wires (6).
(See F5)
6) Disconnect 2 starting motor wiring con-
nectors (7).(See F5)
7) Disconnect wiring connectors (left bank) 5. Left bank fuel hoses

(8) and (right bank) (9) of engine emer- 1) Disconnect priming pump inlet hose (15).
gency stop solenoid. (See F6, F7) (See F12)
2) Disconnect return hose (16). (See F12)
30-26
0
Fl F8 F9
F56103234
F2 F3 FlO
F56103235
F4 F5 Fll
8
7
F56103238 \’ F56103245
F12
F.56103239 F56103240 F56103246
30627
6. Right bank fuel hoses 10. Drive shaft (input end)
1) Disconnect priming hoses (17). (See Fl) 1) Remove guard (24). (See F5) m
2) Disconnect fuel filter hoses (18). (See Fl) 2) Remove drive shaft (25). (See F5)
3) Disconnect return hose (19). (See Fl)
7. Remove cooling water pipe (20). (See F2) 11. Engine assembly
1) Remove mounting bolts (front) (26).
(See F6) m
2) Remove mounting bolts (rear) (27).
(See F6) m
8. Remove engine oil hoses (21). (See F3) 3) Remove engine assembly (28). (See F7) ;;
m g
& kg Engine assembly: For details, see

Weight Table
9. Air p/ping
1) Disconnect hose (22) at delivery end.
(See F4)
2) Disconnect unload hose (23). (See F4)
30-28
0
Fl. F5
I
24
1247 F56103251
F2 F6
F56103248 h F56103252
F3 F7
F4
/ F56103250
30-29
0
INSTALLATION OF ENGINE
ASSEMBLY

to removal.
l Install the radiator assembly.
For details, see INSTALLATION OF RADIA-
TOR ASSEMBLY.
Drive shaft (front) mounting bolt: Thread

tightener (LT-2)
Drive shaft (front) mounting bolt: For

details, see Tightening Torques and
Standard Values Table
Engine mounting bolt: For details, see

Tightening Torquesand StandardValues
Table
When installing the engine assembly,

assemble cushions (29) and (30).
See the procedure for centering the engine
assembly and torque converter, transmis-
sion assembly.
Refilling with water
Refill water to the specified level and run
the engine to circulate the water through
again.
Refilling with oil
Refill oil to the specified level and run the
engine to circulate the oil through the
system. Then check the oil level again.
30-30
0
I
REMOVAL OF RADIATOR, INSTALLATION OF RADIATOR,

TORQUE CONVERTER Oli TORQUE CONVERTER OIL
COOLER ASSEMBLY COOLER ASSEMBLY
1. Drain cooling water. l Carry out installation in the reverse order

2. Radiator guard to removal.
1) Remove wind break plate (1). (See Fl) l Refilling with water
2) Disconnect light wire connector (2). Refill water to the specified level and run
(See F2) the engine to circulate the water through
3) Disconnect air horn hoses (3). (See F3) the system. Then check the water level
4) Remove radiator guard bottom mount (4). again.
(See F4) m
5) Remove radiator guard assembly (5). ml
(See F5) m Sling the assembly when removing or installing
3. Remove fan net (6). (See F6) the mounting bolts.
4. Remove thermostat outlet hoses (7) and (8).
(See F6) lf2(
5. Disconnect aeration hose (9). (See F6) Check the number of the shims.
6. Remove bypass hose (10). (See F6)
7. Remove radiator outlet hose (11). (See F7)
8. Remove radiator bypass hose (12). (See F7) Sling the assembly when removing or installing
9. Remove torque converter oil cooler hoses the mounting bolts.
(13) and (14). (See F7)
10. Remove radiator top mount.
Il. Remove radiator bottom mount.
12. Remove radiator and torque converter oil
cooler assembly.
& kg Radiator, torque converter oil cooler

assembly: For details, see Weight
Table
30-32
0
Fl F6
F.56103254 I 9 F56103259 1
F2 F3 F7
11
F56103255 F56103260
F4
B
F5
F56103258
REMOVAL OF OUTPUT SHAFT INSTALLATION OF OUTPUT
ASSEMBLY SHAFT ASSEMBLY
A Stop the machine on level ground, and l Carry out installation in the reverse order to
put blocks under the wheels. removal.

l Fill with ENS grease.
For details of the procedure, see ASSEMBLY
safety pin.
OF OUTPUT SHAFT ASSEMBLY.
1 Remove drive shaft assembly (1). (See Fl )
m
el kg Drive shaft assembly: For details, see & Drive shaft mounting bolt: Thread tight-
Weight Table ener (LT-2)
2. Remove coupling (2). (See Fl) m m Drive shaft mounting bolt: For details,
3. Remove bearing cover (3). (See Fl) m see Tightening Torques and Standard
4. Remove snap ring (4). (See F2) Values Table
* Sling the cover, then use eyebolts and lf21
guide bolts to remove it.
6. Remove output shaft assemly (6). (See F3) & Spline: ENS grease
m * Remove all other grease completely before
7. Remove bearing (7). (See F4) m using ENS grease; do not mix ENS grease with
any other grease.
ENS grease Part No.: 427-l 2-l 1871
(2 kg can)
& Bearing cover mounting bolt: Thread z

tightener (LT-2)
w Bearing cover mounting bolt: For details,

Values Table
a Output shaft mounting bolt: Thread

tightener (LT-2)
Output shaft mounting bolt: For details,

Values Table
a Bearing: ENS grease
* Coat the whole circumference of the bearing

inside diameter and shaft outside diameter.
30-34
8
Fl
F2
F56103262
F3
I ‘6 F56103263
F4
30-35
0
DISASSEMBLY OF OUTPUT ASSEMBLY OF OUTPUT SHAFT
SHAFT ASSEMBLY ASSEMBLY
1. Oil cage assembly 1. Using push tool, press fit bearing (11) to
Remove oil seal (1) from cage (2). (See Fl) flywheel. (See Fl, F3)
2. Cover assembly 2. Assembly of damper assembly

Remove bearing (3) from cover (4). (See Fl) 1) Coat mating surface at one side of flange
(6) and outer body (10) with adhesive, and
3. Damper assembly (5) assemble. (See Fl, F3)
1) To keep the same balance after assembly 2) Install body assembly (7). (See Fl)
as before disassembly, mark the set 3) Install outer body (lo), body assembly (7),
position of flange (6). body assembly (7) and rubbers (8) and (9). (See Fl, F3)
and outer body (10). (See Fl ) * Check the assembly position of large
2) Remove body assembly (7) and rubbers rubber (8) and small rubber (9) when
(8) and (9) from outer body (10). (See Fl) assembling. (See F2)
* There are two types (large and small) * F2 shows the view as seen from
for rubbers (8) and (9), so confirm the torque converter.
position of installation. (See Fl) * Before assembling, coat outer body
3) Remove bearing (11) from flywheel. (lo), body assembly (7) and rubbers (8)
(See Fl) and (9) with grease. (See Fl, F3)
a_ (lo), (7), (8), (9): Grease (G2-LI)
4) Install flange (6).
& Flange mating surface: Adhesive

(LG-4)
& Mounting bolt: Thread tightener

(LT-2)
m Mounting bolt: See Tightening

Torque and Standard Values Table
* Align the marks on the outer body, inner

body, and flange, then install.
3. Install damper assembly(5) to flywheel.

(See Fl)
a Body assembly shaft spline: ENS

grease
4. Press fit bearing (3) to cover (4).

(See Fl, F3)
6 Bearing: ENS grease
5. Install cover assembly to flywheel.
&I kg Cover assembly: See Weight Table
30-36
0
561 F03356
F2 F3
561 F03357
561 F03358
30-37
8
6. Assemble oil seal (1) to cage (2). (See F3)
& Oil seal: ENS grease
7. Install cage assembly to cover assembly.

(See F3)
l Procedure for filling with ENS grese (See F4)

1) ENS grease Part No.: 427-l 2-l 1871
2) Locations for filling with ENS grease,
amount of grease (total weight: approx.
5009) and locations for coating with grease
30-37-l
8
F4
Coat whole
circumference of Pack 2( n width at
60 % pack outside diameter of three place!s around Portion Q
Komatsu engine : 30 g shaft and inside circum’fere nce of (displacement
Commins engine : diameter of bearing labyrin th Full pack (759) indication)
I /
Full pack (659)
‘Coat between
grea se lip and dust lip
50% pack (58g)
Portion Q
Full pack (9g)
Coat: whole
circumference of
spline
90% pack (559)

60% pack (909)
\ Full pack (759)
Section B-B
561 FO3360 561 FO3356
30-37-2
@J
REMOVAL OF TORQUE CONVER-
TER, TRANSMISSION ASSEMBLY
A Stop the machine on level ground, and 3) Remove pump tubes (6) and (7) for brake.
put blocks under the wheels. (See F6)

safety pin.
1. Drain transmission oil.

2. Drain brake oil. m
A For details, see Lubricant and Coo-

lant Table.
3. Wiring 4) Disconnect pump tubes (8) and (9) for

1) Disconnect transmission control wiring steering and hoist. (See F7)
connectors (1). (See Fl)
2) Disconnect transmission oil level sensor

connector (2). (See F2)
8
4. Remove 6 pump outlet hoses (3). (See F3) 6. Drive shaft (input end) z
1) Remove guard (10). (See F8) ;3
2) Remove drive shaft (11). (See F8) m
5. Pump suction tubes 7. Drive shaft (output end)

1) Remove tube (4) for transmission pump. 1) Remove guard (12). (See F9)
(See F4) m 2) Remove drive shaft (13). (See F9) m
2) Remove clamp (5). (See F4)
30-38
0
Fl
F56103268 / F56103272
F2 F7
‘2
/
F56103269
F8
1270
F4 *
30-39
0
8. Torque converter, transmission assembly PROCEDURE FOR CENTERING
1) Remove front mount (14). (See Fl) m THE ENGINE ASSEMBLY AND
TORQUE CONVERTER,
TRANSMISSION ASSEMBLY
0 When the engine assembly, torque conver-
ter and transmission assembly, or drive shaft
have been removed, carry out centering as
follows.
1. Install tool A to the couplings at the engine

end and torque converter end.
2. While turning coupling at torque converter

2) Remove rear mount (15). (See F2) m
end one turn, carry out centering so that
collar @ rotates smoothly on both shafts.
(See F4, F5)
jr Move the torque converter and transmis-
sion assembly end when centering.
[Reference]
The misalignment should be within 3 mm
in both the up-down and left-right directions.
(See F6)
3) Remove torque converter and transmis- * However, if they are not parallel, the
sion assembly (16). (See F3) m distance at the point where they are
farthest apart must be within 3 mm.
kg For details, see Weight Table
LEY?I
INSTALLATION OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY

to removal.
It is enough to drain about l/3.
m
It contacts the brake pump tube, so remove it.
& Mounting bolt: Thread tightener (LT-2)
w Mounting bolt: For details, see Tighten-

ing Torques and Standard Values Table
N Mounting bolt: For details, see Tighten-

See the procedure for centering the engine

assembly and torque converter, transmission
assembly.
Fl F4
Torque
Engine en% VCend
F56103276 F56103280
F2 F5
Torque
ingine end converter enc
\
F56103281
F3
F66103279
REMOVAL OF TORQUE
CONVERTER CONTROL VALVE
ASSEMBLY

safety pin.
1. Remove cover (1) and hose (2). (See Fl )

2. Disconnect lockup solenoid valve wiring
connector (3). (See F2)
3. Disconnect tube (4). (See F2)
4. Remove torque converter control valve
assembly (5). (See F2) m
INSTALLATION OF TORQUE
CONVERTER CONTROL VALVE
ASSEMBLY

to removal.
Torque converter control valve assembly

mounting bolt: For details, see Tighten-
30-42
0
Fl
F2
30-43
0
DISASSENBLY OF TORQUE ASSEMBLY OF TORQUE
CONVERTER CONTROL VALVE CONVERTER CONTROL VALVE
ASSEMBLY ASSEMBLY
1. Remove plate (I), then remove pistons (2) * Clean all parts, and check for dirt or damage.
and (4). spring (3), and torque converter relief Coat the sliding surfaces of all parts with
valve (5). (See Fl) engine oil before installing.
2. Remove cover (6), then remove spring (7). 1. Insert lockup valve (23), assemble pistons
(See Fl) (22) and (20), and spring (21), then fit O-
3. Remove cover (8). then remove spring (9). ring and install cover (19). (See Fl )
(See Fl) 2. Fit ring (18) and assemble spring (17) and
4. Remove plate (I 0), then remove pistons (11) piston (16). then fit O-ring and install cover
and (13), spring (12), and main relief valve (I 5). (See Fl )
(14). (See Fl) 3. Insert main relief valve (14), assemble
5. Remove cover (15), then remove piston (16), pistons (I 3) and (1 I), and spring (12), then
spring (I 7), and ring (18). (See Fl) fit O-ring and install plate (10). (See Fl)
6. Remove cover (19). then remove pistons (20) 4. Assemble spring (9), then fit O-ring and
and (22), spring (21). and lockup valve (23). install cover (8). (See Fl)
(See Fl) 5. Insert torque converter relief valve (5),
assemble spring (7), then fit O-ring and
install cover (6). (See Fl)
6. Assemble pistons (4) and (2). and spring (3).
then fit O-ring and install plate (1). (See Fl)
Fl
30-45
0
DISCONNECTION OF TORQUE CONNECTION OF TORQUE
CONVERTER ASSEMBLY AND CONVERTER ASSEMBLY AND
TRANSMISSION ASSEMBLY TRANSMISSION ASSEMBLY
1. Remove pump assemblies (l), (2), and (3). 1. Before connecting torque converter and
(See Fl) transmission, check O-ring. (See F5)
2. Remove trunnion (4). (See Fl) 2. Assemble transmission input shaft (9) and
3. Remove cover (5), and disconnect torque seal ring (10). (See F4)
converter oil temperature sensor connector
& Transmission input shaft: Grease
(6). (See F2, F3)
(G2-LI)
4. Disconncet lockup solenoid connector (7).
(See F3) 3. Using lever block, raise torque converter
5. Set with torque converter end at top. assembly (8) horizontally, then lower it
6. Using lever block, raise perpendicularly, slowly, and align torque converter stator and
then disconnect torque converter assembly transmission input shaft spline, then install.
(8) from transmission. (See F4) 4. Using lever block, set transmission assembly
horizontally.
PI kg Torque converter assembly: For
5. Connect lockup solenoid connector (7).
details, see Weight Table
(See F3)
6. Connect oil temperature sensor connector
(6) and install cover (5). (See F3, F2)
7. Install trunnion (4). (See Fl)
8. Fit O-rings and install pump assemblies (3),
(2), and (1). (See Fl)
Fl F4
9
AlO
F2
F56103286 F56103288
F3
O-ring (d)
O-ring (a)
O-ring (c)
-O-ring (b)
30-47
0
DISASSEMBLY OF TORQUE
CONVERTER, PTO ASSEMBLY
1. Control valve assembly 3) Remove turbine and clutch assembly (10).

1) Remove lubrication tube (2). (See Fl) (See F5)
2) Remove control valve assembly (3).
(See Fl )
2. PTO assembly 4. Stator

1) Set torque converter and PTO assembly Rotate stator assembly (11) clockwise, and
in tool Bi. (See F2) pull up to remove. (See F6)
2) Remove holder (6) and input coupling (5).
(See F2) ,
3) Screw in forcing screws, and remove PTO 5. Pump assembly zi

assembly (7). (See F3) 1) Using tool B3, remove nut (12). (See F7) ;3
2) Remove plug (13), then tap inner race
from this hole, and remove pump assem-
bly (14). (See F8, F9)
* If the bearing comes out, pump assem-
bly (14) will fall, so stop and set the
pump assembly facing up before fin-
ishing the operation.
3. Turbine, clutch assembly

1) Remove drain plug (8), and drain oil from
torque converter. (See F4)
2) Remove pump mouting bolts (9). (See F4)
* Set the turbine and clutch assembly
facing up. If it is facing down, the
assembly will fall when the last pump
mounting bolts are removed.
F5
F2 F6
F56103291
F3 F7
8
r
B3
\
7
103292 F56103296
F4 F8 F9
F56103297 If3 F56103298
30-49
0
6. Shaft
1) Remove seal ring (15). (See F2)
2) Remove mounting bolts, then tap out to
transmission end, and remove shaft (16).
(See F2)
* This is not necessary if the shaft is not
to be replaced.
F56103300
DISASSEMBLY OF TURBINE, CLUTCH
ASSEMBLY
1. Shaft 4. Ring gear

1) Using forcing screws, remove gear (1). Remove ring gear (8). (See F5)
(See Fl)
2)Using forcing screws, remove shaft (2). 5. Disc, plate
(See Fl) Remove disc (9) and plate (10). (See F5)
2. Turbine assembly
1) Remove snap ring (3), then remove spacer
(4). (See F2)
2) Turn over turbine, clutch assembly, knock
out bearing inner race from boss end, then
remove turbine assembly (5). (See F2)
* Set the turbine boss on a block (height:
approx. 50 mm).
3. Housing
1) Set housing end facing up, and remove
housing assembly (6). (See F3)
2) Remove piston (7) and bearing (12) from

housing. (See F4)
Fl F5
F56103301 F56 103305
F2
I F56103302
F3
I F56103303
F4
12 7
F56103304
ASSEMBLY OF TORQUE CONVERTER, PTO ASSEMBLY
ASSEMBLY OF TURBINE, CLUTCH

ASSEMBLY
1. Turbine 2) Insert spacer (4), and install snap ring (3).

Set case (11) and turbine assembly (5) in (See F5)
position. (See Fl )
* Put a block under the turbine, and align
the disc mounting surface.
2. Ring gear 7. Shaft

Install ring gear (8). (See F2) 1) Using press fit tool, press fit inner race
(13) in shaft (2). (See F6)
3. Disc, plate
Install disc (9) and plate (10). (See F2)
0
0
4. Piston 2) Install shaft (2), then fit gear (1) and z
Assemble seal ring, and install piston (7) to tighten bolts. (See F7) 8
housing (6). (See F3) * Tighten the mounting bolts uniformly.
&Mounting bolt: Thread tightener

(LT-2)
B Mounting bolt: For details, see

Tightening Torques and Standard
Values Table
5. Housing
Install housing (6). (See F4)

(LT-2)
w Mounting bolt: For details, see

Values Table
6. Bearing
1) Press fit bearing (12). (See F4)
jr Press fit the inner race and the outer
race at the same time.
Fl F5
11 5
4 3
I F56103306K F56103310
F2 F6
1 F56103307 F56103311
F3 F7
B
I F56103308 1
F4
12 6,
/
F56103309
ASSEMBLY OF TORQUE
CONVERTER, PTO ASSEMBLY
1. Shaft 3. Stator
1) Set torque converter housing in tool BI. 1) Assemble the following parts to the stator.
2) Install shaft (16). (See Fl ) 0 Install snap ring (24) to outer race (23).
(See F4)
m Mounting bolt: For details, see
ii) Install one-way clutch (25) to outer
race (23). (See F4)
Values Table
+ Be careful not to damage the sprag.
3) Install seal ring (15). (See Fl)
2. Pump assembly * Install the one-way clutch so that

1) Assemble pump assembly as follows. the arrow showing the direction of
i) Install bearing (19) to guide (18). free rotation points clockwise (right)
(See F2) as seen from the lip of the outer
* Check the common number of the race.
bearing, and the direction of instal- Do not remove the sprag.(See F5)
lation for the A and B marks.
(See F2)
ii) Install pump (20). (See F2)
iii) Fit retainer (21), and tighten bolts.
(See F2)
8
2) Install inner race (22) to shaft (16). iii) Install outer race and one-way clutch
(See F3) assembly (26) to stator (11). (See F6)
* Align the match mark of the bearing
Mounting bolt: Thread tightener
installed to the pump assembly, then
(LT-2)
install.
3) Install pump assembly (14). (See F3) Mounting bolt: For details, see
Sr Fix seal ring (15) with grease, so that Tightening Torques and Standard
the protrusion from the shaft is uni- Values Table
form.
4) Install remaining inner race (22). (See F3)
5) Install nut (12). (See F3)
& Nut thread: Thread tightener (LT-2)
Qd Bearing nut: For details, see Tight-

iv) Expand fit bushing (27). (See F7)
ening Torques and Standard Values
* Fix ball (28) with grease, then align
Table
the position and install. (See F7)
D Stator nut: For details, see Tighten- * Be careful not to damage the
ing Torques and Standard Values contact surface of the bushing.
Table
30656
Fl F4
F56103300 F56103241 K
F2 F5
Drag spring
Arrow showing direction Of

free rotation spmg
\ / /
I F56103312 I 561 FO3g
F3
F56103313 I F56103314
F7
2) Rotate stator (11) clockwise and install. 2) Install coupling (5). (See F5)
(See Fl ) 3) Assemble O-ring, and install holder (6).
(See F5)
4) Tighten bolts.

(LT-2)

Values Table
4. Turbine, clutch assembly 6. Control valve assembly

1) Raise tip of shaft, and align drain plug 1) Fit gasket and install control valve assem-
of pump and drain groove of case, then bly (3). (See F6)
install turbine and clutch assembly (10). 2) Install lubrication tube (2). (See F6)
(See F2)
2) Tighten pump mounting bolts (9) and drain

plug (8). (See F3)
a Mounting bolt: Thread tightener

(LT-2)

Values Table
w Plug: For details, see Tightening

5. PTO assembly
1) Fit O-ring, then mesh PTO gear, and
install PTO assembly (7). (See F4)
6 O-ring: Grease (G2-LI)

Fl F5
F56103291
F2 F6
F4
DISASSEMBLY OF PTO ASSEMBLY OF PTO ASSEMBLY
ASSEMBLY
1. Using push tool, press fit bearing (15) in case
1. Lock pump drive gear, and using tool B2, (16). (See F4)
loosen nuts (1). (See.Fl) j, After assembling, drop approx. 6 cc of
* It is difficult to loosen the nuts after engine oil on the bearing, and rotate the
removing the pump drive gear assembly, bearing several times.
so loosen them at this point. 2. Assemble oil seal (14) and O-ring to oil cage
2. Using forcing screws, remove pump drive (13), then install to case (16). (See F4)
gear cage assemblies (2), (3), and (4).
& O-ring: Grease (G2-LI)
(See Fl)
3. Disassembly of pump drive gear cage & Press fitting surface of oil seal:
assembly Gasket sealant (LG-5)
* Disassembly is carried out with pump
& Lip surface of oil seal:
drive gear assembly (2), but disassemble
Grease (G2-LI)
in the same order for assemblies (3) and
(4). 3. Assembly of pump drive gear cage assembly
-Lr When reusing the bearing, check the * When assembling the bearing, check the
position and match marks of the bearing. manufacturing No. of the inner race and
1) Remove nuts (1). (See Fl, F2) outer race, and the match marks (A and
2) Remove snap ring (5), then remove plate A, B and B).
(6). (See F2) * After assembling, drop approx. 6 cc of
3) Using forcing screws 0, remove gear (7). engine oil on the bearing, and rotate the
(See F2) bearing several times.
4) Remove bearings (8) and (9). (See F2) 1) Using push tool, press fit outer race (11)
5) Using push tool, remove outer races (10) and (10) in cover (12). (See F5)
and (11) from cover (I 2). (See F3) 2) Using push tool, press fit bearing (9) in 8
4. Disassembly of oil seal cage assembly gear (7), then assemble in cover (12). E;
(See F5) 8
Remove oil seal (14) from oil cage (I 3).
(See F4) 3) Assemble bearing (8). and tighten nuts (1)
5. Bearing temporarily. (See F2)
Using push tool, remove bearing (I 5) from
& Nut: Thread tightener (LT-2)
case (16). (See F4)
4) Assemble plate (6), and install snap ring
(5). (See F2)
4. Install pump drive gear cage assemblies (4),
(3). and (2) to case. (See Fl )
5. Using tool B2, tighten nuts (1). (See Fl)
m Nut: For details, see Tightening

Fl F5
F56103316
F2
'0 ‘7 F56103317
F3
12
11 10
F56103318
F4
I F56103319
DISASSEMBLY OF
TRANSMISSION ASSEMBLY
l Disconnect the transmission assembly first. 4. Sleeves

Using forcing screws, remove 5 sleeves (9).
1. Speed sensor (See F6)
Remove input shaft speed sensor (1) and
intermediate shaft speed sensor (2). (See Fl )
2. Speedometer gear assembly 5. Oil pan

1) Remove cover (3), then remove output Raise transmission assembly and remove oil
shaft speed sensor (4). (See F2) pan (11). (See F7)
2) Remove speedometer gear assembly (5). * Remove the oil strainer inside the oil pan,
(See F3) and clean it.
8
3. ECMV assembly 6. Check operation of piston z
1) Remove cover (6). then remove ECMV 1) Raise transmission assembly, then using g
assembly (7). (See F4, F5) lever block, put input shaft end at top, and
f3kg ECMV assembly:

Weight Table
For details, see
set on block (height: approx. 150 mm).
(See F8)
2) Using tool C, check operation of No.1, 2,
and 3 clutch pistons. (See F8)
* Air pressure: 3 - 6 kg/cm2
2) Remove filter assembly (8). (See F5) 7. No.1 clutch assembly

3) Remove wiring. Using eyebolts, remove No.1 clutch assem-
bly (12). (See F9)
Fl F6
5 I
,’
4 F56:h3322 F56103323 8103327

L
F4
8
z
H
8 Ill11
C
6’
F56103324 03328
F5 F9
n F56103325
30-63
0
8. No.2 clutch assembly 11 .No.3 clutch housing assembly
Using eyebolts, remove No.2 clutch assem- Using eyebolts, remove No.3 clutch housing
bly (13). (See Fl ) assembly (19). (See F5)
* For details of the disassembly of the
housing assembly, see Item 1 of Disas-
sembly of No.2 clutch assembly.
9. Transmission case 12.No.3 clutch drum, disc, plate

1) Secure eyebolts with nuts, then raise, and 1) Using eyebolts, remove No.3 clutch drum
remove transmission case (14). (See F2) (20) together with disc, plate, and spring.
Sr Raise vertically. (See F6)
2) Remove disc (21), plate (22), and spring
(23) from drum. (See F7)
2) Remove the following parts from trans- 13. No.3 ring gear
mission case. Remove No.3 ring gear (24). (See F8)
i) Remove cage (16) and bearing (17) as
a set, then remove bearing (17) from
cage. (See F3)
ii) Remove collar (18).from case. (See F3)
iii) Remove bearing (17). (See F3)
10. Check operation of piston 14.Tie bolts

Using Tool C, check operation of No.4, 5, Remove tie bolts (25). (See F9)
6, and 7 clutch pistons. (See F4)
15.No.4 clutch plate, sun gear, spring
1) Using eyebolts, remove plate (26).
2) Remove spring (27). (See F9)
3) Remove snap ring (28), then remove sun
gear (29). (See F9)
30-64
0
Fl F5
19
F56103330 F56103334
F2
F56103331 F56103336 i3
F3 F8
17'
F56103332
F4 F9
'26
F56103333 F56103338
30-65
0
16.No.4 clutch disc, plate, spring 20.No.6 clutch disc, plate, spring
Remove disc (30). plate (31). and spring (32). Remove disc (43), plate (44), and springs (45)
(See Fl) and (46). (See F5)
17.No.4 housing, piston, ring gear 21 .No.4, 5 carrier assembly

Using eyebolts, remove No.4 housing (33) Using eyebolts, remove No.4 and 5 carrier
together with piston (34) and ring gear (35). assembly (47). (See F6)
(See F2)
* If the dowel pin is stiff and it is necessary
to lever the housing off, be careful not
to damage the housing.
18. No.5 clutch disc, plate, spring 22.Guide pin, No.7 spring
Remove disc (36). plate (37) and springs (38) Remove guide pin (48). (See F7)
and (39). (See F3)
19.No.5 housing, piston, ring gear 23.No.6, 7 housing, piston

Using eyebolts, remove No.5 housing (40) l)Using eyebolts, remove No.6 and 7
together with piston (41) and ring gear (42). housing (50). and pistons (51) and (52).
(See F4) (See F8)
* If the dowel pin is stiff and it is necessary Sr If the dowel pin is stiff and it is
to lever the housing off, be careful not necessary to lever the housing off, be
to damage the housing. careful not to damage the housing.
2) Remove spring. (See F8)
Fl F5
,32
30’
31
F56103339 F56103343
F2 F6
F56103344
F3 F7
F56103341 F56103345
F4 F8
r
F56103346
30-67
0
24.No.7 clutch disc, plate, spring 2) Disassemble output shaft assembly as
Remove disc (53), plate (54), and spring (55). follows:
(See Fl ) i) Remove worm (61) from output shaft.
(See F5)
ii) Remove collar (62) from output shaft.
(See F6)
25.No.6, 7 carrier assembly iii) Support cage (63), then push output
Using eyebolts, remove No.6 and 7 carrier shaft (64) with press, and pull out from
assembly (56). (See F2) bearing. (See F7)
26.No.7 guide pin, No.7 clutch ring gear

1) Remove guide pin (57). (See F3)
2) Remove No.7 clutch ring gear (58).
(See F3)
27.0utput shaft assembly

1) Remove output shaft assembly (59) from
cage (60). (See F4)
* This is the last stage of disassembly
of the transmission, so it is removed
last. However, if the output shaft
assembly must be removed for reasons
such as oil leakage from the oil seal,
it is possible to remove the output shaft
assembly simply by removing the
speedometer gear first. .
Fl
F56103352
F2 F7
I
8 F3
F4
F56103350
30-69
0
Disassembly of No.1 clutch assembly Disassembly of No.2 clutch assembly
1. Input shaft 1. Housing assembly

1) Remove plate (1 ), then remove input shaft 1) Using eyebolts, remove housing assembly
assembly (2). (See Fl ) (1). (See F8)
2) Remove snap ring (3) from input shaft,
then remove bearing (4). (See F2)
2. No.1 clutch housing, piston, spring 2) Remove cylinder (2), then remove piston
Remove mounting bolts (5), then turn over (3) from housing (4). (See F9, Fl 0)
assembly, and remove housing (6). piston
(7). and spring (8). (See F3, F4)
8
3. No.1 clutch plate, disc, guide pin 2. Ring gear z
Remove plate (9) disc (lo), and guide pin Remove snap ring (9). then remove ring gear g
(11). (See F5) (10). (See Fl 1)
4. No.1 clutch, ring gear

Remove mounting bolts, then remove ring
gear (13) from clutch plate (12). (See F6)
5. Bearing
Remove snap ring (14), then remove bearing
(15) from cage (16). (See F7)
30-70
0
F8
F56103357
F5 F6 Fll
8
z
8
a
F56103358 IJ F56103359
F7
i103360
30-71
0
3. Disc, plate, spring Disassembly of No.4, 5 carrier assembly
Remove disc (1 1 ), plate (12), and spring (13).
(See Fl) 1. No.6 ring gear
Remove snap ring (l), then remove No.6 ring
4. Drum gear (2). (See F5)
Using eyebolts, remove drum (14). (See Fl)
5. Plate for transmission input shaft speed 2. Bearing

detection Remove bearing (3) from carrier (4). (See F6)
Remove plate (15) from carrier (16). (See F2)
ij
6. Planetary gear 3. Planetary gear for reverse z
1) Remove shaft (17) and ball (18). (See F3) 1) Knock out reverse gear shaft (5) to ball g
* Be careful not to lose ball (18). side, then remove ball (6). (See F7)
2) Knock out shaft (5) from ball end, then
remove reverse gear (7), bearing (8),
spacer (9), and thrust washer (10).
(See F7, F8)
2) Remove gear (19), bearing (20), and thrust 4. Planetary gear

washer (21). (See F4) 1) Knock out shaft (11) and ball (12) to No.4
carrier end. (See F9)
* Be careful not to lose ball (12).
Fl F5
I I
11
F2
F561b3366
F3 F7
I
I F56103367
F4 F9
21
F56103368 F56103373
30-73
0
2) Remove No.4 planetary gear (13), bearing 5. No.7 planetary gear
(14), thrust washer (15), ball, No.5 1) Remove snap ring (10). (See F6)
planetary gear (16), bearing (17), thrust
washer (18), and ball (12). (See Fl )
+ The shaft is stiff, so be careful not to
damage it.
Disassembly of No.6, 7 carrier assembly 2) Using puller 0, remove inner race (11).
(See F7)
1. Collar 3) Disassemble No.7 planetary gear.
Remove collar (1). (See F2) For details, see Item 4, Disassembly of
No.6 planetary gear. (See F7)
2. Plate
Screw in forcing screws, and remove plate
(2). (See F3)
3. Intermediate shaft, No.6 sun gear

Remove intermediate shaft (3) and No.6 sun
gear (4). (See F4)
4. No.6 planetary gear

Pull out shaft (5), and remove No.6 planetary
gear (6), bearing (7), thrust washer (8). and
ball (9). (See F5)
Fl
I F56103374 56103379
F2 F7
F56103375 F56103380
F3 F4
B
F56103376 F56103377
F5
h F56103378
i
30-75
0
ASSEMBLY OF TRANSMISSION
ASSEMBLY
Preparatory work 3. Plate

1) Install bearing (16) to plate (2).
Clean all parts, check for dirt or damage, and (See F6, F7)
correct any burrs. 2) Install seal ring (17). (See F6)
3) Install plate (2) to No.6 and 7 carrier.
Precautions when assembling (See F6, F7)
1) Coat seal ring with grease (G2-LI). 6 Mounting bolt: Thread tightener
2) Coat the sliding and rotating surfaces of all (LT-2)
parts with engine oil before installing.
Assembly of No.6, 7 carrier assembly 4. Collar

1) Press fit inner races (19) and (20) in collar.
1. No.6.7 planetary gear (See F8)
1)Assemble bearing (7) in gear (6), and fit 2) Install collar (1). (See F9)
thrust washers (8) to both sides, then set
in carrier. (See Fl)
2)Push in shaft (5), and assemble ball (9),
then install completely. (See Fl)
* Check that the gear rotates smoothly.
3) Install snap ring (10). (See F2)
4) Press fit inner race (11). (See F2)
5) Install seal ring (12). (See F2)
* Check that the gear rotates smoothly.
2. Intermediate shaft, No.6 sun gear

1) Press fit inner race (13) to intermediate
shaft (3). (See F3)
2) Install snap ring (14). (See F3)
3) Install intermediate shaft (3) to No.6 and

7 carrier assembly (15). (See F4)
* Put a block in the tip (inside the carrier)
of the intermediate shaft.
4) Install No.6 sun gear (4). (See F5)
30-76
0
Fl
F6 F7
L F56103378 17 F56103385 I F56103376
F2
F8 F9
I
20
19
03381 F56103386
I1
F56103382
J
F4 F5
F56103383 F56103384
30-77
0
Assembly of No. 4, 5 carrier assembly
1. No. 4, 5 planetary gear 4. No. 6 ring gear

1) Assemble bearing( 14) in No. 4planetarygear Secure No. 6 ring gear (2) with snap ring (1).
(13), and fit thrust washers (15) to both sides, (See F6)
then set in carrier. (See Fl)
2) Insert spacer at middle of No. 5 planetary
gear (16), assemble bearing (17). fit thrust
washers (18) to both sides, then set in carrier.
(See Fl )
3) Cool shaft (11) with dry ice, then assemble Assembly of No. 2 clutch assembly
to carrier. (See F2)
+ Check that the position of the holes of the 1. Planetary gear
carrier and the bearing and thrust washer 1) Assemble bearing (20) in gear (19), and fit
are aligned correctly, then assemble, thrust washers (21) to both sides, then set
taking care not to damage the bearing and in carrier. (See F7)
thrust washer. 2) Align with bearing and thrust washer, and
* Align the hole for mounting the ball in push in shaft (17). (See F8)
the shaft with the hole in the carrier. 3) Assemble ball (18) and install completely
4) Fit ball (12), and install shaft (11) completely. (See F8)
(See F2) + If it seems that the shaft will come out,
* Check that the gear rotates smoothly. hit with a punch from the carrier end.
+ Check that the gear rotates smoothly.
8
2. Planetary gear for reverse 4) Install inner race (22). bearing (23), and seal z
1) Insert spacer (9) in middle of gear (7). ring (24) to carrier (16). (SeeF9, FlO) s
assemble bearing (8), fit thrust washers (10)
to both sides, then set in carrier. (See F3)
2) Align with bearing and thrust washer, and
knock in shaft (5). (See F4)
3) Knock in shaft (5) until ball hole can be seen
completely, then assemble ball (6), and knock
in to carrier side to install. (See F4)
* Check that the gear rotates smoothly
3. _ Bearing 2. Plate for transmission input shaft speed

Press fit bearing (3) in carrier (4). (See F5) detection
Install plate (15) to carrier (16). (See Fl 1)
a Mounting bolt: Thread tightener (LT-2)

ing Torques and Stand-
ard Values Table
30-78
@I
Fl F6
17 16 18
F56103374 F56103369
F2 F7 F8
F56103373
F9 FlO
8 7, 10
I
F56103372 F56103371 t
F5 Fll
F561b3366
30-79
Co
3. Drum iv) Assemble seal ring (25) to piston.
1) Turn over carrier assembly with plate (See F6)
installed. v) Assemble piston (3) in housing (4),
2) Using eyebolts, align gear of carrier, and then install cylinder (2). (See F6, F7)
install drum (14). (See Fl)
(LT-2)

Values Table
4. Ring gear 2) Using eyebolts, raise housing assembly

Align with carrier and install ring gear (lo), (1). align outside teeth of piston with
then secure with snap ring (9). (See F2) inside teeth of drum, and install housing
assembly. (See F8)
5. Discs, plates, springs
a Mounting bolt: Thread tightener
Install discs (1 l), plates (12), and springs
(LT-2)
(13). (See F3)
jr There are 5 discs, 4 plates, and 5 springs. w Mounting bolt: For details, see
Values Table
6. Housing assembly
1) Assemble housing as follows.
i) Install inner race (8) to housing (4).
(See F4)
ii) Install bearing (5) to housing (4).
(See F4)
iii) Install seal rings (6) and (7). (See F4)
* Install the seal ring with the groove on

the side taking the pressure. (See F5)
30-80
0
Fl
I F56103390 11 F56103391 1
F4
‘5 F56103392
F5
569F052
30-81
0
Assembly of No.1 clutch assembly
1. Bearing
Press fit bearing (15) in cage (16). and secure
with snap ring (14). (See Fl)
2. No.1 clutch, ring gear

Install ring gear (13) to clutch plate (12).
(See F2)
6 Mounting bolt: Thread tightener

(LT-2)

Values Table
3. No.1 clutch plate, disc, guide pin

Install guide pin (1 l), then install disc (IO),
plate (9), and spring. (See F3)
4. No.1 clutch housing, piston, spring

Fit spring (8), and install piston (7) and
housing (6), then tighten bolts (5) from
bottom. (See F4, F5)
W Mounting bolt: For details, see

Values Table
5. Input shaft
l)Press fit bearing (4) to input shaft, then
secure with snap ring (3). (See F6)
2) Assemble input shaft assembly (2), then
secure with plate (1). (See F7)
Fl
16 1103360
F3
F56103359 ~56103356
'8
F56103357 F56103356 1
F6 F7
i<
3’
F56103355 IF56103354
ASSEMBLY OF TRANSMISSION
ASSEMBLY
1. Output shaft assembly v) Install collar (62) to output shaft (64).

1) Press fit bearing (65) in cage (60). (See F6)
(See Fl, F2) vi) Install worm (61) to output shaft (64).
2) Fit seal ring and install plate (66). (See F7)
(See F2)

(LT-2)

Values Table
* Align the seal ring with the outside of 4) Fit O-ring and install output shaft assem-
the plate, and center the outside bly (59) to cage (60). (See F8)
circumference, then fix with grease. Mounting bolt: For details, see
3)Assemble output shaft assembly as Tightening Torques and Standard
follows. Values Table
i) Press fit bearing (67) to output shaft
(64). (See F3)
ii) Install bearing (68) to cage (63). 2. No.7 clutch ring gear
(See F4) 1) Turn over cage, and set on block.
iii) Install oil seal (69) to cage (63). 2) Install ring gear (58) to cage. (See F9)
(See F4)
3. Guide pin
6 Lip surface of oil seal: Grease
Install guide pin (57). (See F9)
(G2-LI)
iv) Set output shaft (64) on press, then

push inner race of bearing, and install
cage (63). (See F5)
30-84
0
Fl F2
F56103394 F56103395
F3
60
I I F56103396
F4
8
i3
58
- 69
F56103397K
F5
63
64
F56103398
4. No.6, 7 carrier assembly 7. Guide pin, No.7 spring
Using eyebolts, raise shaft, then align with Install guide pin (48), then install spring.
gear and bearing, and install No.6 and 7 (See F5)
carrier assembly (56). (See Fl)
* It is possible to install using the same set
(No.4, 5, 6, 7 carrier assembly) as for
disassembly, but if the shaft is raised and
moved in this condition, the bearing at
the middle may come out, so it is better
to assemble in parts.
5. No.7 clutch disc, plate, spring 8. No.4, 5 carrier assembly

Install disc (53), plate (54). and spring (55). Using eyebolts, align with gear and bearing,
(See F2) then install No.4 and 5 carrier assembly(47).
(See F6)
8
6. No.6, 7 housing, piston 9. No.6 clutch disc, plate, spring z
I) Install seal rings to housing and piston. Install disc (43), plate (44), and springs (45) 8
* Install the seal ring with the groove on and (46). (See F7)
the side taking the pressure. (See F3)
2) Install pistons (51) and (52) to housing. IO. No.5 housing, piston, ring gear
(See F4) 1) Assemble tie bolt sleeves (70) to housing
3) Using eyebolts, install No.6 and 7 housing (40). (See F8)
(50). (See F4) ’
* If the dowel pin is stiff, knock in with
a plastic hammer.
30-86
0
F5
r
F2
v F56103344
F3 F7
8
F4
FM103346
30-87
0
2) Assemble seal rings to housing (40) and 14.No.4 clutch sun gear, plate, spring
piston(41), then install piston to housing. 1) Fit seal ring and install sun gear (29). then
(See Fl) install snap ring (28). (See F5)
* For details of the direction of installa- 2) Fit spring (27) and install plate (26).
tion of the seal rings, see Assembly
Item 6. 15.Tie bolts
3) Set No.5 clutch ring gear (42) in position. Install tie bolts (25). (See F5)
(See Fl)
D Tie bolt: For details, see Tightening
* Set with the cut portion of the outside
circumference facing up.
4) Using eyebolts, raise housing (40), align * Push in the tie bolts by hand to the end
with spring, then install housing. face of the tap hole.
* If the dowel pin is stiff, knock in with * Do not use an impact wrench until the
a plastic hammer. (See Fl) bolt has mated with the tap thread.
11 No.5 clutch disc, plate, spring 16.No.3 clutch ring gear

Install disc (36), plate (37) and springs (38) Install ring gear (24). (See F6)
and (39). (See F2)
D Mounting bolt: For details, see
Values Table
12.No.4 housing, piston, ring gear 17.No.3 clutch drum

1) Assemble seal rings to housing (33) and Install drum (20). (See F7)
piston (34). then install piston to housing.
(See F3) 18.No.3 clutch disc, plate, spring
* For details of the direction of installa- Install disc (21), plate (22), and spring (23).
tion of the seal rings, see Assembly (See F7)
Item 6.
2) Set No.4 clutch ring gear (35) in position.
(See F3)
* Set with the cut portion of the inside 19.No.3 clutch housing assembly
circumference facing down. 1) For details of assembling piston, see Item
3) Using eyebolts, raise housing (33), align 6 of Assembly of No.2 clutch assembly.
with spring, then install housing. (See F3) 2) Push drum (20) up from No.4 clutch plate.
* If the dowel pin is stiff, knock in with (See F8)
a plastic hammer. 3) Using eyebolts, raise housing assembly
(19), align outside teeth of piston with
13. No.4 clutch disc, plate, spring drum, then install housing assembly.
Install disc (30), plate (31), and spring (32). (See F8)
(See F4)
(LT-2)

Values Table
30-88
0
F5
‘26
F56103342 F56103338
F2
F56103341 F56103337
F3 F7
21
22\
-20
F56103400
F4
32
F56103339
30-89
0
20. Checking operation of piston 23.No.l clutch assembly
Using tool C, check operation of No.4, 5, 6, Fit O-ring to transmission case end, and
and 7 clutch pistons. (See Fl ) using eyebolts, install No.1 clutch assembly
* Air pressure: 3 - 6 kg/cm’ (12). (See F5)
* Standard piston stroke
Piston No. Stroke (mm)
No. 4 4.2
No. 5 6.6
No. 6 6.8
No. 7 6.8
24. Checking operation of piston
Sr If the movement is not smooth, pour in Using tool C, check operation of N0.1~2, and
engine oil and check again. 3 clutch pistons. (However, the operation of
the pistons of No.2 and 3 clutches cannot
21 .Transmission case be checked directly, so check the movement
1) Assemble the following parts to transmis- of the disc or plate.) (See F6)
sion case. * Standard piston stroke: No.1 clutch 5.5
i) Fit seal ring to outer groove of collar mm
(18), then align with dowel pin of * For details of checking, see Item 20 of
transmission case, and install. assembly.
(See F2)
& Seal ring: Grease (G2-LI)
ii) Install cage (16). (See F2) 8

25.Oil pan z
iii) Install bearings (17) to both ends.
1) Assemble magnet (71) and screen (72) to 8
(See F2)
oil pan (11). then fit O-ring and install
2) Install O-ring to transmission case end.
cover (73). (See F7)
3) Secure eyebolts with nut, then raise and

install transmission case (14). (See F3)
22.No.2 clutch assembly 2) Fit O-ring and install drain valve (74).
Using eyebolts, install No.2 clutch assembly (See F8)
(I 3). (See F4)
30-90
0
F5
F56103333 ’ F56103329
F2
17’
F56103332 F56103328
F3
‘11
F56103331 7i il F56103402
F4 F8
F56103330 F56103403
30-91
0
3) Fit gasket, set mounting surface of oil pan 28.Speedometer gear assembly
(11) horizontally, then raise transmission 1) Fit O-ring and install speedometer gear
assembly and install. (See Fl) assembly (5). (See F5)
2) Install output speed sensor (4). then install
&Oil pan: Gasket sealant (LG-1)
cover (3). (See F6)
26.Sleeve 29.Speed sensor

1) Set transmission assembly in position 1) Fit O-ring and install intermediate shaft
with oil pan facing down. speed sensor (2). (See F7)
2) Fit O-ring and install sleeve (9). (See F2) 2) Fit O-ring and install input shaft speed
sensor (1). (See F7)
27. ECMV assembly

1) Fit O-ring and install ECMV assembly (7).
(See F3)
B ECMV assembly mounting bolt: For

2) Install oil filter (8). (See F3)

3) Install wiring.
4) Install cover (6). (See F4)
30-92
0
F5 F6
F561033 23 F56\;h3322
F7
F56103321
8 F3
z
8
I m F56103325
F4
I
6-w F56103324
30-93
0
REMOVAL OF TRANSMISSION REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY PUMP ASSEMBLY
(ECMV ASSEMBLY)
A Raise the dump body and lock with the safety pin.
safety pin.
l Drain oil from transmission oil pan.
1. Remove cover. :
u Transmission oil pan: For details, see
2. Disconnect wiring connectors (1) and (2).
Lubricant and Coolant Table.
(See Fl)
3. Remove ECMV assembly (3). (See Fl) 1. Disconnect tubes (1) and (2). (See F2)
II W[ 2. Remove transmission pump assembly (3).
(See F2)
INSTALLATION OF INSTALLATION OF
TRANSMISSION CONTROL VALVE TRANSMISSION PUMP
ASSEMBLY (ECMV ASSEMBLY) ASSEMBLY
Before removing the ECMV assembly, clean

thoroughly around the valve, and be careful not
to let dirt get in.
m ECMV assembly mounting bolt: For

30-94
0
Fl F2
F56103404 1’ F56103405
30-95
@
DISASSEMBLY OF ECMV ASSEMBLY OF ECMV ASSEMBLY
ASSEMBLY
0 Before removing the ECMVassemblyfrom the Sr If the pressure valve has been disassembled
transmission assembly, clean all around the or any parts have been replaced, always check
ECMV to be removed, and take care not to the hydraulic pressure.
let any dirt or duct get into the transmission * Clean all parts, and check for dirt or damage.
assembly and ECMV. Coat the sliding surfaces of all parts with
a Store the disassembled parts carefully to engine oil before installing.
protect them from damage.
1. Pressure check valve
1. Remove plate (2) from valve body (1). 1) Assemble valve (14) in body (1).
* When disassembling the valve, check that * Push with a finger from both ends of
the valve moves smoothly. the body to check that the valve moves
smoothly.
2. Flow detector valve 2) Fit O-ring to solenoid valve (15) and install
1) Using bolts (Thread dia. = 8 mm, Pitch to body.
= 1.25 mm), pull out plug (3), then remove
m Mounting bolt: 1.35 + 0.15 kgm
spring (4), valve (5), and spring (6).
2)Pull out connectors (7) and (8) from 3) Assemble piston (13) in valve (14).
bracket, then remove fill switch (9) and * Check that the piston moves smoothly.
bracket (10). 4) Assemble shim (12) and spring (11) in
valve (14), them fit O-ring and install to
3. Pressure control valve body.
1) Removespring(l1). shim(l2), piston (13), l Standard number of shims: 3
and valve (14). l Standard shim thickness: 0.6 mm
* Check the number and thickness of (Thickness of each shim: 0.2 mm)
shim (12), and keep in a safe place. * When using all of valve body (l), spring
2) Remove solenoid valve (15). (1 I), piston (13), valve (14), and solenoid
Sr Mask the opening to prevent dirt or dust valve (15) again, assemble the same
from entering from the mating surface thickness of shim as before disassembly.
of the solenoid valve. If any of the above parts have been
replaced, assemble the standard number
of shims.
j, When replacing solenoid valve (15),
remove plate (2), and check that spring
(11) is assembled securely.
2. Flow detector valve

1) assemble valve (5) in body.
* Push with a finger from both ends of
the body to check that the valve moves
smoothly.
2) Assemble spring (6), then fit O-ring to
body and install fill switch (91 and bracket
(10).
m Mounting bolt: 3.15 + 0.35 kgm
3) Assemble spring (4), then fit O-ring to plug

(3) and install to body.
4) Install plate (2) to body.
w Mounting bolt: 3.15 + 0.35 kgm
5) Install connectors (7) and (8) to bracket.
30-95-l
8
7.8
30-95-2
8
3. Checking ECMV pressure
Check ECMV pressure.
checking ECMV pressure.
4. Adjusting ECMV pressure

l If the results of the check show that the
ECMV pressure is not within the standard
pressure, adjust the pressure with shim
(12).
Amount of adjustment with 1 shim (thick-

ness: 0.2 mm): Approx. 0.19 kg/cm*
Sr To INCREASE pressure, INCREASE shim

thickness.
To DECREASE pressure, DECREASE shim
thickness.
* Install the shim securely, and be careful
not to drop it inside the valve.
* After adjusting the shim thickness, check
the pressure again.
30-95-3
60
Fl
Spring Shim Valve

F5690501: 2
30-95-4
0
REMOVAL OF DIFFERENTIAL INSTALLATION OF DIFFERENTIAL
ASSEMBLY ASSEMBLY
(For standard differential) (For standard differential)
1. Drain oil l Carry out installation in the reverse order

to removal.
& Final drive gear case, differential
gear case: For details, see Lubricant
and Coolant Table
Drive shaft mounting bolt: Thread tight-
ener (LT-2)
2. Remove parking brake spring cylinder
For details, see REMOVAL OF PARKING Drive shaft mounting bolt: For details,
BRAKE ASSEMBLY. see Tightening Torques and Standard
Values Table
3. Remove slack adjuster assembly
For details, see REMOVAL OF SLACK
ADJUSTER ASSEMBLY.
Differential assembly mounting bolt:
Thread tightener (LT-2)
4. Remove hoses (1) and (2). (See Fl)
Differential assembly mounting bolt: For
5. Remove bracket (3). (See Fl) details, see Tightening Torques and
* Loosen the U-bolts, turn over the valve Standard Values Table
assembly bracket and set it on top of the
cross-member. l Refilling with oil
* Refill oil to the specified level and check
6. Remove cover (4). (See F2) the oil level again.
Final drive case, differential gear T:

7. Remove shaft (5). (See F3)
case: For details, see Lubricant and
* Fit an eyebolt, and remove with a bar. z
Coolant Table g
8. Remove guard (6). (See F4)
10. Remove drive shaft assembly (8). (See F5)

m
kg
I??l Drive shaft assembly: For details, see
Weight Table
11. Remove differential assembly (9). (See F6)

m
Sr Fit a shackle to the differential mounting
surface, then fit a lever block to the pinion
end, and adjust the height when
removing.
Sr Be careful not to damage the seal surface
of the housing.
& kg Differential assembly: For details,

see Weight Table
30-96
0
F2 F3
F4 F5
F56103411
30-97
0
DISASSEMBLY OF DIFFERENTIAL
ASSEMBLY
(For standard differential)
1. Set differential assembly in tool DI. l Disassembly of pinion, cage assembly

1) Remove cage (13) together with bearing
2. Spring cylinder assembly inner (14) from pinion gear (15). (See F6)
Pump air into spring cylinder to retract rod, 2) Remove spacer (16), then remove bearing
then pull out connecting pin (2) of slack inner (17). (See F7)
adjuster (1) lever, and remove spring cylinder
(3). (See Fl)
A If the air in the spring cylinder is

released, the rod will suddenly
extend, so be careful not to get 3) Remove holder (18), then remove center
caught. bearing inner race (19) from pinion gear
(15). (See F9)
4) Remove bearing outer races (20) and (21)
3. Caliper assembly
from cage (13). (See F8)
1) Remove plate (4) on one side, then remove
* The bearing is an adjustment-free
caliper (6) together with pad (5). (See F2)
bearing, so check the matching
2) Remove plate on other side.
numbers, and keep as a set in a safe.
place.
3) Remove disc plate (7). (See F3) l Differential gear assembly

1) Remove lock (22). (See FIO)
4. Coupling 2) Using tool D2, loosen left and right side
Remove mounting bolts (8), then remove bearing adjustment nuts (23) until they
coupling (10) together with holder (9) and can be turned by hand. (See Fll)
O-ring. (See F4)
5. Support
Remove support (11). (See F4)
6. Pinion, cage assembly 3) Loosen mounting bolts (24), and remove

Screw in forcing screws, then lift off pinion cap (25). (See F12)
and cage assembly (12). (See F5) 4) Lift off differential gear assembly (26).
* Check the number and thickness of the (See F13)
shims, and keep in a safe place. 5) Remove left and right side bearing
adjustment nuts (23). (See F13)
30-98
@I
Fl F6 F7
F56103412 F5610341 F56103418
F2 F8 F9
21 20 18
'13
F56103413 F56103419 F56103420
F3 F4 FlO Fll
F56103422
F5
F5610341
30-99
0
l Disassembly of differential gear assembly 10) Remove side gear (41). (See F9)
1) Using puller 0, remove bearing (27). 11) Remove thrust washer (42). (See FIO)
(See Fl )
2) Remove mounting bolts (28), then remove
case (29). (See F2)
3) Remove thrust washer (30) from case. 12) Remove bevel gear (44) from case (43).
(See F3) (See Fll)
4) Remove side gear (31). (See F4) 13) Remove bearing (45) from case.
(See Fll)
8
5) Remove pinion gear assembly (32) 14) Bearing z
together with cross shaft (33). (See F5) Remove snap ring (46), then remove 8
6) Hold pinion gear assembly(32) with press, bearing (47) from differential case (48).
and using tool D5, remove ring nut (34). (See F12)
(See F6)
7) Pull out shaft (35) with press, then remove

pinion gear, bearing (36), and collar (37).
(See F7)
8) Remove bearing (38) from shaft. (See F7)
from pinion gear. (See F8)
numbers of the bearing, collar, and
outer race, and keep as a set in a safe
place.
30-l 00
0
Fl F2 F9 FlO
F56103425 F56103433 F56103434
F3 F4 Fll
,F56103428 F56103435
F5 F6 F12
F2
F56103436
3:
Q
I F56103432
30-101
0
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
(For standard differential)
1. Bearing 4) Set cage (13) to pinion gear (15), and

1) Set differential case in tool DI. install bearing (14). (See F7)
2) Using push tool, press fit bearing (47) in 5) Coat bearing rollers and tread surface of
differential case (48), then install snap inside and outside races well with engine
ring (46). (See Fl) oil (E030CD).
2. Pinion cage assembly l Installation of pinion, cage assembly

l Assembly of pinion cage assembly Fit O-ring, and assemble shim, then install
1) Using push tool, press fit outer races (20) pinion and cage assembly (12) to differ-
and (21) in cage (13). (See F2) ential case. (See F8)
* Check that there is no clearance * Assemble the same number and thick-
between the outer races and the cage. ness of shims that was removed during
disassembly.

Tightening Torques and Stand-
ard Values Table
2) Press fit center bearing inner race (19) 3. support

in pinion gear (15). then install holder (18). 1) Install oil seal (49) and O-ring to support
(See F4) (11). (See F9, FlO)
* Shrinkage fit: Heat to 1 OOOC
4. Coupling
Mounting bolt: Thread tightener
Install coupling (10). then install O-ring and
(LT-2)
holder(g), and tighten mounting bolt (8).
Mounting bolt: For details, see (See Fl 1)
Tightening Torques and Stand- * When doing this, rotate the bearing 20
ard Values Table - 30 times and tighten bolt (8) gradually.
* If bolt (8) is tightened without rotating the
bearing, the bearing may be damaged.
6 Mounting bolt: Thread tight-

3) Press fit bearing inner race (17). and
ener (LT-2)
install spacer (16). (See F5)
* Shrinkage fit: Heat to 100°C w Mounting bolt: See Tightening
* The bearing is an adjustment-free Torque and Standard Values
bearing, so check the matching Table
numbers, and keep as a set in a safe
j, After tightening, rotate the bearing again
place.
20 - 30 times to check that it rotates
-k Check that there is no clearance
smoothly and check that bolt (8) is
between the end face of the pinion gear
tightened to the specified torque.
and the inner race.
30-102
8
Fl F7
F56103436 F56103417
I
F2 F3 F8
There
There must be nc
21 20
13 F56103661
F56103419 561 F03361
F4 F9 FlO
/ 18 11
\ / II 11
F56103420
6 Fll
8 9
There
must be no
I F56103418 569FO5237
30-l 03
8
5. Use one of the following methods to check 5) Pinion gear
that the setting of the bearing is normal. The bearing is an adjustment-free
*(I) Fit spring balance (2) in the tap hole bearing, so check the matching
of the coupling, and measure the numbers of the bearing, collar, and
starting torque in the tangential direc- outer race, and keep as a set in a safe
tion. (See Fl) place.
(Do this before installing the bevel gear 0 Using push tool, press fit outer races
end.) (40) and (39) in pinion gear. (See F7)
Starting torque: Max. 5.1 kg ii) Using push tool, press fit bearing (38)
k(2) Measure the end play of the bearing. to shaft (35). (See F8)
(See F2, F3)
End play in axial direction:
0.01 - 0.17 mm
Meethod of measuring iii) Set pinion gear to shaft, then assem-
i) Rotate bearing 20 - 30 times, set ble collar (37), and using push tool,
dial gauge as shown in diagram, install bearing (36). (See F9)
and align 0 mark. (See F2) iv) Hold pinion gear assembly (32) with
ii) With coupling portion raised (lifting press, and using tool D5, tighten ring
load: approx. 300 kg), rotate cou- nut (34). (See FIO)
pling 20 - 30 times, and check that
&Ring nut: Thread tightener (LT-2)
reading of dial gauge is stable. (See
F3) m Ring nut: For details, see Tight-
iii) Reading of dial gauge obtained in ening Torques and Standard
Step ii) = end play in the axial Values Table
direction.
6. Differential gear assembly 6) Assemble pinion gear assembly (32) to “0

l Assembly of differential gear assembly cross shaft (33), then raise and install to Z
1) Install bevel gear (44) in differential gear case. (See Fl 1) ;3
case (43). (See F4) * Align the notched portion of the pinion
gear shaft with the dowel pin of the
case, and install.
(LT-2)
* Move the pinion gear, and check that
m Mounting bolt: For details, see the gear assembly rotates easily.
Tightening Torques and Standrad 7) Install side gear (31). (See F12)
Values Table
2) Install side bearing (45). (See F4)

* Shrinkage fit: Heat to 100°C
* Check that there is no clearance
8) Align with dowel pin, and install thrust
between the end face of the case and
washer (30). (See F13)
the bearing.
* Check that the head of the dowel pin
3) Turn over case, then align with dowel pin
is 0.5+t2 mm lower than the surface of
and install thrust washer (42). (See F5)
the washer.
* Check that the head of the dowel pin
is 0.5+E2 mm lower than the surface of
the washer.
j, Check that there is no clearance
4) Install side gear (41). (See F6)
the bearing.
30-104
8
Fl
39 40
569FO5238 F56103432 F56103437
F2 F3 F9 FlO
‘37 F56103438 F56103430

569FO5239 569FO5240
F4 Fll F12
F56103435
F5 F6 F13 F14
41 30
F56103434 F56103433 F56103427 F56103439
30-105
8
10) Fit case (32) and tighten mounting bolts * Precautions when adjusting pre-
(31). (See Fl) load
If the increase in deflection caused
by overtightening of the adjustment
(LT-2)
nut exceeds the standard amount,
w Mounting bolt: For details, see return the adjustment nuts to the
Tightening Torques and Standard condition before adjusting. When
Values Table doing this, rotate the bevel gear and
tap the bearing cap and bevel gear
with a plastic hammer, check that
there is no clearance at portion (b),
and adjust again. (See F6)
l Installation of differential assembly 7. Adjusting tooth contact, backlash

1) Tighten side bearing adjustment nuts (23) Adjust backlash and tooth contact at the
temporarily, and place differential gear same time.
case assembly (26) temporarily. (See F2) 1) Adjust backlash as follows.
2) Fit cap (25) and tighten mounting bolts i) Move bevel gear with adjustment nut
(24). (See F3) (23). (See F7)
When adjusting the bevel gear, do not
change the preload of the bearing.
(LT-2)
Always turn the adjustment nuts at
w Mounting bolt: For details, see both ends the same amount in the same
Tightening Torques and Standard direction.
Values Table ii) Put a dial gauge at right angles in
* Align the match mark of the cap. contact with the reverse face of the
j, Rotate the bevel gear 20 - 30 turns tooth at the outside of the bevel gear.
to settle the bearing, then tighten. Turn the adjustment nut and adjust the
3) Adjusting preload of bearing backlash.
i) Install measurement adapters D3 to * Backlash: For details, see Tightening
both ends of cap (23). (See F4) Torques and Standard Values Table
ii) Measure dimension between adap- * Adjust at 3 - 4 places. Keep the
ters with depth micrometer D4. pinion gear locked when measuring.
(See F4) 2) Adjust tooth contact as follows.
* When measuring, hold the micro- i) Adjust the in and out movement of the
meter securely with one hand, and bevel pinion by changing the shims
put the probe in contact perallel to between the differential case and
the measurement adapter. bearing cage.
iii) Add 0.4 & 0.15 mm to measured di- ii) Adjust tooth contact
mension, and set scale of micrometer. For details, see 3) Adjusting tooth
* The added dimension becomes the contact.
amount of deflection of the case
between before giving preload and
after giving preload.
iv) Tighten adjustment nuts (23) from
both ends, and continue to tighten
with tool D2, paying careful attention
to the groove that the lock enters.
(See F5)
* When doing this, to settle the
bearing properly, rotate the bevel
gear and tap the bearing cap and
bevel gear with a copper hammer.
30-l 06
@
Fl
Use electric light on

feeler gauge to check
there is no gap.
F56103440
568FO48
F7
\ F56103424’ /1’F56103423 24-
F4
F8
\ D4 D3
F56103445
F5
I
~56103422
30-107
0
3) Adjusting tooth contact
Mix red lead (minium) in spindle oil, then coat the face of 7 or 8 teeth of the driven gear.
Hold down the driven gear by hand to act as a brake, and rotate the drive pinion gear forward
and backward, then inspect the pattern left on the teeth.
Adjust the tooth contact as follows.
Tooth contact Cause Procedure for adjustment
The tooth contact Adjust the drive pinion by adjusting the shims
pattern should start at the drive pinion cage. Adjust the driven gear
from about 5 mm from in the same way as when adjusting backlash.
the toe of the bevel
gear and cover about
50% of the length of
the tooth. It should be
in the center of the
tooth height.
Drive pinion is too far 1. Reduce shims at drive

from driven gear. pinion to bring closer
to driven gear.
2. Move driven gear further
away from drive pinion
and adjust backlash
correctly.
2OBF515
Drive pinion is too 1. Increase shims at drive 8

close to driven gear. pinion to move.away z
from driven gear. z
2. Move driven gear closer
to drive pinion and
adjust backlash correctly. 4
2OBF520
Driven gear is too close 1. Reduce shims at drive

to drive pinion. pinion to bring closer to
driven gear.
and adjust backlash
correctly. 2OBF519
Driven gear is too far 1. Increase shims at drive

from drive pinion. pinion to move away
from driven gear.
2. Move driven gear closer 4
to drive pinion and
1 ,i 2OBF520
8. Lock 2) Adjusting clearance of caliper pad
Install left and right locks (22). (See Fl) Rotate adjustment screw (50) of slack
adjuster, and measure clearance of
caliper pad with gauge 0. (See F5, F6)
* Spring cylinder stroke: 50 mm
* Clearance of pad:
Both ends: 0.8 mm each
When moved to one end: 1.6 mm
9. Caliper assembly
1) Install disc plate (7). (See F2)

(LT-2)

Values Table
2) Fit plate (4) on one side temporarily.

(See F3)
3) Fit pad (5) and install caliper (6). (See F3)
4) Fit plate on other side and tighten fully.
* Make a clearance of 0.1 mm between
the plate and the caliper.
4 Mounting bolt: Thread tightner

(LT-2)

Values Table
1 O.Parking brake chamber assembly

1) Install parking brake chamber (3). and
connect forked portion of rod and lever
of slack adjuster (1) with pin (2). (See F7)
*Pump air into the parking brake
chamber and retract the rod.
30-110
8
Fl
F56103421
F3
F56103413
F4
F56103412
30-111
co
REMOVAL OF DEFFERENTIAL INSTALLATION OF DIFFERENTIAL
ASSEMBLY ASSEMBLY
(For with differential lock) (For with differential lock)
1. Drain oil l Carry out installation in the reverse order

to removal.
: Final drive gear case, differential
- gear case: For details, see Lubricant
and Coolant Table
2. Remove slack adjuster assembly Drive shaft mounting bolt: Thread

For details, see REMOVAL OF SLACK tightener (LT-2)
ADJUSTER ASSEMBLY.
Drive shaft monting bolt: For details,
see Tightening Torques and Stand-
3. Remove hoses (1) and (2). (See Fl)
ard Values Table
4. Remove hoses (IO). (See F2)

* Make match mark on each hose and port.
5. Remove bracket (3). (See Fl) Thread tightener (LT-2)
* Loosen the U-bolts, turn over the valve
assembly bracket and set it on top of the
For details, see Tightening Torques
cross-member.
and Standard Values Table

l Refilling with oil
* Refil oil to the specified level and check
7. Remove shaft (5). (See F4)
the oil level again. 8
* Fit an eyebolt, and remove with a bar.
Final drive case, differential gear si
,0
8. Remove guard (6). (See F5) case: For details, see Lubricant and
Coolant Table
IO. remove drive shaft assembly (8). (See F6)

m
Drive shaft assembly: For details, see

&I kg Weight Table
11. Remove differential assembly (9). (See F7)

m
* Fit a shackle to the differential mounting
surface, then fit a lever block to the pinion
end, and adjust the height when
removing.
* Be careful not to damage the seal surface
of the housing.
Differential assembly: For details,

PI kg
see Weight Table
30-111-l
0
Fl
F2 F7
F56103649
F3 F4
I \~56103/408
30-111-2
0
DISASSEMBLY OF DIFFERENTIAL
ASSEMBLY
(For with differential lock)
1. Set differential assembly in tool Dl. l Disassembly of pinion, cage assembly

1) Remove cage (13) together with bearing
2. Spring cylinder assembly inner (14) from pinion gear (15). (See F6)
Pump air into spring cylinder to retract rod, 2) Remove spacer (16), then remove bearing
then pull out connecting pin (2) of slack inner (17). (See F7)
adjuster (1) lever, and remove spring cylinder
(3). (See Fl)
A If the air in the spring cylinder is

released, the rod will suddenly extend,
so be careful not to get caught. 3) Remove holder (18) then remove center
bearing inner race (19) from pinion gear
(15). (See F8)
3. Caliper assembly
1) Remove bracket (52) and springs (51).
from cage (13). (See F9)
(See F2)
2) Remove plate (4) on one side, then
remove caliper (6) together with pad (5).
(See F2)
place.
3) Remove plate on other side.
4) Remove disc plate (7). (See F3) 7. Differential gear assembly

1) Remove differential lock piping (53).
4. Coupling (See Fl 0)
Remove mounting bolts (8), then remove
coupling (10) together with holder (9) and
O-ring. (See F4)
5. support
Remove support (11). (See F4)
6. Pinion, cage assembly 2) Remove lock (22). (See Fll)

Screw in forcing screws, then lift off pinion 3) Using tool D2, loosen left and right side
and cage assembly (12). (See F5) bearing adjustment nuts (23) until they
* Check the number and thickness of the can be turned by hand. (See F12)
shims, and keep in a safe place.
30-111-3
0
Fl
Dl ‘2 '1
F56103412 F5610341 F5610341 E
F2 F8 F9
4
51
5 52
13
F56103650 F56103420 F56103419
F4 FlO
II
F56103651
F5 Fl 1 F12
D2 23
~56103416 F56163421 F561034i2 1
30-111-4
@
4) Losen mounting bolts (24), and remove 8) Remove plates (57), discs (58), and
cap (25). (See FI) springs (59). (See F5)
5) Lift off differential gear assembly (26). 9) Remove 6 pins (60) from case (61).
(See F2) (See F5)
6) Remove left and right side bearing IO) Remove gear (62). (See F5)
adjustment nuts (23). (See F2) I I ) Remove differential side gear (31).
* Put match mark on each cap together (See F5)
with case.
l Disassembly of differential gear assembly

I ) Set gear case assembly on block
(height: approx 200 mm). (See F3)
2) Using puller 0, remove bearing (27).
(See F4)
3) Remove sleeve (54) (See F3) 12) Differential gear case (See F6)
4) Remove mounting bolts (28). (See F3) i) Turn over case assembly
5) Lift off case (29) with wire (See F3) ii) Remove 8 mounting bolts (63)
iii) Lift off case (43)
kg
&?I Case: For details, see Weight table
* Make match mark on the case before
6) Using 2 eyebolts (Thread dia = 8, pitch removing
= I .25), remove piston (55). (See F3) 13) Remove washer (41). (See F6)
7) Remove washer (30). (See F3) 14) Remove differential side gear (42).
(See’ F6)
15)Remove pinion gear assembly (32)

together with cross shaft (33). (See F7)
30-111-5
0
F2 F5
5? 6CI 6: 3j 5i 5,8 6,’
l‘~66103423 24 A 11’~ F56103424’

I II .
F3
F56103653
27
\
F6
6:
46’
F56103652 F56103654
F4
I
F56103425 F56103655
30-111-6
@
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
(For with differential lock)
16) Hold pinion gear assembly (32) with 1. Bearing

press, and using tool D5, remove ring I) Set differential case in tool DI.
nut (34). (See Fl) 2) Using push tool, press fit bearing (47) in
differential case (48), then install snap
ring (46). (See F6)
17) Pull out shaft (35) with press, then 2. Pinion cage assembly
remove pinion gear, bearing (36), and l Assembly of pinion cage assembly
collar (37). (See F2) 1) Using push tool, press fit outer races (20)
18) Remove bearing (38) from shaft. (See F2) and (21) in cage (13). (See F7)
19) Remove bearing outer races (39) and (40) * Check that there is no clearance
from pinion gear. (See F3) between the outer races and the case.
numbers of the bearing, collar, and
outer race, and keep as a set in a safe
place.
20) Remove bevel gear (44) from case (43) 2) Press fit center bearing inner race (19)
(See F4) in pinion gear(l5), then install holder(18).
21) Remove bearing (45) from case. (See F4) (See F9)
* Shrinkage fit: Heat to 1OOOC

(LT-2)
W Mounting bolt: For dtails, see

Values Table
8. Bearing 3) Press fit bearing inner race (17). and,

Remove snap ring (46), then remove bearing install spacer (16). (See Fl 0)
(47) from differential case (48). (See F5) * Shrinkage fit: Heat to 1OOOC
place.
between the end face of the pinion gear
and the inner race.
30-111-7
0
Fl
F56103436
F3 F7 F8
There
must be nc
13
F56103432 FE8610341 9 561 FO3361
T: F4 F9
18
,43
'44
F5610343E i F56103420
F5 FlO F:I1
There
must be no
F56103436 F56103418 569FO5237
30-111-8
8
4) Set cage (13) to pinion gear (15), and 5. Use one of the following methods to check
install bearing (14). (See Fl) that the setting of the bearing is normal.
5) Coat bearing rollers and tread surface of *(I) Fit spring balance (2) in the tap hole
inside and outside races well with engine (@396) of the coupling, and measure
oil (E030CD). the starting torque in the tangential
direction.
(Do this before installing the bevel gear
end.)
Starting torque: Max. 5.1 kg
*(2) Measure the end play of the bearing.
End play in axial direction:
0.01 - 0.17 mm
Method of measuring
l Installation of pinion, cage assembly i) Rotate bearing 20 - 30 times, set
Fit O-ring, and assemble shim, then install dial gauge as shown in diagram,
pinion and cage assembly (12) to differ- and align 0 mark. (See F7)
ential case. (See F2) ii) With coupling portion raised (lifting
* Assemble the same number and thick- load: approx. 300kg), rotate cou-
ness of shims that was removed during pling 20- 30 times, and check that
disassembly. reading of dial gauge is stable.
iii) Reading of dial gauge obtained in
Step ii) = end play in the axial
direction.
Values Table
3. support 6. Differential gear assembly

1) Install oil seal (49) and O-ring to support d Assembly of differential gear assembly
(11). (See F3, F4) 1) Install bevel gear (44) in differential gear
case (43). (See F9)

(LT-2)

4. Coupling Tightening Torques and Standard
Install coupling (10). then install O-ring and Values Table
holder (9), and tighten mounting bolt (8).
(See F5)
* When doing this, rotate the bearing 20
- 30 times and tighten bolt (8) gradually.
* If bolt (8) is tightened without rotating the
the bearing.
bearing, the bearing may be damaged.

(LT-2)
w Mounting bolt: See Tightening

Torque and StandardValuesTable
* After tightening, rotate the bearing again

20 - 30 times to check that it rotates
smoothly and check that bolt (8) is
tightened to the specified torque.
30-111-9
0
Fl F6
F561034’ 569FO523i
F2
F56103661
569FO52J 569FO524C
T: F3 F9
-43
'44
F56103447 F56103435 ,
F5
8 9
30-111-10
8
3) Pinion gear 8) Differential side gear, gear
* The bearing is an adjustment-free i) Turn over case, and set on block
bearing, so check the matching (height: approx. 200 mm). (See F7)
numbers of the bearing, collar, and ii) Install differential side gear (31).
outer race. (See F7)
i) Using push tool, press fit outer races iii) Install gear (62). (See F7)
(40) and (39) in pinion gear. (See FI) 9) Pins, discs, plates, springs (See F7)
ii) Using push tool, press fit bearing (38) i) Install 6 pins (60) to case (61).
to shaft (35). (See F2) ii) Assemble plates (57). discs (58), and
springs (59). See F7)
* Coat the face of the discs and plates
with E030.
* Assemble in the following order:
iii) Set pinion gear to shaft, then assem- plate, disc, plate, disc, . . . . plate.
ble collar (37), and using push tool,
install collar (37) and bearing (36). IO) Piston, seal
(See F3) i) Install seal (68) to piston (35). (See F8)
iv) Hold pinion gear assembly (32) with ii) Install seal (67) to case (29). (See F8)
press, and using tool D5, tighten ring * Be careful to install the seal facing
nut (34). (See F4) in the correct direction.
iii) Install piston (35) in case (29).
&Ring nut: Thread tightener (LT-2)
(See F8)
m Ring nut: For details, see Tight- 1I)Case
ening Torques and Standard i) Align with dowel pin (70), install
Values Table washer (30) to case (29). (See F8)
*.Check that the head of the surface
4)Assemble pinion gear assembly (32) of the dowel pin is 0.5 ‘t’ mm low- g
together with cross shaft (33) (See F5) er than the surface of the washer z
l Align groove of washer (64) with dowel ii) Align case (29) with position of pin g
pin (65) of case, and install. (See F5) (60), and install (See F8)
* If the groove of the washer is not iii) Tighten I8 bolts (28). (See F8)
fitted completely on the dowel pin,
the cross shaft will not fit properly,
(LT-2)
and the pinion gear will not rotate
smoothly. Check these two points m Mounting bolt: For details, see
carefully. Tightening Torques and Standard
Values Table
5) Install washer (41) to case (43). (See F6)
* Check that the head of the dowel pin 12) Seal, sleeve
is 0.5 ‘t2 mm lower than the surface i) Install 2 seals (69) to case (29).
of the washer (See F8, F9)
6) Install differential side gear (42). (See F6) ii) Install sleeve (54). taking care not to
7) Case damage seals (69). (See F8, F9)
i) Install case (43). (See F6) * Use a block of thiskness IO - I5
* Align match mark on mating case mm to support the sleeve.
(46), and install. 13) Bearing
ii) Tighten with bolts (63). (See F6) Shrink fit bearing (27) to case (29).
(See F8)
Shrink fitting temperature:
(LT-2)
I OOOC for approx. 30 minutes
m Mounting bolt: For details, see * Check that there is no clearance
Tightening Torques and Standard between the end face of the case and
Values Table bearing
30-111-11
8
Fl F2 F7
39 40
38 35
F56103432 F56103437
F56103653
F8
4 I I
‘37 F56103438 F56103430
8 F5
33 3? 64 65
F56103652 F56103656
F9
I
54
69
\
Block
F56AID013A
F56103654
30-111-12
8
7. Installation of differential assembly iv) Tighten adjustment nuts (23) from
1) Tighten side bearing adjustment nuts (23) both ends, and continue to tighten
temporarily, and place differential gear with tool D2, paying careful attention
case assembly (26) temporarily. (See Fl) to the groove that the lockenters.
2) Fit cap (25) and tighten mounting bolts (See F5)
(24). (See F2) * When doing this, to settle the
bearing properly, rotate the bevel
gear and tap the bearing cap and
bevel gear with a copper hammer.
* Precautions when adjusting pre-

load
* When installing cap (25), aling position If the increase in deflection caused
of drill hole in cap (25) with pin (71) by overtightening of the adjustment
mounted tosleeve(54). and install. nut exceeds the standard amount,
(See F3) return the adjustment nuts to the
* Coat outside circumference of pin with condition before adjusting. When
liquid adhesive LG-5. doing this, rotate the bevel gear and
tap the bearing cap and bevel gear
with a plastic hammer, check that
(LT-2)
there is no clearance at portion (b),
m Mounting bolt: For details, see and adjust again. (See F6)
Values Table. 8. Adjusting tooth contact, backlash
Adjust backlash and tooth contact at the
* Align the match mark of the cap. same time.
8
* Rotate the bevel gear 20 - 30 turns
to settle the bearing, then tighten.
1) Adjust backlash as follows. z
i) Move bevel gear with adjustment nut 8
(23). (See F7, F8)
When adjusting the bevel gear, do not
change the preload of the bearing.
Always turn the adjustment nuts at
bothendsthesameamountinthesame
direction.
3) Adjusting preload of bearing ii) Put a dial gauge at right angles in
i) Install measurement adapters D3 to contact with the reverse face of the
both ends of cap (23). (See F4) tooth at the outside of the bevel gear.
ii) Measure dimension beetween adap- Turn the adjustment nut and adjust the
ters with depth micrometer D4. backlash.
(See F4) * Backlash: For details, see Tightening
* When measuring, hold the micro- Torques and Standard Values Table.
meter securely with one hand, and * Adjust at 3 - 4 places. Keep the
put the probe in contact parallel to pinion gear locked when measuring.
the measurement adapter. 2) Adjust tooth contact as follows.
iii) Add 0.4 * 0.15 mm to measured i) Adjust the in and out movement of the
dimension, and set scale of micro- bevel pinion by changing the shims
meter. between the differential case and
* The added dimension becomes the bearing cage.
amount of deflection of the case ii) Adjust tooth contact
between before giving preload and For details, see 3) Adjusting tooth
after giving preload. contact.
30-111-13
6s
F5
r
F56103424 1
, !F56103423 24-- F56103422
F3 F6
Use electric light on

feeler gauge to check
there is no gap.
568FO48
F7
F56103657 F56103445
F4
\ D4 D3 ii ,
30-111-14
8
3) Adjusting tooth contact
Mix red lead (minium) in spindle oil, then coat the face of 7 or 8 teeth of the driven gear.
Hold down the driven gear by hand to act as a brake, and rotate the drive pinion gear forward
and backward, then inspect the pattern left on the teeth.
Adjust the tooth contact as follows.
Tooth contact Cause Procedure for adjustment
The tooth contact Adjust the drive pinion by adjusting the shims
pattern should start at the drivepinion cage. Adjust the driven gear
from about 5 mm from in the same way as when adjusting backlash.
the toe of the bevel
gear and cover about
50% of the length of
the tooth. It should be
2OBF514 in the center of the
tooth height.
Drive pinion is too far 1. Reduce shims at drive

from driven gear. pinion to bring closer
to driven gear.
2. Move driven gear further f
and adjust backlash A -1
correctly.
2OBF515 ’ 177420BF519
0”
Drive pinion is too 1. Increase shims at drive 0”
close to driven gear. pinion to move,away
from driven gear.
2. Move driven gear closer A
to drive pinion and
adjust backlash correctly. +
1 2OBF520
Driven gear is too close 1. Reduce shims at drive

to drive pinion. pinion to bring closer to
driven gear. .
and adjust backlash
correctly. 2OBF519
Driven gear is too far 1. Increase shims at drive

from drive pinion. pinion to move away
from driven gear.
2. Move driven gear closer
to drive oinion and
I 2OBF520
30-111-15
8
9. Lock 12. Parking brake chamber
Install left and right locks (22). (See Fl) 1) Install parking brake chamber (3), and
connect forked portion of rod and lever
of slack adjuster (1) with pin (2). (See F5)
+ Pump air into the parking brake cham-
ber and retract the rod.
lO.Differential lock piping 2) Adjusting clearance of caliper pad

Install differential piping (53). (See F2) Rotate adjustment screw (50) of slack
* Blow in air, and check action of piston. adjuster, and measure clearance of
Air pressure: 4 - 8 kg/cm2 caliper pad with gauge 0. (See F6, F7)
* Parking brake chamber stroke: 50 mm
Sr Clearance of pad:
Both ends: 0.8 mm each
When moved to one end: 1.6 mm
11. Caliper assembly

1) Install disc plate (7). (See F3)

(LT-2)

Values Table
2) Fit plate (4) on one side temporarily.

(See F4)
3) Fit pad (5) and install caliper (6). (See F4)
4) Fit plate on other side and tighten fully.
* Make a clearance of 0.1 mm between
the plate and the caliper.

(LT-2)

Values Table
5) Fit springs (51) and brackets (52). (See F4)

* For details, see Assembly of parking
brake caliper
Fl F5
22
F56103421 F56103412
F2 F6 F7
F56103651
8 F3
z
8
F4
F56103650
30-111-18
8
REMOVAL OF CARRIER DISASSEMBLY OF CARRIER
ASSEMBLY ASSEMBLY
.
1. Drain oil 1. Remove 4 bolts (1) and 6 bolts (2), then
* If the drain plug is not at the bottom, use remove plate (3). (See F4)
a hydraulic jack (5Ot) to jack up the 2. Using a press, pull out shaft (4).
machine, then turn the hub. 3. Pull out pinion gear assembly (5), and
remove 2 bearings (6) and spacer (7).
& Final drive case: For details, see
(See F4, F5)
Lubricant and Coolant Table
4. Remove outer race (8) and spacer (9).
2. Remove cover (1). (See Fl ) (See F6)
3. Remove button (2). (See Fl) * The bearing is an adjustment-free bear-
4. Remove drive shaft (3). (See F2) ing, so keep as a set in a safe place.
A Fit an eyebolt to the tip, then use a bar 5. Remove snap ring (10). (See F6)
to pull out. 6. Remove spacer (11) from carrier. (See F4)
5. Remove snap ring (4). (See F2)
6. Remove sun gear (5). (See F2)
7. Remove spacer (6). (See F2) ASSEMBLY OF CARRIER
8. Remove carrier assembly (7). (See F2, F3) ASSEMBLY
m
1. Install spacer (11) to carrier. (See F4)
Carrier assembly: For details, see
& kg 2. Install snap ring (10). (See F6)
Weight Table
3. Fit spacer (9) and press fit outer race (8).
(See F6)
4. Set spacer (7) and bearing (6) in position,
INSTALLATION OF CARRIER then raise pinion gear and assemble, and
ASSEMBLY install bearing (6) from top. (See F4)
5. Push pinion gear assembly (5) into carrier.
l Carry out installation in the reverse order (See F4)
to removal. 6. Fit plate (3) with bolt (1) temporarily, then
install 2 guide bolts to shaft (4), and press
fit. (See F4)
* Expand fit the shaft, or press fit with a
press.
7. Tighten bolts (2) to specified torque, and
l Refilling with oil after rotating pinion gear 5 - 6 turns,
* Refill oil to the specified level and check tighten 6 bolts (2) and 4 bolts (1) to specified
the oil level again. torque again. (See F4)
Final drive case: For details, see B Plate mounting bolt: Thread tight-
Lubricant and Coolant Table ener (LT-2)
AG= Plate mounting bolt: For details, see

Values Table
30-112'
0
Fl F4
:
4 2
7 3
6
u F56103454
F2 F5
I
6 6
4 L-_-.-l’3 /
F56103452
c F56103455
F3
30-113
0
DISASSEMBLY OF FINAL DRIVE
ASSEMBLY
1. Rear wheel assembly 5. Rear wheel hub assembly

for details, see REMOVAL OF REAR WHEEL 1) Sling wheel hub assembly (10) or support
ASSEMBLY. with forklift, then remove nut (11).
(See F5, F6) .
2. Carrier assembly
For details, see REMOVAL OF CARRIER
ASSEMBLY.
3. Retainer, shim
1) Using tool El, secure inner gear (1) and
outer gear (2). (See Fl)
2) Pull out wheel hub assembly (10) partly,
+ To install the tool, remove bolt (3) from
remove bearing (12), then remove wheel
the outer gear, and use the three tool
assembly. (See F7)
mounting tap holes in the inner gear.
* The bearing comes out easily, so be
* To prevent damage to the floating seal,
extremely careful not to let it drop.
always remove before removing
retainer (4). &Ikg Rear wheel hub assembly:’ For
2) Remove mounting bolts, then remove details, see Weight Table
retainer (4) and shim. (See F2)
3) Remove outer races (13) and (14) from
* Check the number and thickness of the
wheel hub assembly (10). (See F8)
4. Ring gear assembly 6. Bearing

1) Lift off ring gear assembly (5). (See F3) Remove bearing (15). (See F9)
& kg Ring gear assembly: For details, see

Weight Table
2) Disassemble ring gear assembly as

follows.
i) Remove mounting bolts (6), then
remove holder (7). (See F4)
ii) Remove inner hub (9) from ring gear
(8). (See F4)
30-l 14
0
056103
ASSEMBLY OF FINAL DRIVE
ASSEMBLY
1. Bearing 4. Shim, retainer

Install bearing (15). (See Fl) 1) Adjust preload of bearing as follows.
0 With no shim assembled, install
retainer (4) temporarily with bolts.
(See F9)
ii) Remove tool El from 3 places, and
tighten nuts.
iii) Rotate wheel hub 5 - 6 times and
tighten bolts uniformly to a tightening
torque of 15 + 0.5 kgm.
* If the bolts are tightened without
2. Wheel hub assembly
rotating the wheel hub, the bearing
1) Using push tool E2, press fit outer races
will not settle, and the correct
(13) and (14) in wheel hub (10). (See F2)
preload cannot be given.
2) Fit O-ring, then raise rear wheel hub
iv) Using depth micrometer 0, measure
assembly (lo), and set to inner gear.
dimension c between end face of shaft
(See F3)
and retainer. (See F8)
* Measure at two places and take the
average.
v) Remove retainer, and measure thick-
ness a of retainer. Select a shim
thickness (b = c - a) + 0.3 mm.
(See F8)
2) Insert shim, then fit retainer (4) and E
3) Install bearing (12). and tighten nut (11). tighten mounting bolts. (See F9)
z
(See F4, F5) * Rotate the wheel hub 5 - 6 times and
tighten the bolts uniformly until the
& Nut thread: Thread tightener (LT-2)
tightening torque is constant.
w Nut: For details, see Tightening
& Bolt thread: Thread tightener (LT-2)
* Do not remove tool El until the retainer m Bolt: For details, see Tightening
has been completely secured. Torques and Standard Values Table
* After tightening the bolts, rotate the

wheel hub, and check that there is no
abnormality in rotation.
5. Carrier assembly
3. Ring gear assembly For details, see INSTALLATION OF CARRIER
1) Assemble ring gear assembly as follows. ASSEMBLY.
i) Set inner hub (9) to ring gear (8).
(See F6) 6. Rear wheel assembly
ii) Fit holder (7). and tighten mounting For details, see INSTALLATION OF REAR
bolts (6). WHEEL ASSEMBLY.
a Bolt thread: Thread tightener (LT-2)
2) Raise ring gear assembly (5) and install.

(See F7)
30-116'
Co
Fl F8
b
1
F56103466K
F2 F3 F9
‘14
F56103464
F4 F5
B
F56103463 F56103462
F6 F7
L.
1 F5610346OK (( u F5610345g
30-117
0
REMOVAL OF REAR WHEEL DISASSEMBLY OF REAR WHEEL
BRAKE ASSEMBLY BRAKE ASSEMBLY
1. Final drive assembly 1. Outer gear assembly

For details, see REMOVAL OF FINAL DRIVE 1) Remove tool El. (See F6)
ASSEMBLY. 2) Using eyebolts, lift off outer gear (1)
together with disc and plate. (See F6)
2. Drain oil * Be careful not to damage the floating
seal when removing.
& Brake cooling tank: For details, see
Lubricant and Coolant Table. * When using the disc and inner gear
again, put match marks on the meshing
3. Remove retainer (1). (See Fl) portion of the teeth.
* Remove floating seal (2)from the retainer.
(See F2)
2. Damper, disc, plate
Remove damper (2), disc (3), and plate (4)
4. Remove hoses (3). (See F3)
from outer gear (1). (See F7)
5. Remove tubes (4). (See F3)

3. Hub
1) Remove mounting bolts, then remove hub
6. Remove brake assembly (5). (See F4) m
(5) from outer gear (1). (See F7)
kg
&?I Brake assembly: For details, see 2) Remove floating seal (6) from hub (5).
Weight Table (See F7)
* Make match marks before removing.
7. Remove piston (6). (See F5) m
* Loosen the air bleed plug and remove
piston (6). 4. Floating seals
Remove floating seals (8) and (9) from inner
8. Remove cylinder assembly (7). (See F5) m gear (7). (See F8)
INSTALLATION OF REAR WHEEL

ASSEMBLY

to removal.

m
J, Install the piston seal with the grooved side
facing the side taking the pressure.
m
* Install the cylinder seal with the side with
the groove facing the side taking the
pressure.
m Mounting bolt: For details, see Tighten-

30-118
8
Fl F2 F6
F56103467 F56103617 I 1’ El
F56103471
F3 F7
‘6
F56 103468 F56103472
F4 F8
F56103469
F5
I F56103470
30-119
0
ASSEMBLY OF REAR WHEEL
BRAKE ASSEMBLY
* Clean all parts, and check for dirt or damage. 3. Outer gear
Coat the sliding surfaces of all parts with 1) Using eyebolts, assemble outer gear
engine oil before installing. assembly (1) to inner gear. (See F5)
* When assembling the floating seals, use * Coat the sliding surfaces of the floating
alcohol to remove all the white powder from seals thinly with engine oil.
the O-ring surface before assembling. * Assemble slowly and be careful not to
damage the floating seals.
1. Floating seals
Using tool E3, install floating seals (8) and
(9) to inner gear (7). (See Fl)
* After installing the floating seals, mea-
sure dimension a between the inner gear
and floating seal at four places around
the circumference, and check that the
measurement is within 1 mm. (See F2)
8
2. Hub 2) Align center of inner gear and outer gear z
1) Using tool E3, install floating seal (6) to (I), then using tool Et, secure inner gear g
hub (5). (See F3) and outer gear. (See F7)
* For precautions to take after installing
the floating seal, see Item 1.
2) Align match marks, and install hub (5) to 4. Damper, disc, plate
outer gear (1). (See F4) Assemble damper (2), disc (3), and plate (4)
to inner gear and outer gear assembly.
(See F8)
(LT-2)
* When using the disc and inner gear again,
m Mounting bolt: For details, see put match marks on the meshing portion
Tightening Torques and Standard of the teeth.
Values Table -)r Assemble so that the side face of the
damper rubber is in the direction where
it does not contact the disc.
30-120
0
Fl F5
I/ \8 1
F56103476
F56103473
F2 F6
I
568FO56 F56103619
F3 F7
8
E3
1' El
F56103474 F56103471
F4 F8
F56103475 F56103477k
30-121
0
REMOVAL OF PARKING BRAKE DISASSEMBLY OF PAR KING
CALIPER ASSEMBLY BRAKE CALIPER
1. Parking brake spring cylinder assembly 1. Remove snap ring (1), and pull out adjuster
For details, see REMOVAL OF PARKING (2). (See F2)
BRAKE SPRING CYLINDER ASSEMBLY. 2. Remove washers (3) and (4), and seal (5).
2. Remove plate (1). (See Fl) a (See F2)
3. Remove pads (2). (See Fl) 3. Remove bolts, then remove cap (6) and
4. Remove caliper (3). (See Fl) gasket (7). (See F2)
4. Remove piston shaft (8) and thrust bearing
6 kg Caliper: For details, see Weight Table
(9) from piston. (See F2)
5. Remove piston (11) and piston seal (12) from
caliper (10). (See F2)
INSTALLATION OF PARKING ASSEMBLY OF PARKING BRAKE

BRAKE CALIPER ASSEMBLY CALIPER
l Carry out installation in the reverse order 1. Assemble piston seal (12) to caliper (IO).and
to removal. insert piston (11). (See F2)
& Piston, piston seal: Grease (G2-LI)
2. Screw piston shaft (8) into piston, and install

Plate mounting bolt: For details, see
thrust bearing (9). (See F2)
Tightening Torques and StandardValues
* Be careful to install the thrust bearing
Table
facing in the correct direction.
a Thrust bearing: Grease (G2-LI)
3. Fit gasket (7) and install cap (6). (See F2)

4. Install seal (5) and washers (3) and (4).
(See F2)
* Fit the seal securely in the groove.
a Seal: Grease (G2-LI) .
5. Assemble adjuster (2) and secure with snap

ring (1). (See F2)
30-122
0
Fl
2 13
F56103478
F2
F56103479
30-123
0
REMOVAL OF PARKING BRAKE REMOVAL OF FRONT BRAKE
PAD CALIPER ASSEMBLY
A Stop the machine on level ground, and 1. Front wheel assembly

put blocks under the wheels. For details, see REMOVAL OF FRONT

WHEEL ASSEMBLY.
safety pin.
+ Turn the starting switch ON, and release * Disconnect two tubes on both sides.
the parking brake.
3. Remove caliper assemblies (2). (See F3) m
1. Loosen adjustment bolt (1). (See Fl ) + Leave 2 or 3 of the 16 mounting bolts
* Turn the bolt counterclockwise, and make in position, then use a forklift truck or
the clearance between the pad and disc other equipment as support, remove the
larger. remaining mounting bolts, and remove
2. Loosen mounting bolts (2). (See Fl) m caliper assembly (2). (See F3)
It Loosen bolts (2), and sling so that the
&I kg Caliper assembly: For details, see
caliper does not fall.
Weight Table
3. Remove pads (3). (See Fl ) m
* Move plate (4) when removing the pads
so that the pads do not fall.
* After removing the rear pad, move the
caliper to the front, and remove the front
pad.
INSTALLATION OF PARKING INSTALLATION OF FRONT BRAKE

BRAKE PAD CALIPER ASSEMBLY
* Align the grooves of the pad and the

caliper with both sides of the plate
securely. m Mounting bolt: For details, see Tighten-
& Plate mounting bolt: Thread tightener
(LT-2) * Bleed the air from the front brake.
m Plate mounting bolt: For details, see
ING, Adjusting brake and bleeding air.
Tightening Torques and Standard Values
Table
pJ
* Adjust the brake pad wear.
ING.
30-l 24
co
Fl F2
3 4
F56103480 F56103481
F3
F56103482
30-125
0
REMOVAL OF FRONT BRAKE DISASSEMBLY OF FRONT BRAKE
CALIPER PAD CALIPER ASSEMBLY
1. Front wheel assembly 1. Loosen bolts (1) and (2), remove pins (3). (4).
For details, see REMOVAL OF FRONT and (5), then remove pads (6). (See F3)
WHEEL ASSEMBLY. 2. Remove plate (7), then remove plug (8),
2. Pull out pin (1). (See Fl) m backup ring (9), and seal (10). (See F3)
* Loosen bolt (2), and pull pin (1) until the 3. Remove dust seal (1 l), then remove piston
pads can be removed. (12). (See F3, F4)
3. Remove pads (3). (See F2) 4. Remove ring (13) and backup ring (14).
1) Install a vinyl hose to bleeder screw (4) (See F3, F4)
so that the brake oil can be drained out. * Disassemble the other pistons in the same
2) Loosen the bleeder screw, and return way.
piston (5) to the bottom of the cylinder
with a bar.
INSTALLATION OF FRONT BRAKE ASSEMBLY OF FRONT BRAKE

CALIPER PAD CALIPER ASSEMBLY
l Carry out installation in the reverse order 1. Install backup ring (14), ring (13), and dust
to removal. seal (11) in groove of torque plate (15)
securely. (See F3, F4)
2. Install piston (12). (See F3, F4)
* Fit the lip of the dust seal in the groove
m Mounting bolt: For details, see Tighten-
of the piston.
3. Fit seal (lo), backup ring (9), and plug (8),
l Bleed the air from the brake circuit. and install plate (7). (See F3)
For details, see TESTING AND ADJUSTING, 4. Fit pads (6). and install pins (5), (4). and (3),
Bleeding air from brake. then tighten with bolts (2) and (1). (See F3)
a Pin: Grease (G2-LI)
Qa Mounting bolt: For details, see

Values Table
* Move the pin in the axial direction while

tightening the bolts, and check that the
bolt fits securely in the groove of the pin.
* Of thin pins (4) and (5), always install the
short pin (5) at the plate end. (See F3)
* Assemble the other pistons in the same
way.
5. Install caliper assembly.
For details, see INSTALLATION OF FRONT
CALIPER ASSEBMLY.
30-126
0
F3
F56103483
F2
6
569F209
5 F56103484
F4
569F210
30-l 27
0
REMOVAL OF STEERING VALVE REMOVAL OF STEERING VALVE
ASSEMBLY (A) ASSEMBLY (B)
A4
* k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
[If steering
removed
valve yoke (5) is stiff and cannot
easily from the input shaft.]
be
* With the method B for removal and instal-

Ir Pass a rope through the yoke and secure
lation, removal is easy, but when installing
the yoke to the top to prevent the yoke
the steering valve, it is difficult to insert the
from falling out from the column shaft
spline, and it is necessary to align the spline
spline.
position, so normally method A should be
1. Remove yoke lock bolt (1). (See Fl ) used for this operation.
* The lock bolt has a fine thread, so be * Make match marks to show the position of
careful not to lose it or to use force and insertion for the spline at the steering wheel
damage the thread. and yoke (5).
+ Check that the yoke moves up and down
easily on the spline of the steering valve 1. Disconnect hoses (2). (See Fl)
input shaft, and that it comes off easily. * Disconnect 5 hoses.
* If the steering valve input shaft is hit
strongly, it may be deformed and cause 2. Remove steering valve assembly(3). (See Fl )
problems. pJ
* Remove the steering valve assembly from
2. Disconnect hoses (2). (See Fl ) the yoke and spline (4) of the steering
* Disconnect 5 hoses. wheel end input shaft. (See Fl )
3. Removal steering valve assembly (3).

(See Fl)
E?lkg Steering valve assembly: For details,

see Weight Table
* Lower it with a rope and be careful not

to drop it.
INSTALLATION OF STEERING INSTALLATION OF STEERING

VALVE ASSEMBLY (A) VALVE ASSEMBLY (B)
* Align the match marks for the insertion

position of the spline at yoke B and the
steering wheel end, and install the
steering valve assembly.
* If the position of the yoke is not correct,
it may cause variation in the rotation of
the steering wheel.
30-l 28
0
Fl F2
F56103485 F56103486K
30-l 29
0
DISASSEMBLY OF STEERING
VALVE ASSEMBLY
* Maintaining clean working conditions 2. Remove commutator (5) and washer (6).
1. When carrying out maintenance of the (See F2, F3)
power steering system, cleanliness is * Do not remove pin (4). (See F3)
absolutely essential. The hydraulic circuit
must be completely isolated from any dirt
or dust.
2. If it is necessary to disassemble any part
of the unit, always use a clean work stand.
3. Before disconnecting any piping, always
wipe off all the dirt on the outside.
4. Before setting the unit on the work stand,
3. Using 2 mounting bolts (I), remove commu-
always wipe off any dirt on the outside.
tator ring (7) and manifold (8). (See F4, F5)
5. After disassembly, clean with a petroleum
4. Using 2 mounting bolts (1). remove rotor set
base solvent that is free from any impurity,
(9) and wear plate (10) in the same way as
then blow with dry air that is free from any
commutator ring and manifold. (See F4. F5)
impurity.
* If any other solvent is used, it may cause
deterioration of the rubber seal. Do not
wipe any part with a cloth or apply hot
air to the unit.
+ The solvent is a flammable substance, so
be careful to handle it correctly and do
not bring any flame close to it.
T:
Preparatory work 5. Insert screwdriver between sleeve (3) and 5
0
1) Fit blind plugs to 5 ports of the valve body, valve body (1 1 ), and remove sleeve (3).
clean the outer parts, then remove the blind (See F6)
plugs. 6. Remove drive link (12). (See F7)
2) Install tube nut 0 to one of the ports.
(See Fl )
3) Install in vice @ with the end cover facing
up. (See Fl)
* Do not hold the valve body directly in the
vice. This may cause damage to the unit.
1. Remove 7 mounting bolts (I), then insert

screwdriver between end cover assembly (2)
and sleeve (3). and remove end cover
7. Remove ball (13). (See F8)
assembly (2). (See Fl)
8. Remove rod (14). roller (15), rod (16) and
* After removing, check for any breakage
spring (17). (See F9)
around the edge of the end cover hole.
30-ik30
Fl F2 F3
T
a
1 2
5
3
F56103488 F56103489
F4 F5
569FO68
F6 F7
F8 F9
30-J 31
0
9. Install in vice so that input shaft (18) faces * Seal (29) and seal ring (30) may form one
up, then make match marks with a punch unit. (See F4, F5)
in upper cover (19) and valve body (11).
(See Fl )
10. Remove 4 mounting bolts (20). hold input 13. Remove snap ring (31), thrust washer (32),
shaft (18) and move it up, then remove input thrust bearing (33). thrust washer (34), and
shaft, upper cover, and valve spool assembly wave washer (35) from input shaft (18).
(23). (See Fl, F2) (See F6, F7)
* The valve spool is fitted into the body with
an extreme small clearance, so be careful
not to apply any sideways force as it will
become impossible to remove it. When
removing the valve spool from the hous-
ing, never use any excessive force.
11. Remove upper cover assembly (22) ,from 14. Using pin @ (e3.0 mm, length . 16 mm),
input shaft and valve spool assembly (23), remove needle roller (36) from input shaft
then remove shim (24) and spacer (25). (18). (See F8, F9)
(See F2, F3) * To prevent damaging the input shaft, carry
A Check the number and thickness of the out the operation on a wooden block.
12. Remove seal (26) and snap ring (27). then

remove spacer (28), seal (29), and seal ring
(30) from upper cover (19). (See F4, F5)
30-132
0
Fl F5
-
569FO70
F2 F6
3 18
31
32
35 34
F56103496 F56103498 F56103499
F3 F8
I n
25
569FO69
F4 F9
27 0.8mm
i
F56103497
L
30-133
0
15. Set valve spool (37) facing down, then
remove torsion bar (38) and spacer (39) from
input shaft and valve spool assembly (23).
(See Fl)
* Do not remove needle roller (40) from the
torsion bar.
16. Set valve spool (37) facing down, then rotate

input shaft (18) until drive link (41) comes
out. (See F2)
17. Set valve spool (37) facing down, then rotate
input shaft (18) clockwise until ball (42)
comes out. (See F3)
It Ball (42) may come out, so be careful not
to lose it.
* Do not remove ball retaining spring (43)

unless replacing it. When removing it,
make the end horizontal, grip it with pliers,
then pull it up until it comes completely
away from valve spool (37). Be careful not
to damage the control edge or outside
circumference of the valve spool. (See F4)
30-134
0
43 37
F56103503
30-l 35
0
ASSEMBLY OF STEERING VALVE
ASSEMBLY
* Before assembling, wash all parts in clean

petroleum base solvent, then dry with air.
Never wipe with a cloth.
* Check careful that there are no pieces of
paint remaining on the edge of the lapped
surface.
* Unless there are special instructions, do not
coat any part with oil when assembling.
1. Set thrust washer (34). thrust bearing (33),

and thrust washer (32) to input shaft (18), 6
Checkspline of drive link(41) and input shaft
and install snap ring (31). (See Fl, F2)
(18), then align spline of valve spool (37),
2. Install wave washer (35) to thrust bearing
and install drive link (41). (See F8, F9)
(33) and thrust washer (34). (See F3)
* If the drive link and input shaft spline do
3. Install ball (42) on inside of valve spool (37).
not mesh, rotate the input shaft slightly
(See F4)
to mesh them.
* When inserting the drive link, fit the
torsion bar securely.
* If the drive link is assembled correctly, a
clearance of 8.89 mm will be obtained
between the thrust washer and valve
spool.,
* If the spool, drive link, and input shaft are
not correctly installed in relation to each
4. Rotate counterclockwise so that ball and
other, the steering unit will not work
goove are meshed, and insert input shaft
properly.
(18) in valve spool (37). (See F5)
* Keep the spool horizontal when carrying
out the operation.
5. Fit middle of torsion bar (38) between thrust 7. Measure diameter I of pin (40) of torsion
washer (34) and valve spool (37). bar (38) at several places, and check that
(See F6, F7) the difference is less than 0.025 mm.
* The positioning of the valve spool and (See Fl 0)
input shaft is carried out by fitting the 8. Set spacer (39) to torsion bar (38), and insert
torsion bar. valve spool and input shaft assembly (23).
(See Fl 1)
30-136
0
F7
37 38 34
32
F56103504 F56103505 569FO73
F3 F:4 F8
@
42
F56103506 F56103507 F56103510
18
I
F56103508 569FO74
F6 FlO Fll
569FO75
30-137
0
9. Using pin @(outside diameter: 3 mm), align 16. Measure width !I of groove of drive link (12)
pin holes of torsion bar (38) and input shaft at several places, and check that the
(18). (See Fl ) difference is less than 0.025 mm. (See F7)
10. Using pin 0, knock in pin (36) 0.8 mm from
end face of input shaft. (See F2)
569FO77
11. Install spacer (25) on input shaft and valve 17. Pull input shaft down, align drive link (12)
spool. (See F3) with valve spool spline, and install. Rotate
* If there is a lip at one end on the inside spool so that valve body is level with end
of the spacer, install with the lip surface face of spool. (See F7)
facing the wave washer.
12. Install input shaft and valve spool assembly 18. Align drive link(12) and pin (40), then install.
(23) to valve body (11). (See F4) (See F8)
* The clearance is extremely small, so if any
sideways force is applied when assem-
bling, it will not work properly.
13. Set shim (24) on thrust washer, then fit seal,

align match mark of upper cover (19) and
install, ‘then tighten mounting bolts (20)
temporarily. (See F5)
14. Set tool FI in position, and install so that

valve body and upper cover are centered.
(See F6)
15. Tighten mounting bolts (20), and remove tool
Ft. (See F5, F6)

Values Table
30-138
0
F7
F56103517
569FO76
F3 F4 F8
25
23 24
11
\
F56103513 F56103514
569FO79
F5
30-139
0
19. Using depth gauge @I, measure mounting 23. Before installing rotor, inspect rotor as
height “h” of end face of valve spool and follows.
valve body. (See Fl, F2) 1) Set pin side of end cover assembly facing
+ Mounting height h = Within 0.063 mm up, and spline side of rotor assembly (9)
(Improper shim adjustment) facing down, and check that the rotor
If mounting height h = 0.064 mm or more, rotates freely inside the startor. (See F4)
repeat Items 12 - 19 and adjust the
shims to make h = within 0.063 mm.
2) Measure thickness of rotor and stator, and

check that difference is within 0.18 mm.
3) Using feeler gauge 0, check that clear-
ance of rotor from stator is within 0.18
mm. (See F5)
20. Install ball (13). (See F3)

21. Set rod (17) to spring (16), and fit to valve
body(l1),theninstaIIroller(l5)androd(l4).
(See F3)
22. Fit seal to valve body.
30-140
0
Fl F4
I
I II installation height h
9
0 O
0
0
0
0
0
0
-2
@
569FO78
I
F56103519
I
F2 F5
I \ - F56103520
F56103518
30-141
0
24. Using guide pin @, install wear plate (lo),
rotor assembly (9), and manifold (8).
(See Fl, F2)
25. Fit seal to end cover assembly (2).

(See F2, F3)
26. Set sleeve (3) and end cover assembly (2)

in position, then tighten mounting bolts (1)
uniformly and install sleeve, then remove
end cover assembly. (See F2, F3)
Qa Mounting bolt: For details, see

Values Table
27. Fit washer (6) to end cover assembly (2). and

install commutator (5). (See F3, F5)
* Install the commutator with the concave
part facing the end cover assembly side.
* Position so that the hole in the oval
commutator is in a straight line with one
of the bolt holes in the end cover
assembly.
28. Install commutator ring (6). (See F3)
29. Rotate input shaft so that tip of drive shaft

is aligned with oval hole in commutator.
30. Set end cover assembly (2) on sleeve (3)

then tighten 5 mounting bolts uniformly.
(See F6, F7)
30-k42
F------h
F6 F7
1 2 9
(I 569FO82(
F3
F56103522
F4
Concavity of
commutator
569FO81
F5
Set in a straight line

5
\ i-
F56103523
30-143
0
31. Set input shaft end facing up, then install
seal ring (30) and seal (29). (See Fl )
* Install the seal from the small diameter
end.
* Seal ring (30) and seal (29) are supplied
stuck together as one unit. (See Fl)
j, Coat the new seal with oil, and install it
from the lip end.
l When doing this, coat thinly with grease.
32. Using tool F2, install spacer (28) from small

diameter end. (See F2)
33. Install snap ring (27). (See Fl)
34. Fit seal (26) to input shaft, and install to

upper cover. (See Fl)
30-144
0
Fl
569FO84
F56103526K
30-l 45
Q
REMOVAL OF FRONT WHEEL
ASSEMBLY

put blocks on both sides of the rear
wheels.
A Put a hydraulic jack (50t) under the

suspension cylinder, and jack up the
front wheel assembly.
1. Remove wheel clamp nuts (1). (See F2) m
2. Remove front wheel assembly (2). (See F2)

m
i-?kg Front wheel assembly: For details,

see Weight Table
* Use a forklift truck.
INSTALLATION OF FRONT
WHEEL ASSEMBLY

to removal.
* Tighten the wheel clamp nuts uniformly.

* Rotate the wheel, then check that the
runout is within 5 mm.
D Wheel clamp nut: For details, see

Tightening Torques and StandardValues
Table
m
l Align the notch in the wheel hub with the
wheel rim stopper.
30-146
0
Fl
F56103527
F2
F56103528
30-147
0
REMOVAL OF REAR WHEEL INSTALLATION OF REAR WHEEL
ASSEMBLY ASSEMBLY
A Stop the machine on level ground, and l Carry out installation in the reverse order
put blocks on both sides of the front to removal.
wheels.
Put a hydraulic jack (50 t) under the rear
axle, and jack up the rear wheel * Tighten clamp nuts (2) uniformly in the
assembly. correct order of tightening. (See F5, F6)
* Tighten fully after lowering the machine
1. Remove air valve lock plate (1). (See Fl) to the ground.
B Clamp nut: For details, see Tightening

2. Remove clamp nuts (2). (See Fl) m
3. Remove wedge ring (3). (See Fl) m

* Install the wedge ring so that the protru-
4. Remove outside wheel assembly (4). sion of the wedge ring from the cover
(See F2) m surface is uniform around the whole
circumference of the ring.
&I kg Wheel assembly: For details, see
Weight Table
* Using a forklift truck (5t). remove the Sr Align the notched groove in the wheel hub
wheel assembly together with the wedge with the wheel rim stopper.
ring. * Be careful not to break the air valve.
5. Remove spacer (5). (See F3) l Rotate the wheel and check that the runout
is within 5 mm. 8
6. Remove clamp nut (6). (See F4) m l After installing the rear wheel assembly, g
travel approx. 5-6 km to settle all contacting 0
7. Remove inside wheel assembly (7). (See F4) portions, then always check that the torque
m is the specified tightening torque.
kg Wheel assembly: For details, see

&I?
Weight Table
* Use a forklift truck (5t).

* Be careful not to break the air valve of
the inside wheel assembly.
* After removing the wheel assembly, stand
it in a safe place and use blocks to prevent
it from falling over.
30-148
0
Fl F5
Tightening order
F56103533
F2 F6
F56103534
F3
F4
. ---A/ ’ F56103532
30-k49
DISASSEMBLY OF FRONT WHEEL
HUB ASSEMBLY
1. Front caliper assembly 4. Bearing, retainer

For details, see REMOVAL OF FRONT 1) Remove bearing (10). (See F5)
CALIPER ASSEMBLY. 2) Remove retainer (11). (See F5)
2. Cover
Remove cover (1 ).?See Fl )

1) Support wheel hub assembly (2) with
forklift truck. (See F2)
2) Remove retainer (3). (See Fl)
* Check the number and thickness of the
3) Lever wheel hub assembly (2) lightly from

rear, and push out together with bearing
(4). (See F3)
4) Remove bearing (4), then remove wheel
hub assembly (2). (See F3)
&?Ikg Wheel hub assembly: For details, see

Weight Table
5) Disassemble wheel hub assembly as

follows.
i) Remove mounting bolts, then remove
brake disc (5). (See F4)
ii) Remove oil seal (6). (See F4)
iii) Remove outer race (7). (See F4)
iv) Remove outer race (8). (See F4)
30-150
0
Fl F5
F5610353E 569F212
F2
561F115P
!_.
F3
F4
1
7
5
8
F56103537
30-151
0
ASSEMBLY OF FRONT WHEEL HUB ASSEMBLY
1. Retainer, bearing a Fill the shaded portion fully with grease.

1) Install retainer (11). (See Fl) (See F5)
2) Install bearing (10). (See Fl) (Amount of grease: Approx. 17.6 liter
each wheel)
* Select the type of grease to use from Table

A.
* Be careful not to damage the oil seal on

the inside of the hub.
Table A
No. Maker Brand name

1) Assemble wheel hub assembly as follows. 1 Nippon Koyu HIGHREX HD-2
(See F2, F3) 2 MOBIL Mobilgrease HP-2
0 Using push tool, press fit outer race 3 SHELL Super Duty Grease 2
(8). 4 ESSO RONEX MP
ii) Using push tool, press fit outer race
51 BP 1 Enerarease LS-EP 2
(7).
iii) Using push tool, press fit oil seal (6).
* Remove all grease from the seal
surface of the wheel hub and the
outside circumference of the seal. 3) Install bearing (4). (See F6)
a Outside surface of seal:

4) Adjust preload of bearing as follows.
Tread tightener (Loctite #648)
(See F7)
& Between seal and lip: i) Install retainer (3) with 3 mounting
Fill with grease (See table A) bolts without installing any shim,
rotate hub 20 - 30 times and tighten
iv) Set brake disc (5) in position, and uniformly until torque is specified
tighten with mounting bolts. tightening torque.
a Mounting bolt: Thread tightener m Mounting bolt (When adjusting):
(LT-2) 11 + 0.5 kgm
Mounting bolt: For details, see ii) Measure dimension c from retainer to
Tightening Torques and standard tip surface of axle with depth
Values Table micrometer 0.
iii) Remove retainer (3), and measure
2) Support wheel hub assembly (2) with retainer T, then select shim
thickness
forklift truck, then install. (See F4) thickness of difference d in measured
value (d = c -T) + 0.3 mm.
Sr Measure 2 places and take the
average.
* Select the combination of shims
that gives the minimum number of
shims.
* When removing the retainer, be
careful that the bearing does not
come out.
30-l 52
8
Fl F5
,
F2
:( J
569F212 561FO3362
I ‘8
F56103537
F3 F6
Remove all grease, and dry
gill with grease

569FO5243
D 569F211
F4
F56103538
561F115A
30-153
8.
5) Fit shim and retainer (3), rotate hub 20
- 30 times and tighten uniformly until
torque is specified tightening torque.
(See Fl)

(LT-2)

Values Table
* After tightening the bolts, rotate the hub

and check that there is no abnormality
in rotation.
3. Cover
Fit O-ring and install cover (1). (See F2)
6 Fill the inside of the cover (shaded

portion) with grease. (See table A)

Values Table
4. Front caliper assembly

For details, see INSTALLATION OF FRONT
CALIPER ASSEMBLY.
+ Precautions when changing grease

If the grease is mixed with another type of
grease, it may swell and deteriorate, so when
changing the grease or filling with grease,
remove all the old grease, clean the inside
surface of the hub and bearing, and be careful
not to mix the grease.
30-154
8
Fl
I
F56103535
F2
L.
569F214
30-155
0
REMOVAL OF FRONT INSTALLATION OF FRONT
SUSPENSION ASSEMBLY SUSPENSION ASSEMBLY
1. Front wheel hub assembly l Carry out installation in the reverse order
For details, see REMOVAL OF FRONT to removal.
WHEEL HUB ASSEMBLY.
m
2. Loosen vlave (1). (See Fl ) m
m Valve: For details, see Tightening
l Loosen the valve, and release the nitrogen
gas.
* After releasing the gas, tighten the
valve.
3. Remove brake hoses (2). (See Fl)
4. Remove grease tubes (3). (See F2)
5. Remove elbow (4). (See F2)
6. Remove pins (5) and (6). (See F2)
7. Remove tie rod (7). (See F2)
8. Remove steering cylinder rod (8). (See F2)
9. Remove bolts (9). (See F3)

* When removing the bolts marked 0,
rotate the knuckle arm approx. 40”
towards the chassis; when removing the
bolts marked 0, return the knuckle arm
to its original position, put a jack under
the king pin, then jack up and remove.
10. Remove cylinder rod pin (10). (See F4)

* Using a forklift truck, sling the suspension
assembly.
11. Remove suspension cylinder assembly (11).

(See F4)
* Disconnect the suspension assembly from
the knuckle arm.
kg Suspension assembly: For details,

&
see Weight Table
30-156
0
Fl
F2
\ F56103540
F3
8
6
z
F4
F561035421
30-l 57
0
REMOVAL OF VARIABLE
DAMPER VALVE ASSEMBLY
9&c Release the nitrogen gas.

+ For details, see TESTING AND ADJUSTING,
Testing and adjusting suspension cylinder.
1. Remove cover (1). (See Fl)
2. Remove air tube (2). (See F2)
3. Remove air cylinder assembly (3). (See F2)
* rod (4), and remove together
Disconnect
with brackets (5) and (6). (See F2)
When the tube is removed, oil will come
A out, so prepare a container to catch it.
; Front suspension cylinder: See Lubri-
-cant and Coolant Table.
5. Remove variable damper valve assembly (8).
m
INSTALLATION OF VARIABLE
DAMPER VALVE ASSEMBLY
l Carry out installation in the reverse order to
removal.
m
w Mounting bolt: See Tightening Torques

and Standard Values
Table.
l Adding oil and charging with nitrogen gas

Add oil and charge with nitrogen gas.
Testing and adjusting suspension cylinder.
30-157-l
0
Fl
F2
30-l 57-2
0
DISASSEMBLY OF VARIABLE ASSEMBLY OF VARIABLE
DAMPER SELECTOR VALVE DAMPER SELECTOR VALVE
ASSEMBLY ASSEMBLY
1. Variable selector shaft assembly 1. Assembly of orifice plate

1) Remove retainer (1) and flange (2) from 1) Insert pin (14) in orifice plate (12), then
valve body (3). (See Fl) fit 3 rectangular leaf springs (10) and
2) Remove shaft assembly (4). (See Fl) shim (15). and assemble stopper plate
3) Remove bearing (6) from shaft (5). (13). (See Fl)
(See Fl) 2) Assemble 3 round leaf springs (11) from
* Put a thin plate, such as a wide shim, opposite side of orifice plate, then
in contact with the clearance, then tigfhten with bolt (9). (See Fl)
gradually push open and remove the * There is a taper on one side of the
bearing. end face of rectangular leaf springs
2. Disassemlby of orifice plate (10). shim (15). and round leaf springs
1) Remove bolt (7), then remove orifice (11). so always install the taper face
plate assembly (8). (See Fl) facing orifice plate (12). (See Fl)
2) Remove bolt (9), then disassemble into 3) Assemble orifice plate assembly (8) in
3 leaf springs (lo), 3 leaf springs (1 l), valve body (3), then tighten bolts (7).
orifice plate (12), and stopper plate (13). (See Fl)
(See Fl) 2. Variable selector shaft assembly
* The bolts, nuts, and washers are 1) Using push tool, press fit bearing (6) to
special parts, so store them separ- shaft (5). (See Fl )
ately from other parts. 2) Insert shaft assembly (4) in valve body
(3), then assemble flange (2), retainer (1),
and ‘bracket, and tighten temporarily
with mounting bolt at 2 places. (See Fl)
jr Be careful not to damage the O-ring,
backup ring, U-packing, and dust seal
when assembling to the flange.
30-l 57-3
0
Fl
-- --
-- 0 --
F56103634
(30-157-4
0
DISASSEMBLY OF FIXED
ATTENUATION VALVE ASSEMBLY
1. Remove bolt (1) and remove orifice plate

assembly (2) from valve body (3). (See Fl)
2. Sub-disassembly of orifice plate assembly
1) After removing bolt (4). remove stopper
plate (5), plate (6), oblong leaf spring
(7). circular leaf spring (8) from orifice
plate (9). (See Fl)
2) Remove pin (10) from orifice plate.
(See Fl)
ASSEMBLY OF FIXED
ATTENUATION VALVE ASSEMBLY
1. Assembly of orifice plate assembly

1) Install two pins (10) in orifice plate (9).
(See Fl)
2) After setting three kinds of oblong leaf
springs (7) on orifice plate, and install
plate (6) while adjusting pin. (See Fl)
3) After setting three kinds of circular leaf
springs (8) and tighten bolt (4) with
together bolt (4). (See Fl )
* Oblong leaf spring and circular leaf spring
are installed to face chamfering side to
orifice plate side. (See F2)
2. After setting orifice plate assembly (2) with
together O-ring on valve body(3), and tighten
bolt (1).
30-l 57-5
0
Fl
I_ _-
F5610363E i
F2
Chamfer
F56103636 5
30-157-6
0
DISASSEMBLY OF FRONT ASSEMBLY OF FRONT
SUSPENSION CYLINDER SUSPENSION CYLINDER
ASSEMBLY ASSEMBLY
1. Cover 1. Wear ring

Remove cover. Install wear ring (14) to cylinder rod (5).
(See Fl )
2. Intake valve, oil level valve
Remove intake valve (1) and oil level valve 2. Flange
(2). (See Fl) 1) Press fit bushing (13) in flange (8), and
install U-packing (12). (See Fl, F3)
3. Cylinder rod assembly 2) Press fit bushing (11) to retainer (7), and
1) Remove flange mounting bolts (3) and air install dust seal (10). (See F3)
bleed plug (4). (See Fl ) Sr Be careful not to deform the biushing
2) Raise cylinder rod assembly (5) with plate when press fitting.
(6), retainer (7) and flange (8) still
installed. (See Fl) 3. Cylinder rod assembly
* Raise to position where cylinder rod 1) Install stopper (9) to cylinder rod (5).
assembly contacts step of stopper (9). (See Fl)
(See Fl) 2) Install flange (8), retainer (7), and plate
3) Install tool G to cylinder. (See F2) (6) to cylinder rod. (See Fl)
4) Raise cylinder assembly until it rises 3) Using block, stand cylinder upright.
approx. 50 mm from floor, then hit from * Fill inside of cylinder with engine oil.
top of tool G with a plastic hammer so
Cylinder: 10 a (EDIO-CD)
that stopper passes from step in cylinder.
5) Remove tool G, then remove cylinder rod 4) Raise cylinder rod assembly (5), and
assembly. assemble in cylinder.
When assembling the rod assembly in
4. Flange the cylinder, if the rod assembly is
1) Remove plate (6), retainer (7), flange (8), inserted too far, the oil will spurt out,
and stopper (9) from rod assembly (5). so stop at a position where the oil does
(See Fl) not spurt out. (See Fl)
2) Remove dust seal (10) and bushing (11) After installing the suspension com-
from retainer (7). (See F3) pletely, adjust the oil and gas levels.
3) Remove packing (12) and bushing (13) For details, see TESTING AND AD-
from flange (8). (See F3) JUSTING OF SUSPENSION CYLINDER.
5) Install flange (8), retainer (7), and plate
5. Wear ring (6) to cylinder with bolts (3). (See Fl )
Remove wear ring (14) from cylinder rod (5). 6) Install air bleed valve (4). (See Fl)
(See Fl)
w Valve: For details, see Tightening
4. Oil level valve, intake valve

Install oil level valve (2) and intake valve (1).
(See Fl)

5. Cover
Install cover.
30-158
0
Fl F3
1 2
4 11
3
0
6 7
7'
2
/
8 3
F56103545
F56103543
F56103544
30-159
0
REMOVAL OF REAR REMOVAL OF INVERTED TYPE
SUSPENSION CYLINDER REAR SUSPENSION CYLINDER
ASSEMBLY (Standard type) ASSEMBLY
. Release the gas from the rear suspension cyl- 0 Bleed the air from the rear suspension cylinder.
inder. For details, see TESTING AND ADJUSTING
For details, see TESTING AND ADJUSTING OF INVERTED TYPE REAR SUSPENSION CYLINDER.
SUSPENSION CYLINDER.
1. Remove cylinder pin (1). (See F2)
1. Remove rod pin (1). (See Fl) * Sling the cylinder assembly.
* Sling the cylinder assembly.
2. Remove rod pin (2). (See F2)
2. Remove bottom pin (2). (See Fl)
3. Remove rear suspension cylinder assembly (3).
3. Remove rear suspension cylinder assembly (3). (See F2)
(See Fl)
,Rear suspension cylinder assembly:
Rear suspension cylinder assembly: 232 kg
For details, see Weight Table
INSTALLATION OF REAR INSTALLATION OF INVERTED

SUSPENSION CYLINDER TYPE REAR SUSPENSION
ASSEMBLY (Standard type) CYLINDER ASSEMBLY
l Carry out installation in the reverse order to l Carry out installation in the reverse order to
removal. removal.
0 Refilling with oil, charging with nitrogen gas. l Adding oil, charging with nitrogen gas.
0 Adjust the suspension. l Adjust the suspension. B
For details, see TESTING AND ADJUSTING OF For details, see TESTING AND ADJUSTING z
SUSPENSION CYLINDER. INVERTED TYPE REAR SUSPENSION CYLINDER. ??
30-l 60
@
Fl F2
I I
F56103546 ‘I!
561 F03411
30-l 61
@
DISASSEMBLY OF REAR ASSEMBLY OF REAR
SUSPENSION CYLINDER SUSPENSION CYLINDER
ASSEMBLY (Standard type) ASSEMBLY (Standard type)
l Using a block stand the cylinder assembly 1. Wear ring
upright. Install wear ring (14) to rod (15). (See F8)
1. Covers 2. Flange
Remove covers (1) and (2). (See Fl ) 1) Install U-packings (12) and (11) to flange
(9). (See F5, F6)
2. Intake valve, air bleed valve 2) Install flange (9) to rod (7). (See F4)
Remove intake valve (3) and air bleed valve 3) Install seal (13) to plate (8). (See F7)
(4). (See F2) 4) Install plate (8) to rod (7). (See F4)
5) Install backup ring and O-ring to flange.
3. Cylinder rod assembly
1) Remove flange mounting bolts (5) and oil 3. Cylinder rod assembly
level plug (6), then use a crane to raise 1) Using block, stand cylinder (10) upright.
cylinder rod assembly (7) slowly with plate (See F5)
(8) and flange (9) still installed, and 2) Fill inside of cylinder with engine oil.
remove from cylinder (10). (See F2, F3)
2 Cylinder: For details, see Lubricant
2) Drain oil from cylinder. Q
and Coolant Table
4. Flange 3) Raise cylinder rod assembly (7), and

1) Remove plate (8) and flange (9) from rod assemble in cylinder (10). (See F3)
assembly (7). (See F4) * When assembling the rod assembly in
2) Remove U-packings (11) and (12) from the cylinder, if the rod assembly is
flange (9). (See F5, F6) inserted too far, the oil will spurt out,
3) Remove seal (13) from plate (8). (See F7) so stop at a position where the oil does
not spurt out.
5. Wear ring 4) Install plate (8) together with flange (9)
Remove wear ring (14) from rod (15). with 15 mounting bolts. (See F4)
(See F8) 5) Fit packing and install oil level plug (6).
(See F2)
m Plug: For details, see Tightening

4. Intake valve, oil level valve

Install intake valve (3) and oil level valve (4).
(See F2)
* The intake valve and oil level valve can
be installed in either place.
m Intake valve, oil level valve: For

5. Covers
Install covers (2) and (1). (See Fl)
30-162
49
-LK61 03554
F3 F4
I
F56103550 9
F5 F6
Q
9 11
0 0
0
0”
0
0
0
0
0a
000 O
I F5610’3551
F7
8 13
F56103553
30-163
0
DISASSEMBLY OF INVERTED ASSEMBLY OF INVERTED TYPE
TYPE REAR SUSPENSION REAR SUSPENSION CYLINDER
CYLINDER ASSEMBLY
Use a block and stand the cylinder assembly upright. 1. Wear ring
Install wear ring (13) to rod (14). (See F8)
1. Cover
Remove cover (1). (See Fl ) 2. Flange
1) Install U-packings (11) and (10) to flange (9).
2. Oil level valves (See F6, F5)
Remove 2 oil level valves (4). (See F2) 2) Install flange (9) to rod (7). (See F4)
3) Install seal (12) to plate (8). (See F7)
3. Cylinder rod assembly 4) Install plate (8) to rod (7). (See F4)
1) Remove flange mounting bolts (5) and oil 5) Install backup ring and O-ring to flange.
level valve (6), then use a crane to raise
cylinder rod assembly (7) with plate (8) and 3. Cylinder rod assembly
flange (9) still installed, and remove from 1) Use a block and stand cylinder (10) upright.
cylinder (10). (See F2, F3) 2) Fill cylinder with engine oil.
4.
2) Drain oil from cylinder.
Flange
sb Cylinder: 19.7 1 (EOIOW-CD)
Raise cylinder rod assembly (7). and assem-

3)
1) Remove plate (8) and flange (9) from rod ble in cylinder (IO). (See F3)
assembly (7). (See F4) * When assembling the rod assembly in the
2) Remove U-packings (10) and (11 )from flange cylinder, if the rod is pushed in too far,
(8). (See F5, F6) oil will spurt out. Stop the rod at a point
3) Remove seal (13) from plate (8). (See F7) where the oil does not spurt out.
4) Install plate (8) together with flange (9) with
5. Wear ring 15 mounting bolts. (See F4)
Remove wear ring (13) from rod (14). (See F8) 5) Fit packing, and install oil level valve (6).
(See F2)
m Valve: 4.5 f 0.5 kgm
4. Oil level valves

Install oil level valve (6) and oil level vavles (4).
* Oil level valves (6) and (4) can be installed
in either position.
w Oil level valve: 4.5 f 0.5 kgm
5. Cover
Install cover (1). (See Fl )
30-‘;3-’I
F2 F8
I
F4
F5 F6
I
F56103551A - F56;03552P
F7
F56103553A
30-‘;3-2
1
REMOVAL OF PARKING BRAKE
SPRING CYLINDER ASSEMBLY

put blocks under the wheels.

safety pin.
1 Remove pin (1). m

-)r With the parking brake released, turn
adjustment bolt (2) counterclockwise and
check that there is play in linkage (3).
(See Fl)
2. Remove air hose (4). (See Fl)

* With the parking brake applied, discon-
nect the air hose from the spring cylinder.
* Check that the air pressure of the spring
cylinder is released.
3. Remove spring cylinder assembly (5).

(See Fl) m
INSTALLATION OF PARKING
BRAKE SPRING CYLINDER
ASSEMBLY

to removal.
* Adjust the linkage.

ING, Testing and adjusting performance
of parking brake.
m Mounting nut: For details, see Tighten-

30-164
0
Fl
I I
F56103555
30-165
@
DISASSEMBLY OF PARKING ASSEMBLY OF PARKING BRAKE
BRAKE SPRING CYLINDER SPRING CYLINDER ASSEMBLY
ASSEMBLY
* Clean all parts, and check the inside of the
1. Remove screw, then remove holder (1) and cylinder for dirt or damage.
filter (2). (See Fl) * Coat the sliding surfaces of all parts with
grease (G30M or equivalent: Shinetsu
2. Remove retainer (3) and nut, then remove Kagaku Kogyo) and be careful not to damage
boot (4). (See Fl) the rings when installing.
3. Remove nuts (5) and (6), then remove shaft 1. Install rings (18) and (17) to case (16).
(7). (See Fl ) (See Fl )
6 Ring (17): E ngine oil (EO-30CD)

4. Remove nut (8) from shaft (7). (See Fl)
2. Install rings (15) and (14) to piston (IO), and
5. Using press, support piston (10) and support set in case (16). (See Fl )
(1 I), and remove bolts (12). Then loosen
a Ring (15): Engine oil (EO-30CD)
press slowly, and remove support (11) and
spring (13). (See Fl, F2) 3. Set spring (13) and support (11) in position,
and using press, slowly compress spring so
a The piston and support are under
that support bolt hole matches cylinder bolt
high pressure, so be careful when
hole. (See Fl )
operating the press.
6. Remove piston (IO), then remove rings (14)

A The piston and support are under
high pressure, so be careful when
and (15) from piston. (See Fl )
operating the press.
7. Remove rings (17) and (18) from case (16). &Outer circumference of support: 8
(See Fl) Adhesive 6,
g
4. Align bolt hole, and install bolts (12).
(See Fl )
m Bolt: For details, see Tightening

5. Install nuts (9) and (8) to shaft (7). (See Fl)
6. Install shaft (7) to cylinder, then install nuts

(5) and (6). and adjust dimension L.
(See Fl, F3)
m Nuts (8), (6): For details, see Tight--

Table
7. See boot (4) in position, and install nut and

retainer (3). (See Fl)
8. Set filter (2) in position, and install holder

(1). (See Fl)
30-166
0
F3
0 -14
/‘5
cl
@A6
@-------g
427F2048
i
F2
30-167
Co
REMOVAL OF BRAKE VALVE
ASSEMBLY
1. Depress brake pedal several times to bleed

air from air tank.
2. Remove cover.
3. Disconnect tube (1) between air tank and
brake valve at valve end. (See Fl)
4. Disconnect tube (2) between relay valve and
brake valve at valve end. (See Fl)
6. Remove pin (4), then remove brake pedal (5).
(See F2)
7. Remove 3 mounting bolts (6), then leave
mounting plate (7), and remove brake valve
assembly (8). (See F3)
INSTALLATION OF BRAKE VALVE

ASSEMBLY
1. Install brake valve assembly (8) to plate (7).

(See F3)
2. Install brake pedal (5). (See F2)
3. Install cover (3). (See F2)
4. Connect tube (1) between air tank and brake
valve. (See Fl)
5. Connect tube (2) between relay valve and
brake valve. (See Fl)
m Sleeve nut: For details, see Tighten-

ing Torques and Standard Values
Table
* Check that there is no air leakage.

6. Install cover.
30-168
0
Fl
F56103556 ,
F2
F3
30-A69
DISASSEMBLY OF BRAKE VALVE
ASSEMBLY
1. Retainer 8. Snap ring

Push piston assembly (1) and remove Remove snap ring (8). (See F5)
retainer (2). (See Fl)
2. Piston assembly 9. Upper valve

Remove piston assembly (I). (See F2) Pull out upper valve assembly from body (9).
and remove snap ring (IO), then disassemble
3. Spring into washer (1 I), retainer (12), spring (13),
Remove spring (3). (See F2) and upper valve (14). (See F6)
4. Lower cover assembly 10. Check valve assembly

Remove mounting bolts, then remove lower Remove snap ring (15). then remove check
cover assembly (4). (See F3) valve assembly (16) from cover (17).
(See F7)
5. Spring
Remove spring (5). (See F3) 11. Lower valve
Remove snap ring (18). and disassemble into
guide (19), spring (20), and lower valve (21).
(See F7)
6. Inner relay piston

Pull out inner relay piston (6) from body.
(See F4)
* Be careful not to damage the sliding
surface of the piston.
7. Outer relay piston
Pull out outer relay piston (7) from body.
(See F4)
* Be careful not to damage the sliding
surface of the piston.
30-170
0
Fl
F56103563
F2 F6
F56103560 F56103564
F3 F7
F56103561 %5Y F56103565
F4
7
6
I F56103562
30-&71
ASSEMBLY OF BRAKE VALVE
ASSEMBLY
1. Lower valve 7. Spring

Assemble spring (20) and guide (19) in lower Assemble spring (5) in inner relay piston.
valve (21), assemble snap ring (18), then (See F5)
assemble in cover (17). (See Fl )
8. Lower cover assembly
2. Check valve assembly Fit O-ring to mount and install lower cover
Assemble check valve assembly (16) in assembly (4) to body. (See F5)
cover, then assemble snap ring (15).
(See Fl ) 9. Spring
Assemble spring (3) in body. (See F6)
3. Upper valve
1 O.Piston assembly
Assemble spring (13), retainer (12), and
Assemble piston assembly (1). (See F6)
washer (11) in upper valve (14). then
assemble snap ring, and assemble in body
(9). (See F2)
Sr Assemble the O-ring (2 types) to the
retainer.
8
4. Snap ring 11. Retainer z
;2
Assemble snap ring (8). (See F3) Push piston assembly (1) and compress
spring, then install retrainer (2). (See F7)
5. Outer relay piston

Fit O-ring to sliding portion, and assemble
outer relay piston (7) in body. (See F4)
6. Inner relay piston

Fit O-ring to sliding portion, and assemble
inner relay piston (6) in body. (See F4)
30-172
0
Fl F5
F56103565 F56103561
F2 F6
F56103564 F56103560
F7
fz F3
F56103563 F56103559
F4
F56103562
I
30-l 73
0
REMOVAL OF FRONT BRAKE
CHAMBER ASSEMBLY
?,A& Open the drain valve to release the air

4 inside the tank.
1. Disconnect air tubes (1). (See Fl )

2. Remove brake oil hoses (2). (See Fl)
3. Remove front brake chamber assembly (3).
(See Fl)
* When brake oil tubes (2) are removed, the
oil in the brake oil tank will flow out, so
fit corks. (See Fl )
INSTALLATION OF FRONT BRAKE

CHAMBER ASSEMBLY

to removal.
REMOVAL OF REAR BRAKE

CHAMBER ASSEMBLY
*A& Open the drain valve to release the air

4 inside the tank.
1. Disconnect air tubes (1). (See F2)

2. Remove brake oil hoses (2) and (3). (See F3)
3. Remove rear brake chamber assembly (4).
(See F3)
INSTALLATION OF REAR BRAKE

CHAMBER ASSEMBLY

to removal.
30-174
0
Fl
F2
F56103567
F3
30-175
0
DISASSEMBLY OF FRONT BRAKE
CHAMBER ASSEMBLY
l Precautions when disassembling
Before disassembling, make match marks at
all joints to act as a guide when reassem-
bling.
1. Oil cylinder
Remove 4 bolts (1 ), then remove oil cylinder
(2). (See Fl, F2)
2. Oil piston
1) Supply compressed air at 1 - 2 kg/cm*
to air cylinder, and push out rod (4) of
piston and rod complete (3) fully.
(See Fl, F3)
2) Remove ring (5) from ring groove, then
move towards push rod, and pull out pin
(6). (See Fl, F3)
3) When pin (6) is pulled out, it is possible
to remove oil piston (7), bushing guide (8),
and ring (5). (See Fl, F4)
4) After removing oil piston, exhaust com-
pressed air from air cylinder (9).
(See Fl, F4)
3. Remove seal (10) and backup ring (11) from

oil piston assembly. (See Fl).
30-176
0
Fl
3 4 16 19 20 12 21 22 8 7 10
15
F569S3013
I J
F2 F4
7 8 6 5
bs
F56103569 F56103i71
F3
F56103570
30-177
0
4. Air cylinder assembly
* Ahr The spring has a reaction force of

4 65 kg when compressed approx. 100
mm, so be extremely careful when
loosening the bolts.
j, Check that there is no compressed air

inside the air cylinder.
1) Loosen 6 bolts (12), then remove air
cylinder (9), piston and rod complete (3),
and spring (13) from cover assembly (14).
(See Fl, F2)
* When removing bolts (12), it is safer
if 2 - 3 fully threaded bolts 0 with
a length below the head of approx. 150
mm are used as a loosening jig.
(See Fl, F2)
2) Remove packing (15) from piston and rod
complete (3).
5. Cover assembly
1) Remove stop ring (16) with flat-headed
screwdriver, then remove cup support
(17), secondary cup (18), spacer (19),
secondary cup, and cup supporter in
order. (See F2, F3)
2) Use a spatula to push bushing (20) in, then
pull out and remove. (See F3)
3) Remove ring (22), then remove filter (21).
(See F3)
4) Remove plug (23). (See F3)
30-178
0
Fl
F56103572
F2
19
F56103573
F3
io 2i il
F569S3014
ASSEMBLY OF FRONT BRAKE
CHAMBER ASSEMBLY
l Precautions when assembling

1) Coat the outside diameter of air piston rod
(4), the cup groove, cup (14) and air
cylinder (9), and the inside diameter
(sliding part) with a suitable amount of
lithium grease. (See Fl, F2)
2) Coat the outside diameter of oil piston (7),
the cup groove, cup (IO), the inside
diameter of oil cylinder (2). and the inside
diameter (cup groove) of cover (14). and
2 cups (18) with a suitable amount of
brake oil. (See Fl, F2)
1. Cover assembly
1) Install plug (23). (See F3)
6 Plug: Adhesive (LT-2A)
m Plug: For details, see Tightening

2) Install filter (21) and ring (22). (See F3)

3) Assemble bushing (20) secondary cup
(18) spacer (19), secondary cup, cup
supporter (17), stop ring (16) in order.
(See F2, F3)
2. Air cylinder assembly

I) Assemble packing (15) to piston and rod
complete (3). (See Fl )
2) Assemble spring (13), piston and rod
complete assembly (3). O-ring, and air
cylinder (9) to cover assembly (14), then
tighten bolts (12). (See Fl)
* Using 2 - 3 fully threaded bolts @
with a length below the head of approx.
150 mm, compress spring (13) uni-
formly and screw in. (See F4)

(LT-2)

Values Table
3o-ik8o
Fl
/////T-Y
9 17 18 13 14 23
\\\\I1 5 6 11 2
F569S3013
F2 F4
z
14
\ '?
F56103573 F56103572
F3
19 14 17 16 18
io 2i il
2; F569S3014
30-181
0
3. Oil piston assembly
to air cylinder, and extend rod (4) of piston
and rod complete (3) fully. (See F2)
2) Assemble backup ring (11) and seal (10)
to oil piston (7). (See Fl )
3) After moving ring (5) towards air chamber
end, secure bushing guide (8) and oil
piston (7) to oil piston with mounting pin
(6), then install ring (5) to ring groove.
(See Fl, F2)
4) Exhaust compressed air from air cylinder.
4. Oil cylinder
Install oil cylinder (2) with bolts (1). (See F3)

Values Table
5. Checking
1) Bleed air from oil cylinder.
2) Check that at least 180 kg/cm* of oil
pressure is generated in the oil cylinder
when 8 kg/cm* of air pressure is applied
to air cylinder.
3) Check that there is no leakage of air or
oil.
30-l 82
0
Fl
7 8 6 5
F56103571
6 5
F56103i7C
1-----4z$
z,”
F56103569
30-l 83
0
DISASSEMBLY OF REAR BRAKE
CHAMBER ASSEMBLY
0 Precautions when disassembling
Make match marks on each mating surface
before disassembling to act as a guide when
assembling.
1. Oil cylinder
Remove 4 bolts (I), then remove oil cylinder
(2). (See Fl, F2)
2. Oil piston
to air cylinder, and extend rod (4) of piston
and rod complete (3) fully. (See Fl, F3)
2) Remove ring (5) from ring groove, and
move towards rod end, then pull out pin
(6) and remove oil piston (7) and ring (5).
(See Fl, F3)
3) After removing oil piston, exhaust com-
pressed air from air cylinder (8). (See F3)
3. Oil piston
1) Remove seals (9) and (lo), and O-rings
(11) and (12) from oil piston. (See Fl, F3)
2) Remove valve (13). (See Fl)
4. Air cylinder
* k Check that there is no compressed

* air inside air cylinder (8).
* The spring has a reaction force of 65 kg

when compressed approx. 100 mm, so be
extremely careful when loosening the
bolts.
Loosen 6 bolts (14), then remove air cylinder
(8), piston and rod complete (3). and spring
(15)from cover assembly (16). (See Fl )
* When loosening bolts (14), use 2 - 3 fully
threaded bolts @ with a length below
the head of approx. 150 mm as a loos-
ening jig. (See F4)
30-184'
Co
Fl
F569S3015
F? F2 F4
F56103574 F56103576
F3
16
30-185
Co
5. Remove packing (17) and sleeve (18) from
piston and rod complete assembly. (See Fl)
6. Cover assembly
1) Remove ring (19), then remove filter (20).
(See F2)
2) Remove O-ring (22) and plug (21).
(See F2)
30-l 86
0
Fl
F569S3016
F2
19 20 22 21
'II/l \
F569S3017
30-l 87
Co
ASSEMBLY OF REAR BRAKE
CHAMBER ASSEMBLY
l Precautions when assembling

I) Coat the inside diameter (sliding part) of
the air cylinder, the outside diameter of
the air piston and the groove, and the
packing with a suitable amount of lithium
grease.
2) Coat the inside diameter of the oil
cylinder, the outside diameter of the oil
piston and the seal groove, and the seal
parts with a suitable amount of engine
oil (SAElOW).
1. Cover assembly
I)Assemble filter (20) in cover (16), and
install ring (19). (See Fl, F2)
2) Assemble O-ring, and install plug (21).
(See Fl, F2)
& Plug: Adhesive (LT-2A)
Qa Plug: For details, see Tightening

2. Piston and rod complete assembly

Install sleeve (18) and packing (17).
(See Fl, F3)
3. Air cylinder
1) Assemble spring (15), piston rod complete
assembly(3), and O-ring in cover assembly
(I 6). (See Fl)
2) Assemble air cylinder (8), and tighten with
bolts (14). (See Fl )

(LT-2)
Qz Mounting bolt: For details, see

Values Table
4. Cover assembly and air cylinder assembly

* Using bolts 0, install cover assembly(l6)
to air cylinder assembly (8). (See Fl, F4)
30-188
0
Fl
F569S3015
F2 F4
F569S3017
w
F56103576
F3
17 18
F569S3016
30-l 89
0
5. Oil piston
1) Install 0-rings(l2)and(l I), and seals(l0)
and (9) to oil piston (7). (See Fl)
2) Install valve (13). (See Fl )

Torques’and Standard Values Table
6. Oil piston assembly

1) Supply compressed air at 1 - 2 kg/cm’
to air cylinder assembly (8), and extend
rod (4) of piston and rod complete assem-
bly fully. (See Fl)
2) Assemble oil piston assembly (7) to rod
(4). (See Fl )
3) Secure oil piston assembly and rod (4)
with pin (6), and install ring (5). (See Fl)
4) Exhaust compressed air from air cylinder.
7. Install oil cylinder (2). (See F2)

Values Table
8. Checking
1) Bleed air from oil cylinder.
2)Pistons must move full stroke at air
pressure of 1 kg/cm*.
3)There must be no air leakage from any
part at air pressure of 8 kg/cm*.
30-190
0
Fl
F2
F56103574
30-191
0
REMOVAL OF AIR GOVERNOR DISASSEMBLY OF AIR
ASSEMBLY GOVERNOR ASSEMBLY
* Ak Open the drain valve of the air tank and 1. Remove cover (1). (See F2)
4 releasethe air pressure. 2. Remove snap ring (2), then remove adjust-
ment screw and spring assembly (3).
1. Remove tubes (1). (See Fl) (See F2)
2. Remove air governor assembly (2). (See Fl) 3. Pull out piston assembly (4), and remove
stem (5) and spring (6). (See F2)
INSTALLATION OF AIR ASSEMBLY OF AIR GOVERNOR

GOVERNOR ASSEMBLY ASSEMBLY
l Carry out installation in the reverse order * Clean all parts, and check for dirt or damage,
to removal. then coat all parts with grease before
installing.
1. Fit O-ring and install spring (6) and stem

(5) to piston (7). (See F2)
2. Fit O-ring and install piston assembly (4) to
body (8). (See F2)
3. Fit adjustment screw and spring assembly
(3) to body (8), then install snap ring (2).
(See F2)
4. Install cover (1). (See F2)
* After installing to the machine, measure the
air pressure.
Measuring air pressure.
30-l 92
0
Fl F2
-
L_____
--5-fj j
_ _ _ _ _ ==i
569FO92
F3
423FOSl C-K
30-193
0
REMOVAL OF SLACK ADJUSTER DISASSEMBLY OF SLACK
ASSEMBLY ADJUSTER
1. Remove hoses (1). (See Fl) 1. Remove cylinders (I), then remove pistons
2. Remove slack adjuster (2). (See Fl ) (2) and springs (3). (See F2)
2. Remove bolts (4), then remove spacers (5).
(See F2)
3. Remove seals (6) from pistons (2). (See F2)
INSTALLATION OF SLACK ASSEMBLY OF SLACK

ADJUSTER ASSEMBLY ADJUSTER
l Carry out installation in the reverse order 1. Install spacers (5) with bolts (4). (See F2)
to removal. 2. Fit seals (6) and springs (3) to pistons (2),
+ Bleed the air from the brake circuit. and assemble in cylinder, then fit O-rings
For details, see TESTING AND ADJUSTING, and install to body. (See F2)
Bleeding air from brake circuit. j, When assembling, checkcarefullythat there
is no dirt, dust or chips on the inside surface
of the adjuster.
j, Coat the inside surface of the cylinder and
other sliding parts with mineral oil.
* Coat spring (7) with G2-LI. (See F2)
* Fit vinyl plugs to all ports.
30-l 94
0
Fl
F2
569FO91
ii-'
30-l 95
0
REMOVAL OF BRAKE COOLING REMOVAL OF BRAKE COOLER
PUMP ASSEMBLY ASSEMBLY
A Raise the dump

safety pin.
body and lock with the l Before removing the brake cooler assembly,
drain the cooling water and oil.
& Cooling water, brake oil: For details,

1. Remove tubes (1) and (2). (See Fl )
see Lubricant and Coolant Table
2. Remove hoses (3) and (4). (See F2)
3. Remove brake cooling pump assembly (5). 1. Remove cooling water tubes (1). (See F5)
(See F2) 2. Remove oil tubes (2). (See F5)
3. Remove brake cooler assembly (3). (See F5)
&I kg Brake cooler assembly: For details,

INSTALLATION OF BRAKE
see Weight Table
COOLING PUMP ASSEMBLY
* Use a forklift truck or transmission jack
l Carry out installation in the reverse order to remove.
to removal.
REMOVAL OF STEERING, HOIST INSTALLATION OF BRAKE

PUMP ASSEMBLY COOLER ASSEMBLY
A Raise the dump body and lock with the l Carry out installation in the reverse order
safety pin. to removal.
l Refilling with water, oil
1. Remove tubes (1) and (2). (See F3) * Refill with engine cooling water and brake
2. Remove hoses (3) and (4). (See F4) oil to the specified level and run the
3. Remove steering and hoist pump assembly engine to circulate the water and oil
(5). (See F4) through the system. Then stop the engine
and check the water and oil levels again.
INSTALLATION OF STEERING,
HOIST PUMP ASSEMBLY

to removal.
30-196
0
Fl F5
il a3577
I( F56103581
F2
3 4
F56103578
F3
F56103579
F4
5
F56103580
30-197
0
REMOVAL OF DEMAND VALVE
ASSEMBLY

safety pin.
“,A@ Loosen the oil filler cap slowly to release

4 the pressure inside the hydraulic tank.
* After disconnecting the piping, fit blind plugs

to prevent oil from leaking.
1. Remove tubes (1). (See Fl)
2. Remove hose (2). (See Fl)
3. Remove demand valve assembly(3). (See Fl )
el kg Demand valve assembly: For details,

see Weight Table
INSTALLATION OF DEMAND
VALVE ASSEMBLY

to removal.
* Refill oil to the specified level and run the
For details, see Lubricant and Coo-

lant Table
l Bleed the air.

Bleeding air from hydraulic cylinder (for
steeing), Item a.
30-198
0
Fl
I I
30-199
0
DISASSEMBLY OF DEMAND DISASSEMBLY OF RELIEF VALVE
VALVE ASSEMBLY ASSEMBLY
1. Remove cover (2) from demand valve 1. Loosen nut(21),andremovescrew(22),then

assembly (1). then remove spring (3). remove retainer (23), spring (24). and poppet
(See Fl) (25). (See Fl)
-k The spring is under an installed load of 2. Loosen nut (26), and remove holder (27),
35 kg, so remove slowly with a long bolt. then pull out seat (28). (See Fl)
2. Remove plate (4), screw in bolts into end 3. Remove snap ring (29), then remove valve
face thread of plug (5), and pull out seat, (30) and spring (31). (See Fl)
then remove spring (6) and poppet (7).
(See Fl)
3. Remove plug (8), and pull out demand spool
(9). (See Fl)
4. Remove plate (lo), screw in bolts into end
face thread of orifice (1 I), and remove
orifice. (See Fl)
5. Remove relief valve assembly (12). (See Fl)
ASSEMBLY OF DEMAND VALVE ASSEMBLY OF RELIEF VALVE

ASSEMBLY ASSEMBLY
1. Fit backup ring and O-ring and install relief 1. Assemble spring (31) and valve (30).
valve assembly (12). (See Fl ) (See Fl)
2. Fit backup ring and O-ring and assemble 2. Install snap ring (29). (See Fl)
orifice (11) then secure with plate (10). 3. Install backup ring and O-ring to seat (28).
(See Fl) (See Fl)
3. Assemble demand spool (9), then fit O-ring 4. Install O-ring to holder (27). (See Fl)
and tighten plug (8). (See Fl) 5. Assemble seat (28), then screw in holder
4. Assemble poppet (7) and spring (6), then fit (27), and secure with nut (26). (See Fl)
backup ring and O-ring and install plug (5). 6. Install poppet (25), spring (24), and retainer
then secure with plate (4). (See Fl) (23). (See Fl)
5. Assemble spring (3), then fit O-ring and 7. Fit O-ring to screw (22). then screw in and
install cover (2). (See Fl) secure with nut (21). (See Fl )
30-200
0
Fl
F56103620
30-201
0
REMOVAL OF EMERGENCY REMOVAL OF STEERING
STEERING MOTOR PUMP CYLINDER ASSEMBLY
ASSEMBLY
1. Disconnect grease tube (1). (See F3)
A Raise the dump body and lock with the 2. Remove bottom pin (2). (See F3) m
safety pin. * Support with a transmission jack.

‘* Start the engine, operate the steering to
the left, and retract the piston rod, then
disconnect the cylinder bottom from the
1. Drain hydraulic oil. frame.
2. Disconnect motor wiring (1). (See Fl ) 3. Remove head hose (3). (See F3)
3. Remove tube (2). (See F2) 4. Remove bottom hose (4). (See F3)
4. Remove hose (3). (See F2) 5. Disconnect grease tube (5). (See F4)
5. Remove emergency steering motor pump 6. Remove head pin (6). (See F4) a
assembly (4). (See F2) 7. Remove steering cylinder assembly (7).
* Remove the emergency steering motor (See F4, F5)
pump assembly together with the bracket.
& kg Steering cylinder assembly: For
details, see Weight Table
INSTALLATION OF EMERGENCY INSTALLATION OF STEERING

STEERING MOTOR PUMP CYLINDER ASSEMBLY
ASSEMBLY
l Carry out installation in the reverse order to removal.
to removal. B
m z
l Refilling with oil z
* When connecting the pin, assemble the
Sr Refill oil to the specified level and run the
rubber boot.
For details, see Lubricant and Coolant

Table.
30-202
0
Fl F3
+- A---- F56103586
F56103584
F2
2,
’ I F56 8103587
\ ’ F56103585
F5
F56103588
30-203
0
DISASSEMBLY OF STEERING
CYLINDER ASSEMBLY
1. Set cylinder assembly (1) in tool HI. 6. Disassembly of piston assembly

(See Fl ) 1) Remove wear ring (9) from piston (10).
(See F5)
2. Raise lock of cylinder head nut, and using 2) Remove wear ring (11) from piston (10).
tool H2, remove cylinder head assembly (2). (See F5)
(See Fl)
3. Pull out cylinder head and piston rod 7. Disassembly of cylinder head assembly
assembly (3) from cylinder (4) and remove. 1) Remove snap ring (12), then remove dust
(See F2) seal (13). (See F6)
* When the piston rod assembly is pulled 2) Remove rod packing (14). (See F6)
out from the cylinder, oil will come out, 3) Remove bushing (15) from cylinder head
so catch it in a container. (16). (See F6)
4) Remove O-ring (17) and backup ring (18).
4. Remove cylinder (4) from tool HI. (See F6)
(See Fl, F2)
5. Disassembly of piston rod assembly

1) Set piston rod assembly (3) in tool HI.
(See F3)
2) Using tool H3, remove nut (5). (See F3)
3) Remove piston assembly (6) and cylinder

head assembly (7) from rod (8). (See F4)
30-204
co
Fl 5
h-7
11 F5610359:
F2 F6
F56103590K
i5 F56103594
J
F3
HI
F4
6 !
I - F56103592
30-205
0
ASSEMBLY OF STEERING
CYLINDER ASSEMBLY
* Clean all parts, and check for dirt or damage. 4) Assemble wear ring (9). (See F7)
Coat the sliding surfaces of all parts with
engine oil before installing.
1. Assembly of cylinder head assembly

1) Using push tool, press fit bushing (15) in
cylinder head (16). (See Fl )
j, Be careful not to deform the bushing
when press fitting.
2) Install rod packing (14). (See Fl)
* Be careful to install the rod packing
3. Assembly of piston rod assembly
facing in the correct direction.
1) Assemble cylinder head assembly (7) and
3) Assemble backup ring(18) and O-ring (17)
piston assembly (6) to piston rod (8).
in order. (See Fl)
(See F8)
* Do not try to force the backup ring into
position. Warm it in warm water (50
- 60°C) before fitting it.
4) Using push tool, install dust seal (13) to
cylinder head (16), then install snap ring
(12). (See Fl )
2. Assembly of piston assembly 2) Using tool H3, tighten nuts (5). (See F9)
1) Using tool H4, expand piston ring (11). & Nut: Thread tightener (LT-2)
(See F3)
* Set the piston ring on the expander and w Nut: For details, see Tightening
turn the handle 8 - 10 times to expand Torques and Standard Values Table
the ring. 3) Remove piston rod assembly (3) from tool.
2) Remove piston ring from tool, and assem- (See F9)
ble to piston (10). (See F4)
3) Set tool H5 in position, and using clamp

0, compress piston ring. (See F5, F6)
30-206
Go
F6 F7
.I4
i5 F56103594 202F2036
F56103593
F2 F8
Rod packing
-
I 20XF 130 F56103592
F9
202FO5487 11 F56103593
F5
4. Set cylinder in tool HI. (See F2)
5. Assemble cylinder head and piston rod

assembly (3) in cylinder (4). (See Fl)
6. Using tool H2, tighten cylinder head assem-

bly (2). (See F2)
m Cylinder head nut: For details, see

Values Table
30-208
0
Fl
F5610359OK
F2
30-209
0
REMOVAL OF HOIST VALVE
ASSEMBLY

safety pin.
AM Loosen the oil filler cap slowly to release

d the pressure inside the hydraulic tank.
1. Drain hydraulic oil
& Hydraulic tank: For details, see

Lubricant and Coolant Table.
2. Disconnect control cable (1). (See Fl )
3. Remove bracket (2). (See Fl)
4. Disconnect positioner cable (3). (See Fl)
5. Remove spring (4). (See Fl)
6. Remove bracket (5). (See Fl)
7. Remove hose (6). (See Fl)
8. Remove tubes (7) and (8). (See Fl )
9. Remove hose (9). (See F2)
10. Remove hoist valve assembly (10). (See Fl)
4kgWeight
Hoist valve assembly: For details, see
Table
INSTALLATION OF HOIST VALVE

ASSEMBLY

to removal.
* Refill oil to the specified level and run the
30-210
Co
Fl
5
7
i lb F56103597
F2
30-211
0
DISASSEMBLY OF HOIST VALVE
ASSEMBLY
1. Remove main relief valve assembly (1). 5. Insert spool (34), and install valve control
(See Fl) case assembly (23). (See Fl)
2. Loosen nut (2), and remove screw (3), then
ECI& Mating surface of case: Adhesive
remove retainer (4), spring (5), and poppet
(Loctite)
(6). (See Fl)
3. Loosen nut (7), and remove holder (8) and 6. Assemble retainer (22), spring (21), retainer
seat (9). (See Fl ) (20), collar (19), and detent (18), then tighten
4. Remove snap ring (lo), then remove retainer bolts (17). (See Fl )
(11 ), valve (12), and spring (13) from sleeve
m Bolt: For details, see Tightening
(14). (See Fl)
5. Remove tube (15). (See Fl)
6. Remove case (16), and bolts (17), then 7. Fit O-ring and install case (16). (See Fl)
remove detent (18), collar (19), retainer (20),
& Mating surface of case: Adhesive
spring (21), and retainer (22). (See Fl)
(Loctite)
7. Remove valve control case assembly (23).
(See Fl) 8. Install tube (15). (See Fl)
8. Remove cover (24), then loosen bolt (25), 9.Assemble spring (13), valve (12), and
move lever (26), and remove key (27). retainer(l1) in sleeve(l4). then fit snap ring
(See Fl) (10) and install seal (9), holder (8), and nut
9. Remove plate (28). then remove dust seal (7). (See Fl)
(29), oil seal (30), shaft (31), and bearing (32)
w Nut: For details, see Tightening
from case (33), and pull out spool (34).
(See Fl)
10. Remove plate (35), and seat (36). then 10. Install poppet (6), spring (5), retainer (4),
remove spring (37) and valve (38) from valve screw (3), and nut (2). (See Fl)
body (39). (See Fl) w Nut: For details, see Tightening
ASSEMBLY OF HOIST VALVE 11. Install main relief valve assembly (1).
ASSEMBLY (See Fl)
w Main relief valve: For details, see

1. Insert valve (38) and spring (37) in valve body Tightening Torques and Standard
(39), then fit O-ring and assemble seat (36). Values Table
and install plate (35). (See Fl )
a Mating surface of plate: Adhesive

(Loctite)
2. Press fit bearing (32), oil seal (30), and dust

seal (29) in case (33). (See Fl )
& Bearing, oil seal, dust seal: Grease

(G2-LI)
3. Insert shaft (31), assemble key (27) and lever

(26), then align position of notch in spool
(34) with lever (26), and secure with bolt
(25). (See Fl)
4. Install plate (28) and cover (24). (See Fl)
& Mating surface of plate and cover:

Adhesive (Loctite)
30-212
Co
Fl
‘_.-.-.-.-._.-.-.-.-._,
*\
Y.
F56103599
30-213
Co
REMOVAL OF HOIST CYLINDER
ASSEMBLY
* Fit a block (approx. 100 mm) at the contact

surface of the frame and body.
1. Disconnect positioner cable and bracket (1).
(See Fl)
* The positioner is on the left side only.
2. Remove bottom mounting pin (2). (See F2)
* Fit a nylon rope around the hoist cylinder
assembly, then sling using a forklift truck:
3. Disconnect hoses (3) and (4). (See Fl)
* After disconnecting the hoses, fit blind
plugs to prevent the oil from leaking out.
4. Remove holder (5). (See Fl)
5. Remove hoist cylinder assembly (6). (See F2)
& kg Hoist cylinder assembly: For details,

see Weight Table
INSTALLATION OF HOIST
CYLINDER ASSEMBLY

to removal.
* Refill with engine oil (EOlO-CD) to the
specified level, start the engine, and raise
and lower the body 2 - 3 times to
circulate the oil through the system. Then
check the oil level again.
30-214
0
Fl
w
F56103600
F2
F3
1 I
] F56103601 1
30-215
Co
DISASSEMBLY OF HOIST
CYLINDER ASSEMBLY
1. Set cylinder assembly on tool II. 10. Remove snap ring (19) from cylinder II (6),
2. Remove mounting bolts (2) of cylinder head then remove dust seal (20), rod packing (21)
assembly (1). (See Fl ) and bushing (22). (See F7)
3. Remove cylinder II and rod assembly (4) from

cylinder I(3). (See F2)
4. Remove piston mounting nut (5). then lift

off rod (7) from cylinder II (6). (See F3, F4)
5. Remove cylinder head assembly (1). (See F4)
6. Remove dust seal (9). rod packing (10) and

busing(l3). 0-ring(l2). and backup ring(ll)
from cylinder head assembly. (See F5)
7. Remove wear ring (14). (See F6)
8. Remove snap ring (15), and pull out piston
assembly (16). (See F6)
9. Remove piston ring (17) and wear ring (18)
from piston assembly. (See F6)
30-216
co
Fl F7
F56103603
19 22 21 F56103609
F2
-F66103604
F56103605 F56103606
I
F56103607 F56103608
30-217
0
ASSEMBLY OF HOIST CYLINDER
ASSEMBLY
1. Using push tool, press fit bushing (22).

(See Fl)
2. Fit rod packing (21) and dust seal (20), and
install snap ring (19). (See Fl)
3. Using tool 12, fit piston ring (17) to piston,

and install wear ring (18). (See F2)
4. Assemble piston assembly (16), and install
snap ring (15). (See F2)
5. Install wear ring (14). (See F2)
6. Using push tool, press fit bushing (13) to
cylinder head. (See F3)
7. Install rod packing (10). dust seal (9) and
backup ring (11). and O-ring (12) to cylinder
head (1). (See F3)
8
8. Assemble cylinder head assembly (1) to z
cylinder II (6). (See F4) 8
9. Raise rod (7) and assemble in cylinder II (6).
(See F4)
* Align the stud bolt hole and assemble.
10. Tighten piston mounting nut (5). (See F5)
Qa Mounting nut: For details, see Tight-

Table
11. Assemble cylinder II and rod assembly (4)

to cylinder I (3). (See F6)
12. Install cylinder head assembly (1) with
mounting bolts (2). (See F7)

Values Table
30-218
0
Fl
19 22 21 F56103609
F2 F3
F56103608 F56103607
F4 F5
F56103605
F7
I
F56103603
REMOVAL OF BODY ASSEMBLY INSTALLATION OF BODY
ASSEMBLY
fix the stone remover bar to the body l Carry out installation in the reverse order
with a pin. to removal.
1. Remove hoist cylinder bottom pin (1). m

(See Fl) * Check the number and thickness of the
* Using tool J, sling the body assembly. shims, and keep in a safe place.
* Pull the hoist cylinder with lever block 0
to prevent it from falling when pin (1) is El
pulled out. (See Fl) * Testing and adjusting of body mount
1) Testing height of body front mount

2. Remove body hinge pin (2). (See F2) m
Inspect the height of rubber pad (2) of body
3. Remove body assembly (3). (See F3) m
front mount (1). (See F4)
kg
&?I Body assembly: For details, see * Standard height: 50 mm
Weight Table 2) Adjusting body front mount
If it is higher than the standard height,
Sr Tie ropes to the left and right sides of the
or there is a clearance between the mount
body assembly, and support the body to
and the body, add shim (3) to adjust to
prevent it from turning when it is raised.
the standard height. (See F4)
3) Adjusting body side mount
i) After adjusting the body front mount,
inspect the clearance of side mount
rubber pad (4) and frame top surface
(5). (See F5, F6) 8
ii) If any clearance is found, add shim (6) z
to adjust clearance. (See F6)
8
30-220
0
F4
I
F2 F5
I
5
F56103614
F3 F6
I
( ‘:‘i F56103615
F56103612
30-22 1
0
REMOVAL OF TRANSMISSION
CONTROLLER ASSEMBLY
l Open the cover at the rear of the operator’s

cab.
1. Disconnect 4 connectors (1). (See Fl )
2. Remove transmission controller assembly
(2). (See Fl )
INSTALLATION OF
TRANSMISSION CONTROLLER
ASSEMBLY

to removal.
30-222
0
F5610361
30-223
0
40 MAINTENANCE STANDARD
Output shaft .................................................. 40- 2

Torque converter valve ............................... .40- 3
Torque converter .......................................... 40- 4
Transmission (HD785-3) .............................. .40- 6
Transmission (HD985-3) ............................... 94- 2
ECMV
(Electronic Control Modulation Valve). .... 40-I 1
Front axle ..................................................... -40-I 2
Rear axle support (HD785-3) ........................ 40-13
Rear axle support (HD985-3) ........................ 94- 7
Differential.. ................................................... 40-14
Final drive (HD785-3) .................................... 40-I 5
Final drive (HD985-3) ................................... .94- 8
Front brake ................................................... .40-l 6
Rear brake ..................................................... 40-17
Parking brake ............................................... .40-18
Steering linkage.. ......................................... .40-20
Front suspension cylinder.. ......................... .40-22
Rear suspension cylinder (HD785-3) .......... .40-23
Rear suspension cylinder (HD985-3) .......... .94- 9
Parking beake chamber.. ............................. .40-24
Slack adjuster.. .............................................. 40-25
Hydraulic pump (SAR4-160) ....................... .40-26
Demand valve .............................................. .40-28
Closs-over relief valve .................................. 40-28
Hoist valve .................................................... 40-29
Steering cylinder ......................................... .40-30
Hoist cylinder ................................................ 40-31
40- 1
0
OUTPUT SHAFT
a=
11.5~lkgm
18&2kgm 11.5rlkg
561 FO3183 Unit: mm
No. Check item Criteria
Clearance between flywheel

1
and bearing
Clearance between shaft and

2
bearing
Clearance between bearing and

3
cover
I
Clearance between bearing and

shaft
Wear of oil seal contact

5
surface of coupling
6 Backlash at spline
Dimension at e Qo Repair limit (2)

smallest width: Q
Original Replace
Deformation of 100 90
dimension: Q,
rubber cushion Qa
7
IF3 67
75
561 F03184
1 External Without cranks
40-2
TORQUE CONVERTER VALVE
561 F03187 Unit: mm
Criteria
Clearance between lockup
Standard size Repair limit

Installed Installed
Free length Free length Installed load
4 Main relief valve spring length load
Replace
118 94.5 123.8kg 116.6 111.4 kg
5 Torque converter relief valve

spring 144.1 95 30.1 kg 142.4 27.1 kg
6 Lockup valve spring 108.1 89.7 13.9kg 106.8 12.5 kg
7 Poppet spring (torque converter

relief, main relief) 26 17.6 3.5kg 25.7 3.2 kg
8 Lockup valve poppet spring 30 16 2.1 kg 29.6 1.9 kg
40-3
TORQUE CONVERTER
6.75 z!z0.75 kam
28.25 * 3.25 kgm 11.25f1.25kgm. /- 5.5kO.5 kgm

-- 8.75 * 0..75 kgm
I I
8
z
8
11.25 f’1.25 kgm i b 1’1 1‘3 1‘2
561 F03185
40-4
Unit: mm
Inside diameter of coupling

and oil seal sliding portion’
0.2 (Amount of wear)
ransmlsslon
Inside diameter of sliding

12 121.65 121.73
portion of bushing
Thickness of sliding portion

13 7.0 6.5
of bushing
14 Thickness of disc 5.4 4.8
40-5
TRANSM ISS ION
2-----L
561FO3186
40-6
Unit: mm
No. Check item Criteria Remedy
Installed
Free length length ’ nESd Free length Installed load
1 No.1 clutch spring
52.0 44.0 13.7 kg 48.9 11.0 kg
2 No.4 clutch spring 41.5 33.0 13.6 kg 39.0 10.9 kg
3 No.5 clutch spring 1 84.0 1 69.2 / 18.9 kg 1 79.0 1 15.1 kg 1

I I
Standard size Tolerance Repair limit

otal thickness of 4 discs and
6
plates for No.1 clutch
39.0 +0.26 37.8
7 Total thickness of 5 discs and, 50.2 kO.30 48.7

,4 plates for No.2 clutch
T: Replace
Z 8 Total thickness of 4 discs and
% 3 plates for No.3 clutch 39.0 kO.26 37.8
g Total thickness of 3 discs and

27.8 kO.22
2 plates for No.4 clutch.
Total thickness of 7 discs and

IO 62.2 +0.34 60.1
6 plates for No.5 clutch 1
11
I 4 plates for No.6 clutch
50.2
I
+0.30
I 48.7
I

12 50.2 +0.30 48.7
4 plates for No.7 clutch
40-7
Unit: mm
No Check item Criteria Remedy
-0.0 1
Wear of No.2,3 clutch Width 4.0 3.6
17 -0.03
collar seal ring
Thick-
ness 5.1 kO.12 4.85
Width 4.0 -0.01 3.6

Wear of No.4, 5 carrier -0.04
18
seal ring Thick-
ness 6.3 +0.15 6.05
.-
Width 4.0 -0.0 1 3.6

-0.04
Wear of No.6,7 carrier
19
seal ring Thick-
ness 4.0 +0.15 3.5
Width 4.0 -0.01 3.6

Wear of No.6,7 carrier -0.04
20
seal ring Thick-
ness 4.0 +0.15 3.75
Width 4.5 -0.01

Wear of No.6, 7 carrier -0.03 4.1
21
seal ring Thick-
ness 5.8 +0.15 5.55
Width 3.0 -0.01

Wear of No.3 sun -0.03 2.6
gear
22 Replace
seal ring
Thick-
ness 4.0 kO.12 3.75
Backlash between No.1 sun gear

23 0.13 - 0.36
and planet gear
-
Backlash between No.1 planet
24 0.15 - 0.39
gear and ring gear
-
Backlash between No.1 carrier
25 0.17 - 0.52
and No.2 clutch inner drum

26 0.13 - 0.38
and planet gear

27 0.16 - 0.41
gear and ring gear

28 O.i3 - 0.38
and olanet aear

29 0.13 - 0.34
gear and Planet aear I
30 0.16 - 0.41
gear.and ring gear
-
31 0.13 - 0.37
and planet gear

32 0.14 - 0.40
~gear and ring gear
-
Backlash between No.4, 5 carrier
33 0.18 - 0.55
and No.6 ring gear
40-8
I
34 Backlash between No.7 sun
0.12 - 0.34
gear and planet gear
35 Backlash between No.7 planet

0.14 - 0.40 Replace
gear and ring gear
Deformation of inside teeth of

Repair limit: 0.3
36 disc

37 Thickness of thrust washer
Replace
(No.l,4,5 planet gears) 2 co.05 1.5
thrust
washer
3B Thickness of thrust washer
3 +0.05 2.5
(No.6 and 7 planet gears)
Location Standard clearance Clearance limit
No.1 gear train 0.30 - 0.80 1.5
Replace
No.4 gear train 0.30 - 0.80 1.5 thrust
- washer, or
39 Planet gear side clearance
No.5 gear train 0.30 - 0.80 1.5 replace
carrier
No.6 gear train 0.30 - ‘0.80

I I
No.7 gear train 0.30 - 0.80 1.5

I I I
Standard size Amount of wear
- 0.05 max.
Standard size Repair limit Replace
41 Oil seal contact surface of

output shaft 120 119.9
No.1 -0.5 +0.097 0.5 -

Outside 430 -0.7 0 0.797 0.88
If the surface
has seizure
Inside -j:;;; 1;*Og7 /““,“.“,,, 1 0.36 stripes or
I 405 I other damage,
No.2 repair and
Clearance between cylinder and -0.110 .O.llO - reuse if it is
42 Middle 275 iO.081 0.30
prston -0,191 0 0.272 within the
clearance
limit.
..Inside 1 180 1 1;:; 1+;-063 1o.5&63 1 0.84 Replace if
there is mark-
ed damage.
N;;dle 1 275 1 2:;;; 1 +;‘Osl ID.‘;&2 1 0.30
Inside 1 180 1 2:; / T.063 1°*5i763 / 0.84
No.2,3 -0.5 +0.081 0.5 -

Outside 300 -0.7 0 0.781 0..86_
40-9
Unit: mm
I
NC1. Check item Criteria Remedy
IClearance
limit
No.4 -0.5 +0.063 0.5 -

0.84
Outside 470 -0.7 0 0.763
If the surface
has seizure
0.29
stripes or
other damage,
repair and
Xearance between cylinder and 0.84 reuse if it is
42 within the
Gton clearance
0.29 limit. Replace
if there is
marked
damage.
0.84
0.29
0.84
Inside 410 -0.135 HI.063 0.135 -

0.29
-0.198 0 0.261
40-10
ECMV (Electronic Control Modulation Valve)
561FO3188
Unit: mm
Standard Standard
Repair limit
size +I clearance
Clearance between flow
1 I I I I
sensor valve and valve body I I
-
19 -0.035 +0.013 0.035 0.064
-0.045 0 0.058
Clearance between pressure

2
control valve and valve body
Clearance between pressure

3
control valve and piston
I 1 I
I
I
- Replace
Standard size I Repair limit
I
Installed Installed
4 Fill switch spring Free length Free length Installed lox I
lenath load
Flow sensor valve return

5 33.5 1 29.5 1 0.5 kg 1 33.1 / 0.45 kg
spring
11.7 1.08 kg
6 Pressure control valve spring 16.2 15.8 0.97 kg
(Normal) (Normal)
40-11
FRONT AXLE
w
94.5*10 kgm :
561 F03189
Unit: mm

1 Wear of oil seal sliding surface Repair or
- replace.
330
40-12
REAR AXLE SUPPORT
Section A - A 3 4
Section C - C
Section B - B
561 FO3195
Unit: mm
1 Sta$eard 1 Sha:o’e;anceHo,e 1 ,SSJarz 1 CI;;y / -

Clearance between rod mount-
1 I I I I
ing pin and bushing t I I
I 80 -0.060
-0.030 +0.046
0 0.030
0.106
- 0.3 I
Clearance between inner 0.080 - Replace
2 115 0.150 0.5
and outer for bushing
Clearance between suspension

cylinder mounting pin and 80 -0.030 +0.046 0.030 -
frame or axle 0.3
-0.060 0 0.106
Clearance between inner 0.080 -

and outer for bushing 115 0.5
0.150
40-13
DIFFERENTIAL
m
94.5+10 kgm
\ ‘\
56*6 kgm
94.5*10 kgm 11.5*1 kgm
L6;.5*8 kgm
561 FO3190
Unit: mm
Wear of oil seal contact surface Repair or

1 0 replace
of coupling 150 -
-0.100
Thickness of side gear thrust 0

2 9 8.5 Replace
washer -0.05
Backlash between bevel gear

3 0.41 - 0.56 Adjust
and pinion
40-l 4
WITH DIFFERENTIAL LOCK
3 W
I=56103659
Unit: mm
1 Wear of coupling oil seal contact Repair or

surface replace
150 -
-LO
2 Thickness of differential lock disc 3.3 2.8

Replace
3 Thickness of differential lock plate 3.1 2.9
Backlash between bevel gear and

4 pinion 0.41 - 0.56
adjust
Backlash between differential side
5 gear and pinion 0.30 - 0.40
FINAL DRIVE
3 11.5?1 kgm
561 FO3191
Unit: mm
Standard backlash Repair limit

Backlash between planet gear
1
and sun gear 0.26 - 0.58 1.2
Replace
Backlash between planet gear 0.30 - 0.78 1.0

2
and ring gear
Repair or
3 Curvature of drive shaft Repair limit: 1.5 TI R
replace
I
4 Thickness of spacer Replace

51 kO.1 49
40-15
FRONT BRAKE
m m m
94.5& 1 Okgm 94.5+- 10kgm 5.25*0.25kgm
\ I 1
3
561 F03192
Unit: mm

Repair or
1 Face runout of disc
replace
0.15 0.50
Rebuild
(Thickness of
Min. 22 disc must not be
under 22 mm)
2 Thickness of disc 25
Less than 22
Replace
3 Thickness of pad 19.5 3.0
40-16
REAR BRAKE
Backlash between outer gear
Thickness of pla
Warping of disc friction surface

Max. 0.45 0.7
Warping of plate and damper

7, Max. 0.50 0.7
friction surface
Standard size Repair limit,

Assembled thickness of plate
.8
and disc
123.9 115.0
40-17
PARKING BRAKE
w w m
56+6 kgm 94.5Y 0 kgm 2022 kgm
F56103021
8
z
Ez
Unit: mm
.-
Repair or
1 Face runout of disc
replace
0.4 0.8
Rebuild
(Thickness of
Min. 20 disc must not be
under 20 mm)
Thickniss of disc 25
Max. 20
1
Replace
Thickness of pad (including
21.5 11.5
thickness of plate)
40-18
STEERING LINKAGE
m
28.5*3 kgm
/
i i 4
Section A - A Section B - B
T:
ii
.8
10 11 12
Section C - C Section D - D
Section E - E \ / Section F - F
3
561 F03196
40-20
View Z
t
Z
561 FO3197
Unit: mm
Clearance between inner

1 and outer for knuckle arm!
8 bushing
z 190 0.150 -
0.270 0.7
8
2 Clearance between arm and pin 105 0 +0.054 o-

-0.022 0 0.076 0.3
3 Clearance between steering cyl- 50 -0.025 +0.039 0.025 -

mder mounting pin and bushing -0.064 0 0.3
0.103
Clearance between inner 100 0.12-
4
and outer for bushing 0.25 0.4
31
Clearance between tie rod
5
mounting pin and bushing
Clearance between inner

6
and outer for bushing Replace
Clearance between arm
7
mounting pin and bushing
fl Clearance between inner 0.12 -.

8 120 0.4
and outer for bushing I 0.25 I
Clearance between arm -
9 -0.060 0
mounting pin and bushing 0.106 0.3
75 -0.030 +0.046 0.030 I
Clearance between center lever 60 -0.030 +0.197 0.167 -
IO -0.076 +0.137
mounting pin and bushing 0.273 1.0
Clearance between tie rod -

11 100 0.12 0.4
and bushing 0.25
Clearance between tie rod -
12 50 -0.025 +0.039 0.025 0.3
mounting pin and bushing -0.064 0 0.103
,3 !Zlearance between suspension cyl- -
under mounting pin and bushing 70 -0.030 tO.046 0.030 0.3
-0.076 0 0.122
40-21
FRONT SUSPENSION CYLINDER
m
28.25 + 3.25 kgm
‘m
4.5 + 0.5 kgm
561 FO3198-1
Unit: mm
8
Standard Clearance ;;
clearance limit
Clearance between piston rod Replace g
1 bushing
and bushing
I.103 -
0.4
0.352
_Y
Clearance between piston rod 3.158 - Replace

2 0.5
and bushing 0.452 bushing
_-
Clearance between cylinder Replace
3 ‘.050-375 1 0.8
and wear ring wear ring
_-
Measuring method: Repair limit
Place the spring on a flat bench and
measure the amount that the spring
curves.
4 Elasticity of leaf spring Bench Spring

Max. 0.3 mm
,561 F03199
Replace
Measuring method:
Measure protrusion of stopper.
5 Elasticity of stopper Less than 5 mm
!I 561 FO3200
40-22
0
F56103022
Unit: mm
No.
I Check item
I Criteria
I Remedy
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between piston rod Shaft Hole
1
and bushing
-
200 -0.050 +0.246 0.05 0.4
-0.122 0 0.368
Replace
Clearance between piston rod -
2 and bushing 200 -0.050
-0.122 +0.246
0 0.05 0.368 O-4
-
3 and
Clearance
wear ring
between cylinder 250 -0.260
-0.050, +o
0’ 115 0.05 0.375 O-8
40-23
PARKING BRAKE CHAMBER
2 4 7.25k1.75 kgm
426F191A
Unit: mm
Tolerance Standard
Standard Clearance
Clearance between cylinder size clearance limit
Shaft Hole
and piston , I
Hole: 159
Shaft: 158.65 0.35
Clearance between piston Hole: 38.8

Shaft: 38.04 0.76
insert center boss
Replace
Installed installed
Free length Free length Installed load
Piston spring length load
260 750 + 50 kg
Play of rod in axial direction 2.1

Adjust
Installed dimension of rod 128
40-24
SLACK ADJUSTER
w
1.75Y.5 kgm
561 FO3202
No. Check item Criteria

I Remedy
Standard Tolerance Standard Clearance

Clearance between body and Shaft Hole
1 Replace
piston
80 -0.030 +0.074 0.03 -
-0.076 0 0.15 0.25
40-25
HYDRAULIC PUMP (SAR4-160)
(For torque converter and transmission)
‘w
18+2 kgm
F56A02061 A
Unit: mm
No. Check item. Criteria Remedy
Model Standard clearance Clearance limit

Clearance between gear case
1
and side plate, gear
SAR4-160 0.11 -0.16 0.19
Clearance between inside dia-

2 meter of plain bearing and out- SAR4-160 0.06 - 0.140 0.20
side diameter of gear shaft
Replace
3 Depth to knock in pin

I 214.5
Rotating torque of splined

4 2.0 - 3.0 kgm
shaft I
Delivery Standard
Speed Delivery
Delivery amount Model pressure delivery
amount limit
(rpm) amount
(kg/cm2 1 (Q/min.)
(Q/min.)
-
EO ‘lo-CD j SARA-160 / 2200 / 30 1 305 1 279

45 - 55Oc
40-26
HYDRAULIC PUMP
(SAR4-180+180: For steering, work equipment)
(SAR4-285+285: For brake cooling)
w
18*2kgm 18?2kgm 18+2kgm
561 FO3203
Unit: mm

I
Type Standard clearance Clearance limit
Clearance between gear case SAR4-180 0.11 - 0.16 0.19

1
and side plate, gear I I
SA R4-285 0.14 - 0.19 0.22

I I
Clearance between inside dia-
SAR4-180
2 meter of plain bearing and 0.06 - 0.14 0.20
SAR4-285
outside diameter of gear shaft Replace
Type Standard size Tolerance

3 Depth that pin is knocked in
SAR4-180 0
SAR4-285 21
-0.5
SAR4-180
4 Spline shaft rotating torque 2.0 - 3.0 kgm
SAR4-285 I
--I
Delivery Standard Delivery
Speed
Type pressure delivery limit
Del ivery (rpm)
(kg/cm* 1 (!Vmin) (P/min)
(Oil: EOIO-CD,
-
oil temperature: 45 - 55’C)
-
2000 30 350 321
2000 30 540 494
40-27
DEMAND VALVE
m
32.75+4.7kgm
w
3.75&0.25kgm
2kgm
Q=
m 3.75+0.25kgm
21.5+3kgn
m
1.15+0.15kgm
561 FO3204
Unit: mm
l,n,snfsa:;d Free length Installed load

Free length
1 Spool return spring ‘nE?d
221.7 155 125.6 kg 100.5 kg Replace f:

G
.8
2 Check valve spring 56 47 0.345 kg 0.276 kg
CROSS-OVER RELIEF VALVE
\.
lEl.5E :gm
561 FO3205
40-28
HOIST VALVE
a=
521 kgm
\
561 FO3206
m
1751 kgm 7Y kgm
3.252475 kgm 9+-l kgm
561 FO3207
Unit: mm
Installed Installed
1 Spool return spring Free length Free length Installed load
length load
95.6 67 16 kg 12.8 kg
Replace
2 Check valve return spring 84.7 47.5 1.3 kg 1.04 kg
3 Detent return spring 20.5 17 3.7 kg 2.96 kg

I
40-29
STEERING CYLINDER
w
95+9.5 kgm 405k40.5 kgm
561 FO3208
8
z
z
Unit: mm
Tolerance Standard Clearance

Standard
Shaft Hole Replace
1 Clearance between piston bushing
rod and bushing
-
70 -0.030 +0.27 1 0.105 0.675
-0.104 +0.075 0.375
+0.039
2 Clearance between piston rod 50 1 .o
support shaft and bushing 0
- Replace
Clearance between cylinder +0.039
3 bottom support shaft and 50 1.0
0
bushing
40-30
HOIST CYLINDER
535
33*3.3 kgm 4
I \
561 FO3209-1
5428.0 kgm
Unit: mm
I I I
Clearance between outer

1 circumference of cylinder and
bushing
-
200 -0.050 +0.260 0.104 0.725
-0.165 +0.054 0.425
Clearance between piston rod -

and bushing 130 -0.043 +0.214 0.077 0.657 Replace
-0.143 +0.034 0.357
Clearance between piston rod

support pin and bushing 80 +O.o04 1 .o
-0.019
Clearance between cylinder +6.004

4 80 1 .o
support pin and bushing -0.019
40-31
@
CONTENTS
(For H D985-3)
10 STRUCTURE AND FUNCTION .......................................................‘lf%-7””
20 TESTING AND ADJUSTING ................................................................ 92-I
30 DISASSEMBLY AND ASSEMBLY .................................................... 93-I
40 MAINTENANCE STANDARD .....................................‘.......................... 94-I
+ For details of the applicable serial numbers for the contents of each item in this shop manual, see
CONTENTS for each section.
<Explanation of applicable serial numbers>

1. When no model is listed after the CONTENTS : Applicable to both HD785 and HD985
2. When a model is listed in ( ) after the CONTENTS : Applicable only to the model given in ( ).
90-l
0
10 STRUCTURE AND FUNCTION
Radiator, torque converter oil cooler .......... IO- 3 Suspension system ...................................... IO-42
Brake oil cooler.. ........................................... IO- 4 Suspension cylinder.. ................................... IO-44
Power train skeleton.. ................................... IO- 5 Front suspension cylinder.. .......................... IO-44
Output shaft .................................................. IO- 6 Rear suspension cylinder (HD785-3) ........... IO-48
Torque converter and transmission Rear suspension cylinder (HD985-3) .......... .91-12
hydraulic piping.. ........................................ IO- 7 Air circuit diagram ........................................ IO-51
Torque converter and transmission Air piping ................................................... 10-52-I
hydraulic circuit diagram ........................... IO- 8 Air governor.. ................................................ IO-53
Torque converter and transmission Safety valve.. ................................................. 1O-55
hydraulic circuit schematics ...................... IO- 9 Check valve ................................................... IO-55
Hydraulic pump (SAR4-160) ........................ IO-IO Double-check valve ...................................... IO-56
Torque converter (HD785-3). ........................ IO-12 Auto drain valve ........................................... IO-57
Torque converter (HD985-3). ....................... .91- 2 Hand brake valve
Torque converter valve ................................ IO-14 (Retarder control valve) ............................. IO-58
Lockup solenoid valve.. ................................ IO-19 Brake valve .................................................... 1O-60
Transmission (HD785-3) ............................... IO-20 2-way control valve (Parking brake valve,
Transmission (HD985-3) ............................... 91- 4 emergency brake valve). ............................ IO-63
Transmission valve ....................................... IO-22 Emergency brake control valve
ECMV (Electronic control (Variable control type). ........................... 10-64-I
Modulation Valve) ...................................... IO-23 Parking brake pilot valve.. ............................ IO-65
Lubrication relief valve.. ............................... IO-28 Relay valve
Front axle (HD785-3) ..................................... 1 O-29 (Acts also as emergency relay) ................. IO-66
Front axle (HD985-3) ..................................... 91- 6 Parking brake relay valve.. ........................... IO-69
Rear axle (HD785-3) ...................................... 1 O-30 Quick-release valve ...................................... IO-71
Rear axle (HD985-3) ...................................... 91- 7 Brake chamber.. ............................................ 1O-72
Differential ..................................................... IO-31 Parking brake chamber ................................ IO-74
Differential lock control ............................ 10-31-2 Slack adjuster.. .............................................. IO-75
Structure of system ................................. 10-31-2 Hydraulic piping
Differential lock system diagram .......... 10-31-3 (Steering and hoist, and brake cooling) ... IO-77
Switch ....................................................... 10-31-3 Hydraulic circuit diagram
Differential lock solenoid valve ............. 10-31-4 (Steering and hoist, and brake cooling). .. IO-78
Final drive (HD785-3). ................................... IO-32 Dump body control ...................................... IO-79
Final drive (HD985-3). ................................... 91- 8 Hydraulic tank and brake cooling
Front brake .................................................... IO-33 oil tank.. ....................................................... IO-80
Rear brake ..................................................... IO-34 Hydraulic pump ............................................ IO-81
Parking brake ............................................. 10-34-2 Brake cooling oil control valve (BCV). ......... IO-82
Wheels (HD785-3) ......................................... IO-36 Steering valve ............................................... IO-83
Wheels (HD985-3) ......................................... 91- 8 Clossover relief valve ................................... IO-87
Axle support (HD785-3) ................................ IO-37 Demand valve ............................................... IO-88
Axle support (HD985-3). ............................... 91-10 Hoist valve .................................................... 1o-92
Steering system (HD785-3) .......................... IO-38 Steering cylinder .......................................... IO-94
Steering system (HD985-3) ......................... .91-11 Hoist cylinder. ............................................... IO-94
Steering wheel.. ............................................ IO-39 Dump body(HD785-3) ................................... IO-95
Steering linkage.. .......................................... IO-40 Dump body(HD985-3). ................................. .91-14
91-1
0
Main fram (HD785-3) .................................... IO-95 Automatic emergency steering
Main fram (HD985-3) .................................... 91-14 system (HD785-3) .................................... 1O-l 24
Electrical circuit diagram ......................... 10-96-2 Automatic emergency steering
Pressure switch.. ......................................... 1 O-l 01 system (HD985-3) .................................... 91- 21
Stop lamp swich ......................................... IO-101 Electrical circuit diagram ......................... IO-125
Horn valve ................................................... IO-102 Flow switch ............................................... lo-126
Parking brake switch .................................. 1 O-l 02 Relay timer.. .............................................. IO-128
Front brake cut-off valve ........................ 10-102-I Automatic suspension system .................. IO-129
Automatic retarder valve ........................... 1 O-l 03 Automatic suspension mode
Exhaust brake valve ................................... IO-103 selection control ..................................... 1 o-131
Tilt switch .................................................... IO-104 Suspension controller.. ............................ IO-132
Air conditioner ......................................... 1O-l 04-I Sensors, switches ..................................... 1O-l 33
Piping diagram .................................... ..lO-104- 1 Steering angle sensor .............................. IO-133
Electrical circuit diagram ..................... 10-104-2 Pressure sensor ........................................ IO-133
Refrigerant circuit diagram.. ................ 10-104-2 Payload meter.. ........................................... IO-134
Condenser.. ............................................ IO-I 04-3 Structure of system .................................. 1 O-l 34
Compressor ........................................... 1O-l 04-3 Electrical circuit diagram ..................... 10-134-I
Engine control system Principle of calculation.. ....................... 10-134-2
(Mechanical governor type). .................... IO-105 Features of equipment ......................... 10-134-4
Electrical circuit diagram ......................... 1 O-l 06 Electronic monitor system ......................... IO-135
Hydraulic circuit diagram.. ....................... IO-106 Electronic monitor panel.. ........................ IO-136
Servo cylinder.. ......................................... IO-107 Electronic monitor dislays, functions ...... IO-137
AISS Sensors, switches.. ................................... IO-140
(Automatic Idling Setting System). ....... IO-108 Engine speed sensor.. .............................. IO-140
Engine control system Engine oil pressure sensor ...................... IO-140
(Electronic governor). ............................ 10-108-I Engine water temperature sensor.. ......... IO-147
System diagram .................................... 10-108-I Retarder oil temperature sensor ............. IO-141
Electrical circuit diagram ..................... 10-108-2 Torque converter oil temperature
Fuel injection pump with electronic sensor.. .................................................... I O-l 41
governor .............................................. 10-108-3 Air pressure sensor .................................. IO-141
Hydraulic circuit diagram.. ................... 10-108-4 Fuel level sensor.. ..................................... IO-142
AISS Maintenance monitor system.. ................ IO-143
(Automatic Idling Steering System). . 10-108-4 System diagram ....................................... IO-143
Engine controller .................................. .lO-108-5 Monitor panel ........................................... IO-144
Sensors, switches.. ................................ 10-108-5 Monitor display, functions ....................... IO-145
Accelerator sensor ................................ 10-108-5 Functinos of switches.. ............................. IO-147
Engine speed sensor.. ........................... 10-108-5 Sensors, switches ....................................... IO-149
Exhaust brake .......................................... 10-108-6 Engine oil level sensor.. ........................... IO-149
System diagram .......... . ......................... 10-108-6 Radiator water level sensor ..................... IO-149
Automatic shift control system ................. IO-109 Transmission oil level sensor .................. IO-149
Transmission controller ........................... IO-I 10 Hydraulic oil level sensor.. ....................... IO-150
Shift lever positions and automatic Retarder oil level sensor .......................... IO-150
gear shifting ranges ............................... IO-1 11 Air filter clogging sensor ......................... IO-150
Shift lever switch ........................................ 1 O-l 14 Retarder brake water sensor ................... IO-151
Sensors, switches ....................................... IO-I 15 Hydraulic filter sensor.. ............................ IO-151
Transmission speed sensor ..................... IO-I 15 Retarder oil filter sensor .......................... 1 O-l 51
Transmission oil temperature Transmission oil filter sensor .................. IO-151
sensor.. .................................................... IO-I 15 Battery electrolyte level sensor ............... 1 O-l 52
Fill switch .................................................. IO-I 16 ABS/ACR system (Option). ......................... IO-154
Accelerator sensor ................................... IO-I 16 ABS/ACR controller (ECU) .......................... IO-161
Shift limit switch ....................................... IO-I 17 ABS pressure control valve ....................... IO-162
Mode selector switch ............................... IO-I 17 ASR control valve ....................................... IO-165
Shift-indicator system ................................ IO-120 Wheel speed sensor ................................... IO-I 67
Shift indicator ........................................... IO-121
91-1-1
0
TORQUE CONVERTER
Model: TCA49- 1A
Type: 3 element, l-stage,
2-phase with lockup clutch
Stall torque ratio: 2.4
Lockup clutch: Oil-cooled multiple-disc clutch
Hydraulic control
(with modulation valve)
/ I
19
\18
21 20
x-x
561 FO3009
91-Z
0
SZH00023
1. Gear (No. of teeth: 63) 11. Disc A: From pump

2. Gear (No. of teeth: 53) 12. Plate B: To transmission valve
3. Spline for brake 13. Turbine C: To transmission
cooling pump drive 14. Drive case lubrication
4. Spline for steering and 15. Stator a: Torque converter outlet
hoist pump drive 16. Pump pressure measurement
5. Spline for torque 17. Rear housing port
converter and 18. Stator shaft b: Torque converter outlet
transmission charging 19. Retainer temperature pick port
pump drive 20. Drain plug
6. Torque converter valve 21. One-way clutch
7. Solenoid valve 22. Gear (No. of teeth: 56)
8. Front housing 23. Input shaft
9. Lockup clutch housing 24. Coupling
10. Lockup clutch piston
91-3
0
TRANSMISSION
i K 7
Z
H 4 i 6
SKH00024
1. Speed sensor mount port A: Low clutch port I: From torque converter
(for input shaft rotation) B: 1st clutch port (main circuit)
2. Speed sensor mount port C: 2nd clutch port J: From torque converter
(for intermediate shaft rotation) D: R clutch port (lubrication circuit)
3. Input shaft E: 3rd clutch port K: To pump (suction)
4. Transmission lubrication valve F: 4th clutch port L: From torque converter
5. Speedometer cable pickup port G: High clutch port (drain circuit)
6. Coupling H: From oil cooler
7. Drain valve
8. Speed sensor mount port
(for output shaft rotation)
9. Strainer
91-4
0
input shaft
No. 1 sun gear (No. of teeth : 34)
No. 1 clutch inner drum
No. 1 clutch
No. 1 planetary pinion
(No. of teeth : 32)
6. No. 1 planetary carrier
7. Counter gear
(for input shaft, No. of teeth : 130)
8. No. 2 clutch inner drum
9. No. 1 ring gear (No. of teeth : 98)
IO. No. 2 clutch
11. No. 2 clutch housing
12. No. 3 clutch housing
13. Counter gear (for intermediate shaft,
No. of teeth : 130)
14. No. 3 clutch inner drum
15. No. 3 clutch
16. No. 3 clutch outer drum
17. No. 4 clutch
18. No. 4 planetary pinion
(No. of teeth : 20)
No. 4 ring gear (No. of teeth : 86)
No. 4 sun gear (No. of teeth : 46)
No. 5 clutch
(No. of teeth : 28)
No. 5 planetary pinion
(No. of teeth : 20)
24. No. 5 sun gear (No of teeth : 38)
25. No. 6 clutch
(No. of teeth : 28)
28. No. 6 sun gear (No. of teeth : 42)
29. No. 6,7 planetary carrier
30. No. 7 clutch
31. No. 7 ring gear (No. of teeth 96)
32. Output shaft
33. Counter gear
(for output shaft, No. of teeth : 60)
(No.of teeth : 35)
35. No. 7 clutch piston
Speed
Clutches engaged
Speed reduc- 36. No. 6 clutch piston
range tion ratio
37. Intermediate shaft
Fl No. 2 - No. 7 (L - 1st) 4.692 il iii\iI!\\ (No. 7 sun gear; No of teeth : 26)
F2 No. 2 - No. 6 IL - 2nd) 3.333 44 43 42 41 40 39 38 37 36 35 34 38. No. 5 clutch piston
F3 No. 1 - No. 6 (H - 2nd) 2.475 39. No. 5 planetary pinion
(No. of teeth : 19)
F4 No. 2 - No. 4 (L - 3rd) i ,838 No. 1 clutch No. 2 clutch ~0.3 Clutch ~0.4 clutch No. 5 clutch No. 6 clutch No. 7 clutch
1
40. No. 4 clutch piston
F5 No. 1 - No. 4 !H - 3rd) 1.365 4 . .1 . .1 . .1 . .1 r. .1 r. . 1 41. No. 4, 5 planetary carrier
F6 No. 2 - No. 3 (L - 4th) 1 .ooo
(R) @rd) (1st) 42. No. 3 clutch piston
(High) (Lo& (4th) (3rd)
F7 No. 1 - No. 3 (H - 4th) 0.742 43. No. 2 clutch piston
A-A 44. No. 1 clutch piston
R No. 2 - No. 5 (L - R) 3.934 SKH00025
91-5
0
FRONT AXLE
i__---‘
SKH00026
1. Cover
2. Holder
3. Wheel hub
4. Retainer
91-6
0
REAR AXLE
A-A
SK~00027
1. Parking brake
Specifications
Reduction ratio
2. Differential
Differential : 3.467
3. Axle housing
Final drive : 6.500
4. Brake
Oil
5. Final drive Differential : EOSO-CD (130 liters)
Final drive : E030-CD (66 liters each side)
Tire size : 30.00R51
Rim size : 22.00X51
91-7
0
FINAL DRIVE
12’ 11’ 10
WHO0028
1. Carrier Specification
2. Planet gear shaft Type: Planetary gear, splash-type lubrication
3. Planet gear (No. of teeth: 39) Reduction ratio: 6.50
4. Sun gear (No. of teeth: 18) Oil: E030-CD (80 liters each side)
5. Button
6. Cover
7. Ring gear (No. of teeth: 99)
8. Spacer
9. Holder
10. Inner hub
11. Drive shaft
12. Wheel hub
91-8
0
WHEELS
. FRONT WHEEL
1. Stud (x26)
2. Clamp (x13)
3. Nut (x26)
4. Valve
5. Rim assembly
6. Tire
Specifications
Rim size : 22.00 x 51
Tire size : 30.00R51 -& f?
1 FO3040
l REAR WHEEL
1. Stud (x26)
2. Clamp (x13)
3. Nut (x26)
4. Rim assembly
5. Valve
6. Tire
7. Spacer
Specifications
Rim size : 22.00 x 51
Tire size : 30.00R51 b a
SKH00029
91-9
0
AXLE SUPPORT
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
/’
/’
A-A B-B c-c
561F03042-1K
91-10
0
STEERING WHEEL
SZH00031
1. Steering wheel Specifications

2. Steering shaft l Tilting range: 94 mm
3. Steering column l Telescoping range: 50 mm
4. Steering post
5. Lock lever
6. Yoke
7. Joint shaft
8. Steering valve
91-l 1
0
.5
---I-----?.-. -----I---
/’
SKH00032
1. Cylinder 5. Rod
2. Ball 6. Valve (for bleeding air and
3. Flange mounting pressure sensor)
4. Retainer 7. Feed valve
91-12
0

The suspension cylinder has the function of
both a shock absorber and a spring.
When a fixed amount of oil is sent from oil
chamber (6) through orifices (4) and (5) to
cavity (2), the oil is throttled by the orifices
and a shock-absorbing effect is obtained.
a) Retracting action
When the machine is traveling and it hits
a bump or object on the road, the wheels
are pushed up, and the cylinder rob is
pushed inside the cylinder.
When
When this happens, the nitrogen gas in-
extending
side chamber (7) is compressed, the oil in
chamber (6) is sent through both orifices
(4) and (5) to cavity (2), and cavity (2) is
filled more quickly than when extending.
b) Extending action
When
When the machine has passed any bump
or object on the road surface, the cylinder
rod is pushed up by the weight of the
wheels and axle and the pressure of the
nitrogen inside chamber (7).
As a result, the amount of oil in cavity (2)
is reduced, and pressure is applied to the
oil remaining in cavity (2).
This pressurized oil closes orifice (4) with
check ball (3), and is sent to chamber (6)
through only orifice (5), so the flow of oil
passing through the orifice is controlled
so that it is less than during retraction. 1. Feed valve 7. Nitrogen gas chamber
In this way, the amount of oil returning to 2. Cavity 8. Cylinder rod
chamber (6) is restricted to provide a 3. Check ball 9. Cylinder
shock absorbing effect. 4. Orifice 10. valve (for bleeding air
5. Orifice and mounting pressure
sensor)
6. Oil chamber
91-13
0
DUMP BODY
561 FO3092
Specification
Capacity
Heaped : 64 m3
Struck : 46 m3
Max. payload : 100,000 kg
MAIN FRAME
561 FO3093
91-14
0
AUTOMATIC EMERGENCY STEERING SYSTEM
SYSTEM DIAGRAM
SZH00037
1. Battery OUTLINE
2. Emergency relay switch If the engine should stop when the machine is
3. Timer
traveling, or there is anyabnormality in the
4. Emergency steering switch hydraulic pump and the specified amount of oil
5. Flow switch
does not flow to the steering circuit, the
6. Steering pump emergency system automatically actuates an
7. Check valve
electric pump to ensure the hydraulic pressure
8. Demand valve
for the steering, thereby making it possible to
9. Emergency steering pump use the steering.
10. Hydraulic oil tank This system can also be operated .manually.
* Same machines have only manual operation.
91-15
0
-
I ‘uemana
va’ve
To s+edringkeTo hoist “““’
1.258 _l.ZSLB --
1 ygp L
: ‘oos
4,
_-_
r
UJOI CNJOZ
CNDMJ
r----
Diodo
7 Park
Pilot lamp 1 1 1 _I Ill
1 Relay timer
,
SZH00038
91-16
0
20 TESTING AND ADJUSTING
Standard value table for engine related Bleeding air from brake circuit .................... 20-23
parts (HD785-3) ........................................... 20- 2 Testing wear of front brake pad.. ................ .20-24
Standard value table for engine related Testing wear or rear brake disc .................. .20-24
parts (HD985-3) ........................................... 92- 2 Adjusting parking brake .............................. .20-25
Standard valve table for chassis Testing brake performance ...................... 20-25-I
(HD785-3) .................................................... 20- 3 Testing and adjusting suspension
Standard valve table for chassis cylinder.. ...................................................... 20-26
(HD985-3) .................................................... 92- 3 Testing and adjusting suspension air
Standard valve table for electrical cylinder.. ...................................................... 20-31
system ......................................................... 20- 8 Testing and adjusting air pressure
Tool for testing, adjusting, and in air circuit ................................................. 20-32
troubleshooting .......................................... 20-12 Adjusting hoist lever linkage ...................... .20-33
Adjusting valve clearance ........................... -20-13 Adjusting body positioner ........................... 20-34
Measuring compression pressure.. ............ .20-14 Testing and adjusting hydraulic
Measuring blowby pressure.. ..................... -20-15 pressure in steering, hoist circuit.. ........... .20-35
Cheching and adjusting fuel Air bleeding from steering cylinder ........... .20-37
injection timing ...................................... ..20-15- 1 Adjusting engine speed sensor.. ................ .20-38
Adjusting accelerator pedal ........................ .20-17 Adjusting Q [Fuel injection amontl
Adjusting of AISS linkage ........................... .20-18 when replacing engine controller ......... 20-38-I
Adjusting engine stop motor cable ............ .20-18 Procedure for operating shift checker
Testing hydraulic pressure of torque and modulation checker ........................... .20-39
converter valve ........................................... 20-19 Method for emergency operation of truck
Testing ECMV hydraulic pressure .............. .20-20 when there is failure in electrical
Testing transmission lubrication system of transmission control
pressure .................................................. .20-20-l system of engine control system .............. 20-53
Testing torqure converter stall speed ....... ..20-2 1 Troubleshooting.. .......................................... 20-55
Testing brake pressure ............................... .20-22
A Before performing inspection, adjustment

check the safety pin and chock.
or faultfinding, park the machine on level ground and
A When performing
the machine.
joint work, make appropriate signals and allow only authorized personnel near
A When checking the water level, allow the engine to cool down before removing the radiator cap to
prevent the risk of being scalded by hot water which may spurt out if the engine is hot.
A Take great care to avoid getting caught in rotating parts such as the fan, etc.
92-1
0
STANDARD VALU’E TABLE FOR ENGINE RELATED PARTS
Applicable model HD985-3
Engine SAlZVl40-1
f
Measurement conditions Unit Standard value Permissible valve
With mechanical
2,450 t 50 2,450 * 50
governor
High idling mm
2,450 + 50
2,100 f 50
Engine Low side 650 + 25 600 i: 25

Low idling rpm
speed
High side 1,000 f 30 1,000 r 30
With mechanical
governor 2,100 i 50 2,100 * 50
Rated speed
2,100 * 50
With electronic
governor
1,700 * 50
At sudden acceleration Bosch index 7 .o 8.0

Exhaust
gas color At high idling Bosch index 1.5 2.5
Valve Intake valve mm 0.43

clearance
(when cold)
Exhaust valve mm 0.80
Compression
Oil temperature: 40-60°C kg/cm ’ Min. 20 Min. 20
pressure
(Engine speed) (rpmj (1,600 - 2,000) (1,600 - 2,000)
(SAE30 oil)
Blowby
(Water temperature:
pressure
Operating range) mmHz0 Max. 150 Max. 300
(Reference
At rated output
(Water temperature:
Operating range)
At high idling kg/cm ’ 2.5 - 5.2 Min. 2.3

Oil pressure
At low idling (SAEBO) kg/cm ’ Min. 1.0 Min. 0.8
At low idling (SAElOW) kg/cm’ Min. 1 .O Min. 0.8
Oil Whole speed range

OC 90 - 120 Max. 120
temperature (inside oil pan)
With mechanical governor 24 + 1 24i 1

Fuel injection
Before top dead center
timing
With electronic governor 18+ 1 18+ 1
Deflection when pressed

Belt tension
with finger force of mm 20 t 1
(Alternator) 20
approx. 6 kg
92-2
0
STANDARD
f..
VALUE TABLE FOR CHASSIS
1
Com-
Item Vleasurement conditions Jnit Standard value Permissible value
Donent
Engine water tempera-

ture: Within operating
range
Fl Transmission oil temper
ature: 70 - 90°C
F2
When empty
Travel F3 Total resistance 2.0 % 22i5% 22*5%
n/h
speed
F4 29?5% 29 i 5%
F5 3925% 39+5%
F6 53 & 5% 53?5%
F7 7Oi5% 70??5%
R
T
13f5% 13f5%
-
. 2,230 i 50 2,230 i 50
Engine water tempera-
I
ture: Within operating 1,500 It 50 1,5OO*50
range
. Transmission oil tempe 1,450 + 50 (F2 - Fl only) 1,450 i 50 (F2 - Fl only)
ature: 70-90°C
Shift
UP
. Hydraulic oil tempera- 2,230 f 50 2,230 i 50
s Power ture: 50-80°C
T! mode ,1,500*50
E E Shift . “Braking mode” refers 1 1,500 * 50
e !z down when the accelerator is 1,400 + 50 (F2 - Fl only) I.400 + 50 (F2 - Fl only)
g OFF or the rear brake is
2m .g ON.
Shift rDm 1,800 f 50 1,800 !c 50
.o e
+rG 4 Econ- up 1,850 f 50 (Fl - F2 only) 1,850 + 50 (Fl - F2 only)
E omv
0 0
.c mode 1,250 * 50
2 .=
3
Shift
down
1,250 !c 50
0)
.r
P Shift
m Brak- UP
ing
2
mode Shift
- down
-
Fl, F2
9 Set
t -;c F3-F’ 7 1,250 f 50 1,250 f 50
5
0 Fl, F2 1,200 1,200
2 Reset
- 1
F3-F’ 7 1,100*50 1,100*50
Set 2,600 + 10 2,600 + 10

5
‘B
,b. Reset 2,350 f 10 2,350 i 10
-
Same as shift down for
Down-shift Same as shift down for automatic shift
inhibitor automatic shift control
control given above.
- given above.
b Transmission oil tem- For engines with
oerature: 70-90°C mechanical governor 2,040 f 100 2.040 f 100
Engine Spped at l ‘Hydraulic oil tempera-
torque converter ture: 50--8O’C rpm 222
.c $ $ Power 2,040 + 100 2,040 * 100
stall * Engine water tempera- mode
py B
ture: Within operating Economy
ranqe 2 .g .; mode 1,780 * 75 1,780 + 75
For engines
* Operating force at a mechanical with 2.7 rt 0.5 2.7 i 0.5
Starting to governor
point 150 mm from
depress pedal fulcrum. For engines with
Operat- electronic 2.0 * 0.5 2.0 * 0.5
ing governor
km
force For engines with
mechanical 4.2 i 0.5 4.2 f 0.5
governor
Full
For engines with
electronic 3.5 * 0.5 3.5 * 0.5
governor
Starting t( ,
* Travel at a point 150
Travel depress mm 32 -t 5 32*5
mm from pedal fulcrur
-full
92-3
0
Component Item Measurement conditions Unit Standard value srmissible value
Operating force . At center of lever knob kg 1.6 + 0.4 Max. 2
R-N
N-D
Transmis-
sion shift D-5
lever Travel mm 18.5i 1 18.5i2
5-4
4-3
3-L
. Oil pressure: 70-90°C Low 1.3 * 0.5 1.3 * 0.5

Oil pressure at inlet port . Engine: Low idle and
High idle High 81tl 8+1
t
Low 1 .o * 0.5 1 .o + 0.5

Oil pressure at outlet port
High 4*1 4+1
Torque
<g/cm2
Low 16 rt 0.5 16 f 0.5
Lockup pressure
High 16 i 0.5 16 i 0.5
Low 34.5 f 2 34.5 f 2

Main relief pressure
High 39 * 2 39+2
. 16.5 + 1.5 8
16.5 f 1.5
Oil temperature: 50 - 80°C X
. Engine: Low idle and Hi idle
20.5 i 1.5 20.5 f 1.5
31.5 i 1.5 31.5fl.5
1 R clutch 30+ 1.5 3oi 1.5
1612 16+2
Transmissior kg/cm2 20*2 20&2
lst, 2nd R clutch 33 f 2 33 * 2
. Water temperature:
Within operating range.
. Oil temperature:
Lubrication pressure 1.25 i 0.5 1.25 i 0.5
50 - 80°C (Using EOIO-CD)
70 - 90°C (Using EOBO-CD)
. Engine: High idle
. When empty
Tires Standard tires 30.00R51 *b
(inflation kg/cm2 7.0 7.0
(Front and rear wheels)
pressure)
. Oil temperature: 50 - 80°C
Operating force (turning speed

. With machine stopped (if it is
for steering wheel: 30 rpm) impossible with the machine kg Max. 3.0 Max. 3.6
stopped, travel at low speed with
Steering engine at low idling)
wheel
. Lentgh at circumference of steer-
Play ing wheel 130f30 13oi30
. Engine stopped
92-4
0
Item Measurement conditions Unit Standard value ‘ermissible value
I
Vo. of turns * Lock - lock Turns 3.5 * 0.4 3.5 f 0.6

I
Steering l Oil temperature: 50 - 80°C
wheel l Engine speed: Whole range
Turning time * Lock - lock sec. Max. 4 Max. 5
l Oil temperature:
50 - 80°C Low 180+; 180+;
l Demand valve relief
Steering
Relief pressure valve kg/cm2
valve
l Engine: Low idle and
High idle High 210 ‘A 210+;
;Irg force 1 Tip of pedal kg Max. 30 Max. 30

Brake oedal
mm 78*8 78rt15
$ngforce ~10mmfromtipoflever kg 1 .o - 4.0 0.5 - 6.0

Retarder
control leve
degree
o-90+3 O-90*6
(mm)
Parking * Tip of lever

s Operating force kg Max. 2.0 Max. 3.0
brake lever
X
I
I
Emergency l Tip of lever

Operating force kg Max. 2.0 Max. 3.0
brake lever
l Run engine at full throttle, startin

with air pressure at 0 kg/cmz,
Air govern0 Set pressure kg/cm2 8.3 * 0.3 8.3 zt 0.3
accumulate air and measure pres-
sure when unloaded.
Service 100 ton payload l Initial speed: 32 km/h m Max. 25.6 Max. 35.6
brake . Distance from starting to lose
braking speed stopping
distance . Max. actuating air pressure:
Empty m Max. 22.3 Max. 22.3
I 8.3 kg/cm2
Max. hydraulic pressure
Rear: 45 kg/cm*
Retarder Front: 127 kg/cm2 m Max. 29 Max. 38
brake On flat, dry road surface
braking
distance m Max. 21 Max. 30
Brake Front chamber I l Max. actuating air pressure: 8.3 Min. 187 Min. 187
kg/cm2 -
- Engine: Stopped
Brake Rear chamber l When first operated
kg/cm2 Min. 45 Min. 45
actuating
pressure
Min. 45 Min. 45
Carrying IOOt payload Initial speed

m Max. 69.9 Max. 69.9
32 km/h On flat, dry road Surface
92-5
0
Item Measurement conditions clnit Standard value ‘ermissible value
With 78t payload

After adjusting clearance between
Parking disc and pad Double caliper : Double caliper :
brake
Braking capacity %
Min. 15 Min. 15
-
Service brake F2 Min. 1600 Min. 1600
Torque converter stall
Water temperature:
Retarder brake Within operating range
Min. 1200 Min. 1200
Air pressure: 8.3 + 0.3 kg/cm2
Transmission oil temperature:
Braking 70 - 9ooc
Emergency brake rpm Min. 1900 Min. 1900
capacity Hydraulic oil temperature:
50 - 8O’=C
Parking brake Double caliper : Double caliper:

Min. 1,400 Min. 1,400
-
HOLD - RAISE Center of control lever knob Max. 10 Max. 10
RAISE - HOLD rutomatically return tutomatically return
HOLD - FLOAT
Operating
force kg
FLOAT - HOLD 3-6 3-6 8
2
LOWER - FLOP iutomatically return iutomatically return ::
Hoist lever FLOAT - LOWE Max. 13 Max. 13

-
RAISE -
1512 15+2
HOLD @
HOLD -
Travel mm 11 i2 11*2
FLOAT @
FLOAT -
11 i2 11*2
LOWER @
F56103023
-
l Oil temperature:
50 - aooc Low 185 +;o 185 +A0
* Engine: Low idle and
Hoist valve Relief pressure high idle k j/cm;
l Measure at end of stroke
when raising body High 200 +;s 200 ‘A”
-
Lifting speed * Oil temperature: 50 - 80% 9- 13 9-13
) Engine: Full throttle
) Use FLOAT when lowering jet.
Lowering speed *17* 1.5 *17+1.5
-
1 Oil temperature: 50 - 80°C
Hydraulic drift
* Set with No. 2 cylinder extended nm/
n
Max. 85 Max. 170
200 mm
5 min.
) Hydraulic drift for 5 minutes

so this value is given only for reference
92-6
0
Component item Measurement conditions Unit Standard value Permissible value
I
A 262ztlO 262 f 20
b On flat road surface
Front - * When empty
5 4841tlO 484 ?z 20
Front Rear
Installed
length mm
Suspension
cyliner Rear A 250 i 10 250 i: 20
Front * 39.5 f 5 * 39.5 * 5

Pressure kg/cm2
Rear 569F108 561FO3401 * 26.0 i: 5 * 26.0 * 5

so this value is given only for reference
92-7
0
TYPE AND LOCATION OF CONNECTOR, SENSOR
l For engines with electronic governor and exhaust brake.
l For machines with electronic display panel, maintenance monitor, auto suspension and payload
meter.

Type No. of pins
AS1 X type 2 Exhaust brake E-8
AS2 X type 2 Parking brake G-9
AS3 X type 2 Retarder brake G-9
AS4 X type 2 Emergency brake F-9
AS6 X type 2 Service brake F-9
BTI Terminal 20 Fuse box w-2
BT3 S type 12 Fuse box w-2
BZ M type 2 Buzzer R-4
Cl I M we I 1 For canceling memory I a-2
CM S we 8 Combination switch T-8

I I I
CNS S we 12 Power set selector switch P-l
CVT X type 2 Transmission oil temperature sensor X-6
ECA S type 16 Engine controller intermediate X-l

I

I I I
EC2 I MIC I 13 1 Engine controller I

Y-l
Left bank engine controller

E7 SWP type 14 G-l
intermediate
Right bank engine controller
E8 SWP type 14 F-l
intermediate
B-3
E9 X type 4
I Left bank rack sensor I
El0 X type 3 Left bank pre-stroke c-2
El1 X type 2 Left bank governor solenoid D-2
El2 X type 2 Engine speed sensor B A-6
92-8
0
No. No. of pins
Type
El3 X type 4 Right bank rack sensor A-5
El4 X type 3 Right bank pre-stroke A-4
El5 X type 2 Right bank governor solenoid A-4
El6 I X type I 2 Right bank speed sensor A I A-6
HPS X type 2 Transmission solenoid valve W-8
HSW X type 1 Transmission solenoid valve fill switch W-8

I I I I

JO1 S type 16 V-4
connector
JO2
I S ww I
16
connector I v-4

JO3 S type 16 v-4
connector
JO4 S type 12 w-4
connector
JO6 Terminal 1 v-3
connector

JO7 Terminal 1 v-3
connector
JO9 S type 12 Engine controller intermediate Y-l
LCT X type 2 Torque converter lockup solenoid valve V-8
LS M type 3 Rheostat u-7
LPS X type 2 Transmission solenoid valve W-8
LSW I X type I 1 Transmission solenoid valve fill switch W-8
MM1 040 type 16 Maintenance monitor U-l
MM3 040 type 8 Maintenance monitor T-l
MM4 040 type 8 Maintenance monitor T-l
MM5 040 type 2 Maintenance monitor u-2

MM7 S type 16 P-2
connector
92-9
0
MM9 X type 2 Engine oil level sensor c-2
MM10 Terminal Full-flow filter clogging sensor A-3
MM11 X type 1 Battery electrolyte sensor B-7
MM12 X type 2 Brake oil level sensor C-8
MM13 X type 1 Air cleaner clogging sensor E-8
MM14 X type 1 Hydraulic oil level sensor K-3
MM15 X type 1 Retarder oil level sensor L-4
MM16 X type 2 Transmission oil level sensor J-3

I I I I
MM17 X type 3 K-9
connector
MM19 X type 2 Rear left brake wear sensor M-8
MM20 X type 2 Rear right brake wear sensor l-9
Nl X we 2 Transmission input speed sensor V-8
N2 X type 2 Transmission intermediate connector V-8
N3 X type 2 Transmission output shaft sensor z-9
PM1 MIC 21 Payload meter Q-7
PM2 M type 4 Model selection H-2
PM3 X type 3 Inclinometer l-2

I I I
PW Socket 7 Power set selector switch R-l
92-10
0
Type No. of pins
PO7 040 type 2 Electronic display panel s-9
PI1 040 type 8 Electronic display panel S-8
PI3 I 040 type I 4 Electronic display panel I R-6
RPS X type 2 Transmission solenoid valve x-9
RSW X type 1 Transmission solenoid valve fill switch x-9
RE3 Socket 2 Resistor x-2
RE4 Socket 2 Resistor Z-4
RHI S type IO Intermediate connector z-4
ROI Relay 5 Engine start relay v-3
R02 Relay 5 Transmission neutral relay v-4
R03 Relay 5 Service brake relay w-4
R04 Relay 5 B.C.V control relay w-4
R05 Relay 5 Backup alarm relay w-5
R06 Relay 5 Head lamp relay Hi v-2
R08 Relay 5 Head lamp relay Lo v-4
92-11
0
No. No. of pins
Type
I
R09 I Relay 1 6 1Rear brake pilot relay I w-4
RlO I Relay I 5 Charge level caution relay I x-5
RI1 Relay 6 Payload relay w-2
RI2 Relay 6 Parking body FLOAT relay v-2
RI3 Relay 5 Coolant temperature caution relay v-2
R14 Relay 5 Transmission filter relay x-5
RI5 Relay 5 Fog lamp relay x-5
RI6 Relay 5 External display lamp relay No. 5 w-2
RI9 Relay 5 External display lamp relay No. 2 Y-4
R20 I Relay / 5 External display lamp relay No. 1 I Y-4
R21 Relay 5 Parking brake relay w-2

I I I
R22 Relay 5 R. governor cut relay w-2
R23 Relay 5 L. governor cut relay x-2
R24 Relay 5 Lock-up display relay Y-4

I I I
R25
I
Relay
I
5 Transmission cut relay
I z-4
SC1 MIC 13 Transmission controller G-l
SC2 MIC 21 Transmission controller H-l
SC3
I
MIC
I
17 Transmission controller
I l-2
SC4 MIC 13 Transmission controller J-2

I I I
SF I S we I 12 Transmission shift lever P-l

I
nket 1 7 IShift limit switch I P-2
-I_ Xtype 1 2 Suspension control solenoid valve A x-5

I
92-12
0
No.
Type No. of pins
I
SL2 I X me I 2 1Suspension control solenoid valve B 1 Y-4
SL3 I X we I 2 Suspension control solenoid valve C I Y-4
SL4 X type 2 Auto retarder Y-4
SL5 X type 2 Exhaust brake Y-4
SRI X type 3 Accelerator sensor D-l
SR2 X type 3 Steering sensor E-l
SUI MIC 21 Suspension controller z-3
su2 I MIC I 13 Suspension controller
su3 S type 16 Intermediate controller z-3
su4 M type 4 Model selection z-1
TC, SE X type 2 Transmission oil temperature sensor v-7
TMA S type 16 Transmission controller intermediate x-2
TMB S type 12 Transmission controller intermediate x-2
TMC S type 12 Transmission controller intermediate X-l
TM2 JWP type 14 Transmission controller intermediate a-9
WL M type 2 Caution lamp Q-4
IPS X we 2 Transmission solenoid valve Y-9

I I
92-13
0
I
ISW
I
I
X me I
I
1
I
1
Transmission solenoid valve fill switch
I
I
Y-9
I I I I
2sw X we Transmission solenoid valve fill switch Y-9
I
I
I
1
’ I
I I
3sw X type 1 Transmission solenoid valve fill switch x-9

I I
X type 1 Transmission solenoid valve fill switch w-9

I
01 SWP type 14 Lighting intermediate connector C-8

02 SWP type 8 D-8
connector
13 X type 2 Front suspension (left) E-l
20 SWP type 14 Intermediate connector E-8
26 I X ww I 2 Water temperature sensor I B-3

30 SWP type 14 B-7
I I connector I
39 I X We I 2 Front suspension (right) I A-7
52 X type 2 Transmission filter sensor K-3
53 X type 2 Retarder filter sensor M-4
54 X type 2 Hydraulic filter sensor L-3
61 X type 2 Fuel sensor H-9
62 X type 2 Rear suspension left sensor L-8
63 X type 2 Rear suspension right sensor l-9
64 X type 2 Retarder oil temperature sensor M-4
92-14
0
LOCATION OF CONNECTOR AS2 AS3
I’ fi
AS4
,
MM19
/
‘64
..
./..A
.,I. :..:...:.
A:::,:.:.
..,.,.,
B
I..... ‘. :‘::.:‘;:p~; ...: iiii:.,
D lii;,iyi_:i:i$~, ::::E:y :.. .: ..:j F I:: ;jy ‘G:,.ii” :, ,,I
H . ST?-:;,
. A:;.:’ :. :. 1 J .:, ” ::K::;-i_
:.: :: .:...: .( L :‘MF.
...:
.. .. :.. ,.,i N I
561FO3311
92-16
0
2PS
2sw ISW
RPS \ I I 1PS
PO2
PO4
PO7
\\ \ PO8 M-2
i
CVT
RlO
MM8
MM6 MM2 MM5
\ I /
‘Cl
RH2
Jb9
MM4 MM3 MM1
B
D
1 ,: : () ..: . : .,.,... ‘1
P f: ‘. i.:.0 jj ::,::.::q
R
t”.: ..?,::: :.:. .s, 1 T 1:i.L.. : u. .I V ~,:..::.I x I,:,,. .y ... -:I z I .a:- 1 b
561F03335K.1K
92-17
0
TROUBLESHOOTING OF ENGINE
CONTROLLER SYSTEM
(FOR ENGINES WITH ELECTRONIC GOVERNOR)
Judgement table for engine controller and engine related parts . . . . . . . . . . . . . . . . . . . . . . . . 92-21
Red Green
0 0
G-l OFF OFF Abnormality in power source system ............................... 92-23
Red Green
0 a
G-2 ON ON Abnormality in controller system .................................. 92-24
Red Green
l (>
G-3 ON Slow a. Abnormality in right bank rack sensor system ..................... 92-25
flash-
ing
Red Green
@O
Slow OFF b. Abnormality in left bank rack sensor system ...................... 92-26
8 flash-
ing
3
8 Red Green
0 Qr
G-4 ON Fast a. Abnormality in right bank governor solenoid system ................ 92-27
flash.
ing
Red Green
OF 0
Fast Slow b. Abnormality in left bank governor solenoid system . . ............... 92-28
flash- flash.
ing ing
Red Green
0 0
G-5 ON OFF
a. Abnormality in right bank governor cut relay system ............... 92-29
Red Green
OF 0
‘ast OFF
b. Abnormality in left bank governor cut relay system . ............... 92-30
‘lash-
ng
Red Green
0 OF
G-6 a. Abnormality in right bank pre-stroke solenoid system ............... 92-31
IFF Fast
flash-
ing
Red Green
0 #I
IFF Slow
b. Abnormality in left bank pre-stroke solenoid system . ............... 92-32
flash-
ing
92-l 9
0
Red Green
0 OF
G-7 Slow Fast
Abnormality in rack sensor power source system . . . . . . . . . . . . . . . . . . . . . 92-33
:lash- ri;h-
ng
Red Green
Q Q
G-8 Slow Slow a. Abnormality in engine speed sensor A system .........
‘lash- ;Fgsh-
ng
Simultaneous
Red Green
Q Q
Slow Slow b. Abnormality in engine speed sensor 8 system . . . . . . . . . . . . . . . . . . . . . 92-35
‘lash- flash-
ng ing
Alternate
Red Green
@I a
G-9 Abnormality in accelerator sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-36
Slow ON
‘lash-
ng
Red Green
G-10 Abnormality in water temperature sensor system . . . . . . . . . . . . . . . . . . . . 92-38
Red Green
OF OF
G-l 1 Fast Fast
a. Abnormality in right bank governor servo system . . . . . . . . . . . . . . . . . . . 92-39
flash- ylyh-
ing
Alternate
Red Green
OF OF b. Abnormality in left bank governor servo system . . . . . . . . . . . . . . . . . . . . 92-39
Fast Fast
flash- flash-
ing ing
Simultaneous J
G-l 2 Enginedoesnotstart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-40
Electrical circuit diagram for engine controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-43

conditions.
Therefore, always check the resistance value, voltage, etc. of the place giving the failure display,
that the problem occurred, and try to re-enact the failure conditions when carrying out
troubleshooting.
92-20
63
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS
Self diagnostic display (abnormal display) Pilot lamps
Troubleshoot-
S ing code when
, Engine speed does not change to

0 0 0 G-9
actuated accord- high-speed low idling
ing to operation 2 Engine speed does not change to low-
0 0 0 G-9
speed low idling
Exhaust smoke is normal See Engine
8 Fuel consumption ’ (in operator’s judgement) Shop Manual
IS excessive *__ .___* See Engine
2 Exhaust smoke is extremely black Either of these Shop Manual
0
I 0
1 Enaine soeed does 1 Does not rise to high idling G-9
I 1 I I 1 I I I / / I I 1 I I
9 nocincrease to
high idling
2 Rises to high idling but returns to
low idling
II 0 I -
10 Defective automatic warming-up operation I-l I I I I I II I I I I.1 I I -
*__.___* -
1 Engine speed stays accelerated Either of these
Engine does
11
not stop 2 Even when starting switch is turned OFF, l _______@ -
engine continues to run at low idling Either Of these
1 Rotation at low idling is unstable See Engine

There is hunting
12 Shop Manual
from engine 2 Rotation at high idling is unstable
See Engine
13 Oil consumption is excessive or exhaust gas is blue
Shop Manual
See Engine
14 Oil soon becomes dirty
Shop Manual
See Engine
15 Oil in cooling water
Shop Manual
See Engine
16 Oil pressure lamp lights up
Shop Manual
See Engine
17 Oil level has risen
Shop Manual
See Engine
18 Water temperature rises too high
Shop Manual
See Engine
19 Abnormal noise is made Shop Manual
See Engine
20 Excessive vibration Shop Manual
Troubleshooting code when there is abnormal display 1 G-l 1 G-2 1 G-3 G-3 G-4 G-4 G-5 G-5 G-6 G-6 G-7 G-8 G-8 G-9 G-10 G-l 1 G-l 1 G-12 F-4 F-5 F-3I 1 F-l 1 P-26 1
I I I I 1 I
92-21
0
G-l 1 Red Green
0 0 Abnormality in power source system
* When fuse BT2(1)(1-2) and (7)(13-14) are not blown.

If the fuse is blown, check for any short circuiting with the ground by any part inside the controller
or the wiring harness between the fuse and controller.
Cause Remedy
YES
Is voltage
between
YES
harness between EC3 Repair or
EC3 (1) - (2).and (female)(l3) - ECA reDlaCe
(12) - (13) normal? (female)(l3),(15) - EC3
(femaleMl2). or between EC3
(female)(2) - ECA(female1
(131.(15) - ECS(female)(1).

replace
harness between ECA(male)
(13) - JO6 - earth
2) Turn starting
‘1) ::;h3:.
NO harness between ECAlmale) replace
1)20-30V
2) Turn starting (151- BT2 (No. 1) -starting
switch ON. switch terminal B - BT2 -
J03(14)(13)(No. 7) -fuse
unit-battery terminal (cl
Engine controller
EC3(MIC21)
Fuse unit
To battery
terminal(+)
TKH00027
92-23
0
G-2 I
Red Green
0 0 I Abnormality in controller system

CalkX Remedy
YES
11
Is voltage between harness between EC3 Repair or
YES
EC3 (1) - (2). and - (female )(13) - ECA (female) leolace
(12) -_(13) normal? (13),(15) - EC3 (female)(l2),
or between EC3 (femaleI(2)
2
- ECA ifemale)(l3i.(l5) -
1) 20-30V EC3 (female) (1)
2) Turn starting is voltage between
switch ON. - ECA(131 and (15) -
NO normal ?
3 YES disconnection in wiring
Repair or
replace
1) 20-30V harness between ECA(male)
Is voltage between (13)-JOG-earth
2) Turn starting
_ ECA(15) and
switch ON.
NO chassis ground
normal ? Defective contact, or Repair or
disconnection in wiring EDlaCe
1) 20-30V NO harness between ECA
2) Turn starting (malei(l5) - BT2 (NO. 1) -
switch ON. starting switch terminal B-
BT2 (No. 7) - JO3(14) -
fuse unit - battery terminal
(+I
Engine controller BT2 Starting

ECA(S16) switch JO3(S16)
EC3(MIC21)
Fuse unit
c Q
14 13
- @ - To battery
a- terminal(+)
30A
@ = $$
JO6
GND @ $j d
ER
TKH00027
92-24
0
Red Green
G-3 (a) l 0 Abnormality in right bank rack sensor system
El
Call%? Remedy
YES
2
4 YE Defective right bank rack
Yl ; Is voltage between Se”SOr
Is resistance
- EC2 (3) and (8) between El 3
normal? Y
(female) (2) - (4).
and between (2) -
1) Engine stopped 3 (3) normal? Wiring harness between EC2
(Starting switch
K
NI
(female) (11) - E8(3) - El 3 Repair or
1) 50KR-1 MR (female) (3).(4) - E8(7) - EC2 replace
ON1 Is voltage between 2) Turn starting
0.25-0.45V. (female) (5) short circuiting
- El3 (1) and (2) switch ON. with chassis ground
2) Engine running NO “prmal,
Is voltage
between
0.25-35V
3) Disconnect El3
I I
1) 4.6-5.4V Defective contact, or discon-
2) Turn starting nection in wiring harness Repair or
1) 4.6-5.4v switch ON. between EC2 (female) (1) -
2) Turn starting E8(1) - El3 (female) (1 L(2) -
switch ON. E8(2) -EC2 (female) (8)
B
5
:: See G-7
NO
ECZIMIC 13)
I
El3(X4) Right rack sensor
- (Inner controller)
561 FO3409
92-25
0
G-3 (b) I Ab normality in left bank rack sensor system
Cause Remedy
4 YE Defective left bank rack

sensclr OUtpUt sensor
voltage) between

Repair or
(female) (13) - E7(3) -
replace
E9(3’.(4’- E7(7’- EC2
(female’ (7) short circuiting
with chassis ground
0.25-0.45V.
Isvoltage between 2) Engine running
EC2 (2’ and (9’
normal?
y1) 4.6-5.4V
2) Turn starting
/ “zzkEing + between EC2 (female) (2’-
E7(1) - E9 (female) (l),(2) -
reDlaCe
E7(2’- EC2 (female) (9)
See G-7
NO
Engine controller
EC2(MlCl31
E9 (X4) Left rack sensor
.@
Left rack sensor
@
(Inner controller)
561 FO3410
92-26
0
G-4 (a) 1“gd Gg:“l Abnormality in right bank governor solenoid system
Remedy
Defective controller WAace

?epair or
(female) (1 I- ES(14) -
eDlace
chassis normal? fl5(2).(1) - E8U3) - EC1
(female) (10) short circuiting
2
with chassis ground
2) Turn startmg
switch OFF.
3) Disconnect ECl, Defective right bank governor
ilep1ace
IS resistance solenoid
YES between EC1
nOrmSI?
1) lo-21n
2) Turn starting
nection in wiring harness ?epair or
between EC1 (female) (1) - ‘eplX&?
1 3) Disconnect ECl.
E8(14)--15(2).(l)-ES(13)
- EC1 (female) (10)
EC1 (4) -chassis,
and between EC1
(16) - chassis Defective right bank governor
8 3epkze
NO solenoid
1) lo--2lG
1)20-30V 2) Turn starting
8
switch ON. 3) Disconnect El 5.
See G-5 (a)

NI
EE(SWP14)
Right bank governor
ECA (S 16) 561F03320A-K
92-27
0
G-4 (b) lR;; G;n 1 Abnormality in left bank governor solenoid system
CaLi Remedy
YES
3
Isresistance
between EC1 Wiring harness between EC1
(female) (3) - E7(14) - El 1
(female) (3) and 4 YE!
(female) (2),(l) - E7(13) -
chassis normal?
EC1 (female) (12) short cir-
p Is resistance
1) Min. 1MR between El 1 (male)
2) Turn starting NO (1) and chassis
switch OFF. normal?
Defective left bank governor ReDlace
3) Disconnect EC1
NC solenoid
1) Min. 1MR
2) Turn starting
I (female)
normal?
(3) and (12) switch OFF.
3) Disconnect El 1
1) lo--2lQ Defective contact, or discon-

switch OFF. YES between EC1 (female) (3) -
1 3) Disconnect EC1 E7(141- El 1 (female) (2),(l)
- E7 (14) - El 1 (female)
voltage between Is resistance
Is
- between El 1 (male)
I (2),(l) - E7(13) - EC1
EC1 (8) -chassis, (female) (12)
and between EC1 (1) and (2) normal?
(131 - chassis Defective left bank governor Replace
klld? NO solenoid
1) lo--2ls-J
1) 20-30V 2) Turn starting
switch ON. 3) Disconnect El 1.
See G-5 (bl
Ef(SWP14)
Left bank governor
Solenoid power
ECA(S 161
561F03321-lA-K
92-28
0
Abnormality in right bank governor relay system
* When fuse BT2 (I)(1 - 2) and (7)(13 - 14) are not blown.
Cause Remedy
YES
2 I
harness between EC1 replace
(femaleK4) - EGA(1) -
R22E (2). (1) - BT2 (2)
Difective right bank RePlace

governor cut relay
2) Turn staning
switch OFF.
3) Disconnect R22E
switch ON. 4 YES
s between R22E _ -fuse ““It - battery

Imale) (31 and (6) termianl(+)
normal ?
Defective right bank
z
‘IrP’ar=
RlQht bank governor

cut relay
EnQine controller
ECI(MIC17)
TO bUJ.WY
terminal(+)
TKH00028
92-29
0
G-5 (b) /R;;Gyn( Abnormality in left bank governor cut relay system
* When fuse BT2 (I)(1 - 2) and (7)(13 - 14) are not blown.
+ When the battery is normal.
I Cal22 RemedY
v Isvoltage between Defective contact. or

EC1 (13) and chas- disconnection in wiring
3 YES
harness between EC1
Repair or
I
replace
(female)(l3) -ECA (11) -
Is resistance I
1) 20-30V
2) Turn starting
‘1NC )
between R23E
(male) (I) and 12) tl
R23E (2), 111- BTZ(2)
switch ON. normal ?

.. II Defective left bank governor
Replace
ISvoltage between 1)200-9000 NO C”t re1av
EC1 (8) and chassis 2) Turn starting
switch OFF.
3) Disconnect R23E Defective contact, or
disconnection in wirincl
1) zo-3ov harness between EC1 -
2) Turn starting (femalelW - ECA (16) -
switch ON. 4 YES Fi23E 161. (1). (3) - BT2 (NO Repair or
8 1) -starting switch terminal replace
Is resistance B - BT2 (No. 7) - JO3 (141
between R23E _ -fuse unit -battery
(maleI(3) and 161 terminal (cl
normal ?
Replace
NO wt r&v
1) Max. IR
2) Turn starting
switch OFF.
3) Disconnect R23E
Lefl bank
governor cut relay
Engine controller
ECI(MIC17)
JO3(S16)
Left bank
overnor cut nm
8 olenoid
power source To battery
terminal(+)
TKH00029
92-30
0
G-6 (a) Abnormality in right bank pre-stroke solenoid system
CalSe Remedy
YES
Y Wiring harness between EC1

‘Eli (female)(l4)-E8(11)-El4
3 YES
(female) (l),(2) - E8 (12) -
igjj&jH- ing with chassis ground
1) Min. 1MR 1
2) Turn starting NC
1 switch OFF.
Defective right bank pre
3) Disconnen ECl. Replace
Is resistance stroke solenoid
1) Min. 1MSI NO
between EC1 2) Turn starting
normal?
r-l 3) Disconnect El4
1) lo-21R
switch OFF. Repair or
3) Disconnect EC1
E8 (11) - El4 (female) (l),(2)
I
between El4 (male)
(1) and (2) normal?
Defective right bank pre.
NO stroke solenoid
1) lo-210
2) Turn starting
switch OFF.
3) Disconnect E14.
Engine controller E8 (SWP14)

Right bank pre-stroke
EC I [MIC 17) solenoid
II
561 F03324
92-31
0
G-6 (b) 1 A b normality in left bank pre-stroke solenoid system
CaUSe Remedy
YES RSA+X
2
Is resistance
i~~~H~
II
(female) (15) - E7 (11) - El0
(female) (l).(2) - E7 (12) -
1
Defective left pre-stroke
Replace
solenoid
Is resistance NO
1) Min. 1MR
between EC1 2) Turn starting
normal? 3t Disconnect E10.
1) lo-21n Defective contact, or discon-

switch OFF. 4 YES between EC1 (female) (15) -
3) Disconnect EC1 E7 (11) -
El0 (female) (1 L(2)
- E7 (12) - EC1 (female) (7)
Is resistance
between El0 (male) -
(1) and (2) normal?
Defective left bank pre-stroke Replace
NO solenoid
1) IO-21R
2) Turn starting
switch OFF.
3) Disconnect El 0.
E7(SWPl4) Left bank prestoke

Engine controller
EC I (MIC 17) El0 (X3) solenoid
0
@ c3
J
561 F03325
92-32
0
G-7 El Ab normality in rack sensor power source system
L I
* Before carrying out troubleshooting, check that all the related CalJse Remedy


3 YE (female)(l)-ES(l)-El3 Repair or
(female) (l),(2) - ES (2) - replace
n
I Is resistance EC2 (female) (8) short cxcuit-
(female) (1). (2). (8). lr between El 3 (male) 1”g with chassis ground
(1). (2) - chassis
* If there is defect
rlOr!llal?
between EC2 Defective right bank rack
L
1) Min. 1MO (female) (1) and chas- S?“SOr Replace
N(
2) Turn starting sis, or between EC2 1) Min. 1MO
switch OFF. (female) (8) and 2) Turn starting
3) Disconnect EC2. chassis. switch OFF.
3) Disconnect El 3.
NC
4 YE (female) (2) - E7 (1) - E9 Repair or
(female) (l).(2) - E7 (2) - replace
HUH
between EC2 Defective left bank rack
(female) (1)-(8).
N( Se”SOr
t33pl.Xe
and between (2) - sis. or between EC2 1) Min. 1MO

(female) (9) and 2) Turn starting
chassis. switch OFF.
1) Min. 500 kQ 3) Disconnect E9.
2) Turn starting Contact of wiring harness
3) Disconnect EC2. ES (1) - El3 (female) (1) with
5 YES RepaIr or
wiring harness between EC2 replace
II (female) (8) - ES (2) - EC13
Is resistance (female) (2) (short circuit
between El 3 (male) -
between wires)
* If there is defect (1) and (2) normal?
between EC2
(female) (1) and (8). - Defective right bank rack Replace
1) Min. 500kQ NO SfZ”S0r
2) Turn starting
switch OFF.
3) Disconnect El 3.
Contact of wiring harness

6 YES E7 (1)- E9 (female) (1) with Gpair or
wiring harness between EC2 ‘eplace
Is resistance (female) (9) - E7 (2) - E9

between E9 (male) - (female) (2) (short circuit
* If there is defect (1) and (2) normal? between wires)
between EC2
(female) (2) and (9). Defective left bank rack
NO ?eplace
1) Min. 500kQ sensor
21 Turn startina
switch OFF.”
3) Disconnect E9.
Engine controller
E7(SWPl4)
561 F03326
92-33
0
1
Red Green
G-8 (a) S$,,,,~~O,, Abnormality in engine speed sensor A system
I I
*If engine is cranking more than 1 second at too low speed (less than 20 rpm) when engine
starting, the self-diagnostic display displays abnormality and holds the display for 5 minutes
even if engine is normaly started. That is normal
C.2U.W Remedy

sensm A
,YiFH---
I
NO
For details, see
‘ES between EC3 TESTING AND
ADJUSTING.
chassis normal?
(female) (7) - E8 (4) - El 6 Repair or
4 YES
(female) (l).(2) - E8 (5) - replace
1) Min. 1MR EC3 (female) (17) short cir-
2) Turn starting cuiting with chassis ground
switch OFF.
3) Disconnect EC3.
I I Defective speed s?nsw A Replace
between EC3 1) Min. 1MR
(female) (7) and (17) 2) Turn starting
swtch OFF.
3) Disconnect El 6.
1)5DC-lcuDn
2) Turn starung Defective contact, or discon-
switch OFF. nection I” wiring harness Repair or
5 YES
3) Disconnect EC3. replace
EB (4) - El 6 (female) (1 l.(2)
. between
NO El6 (male) -
’ (1)and (2) normal?
Defective speed sensor A FC?plXZ

NO
1) 500-1157
2) Turn starting
switch OFF.
3) Disconnect E16.
E8 (SWPII)
Engine controller
Speed sensor A
EC3 (MIC21) El6 (X2)
I v_l 561 F03327
92-34
0
Abnormality in engine speed sensor B system
Cause Remedy
Defective adjustment of speed

sensor B
Does speed sensor
YI B return to normal
after being
adjusted?
k For details, see No
TESTING AND
ADJUSTING. Disconnection in wiring
1 harness between EC3
(female)@) - E7(4) -
ElZ(female) (lj.12) - E7(5) -
Is resistance
EC3 (female)(l8), or short
between EC3
I
circuit with chassis ground, Repair or
(female) (8) and (18) YES
or wiring harness between replace
lVXllla1? 3 I E7(female)~4)-J09(11l-
transmission controller -
1) 500-1DDon JO9(12) - E7ifemale)(5)
2) Turn starting between El2 (male) short circuiting with chassis
switch OFF. (1) and chassis ground
3) Disconnect EC3 4 normal?
1) Min. 1 MR Defective speed censor B Replace

between El 2 (male) 2) Turn starting
L (1) and (2) normal? switch OFF.
3) Disconnect El 2.
Defective soeed sensor B Replace
E7 (SWP 14)
561 F03328A-K
92-35
0
G-9 :,,,I Abnormality in accelerator sensor
Sr Use this flow chart also if the Judgement Table for engine related parts shows that there may
be an abnormality in the accelerator system.
Cause Remedy
2 YES
Defective controller eplace
Does voltage
between EC3 (10)
and SC314) change
according to accel- - djust
erator pedal angle 3 YES Defective adjustment of accel- :or details, see
as shown in Dia- erator sensor ESTING AND
gram l? In test in Item 2,
.DJUSTING)
does voltage
1 1) Turn start,“g
NO change, bu tis out-
side specified value?
switch ON.
Is voltage
between 2) Operate acceler-
NO
To (A)
ator pedal.
1) 4.6 - 5.4v
Defective controller leplace
2) Turn starting 8
switch ON.
Is resistance
I Wiring harness between SC3
(female)(S) -TMA(lG) -
SRl (female (l),(3) -TMB
(9) - SC3 ifemale)(4i short lepair or
circuiting with chassis eplace
ground, or contact with other
wiring harness
Defective accelerator sensor leplace

and chassis : I) Between (1) and NO
Min. 1MR
2) Turn starting (3): 4.6 - 5.4kR
switch OFF. Between (1) and
31 Disconnect EC3 chassis: Min. 1 MR
2) Turn starting
switch OFF.
3) Disconnect SRl.

ECA (12) - SRl (female) (2).
or between ECA (male) (12) -
c
TMA (13) - SC1 (female) (4)
Does voltage Wiring harness between EC3

between SRl (2) (female) (10) - ECA (12) -
SRl lfemalei 12). or between
YES
and (3) change 7 YE
l-l
according to accel- II- ECAimale)(l?j-TMA(13) qepair or
erator pedal angle Does resistance - SC1 (female) (4) short cir- .eplace
as shown in Dia- between SRl (male) cuiting with chassis ground,
gram l? ES (2) and (3) change or contact with other wiring
according to accel- harness
i( erator pedal angle
1) Turn starting
as shown in Dia-
switch ON.
gram 2?
2) Operate acceler- Accelerator sensor linkage Repair or
ator pedal. out of position, or defective
From
Is voltage between between SRl (male)
1) Turn starting N( Sensor
replace
SRl (1) and 13) (1) and (3) normal?
switch OFF.
(Ai normal?
i I I I 21 Disconnect SRl.
I I 1) 4.6 - 5.4kR
1) 4.6 - 5.4v 2) Turn starting Defective accelerator sensor Replace
2) Turn starting switch OFF. N
switch ON 3) Disconnect SRl.
, harness between SC3 Repalr or
NO (female1 (8) -TMA (16) - replace
SRl (female) (1). (31 -TMB
ISI - SC3 (female)(a)
92-36
0
Engine controller
EC3(MIC21) ECA(Si6) SRI (X3) Accelerator sensor
Accelerator
a
signal @
i
3
SC1 SC3(MIC17)
(MIC13)
Transmission
controller THK00030
Fig. 1 Fig. 2
Accelerator signal voltage

(Kfi) ) Sensor resistance value
Approx.4.3- Approx. 4.3 -
Approx. 1.0 - Approx. l.O-
I I
Low idling - C Full Low idling _ Full

c
561 FO3330 561 F03331
92-37
0
Abnormality in water temperature sensor system
* Before carrying out troubleshooting, check that all the related connectors are properly inserted
Cause Remedy
2 YES
, - ECZ(4)andchassis -
normal? Defective contact, or discon-
IS water tempera-
ture gauge on moni- NO I between EC2 (female) (4) - replace
_ 1) 1.1 -4.7v ECA (9l- JO2 (female) (1 j
tar panel actuated 2) Turn starting
normally? switch ON.
b seeP-22
-
Monitor panel
PO9 (040)
\ I Water temperature
JO2(Sl6) 2O(SWP 14) 26 (X2) sensor
1
@ 0
@ -0
L I I
EC2 (MIC 13)
561 F03332
Engine controller
92-38
0
r-l
Red Green
G-l1 (a) OF @F Abnormality in right bank governor servo system
Alternate
CalIS. Remedy
2 YES
Defective fuel injection pump
I I I (see engine shop manual)
- ECZ(ll)and(5) -
normal?
Defective contact, or dw.on-
1 nectlon in wiring harness
Repair wiring
harness or
1) 0.1 -4.5v NO between EC2 (female) (11). (51
Is voltage between 2) Turn starting E8 (3). (7) - El3 (female)
EC1 (16) and chas- - switch ON. n. (4)
sis normal?
1) 20-30V
2) Turn starting Defective contact, or Repair wiring
switch ON. disconnection in wiring harness or
NO harness between EC1
(femalei(l6) and R22E (6)
Abnormality in left bank governor servo system
2 YES
Defective fuel mlection pump
(see engine shop manual1
- EC2 (13) and (7) -
normal?
1 Defective contact, or Repair wiring
disconnection in wiring harness or
1) 0.1 -4.5v NO harness between EC2 replace
Is voltage between 2) Turn starting Ifemale)(l3), (7) - E7 (31,(7)
EC1 (8) and chassis - switch ON. -ES (female) (3),(4)
normal?
1)20-30V
2) Turn starting
switch ON. Defective contact.
or Repair wiring
NO disconnection in wiring harness or
harness between ECl(81 and replace
R23E(6)
92-39
0
G-l 2 Engine does not start
A When starting motor does not turn.

* Check that the circuit breaker is not OFF before starting the troubleshooting.
4 YES
Is voltage between
sta*,ng motor ter-
minal B and chas-
*IS normal?
NO
1) Approx. 24V
Is there sound of YES

starting motor pin-
ion moving in?
1) Turn starting
switch to START.
YES
H
7r
transmission
IS resistance
r
‘ES
between ROl (male)
* Abnormality in (3) and (6) normal?
transmission
neutral relay
1) Max. 1O
2) Turn starting NO
switch OFF.
3) Disconnect ROl
(relw)
1) Turn starting
switch to START.
2) Approx. 20 - 30V
switch is turned h
OFF, is sound
heard from battery
11 YES
pig$!gg[
1) Turn starting
switch ON -
OFF.
YI
10
1) Max. 157 NO
Is resistance
YES between starting _
switch BR and
relav switch (+I
9 1) Between starting
switch BR and
Is resistance relay switch (+)
” between starting _ Max. 1R
switch terminals B 2) Between wiring
and BR normal? harness and
a :
chassis Min. 1R
1) Min. 24V 3) Disconnect both
2) Specific gravity: 1) Max. 1O
2) Turn starting starting switch
Min. 1.26. IS voltage of start- and relay switch
switch ON.
ing switch terminal
3) Remove terminal 6. NO
,) connect (-) end

of tester to bat-
tery terminal (-_).
2) Approx. 20 - 30V
92-40
0
I Cause Remedy
Defective starting motor

nection in wiring harness lepair or
between battery terminal (+I ep1ace
and starting motor terminal 6
Go to troubleshooting of
trawmission controller
harness between star&g Zepair or
switch terminal C - ROl ep1ace
(femaleN3) - (6) - JO1 (2)
-24(l) or 2511) -starting
motor terminai C
Defective engine starting

7ep1ace
relay [between (3) and (6)]
Defective starting switch

%?p1ace
[between B and C]
Defective relay switch Replace
Defectwe contact, or
disconnection in wlrlng Repair or
harness between battery r&Xe
termfnal c-i - relay switch
terminal C-1.
disconnection in wring
Repair or
harness between starting
replace
switch terminal BR -
JOl(lOl-30(101-relay
switch terminal (+I
Defecwe starring switch Replace
dlsconnectlon I” wnng
harness between starting RepaIr or
swtch terminal B - JO3 - replace
fuse unit - battery terminal
I+)
Repair or
Defective battery
92-41
0
F
I
/ 1
P
M M E
E
Starting C
Starting
motor motor B
B
S S
RO I30
ROl
(Realay) JO1 (S16)
To tr=ission -
neutal relay I
92-42
0
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM
II
i/r
II
-
-
(1,.
561FO3106-1
92-43
0
TROUBLESHOOTING OF
TRANSMISSION CONTROLLER SYSTEM
Points to remember when carrying out troubleshooting of controller system . . . . . . . . . . . . 92-47
Judgement table for transmission controller, transmission related parts . . . . . . . . . . . . . . . . 92-48
Abnormality in power source
a. (OFF) Self testing display of controller does not light up ............ 92-49
b. Drop in voltage of controller power source displayed ............... 92-51
c. Abnormality in transmission cut relay power source displayed ....... 92-52
Abnormality in neutral safety system displayed ..................... 92-53
Abnormality in controller system
(only dot lights up) or a. Only dot lights up or abnormality in controller

displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-54
b. Double system for clutch displayed . . . . . . . . . . . . . . . . . . . . . . . . .. . . 92-65
Abnormality in transmission [out relay] system displayed . . . . . . . . . . . . . 92-56
Abnormality in auto-retarder brake solenoid system displayed . . . . . . . . . 92-57
Abnormality in speed sensor system
A-6
mE
c’r
E.
.I-
IC
I
lJJ
Ic’
I
a. Abnormality
b. Abnormality
in engine
in intermediate
speed sensor system displayed
shaft speed sensor system

. . . . . . . . . . . . . 92-59
m .I_ 1.L
displayed ‘. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-61
EH+
E 1.3
,:‘I-
I .I_ 1.3
c
Disconnection
speed sensor) displayed
in travel speed sensor (transmission output shaft
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-62
Speed sensor system, clutch slipping
Input shaft sensor or H.L clutch system displayed ......... 92-63
Travel speed sensor or speed clutch (1,2,3,4,R) system

displayed.. ....................................... . 92-64
Abnormality in model selection displayed .......................... 92-65
92-45
0
Abnormality in transmission shift lever system
a. Short circuit in transmission shift lever assembly power source

displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-66
A-9 b. Transmission shift lever position signal displayes 2-system

abnormal input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-67
c. Transmission shift lever position signal is not input ................ 92-79
Abnormality in accelerator signal displayed ......................... 92-74 .
Abnormality in transmission oil temperature sensor displayed .......... 92-77
Abnormality in pressure control valve system
Fill signal displayes ON regardless of command ........... 92-78
Fill signal is not input and clutch slipping

is displayed
1) Whenm . ~‘~;di;b;ayed::::::::::::::::::::::::::: ~~:~~

8
X
ii
A_,S@_$jejm’ r~‘c When m
fill srgnal isd~splaye~.:::::::::::::
IS not Input :::::::::::::: ;;;;;
3JJ (flow detector Valve SyStetTI)
f 8 Short circuit in pressure control valve solenoid system

m-m displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-83
A-14 or
I- D Disconnection in pressure control valve solenoid system
m-m displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . 92-99
Sr Re-enacting failures in electrical system

of wiring harnesses and connectors, occur only under special conditions particularly at the
initial stage of the occurrence of the failure.
Therefore, investigate the values for the resistance and voltage at the locations indicated by the
abnormal display. Even if no abnormality is found, it is necessary to investigate the conditions
troubleshooting.
92-46
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-
SHOOTING OF TRANSMISSION CONTROLLER SYSTEM
Connection between troubleshooting of electrical system and mechanical system

If the failure display shows ,iTn, 3.0, ‘-:.n, 5.0, there are some cases where there is a failure
in the electrical system (sensors, wiring harnesses), and other cases where the failure is in
the mechanical or hydraulic system (ECMV or clutch).
Therefore, if troubleshooting is carried out on the electrical circuit and no failure is found,
go to troubleshooting of the mechanical and hydraulic system; on the other hand, if no abnormality
is found during troubleshooting of the mechanical and hydraulic system, go to troubleshooting
of the electrical system.
(For details if the display is ,:?n, g.n, ‘-/.n, 5.0, see the action taken by the self-tester and
the section on “Transmission controller system” dealingwith the chassis.)
* : One of 0 - I?,~‘-/,S,&,3,Z
Recording failure code

The transmission controller records failures that have occurred in the past, and when the starting
switch is turned OFF - ON, the recorded codes are displayed as shown in Fig. 1.
Therefore, by seeing these recorded failure codes, it is possible to obtain information about
problems that have occurred in the past.
I I - - ---
l-l I-l I I l-1’
lI.l:l IJ .-I I I-.-I I I I-.-I I I !.‘:I u.i_1 i.b !_i.i_i
E$tingg;witch
All
Ii ht Recorded failure codes are displayed p Present code is displayed
u8 (all recorded codes are displayed) (normal)
- I--k
F56103103
Note:
When investigating failures, if the starting switch is turned ON/OFF with the connector
disconnected, the controller may judge that there is an abnormality, and the failure code may
be recorded.
Therefore, after carrying out troubleshooting, always delete the recorded data and check that
the failure code has been deleted.
When carrying out an investigation of any other controller or monitor system, check that the
transmission controller is not recording the failure codes even when the connector is disconnected.
92-47
0
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS
Self-tester display (abnormal display) Monitor panel display Pilot lamp
;:u’vz; Neutral Control- Trans Pressure Flow p,b”,‘:yL,e

safety ler box mwon brake brake sensor control detector valve
system system Cf;s’J,“y solenoidsolenoid system $$?zfr valve valve solenoid Engine Troubleshooting
Check Shift
system system system system system con- Mode Shift Shift Body Exhaust code when no
item Brake
C’.I’ 0.3 C’.L1 0.6 0.8 1 .o 1 .o 2.0 1.4 0.7 1.7 1.9 3.0 5.0 7.0 troller selector A$; position limiter float brake abnormal dis
0.1 0.4 1.2 218 1.5 4.0 t 9.0 display played is given.
0.2 0.5 1.3 1.6 t 2-8 t
2-8 l-8
Engine does not

start
, Engine
does not start
# 0 0 0 0 0
See engine
- shop manual
2
Machine does not 1 Does not start in any speed range 0 0 0 0 0 0 0 0
start
2 Cannot start in R or D - L 0 0% 0 0 0 H-l
3
Atter stcrpping and placing in N, it is
impossib le to start aaain I I I I I I I.1 I I I I I I.1 I I I I I I I I I
Movement of 1 Travels forward even when lever is at N
0 0
machine is -
abnormal when 2 Travel forward when lever is in R
0 0
starting
3 Starting shock is abnormally large 0 0 0 H-4
Starts in _I._ ._ r_ I.__ ._.__ L__
tsrarung wnen
I I I I I I I.1 I I I I I I I, I I I I II I I I I-
aowe r.2
4 machine is stoooedl
..- _....._ .__.. rr.~,
-
4 Movement of Transmission enters R, Fl, F2, but does
machine is
1
not enter F3 or above a 0 0
abnormal during
travel 2 Suddenly shifts down 0 0 -
Repeatedly shifts between certain speed

3
ranges 0 0 0 0 H-2
4 Will not shift from a certain speed range

when traveling 0 0 0 -
Engine stalls 1 0 0 H-3
Transmission shock is abnormally large 0 a 0 H-4
c
Brake is applied when traveling
Even whcen shift limiter switch is ON
8 transmis! sion shiftsup to F7 when le\jeris
at D and to F2 when lever is at L
0
-
a Abnormi ?;,d,‘;p$y given when overrun
n
Suddenly returns
to neutral when
traveling
6 Long time taken

to shift up
7 No power
2 Lack of power at certain speed range 0 0
3 Does not lock up 0 H-5
8 Excessive time lag 1 Time lag is excessive when starting 0

H-7
2 Takes time to shift gear 0 0
Takes time to shift from FORWARD to
3 REVERSE 0
9 Defective shift 1
Ci;t?;hifting is normal, but E display is
0
indicator display -
Gearshifting is normal, but display is
2
wrong 0
IO Defective actua- 1 Exhaust brake does not work
tion of exhaust
I I I I I 1.1 I I I I.1 / I I I I I I I loi ,:,I”

brake Method of operation of exhaust brake
I 2/ does not match operation of machine
.orque converter oil

I1 : emperature is high ’ Torque converter oil temperature is high 0 H-8
I
Trou bleshooting code when abnormal display is given A-l A-2 A-3 A-4 A-5 A-5A A-6 A-7 A-8 A-9 A-IO A-l 1 A-12 A-13 A-14 P-26 P-l 1 P-6 P-7 F-l F-2 F-4
zlnthecaseof m _m ‘-ID display (A-l 1 b)) only, measure the oil pressure of the clutch first, and if the oil pressure is normal,
I_;.;< carry out troubleshooting of the electrical system. (The probability of the clutch slipping is high.)
Troubleshooting
by displayed code
92-48
0
A-l Abnormality in power source
a) ID\&, \,$., [OFF] Self testing display of controller does not light up
* When fuse BTI (7)(13 - 14) is not blown.

If it is blown, check with ground of wiring harness between
for contact fuse and controller.
Remedy
2 YES
I I I
Defective starting switch, or
defective contact, or
harness between fuse BTl replace wiring
(lo)-TMB(ll)-SC3 harness
(female) (14). or defective
contact, or disconnection in
wiring harness between SC3
(female) (14) - TMC (1) -
1) Turn starting JO6 - battery terminal E
switch ON.
2) 20 - 3ov NO disconnection in wiring replace wiring
harness between batery harness
terminal (+)-fuse unit -
JO3(13)(14) - BT2 (7) -
starting switch terminal B
JO3
I/ I Transmission
To battery
terminal(+)
J
TKH00032
92-49
0
Remedy

Repair wiring
harness or
between fuse ET1 (No.10) -
EplaCe
TMB (11) - SC3 (female) (14)
I Defective starting switch ReplaCe
1) Turn starting Is voltage

between
switch ON. starting switch ter-
‘I
N( minal 6 and chassis
Repair wiring
harness between battery
NO harness or
1) Turn starting terminal (+) -fuse unit -
V?pkXe
switch ON. JO3(131(14) - BT2 (No. 7) -
2) 20 - 3ov starting switch terminal B
BTl Starting switch Fuse unit
To engine controller
selection switch
Shifl limit switch
Exhaust air brake

solenoid Exhaust air brake
Rear brake
solenoid
Transmission
cut relay
TKH00033
92-50
0
Drop in voltage of controller power source displayed
1 YES Disconnection in wiring

harness between alternator Repair or
terminal I3 - relay switch WplXX?
Is voltage between
terminal M.6 - battery
alternator terminal
terminal C+), or loOSeneSS of
R and chassis
terminal
IlOUllal?
Defective generation of Repair or
NO electricity by alternator replaCe
1)20-30V
2) Start engine.
Relay switch
Battery
F56103105-IK
92-51
0
Abnormality in transmission cut relay power source displayed
and charging voltage are normal.

* When fuse BTI (10) is normal.
YES
See A-4
1
Does
,- ,-
7,r:,
_ ,..I.
c 2 YES
Defective transmission cut Replace
w
display appear?
relay transmission
Replace wt relay
transmission cut
1) Turn starting NE
relay. Does it
switch ON. become normal?
A Defective contact. or Repair or
NO disconnection in !wiring replace wiring
1) After replacing
relay, turn
(female) (15) - TIVIC (2) - I
starting switch
R25 (female1 (5)
ON.
Transmission cut relay
To fuse BTl(10)
F56103106
92-52
0
* When the starting switch is turned to ON with the transmission shift lever at a position other
than N, or when the power source is momentarily cut when traveling.
*
YES
set
Mistaken operation transmission
1 I l See Operation Manual shift lever to N,
and t”r”
Was starting key starting Switch
turned to START Defective starting switch, or ON.
when lever was at - defective contact, or
2 YES Repair or
position other than disconnection in wiring
N? harness between starting replace wiring
switch terminal ACC - BTl harness
starting switch
(lo)-TMB(ll)-SC3
NO terminal Band
(female) (14)
chassis normal?
1)20-30V
harness between battery harness
terminal (+)-fuse unit -
JO3(13)(14) - BT2(7) -
starting switch terminal 8.
battery
minal(+)
TKH00034
92-53
0
A-3 Abnormality in controller system

(only dot lights up)
Cause Remedy
3 YES
Does problem occur
even when wireless
and electronic
equipment are
2 removed?
.
Wireless: Check method of
NO ‘
ISwireless or ilnstallation
electronic EIlectronic equipment: Install
equipment 5;urge absorber
installed?
-7 4 YE:
2 ,Check wiring harness of
Does problem ocwr

Ixoblem circuit
Surge absorber diode has
0
1 when a certain ,:ome O”f, etc.)
switch is operated?
IDefective controller Reolace

NC 1
1) Turn starting
switch ON.
2) 20 - 3ov
See A-l, a)
92-54
0
Double system for clutch is displayed
CaWZ Remedy
1 YES -
See A-l 2, a).
IS ,F - -,
7.0
(No.2 - 8)
displaYed at Same
time?
Failure in controller ReplaCe
NO
1) Turn starting
switch ON.
92-55
0
Abnormality in transmission [cut relay] system displayed
* Displays disconnection, short circuit, or contact with ground in transmission cut relay system.
CalSe Remedy
YES
-I Defective relay Replace
1 I
&?place relay. Does

z.5 display
2 YES ReplaCe
disappear?
P Is resistance value
1) Turn starting _ between SC3
switch OFF- ON. NO (female) (7) and (14)
normal?
I I I Defective contact. or Repair or
1) 100-50021
2) Turn starting
switch OFF. (female) (7) - mc (3) - ~25
3) Disconnect SC3. (21, or between SC3 (female)
(14)-TMB(ll)--2511)
Transmission,
cut relay
il R25
SC3 (MIC 17) TMCISIP)
Transmission @
power source 0
Transmission
TMB (Sl2)
F56103108A-K
92-56
0
Abnormality in auto-retarder brake solenoid system
Defective contact. Or Repair or

Is resistance value disconnection in Wiring replace wiring
YES between SL4 (male) harness beween SL4 (female) harness
, - (lk-W,and(l)or - (2) - TMC (10) - SC3
(2) -chassis as (female) (3)
shown in Table l?
Defective solenoid Replace
Is voltage between NO
SL4 (1) and chassis
1) Turn starting
-
switch OFF.
normal?
2) Disconnect SL4.
1) 20-30V See A-l (power source

2) Turn starting NO ~ system)
switch ON.
Table 1
Measurement Normal
location value
Between SL4(male) 2. _ 6OQ
(1) and (2)
Between SL4 pin
Min. 1Ma
(1) - chassis
Between SL4 pin Min. 1MQ

(2) - chassis
Transmission contrOl(er
SC3 t MICl7)
SL4 (X2) Rear brake solenoid
Fuse B T 1
t
Transmission cut relay resistor
F56103109-IK
92-57
0
Displays abnormality in exhaust brake solenoid system
Remedy

between SL5 (female) (2) - harness or
TMC (9) - SC3 (female) 112) replace.
Defective solenoid Replace

ISvoltage between
SL5 (1) and chassis
1) Turn starting
switch OFF.
21 Disconnect SL5. See A-l (Power source
l)ZO-3ov -
2) Turn starting 0 system)
switch ON.
Table 1
Places for measurement 1 Normal value
?n fr,A
SC3 (MICl7)
Exhaust brake
solenoid
Fuse B T 1
t
Transmission
cut relay resistor
561 FO3335-1 K
92-58
0
A-6 Abnormality in speed sensor system
Abnormality in engine speed sensor system displayed
4 YES kfective adjustment of speed Adjust

ie”SOr
Adjust speed
2 YES
_ sensor. Does it _
become normal?
After measuring kfective controller Replace
Item 1, return NO
Y
connector to
orig!nal position. Is
’’
’ L! displayed?
,_
1
1) Start engine. IS reset
NO
Disconnection in wring
harness between SC1
3 YES
:female) (7) (13) - TMA(14)
:15)-JO3(15)(16)-Zl (13) RepaIr or .
1) 500- 1ooon replace wiring
:14) - El2 (female) (1) (2). or
2) Turn starting wiring harness between SC1 harness
switch ON. Ifemale) (7) - TMA (14) -
3) Disconnect SCl. b & JO3(15)-Zl (13)-El2
[female) (1) in contact with
ground
Defective engine speed Replace

switch OFF. NO Se”SOr
2) Disconnect El 2.
Between (1) and

Min. 1 MS-2
chassis I
SC I (MIC 13)
Engine speed sensor
TMA(SI6) JO9(Sl2) El2(X2)
@ 12
@ 0
F56103110
92-59
0
Call% Remedy
See G-8 b) (Speed sensor 8

system)
Repair or
Defective controller replace.
Does engine con-
troller also display Y
abnormality?
displayed? Already reset

I) Turn starting Hz-----
switch ON. 1) Delete abnormal
display memory.
between SC1 2) Turn starting switch OFF -ON, then start the
(female) (7) and (13) engine.
3) Wait for 20 seconds.
1) 5oD- 10000
2) Turn starting
switch ON.
drsconnection in wiring Repair wiring
3) Disconnect SCl.
harness between SC1 harness or
(femsle)(7),(131 -TMA replace.
(14),(15) - JO9 (male)
(111.(12)
TMA(SI6)
Monitor panel
Engine controller
Speed sensor B
561 F03336
92-60
0
* Check that the mounting bolts of the intermediate shaft speed sensor are not loose.
CaUSe Remedy
1 YES
-
1
ESm I troubleshooting again
Y
travels, is ; ,> -
displayed?
1
IS reset -
between SC1 2) Turn starting switch OFFdON.
(female) (6) - (12). 3) Start engine and travel.
and between (6) -
Is resistance value disconnection in wiring replace wiring
1) Disconnect SC1 between N2 (male) harness between N2 harness
(I)-(2Lsnd lfemale)(l)lZ) -TM2 (3K4)
rJO between(l)- - SC1 (female)l6)(12)
chassis as shown in
Table l? Defective intermediate shaft Replace
speedsensor
1) Disconnect N2.
Table 1
pi
SC I LMIC 13) Transmission input shaft
Intermediate TM2 (SWPl4) N (X21 speed sensor
F56103111
92-61
0
Disconnection in travel speed sensor (tiansmission output shaft speed sensor)
displayed
jr Before c&rying out troubleshooting, check that all the related connectors are properly inserted.
CalSe Remedy
2 YES
Replace
When machine
YES
travels, is ; 2
f-l II
1NO
1I
1 displayed? ]
IS reset
Is resistance value 1) Delete abnormal display memory.
between SC1 2) Turn startmg switch OFF - ON.
(female) (3) - (10). - 3) Start engine and travel.
and between (3) -
Table 1 ? I 1r disconnection in wiring replace wiring
Is resistance value
1) Turn starting between N3 (male) harness between N3 (female) harness
switch OFF. L (1) - (2). and (1). (2) - TM2 (5). (6) - SC1
NO between (1) - chas- (female) (3). (10)
2) Disconnet SC1
sis as shown
in Table l? Defective travel speed sensor R&3X?
- NO
1) Disconnect N3.
- Between (1) and

Min. 1 MC2
chassis
Monitor panel
TMA(SI6) PO8(04016)
0
SCI (MICl31 Transmission output shaft
speed sensor
TM2(SWPl41 N3(X2)
Transmission
output C-4 IO @
Transmission O-0
output (i-j
I I J
F56103112
92-62
0
A-7 Speed sensor system, clutch slipping
r
P
Remedy
YES
See H-6, c).
1 I (Oil pressure of H.L. clutch)
*If the 011pressure is normal.
Is resistance value
return to Item 1 and start
between SC1
(female) (5) - (11). -
and between (5) - Defectwe contact, or Repair or
chassis as shown in Is resistance value disconnection in wiring replace wiring
Table l? between Nl (male) harness between SC1 harness
1) Turn starting - (1)- P).and (female) (5) (11) -TM2 (1) (2)
switch OFF. NO between (1) and - Nl (female) (1 l(2)
2) Disconnect SCl. chassis as shown in
Defective transmission InPut Replace
Table l?
p NO shaft speed Sensor
1) Turn starilng
switch OFF
2) Disconnect Nl
Table 1
SCI (MICl3) Transmission input shaft

TM2(SWPl4) sensor speed
NI (X2)
F56103113
92-63
0
Travel speed sensor or speed clutch (1.2.3,4.R) system displayed
CZalKSe Remedy
See H-6, c).

(,O;pysy; of speed clutch
YES , , , -
*If the o;l pressure is normal.
1 I return to Item 1 and start
between SC1 Disconnection in wirina

(female) (3) - (10). n harness between N3 -
YlES (female)(lK?) -TM2 (W(6) Repair or
and between (3) -
chassis as shown in Is n?SiStance value - SCl(femalel~3l(l0~, or replace wiring
Table l? between N3 (male) contact with ground, or harness
-
(1) 12). and wiring harness between TM2
1) Turn starting NC between (1) and (female)(5) - TMA(1) - SU3
switch OFF. chassis as shown in (2) -SW (female)(l), or
21 Disconnect SCl. between TMA imale) -
PO8 (female)(l) in contact
1) Turn starting with ground
switch OFF.
i Difective travel speed sensor Replace
2) Disconnect N3. ..^
NV
Table 1
Resistance
value
Transmission output shaft

sensor #speed
F56103114
92-64
0
Abnormality in model selection displayed
When controller power source is normal.

C.3US.e Remedy
1 YES
Defectwe transmission Replace
controller
YES as when measuring
L_
Isvoltage between
Is reset
SC1 (2) - (13). (1)
- (13), and (8) -
(13) as shown in
Table 1 ?
1) Turn starting
switch ON.
Note:
Connect pin (13)
(female) (2) and SC3 (female)
to the ground
(4) - TM3 (12) - chassis
connection inside
., ground
Table 1
SC1 1 Voltage
(2)-- (13) / Max.lV
SCI (MICl3)
SC3(MIC17) TM3(SWPl4)
F56103115
92-65
0
A-9 Abnormality in transmission shift lever system
Short circuit in transmission shift lever assembly power source displayed
j, When controller power source is normal.

CaUSe Remedy’
2 YES
ReplaCe
Return cOnnectOr to
YES original position. Is
c, 7 displayed? ] 1NO
IS reset
-
I) Delete abnormal display memory.
2) Turn starting switch OFF-ON.
Defective transmission shift ReplSX

1) Min. 1Mfl lever ass’y
2) Turn starting
switch OFF.
3) Disconnect SC~. NO

(female) (6) - TM8 (1) - SF replace wiring
(female) (1) in contact wth harness
1) Min 1Mn
2) Turn starting switch OFF. ground
31 Disconnect SF.
SC3 IMICI71
w--l
Transmission
shift lever
F56103116
92-66
0
Transmission shift lever position signal displays 2-system abnormal input.
Remedy
2 YES
Return connector to
YES original position.
Does display
disappear with
I
IS reset
1) Delete abnormal
NO
1 display memory
2) carry O”t
Are all monitor operation in Item
1. YES
panel displays Defective transmission shift Replace
normal? lever ass’y
i
*Procedure for
operation If display on panel
1) Turn starting does not disappear, Abnormal system (D,5,4, 3, L) Wiring harness for position Repair or
switch ON. shown in Table in contact replace wirmg
g 2) Set lever to N measurement with ground harness
X position.
3) Is lever position disconnect SF. Does
display on
monitor panel Defective transmission Replace
Keep same
only N? meas”reme”t neutral relay (internal short
*The operation is circuit)
(If position other conditions as in
the same as Item Abnormal system (N)
than N lights up. Item 3, and remove
that position neutral relay. does Wirino harness between R02
indicates the NC display disappear?
”
(female) - transmission Repair or

failed system.)
neutral relav - SF (female1 (41 replace wiring
4) Set lever to D
1) Turn starting - TM6 (3) i SC2 (iemale)(i) harness
position.
switch ON. in contact with ground
5) Is lever position fi * See Table.
display on
monitor panel Keep same Defective back-up alarm relay
only D? meas”reme”t
(If position other conditions as in
than D lights up, I- Abnormal system (R) - Item 3, and remove Defective wiring
that position back-up alarm harness or
indicates the relay. Does display connec.tor
failed system.) disappear? Wiring harness between SF between lever
6) If no failure is (female) (3) - R05 (2). or assembly SF-(3)
indicated by between SF (female) (3) - - tra”SmlSslOn
1) Turn starting
above procedure, TMB (2) - SC2 (female) (1) in Controller scz-
switch ON.
all systems are contact with ground (1) - monitor
normal. panel PO%(9) -
*For details of the back-up alarm
abnormal position r&v (Short
and the related circ;i; wtth
wiring harness, GND wire or
see Table 1. chassis)
Table A-10-3
92-67
0
,
4 SF-(7)--SC2-(3)-
PO8(13)
Transmission contrdler
SC3 lMICl71
TM8 IS121
Transmission
ft lever
ransmission neutral
relay
R02
I
I D /II
Back-up alarm relay
R05
F56103117A-K
92-68
0
Shift lever position signal displays two or more systems.
* Always cbnnect any disconnected connectors before going on to the next step.
2 YES
When connector is
returned to original
Yl
_ position, does dis-
INO
play disappear with
1) Deleteabnormal
display memory
21 Carrv O”t poem-
tion /n Item’ 1.
*Order of operation
1) Turn starting
switch ON. - Abnormal system (D, 5.4, 3, L)
iT
2) Place lever at N 3
position.
3) Check if lever If panel display does
position display not disappear in
on monitor panel Item 1, does display YES
indicates only N. go out if system is
If any position UO left in condition for
, 4
other than N Does display disap-
lights up, this pear when system
shows the failed - Abnormal system (N) - is left in measure-
8
system. ment condition for
*Same order of X
4) Place lever at D Item 3 and neutral
operation as Item 1.
position. relay is removed? Does display disap-
5) Check if lever pear when system
position display 1) Turn starting is left in measure-
&7 monitor panel swttch ON. NO ment condition for
indicates only D. Item 4 and payload
If any position relay is removed?
other than D t I
lights up, this 1) Turn starting
shows the failed switch ON.
system.
6) If this operation
does not show
any failure, all
systems are
normal.
*The relatronship between the position display-
ing the abnormality and the related wiring har-
ness is shown in Table 1.
I- . Abnormal system(R)
1
IDoes panel display
disappear when
sy*tem is left in
~$%%?&?$d
11 Turn starting
switch ON. NO
92-70
0
I Cause Remedy
-
Alreadv reset
Wiring harness in position Repair wiring

shown in table short circuit- harness or
ing with chassis ground replaCe
Defective transmission neu-

tral relay(internal short R&%X
circuit)
Defective payload relay (Inter- Replace

nal short circuit)
Wlrina harness between

trans&sion neutral relay
R02 (female) (2) - SF
[female) (4) - TMB (3) - SC2 Repair wiring
(female) (2). or between pay- harness or
load relay Roll (female) (2) - replace
PO8 (female) (10) - MM7 (5)
- MM2 (female) (2) short cir-
* See Table 1.
Replace
Wiring harness between SF

(female) (3) and backup alarm
relay R05 (female) (2). or Repair wiring
between SF (female) (3) - harness or
TMB (2) - SC2 (female1 (1) replaCe
short circuiting with chassis
ground
92-71
0
Table 1
I Place lighting up
on monitor panel
ystem for wiring harness
at failure location
SF-~4)-SC’2-(2)-PO8-~10)
I
N -MM2-(2kTransmission
neutral relay-Payload relay
R SF-(3)-SC2-(l)-Back-
alarm relay-P08(9)
y4)l~sc2-(12)-
D
SF-(6)-SC2-(13)-
5
PO8(12)
SF-(9)-SC2-(14)--
L
PO8(15)
SC3(MIC17)
-1 TMS(S12)
Transmission
neutral relay
Backup alarm relay
Payload relay
TKH00035
92-72
0
Transmission shift lever position signal is not input
A Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
See A-9, a)
1 Re-enact test 3 YES

Defective controller ReDlace
YE
FHH..
Is reset
2) Turn starting switch OFF - ON.
3) Operate transmission shift lever in
order shown in Table 1.
1) Turn starting 4 YES
I
switch ON. replace wiring
Is voltage between disconnection in wiring
2) Operate lever N - harness
each position of SF harness between problem
R-D-5-4-
and (2) as shown in SC2 (female) and SF (female)
_IINO
3- Land check h
signal input. Table l?
See Table 1 to Defective transmission shift Replace
1) Turn starting lever ass’y
switch ON.
2) set lever to
position where
failure occurred.
and measure
+24V wwer
sourciand
signal from
position of
failure. See Table
1 to judge.
Table 1
Terminal of oltage when

TORQFLOW trans- position is
mission controller selected
SC3 (MIC17)
Transmission
shift lever
F56103116
92-73
0
Abnormality in accelerator signal displayed
For engines with

mechanical governor Y
2
Is voltage between - - Voltage does not change.
SC1 (4) and (2) as
‘ES
- shown in Fig.1
when accelerator 1
pedal is operated?
YES
1) Turn starting
switch ON.
2) operate
4
accelerator
pedal. Does voltage
I Y
between SRl (2)
and (3) change
according to angle
as in Fig. l? 5
1) Turn starting
siwtch ON. Is resistance value
2) operate a between SRl (male) -
Isvoltage between accelerator NO (1) and (3) normal?
SC3 (8) and SC1 (2) pedal.
I I
normal?
1) 4.6 - 5.4 kQ
2) Turn starting
1) 4.6 - 5.4v 1) 4.6 - 5.4V switch OFF.
2) Turn starting 2) Turn starting 3) Disconnect SRl.
switch ON. switch ON.
IO
I
Is resistance value
between SC3
(female) (8) - SC1
i* (female) (2). and
NO between SC3 8 YES
(female) (8) -
Is resistance value
chassis as shown in
between SF?1 (male)
Table l?
E II)-_(3).a”d(l)- -
1) Turn starting chassis as shown m
watch OFF. Table l?
21 Disconnect SC1
1) Turn starting NO
and SC3.
switch OFF.
2) Disconnect SRl. Table 1
Resistance
Connector
value
(v) .Accelerator signal Voltage (KQ) Sensor resistance value

I
I
I
,Low idling - Full Low idling +---w Full
Accelerator pedal position Accelerator pedal pktion
F56103119 Fig. 2 F56103120

Fig. 1
92-74
0
CaUSe Remedy

controller
Defective adjustment of Adjust

acc+?rator sensor
Xfective contact. or
jisconnection in wiring
wrness between SC1
;female)(4) -TMA(13I - Repair or
SRI ifemale)( or between replace wiring
SC1 (female)(2), SC3 hanress
(female)(4) - TM6 IS) -
SRl (female j(3)
6 YES
Does resistance [female) (8) - TMA (16) - replace wiring
YES
; between SRl (male) SRl (female)(l) m contact hanress
- (Z)and(3)change - with ground, or contact with
according to angle other wiring harness
as in Fig.Z? Accelerator sensor linkage correct or
- NO has come o”t, or defectwe replace
1) Turn startmg accelerator sensor
swtch OFF.
2) Disconnect SRI.
-I
I Defective aCc&.ratOr SenSOr Replace
NO

disconnection in wiring replace wring
(female) (8) - TMA (16) -
SRl (female) (lb

controller
W,rlng harness between SC3

(female)(8) -TMA (16) -
SRl (female)(l), or between
SC1 Ifemale)(ZLSC3 Repair or
(female)(l) -TMB (9) - replace wiring
SRl(female)(3) I” contact harness
with ground, or in contact
with other wiring harness
Iefective accelerator sensor Replace
SC3tMIC17) TMA(Sl6)
TMB(S12)
Sensor SIG
GND
I TKH00036
92-75
0.
CaUSe Remedy
See G-9 (Accelerator sensor

system)
!
Defective controller RC&SX
ES
1) Turn starting
switch ON. I---+ NO
Already reset
;~GJEr:::; 1
1) Delete abnormal
display memory.
F
/ 2) Turn starting
switch OFF - ON.
1) 0.6 - 4.75V
2) Turn starting Repair wiring
switch ON. harness or
NC between SC1 (female) (4) -
3) operate accek?r- replace
TMA (13) - SRl (female) (2)
ator pedal
slow -full.
Engine controller
E63(MIC21) ECA(S1 E9 Accelerator sensor
Accelerator
SC1 SC3(MIC17)
(MIC13)
Transmission
controller
92-76
0
3 YES
YES With item 1 normal,

is 1.9 displayed?
2 -
- Isreset
1) Delete abnormal NO
Isresistance value
display memory.
YES between SC3
(female)(d) and (13) - 2’ T”r” starti”g
switch OFF -
normal ?
ON. A .,_.. Defective contact. or
1) Turn sta harness between CVT replaCe
switch C female )(l)(2) -TM4 wiring
2) 1 - 500 w IEtween G” I (male, (13)(14) - SC3 (fmale)(l3) harness
Is transmission oil 3) Disconnect SC3. (I) and (2) normal? (4). or contact with ground
temperat”“? normal?
x
Defective transmission oil
t temperature sensor
2) Disconnect WT.
1) Check with moni-
tor panel display.
I
SC3(MIC17) TM4(SWP14)
Transmission oil
temperature
sensor
TKH00037
92-77
0
A-l 2 Abnormality in pressure control valve system
+j--J+~$J$J Fill signal displays ON regardless of command
* Bike carrying o~~troubleshooting, check that all the related connectors are properly inserted.
ir Always connect any disconnected connectors before going on to the next step.
YES
See H-6, C)
1 I *If the hydraulic pressure is
normal, return to Item 1 and
start troubleshooting again
?. YES
Wiring harness in problem Repair or
circuit in contact with ground replace
*See iable 1. wiring
harness
Defective fill swtch in problem Replace

2) When measuring *See Table 1. NO circuit
resistance. turn 1) The measurement *See Table 1.
starting switch conditions are the
OFF. - same as for Item
3) Disconnect con- 1.
nectcm to be
measured.
Connection of connector and fill switch Fill switch

Transmission
Abnormal Corresponding ,When connected When released
controller Monitor
display Clutch Fill switch
connector and panel
Voltage Resistance Voltage Resistance
pin number
I /
E. - 3.2 Hi clutch SC2-(20) - PO5-(1) - H.SW Max. IV Max. 152 15-25V Min. lMa
E. -3.3 Low clutch SC2-(11) - PO5-(2) - L.SW Max. IV Max. IS2 / 15-25V Min. 1Ma
E. - 3!-1 1 clutch sc2-(8) - PO5-(6) - 1. SW Max. IV Max. 152 15-25V Min. IMR
_. - 3.5 2 clutch SC2-(18) - PO5-(5) - 2.SW Max. IV Max. ‘Ia 15-25V Min. 1Ma
F
F_. -3.5 3 clutch sc2-(9) - PO5-(4) - 3. SW Max. IV Max. IR 15-25V Min. IMa
E. - 3.: 4 clutch sc2-(19) - PO5-(3) - 4.sw Max. IV Max. Is2 15-25V Min. IMR
F
_I
- 3.E R clutch sc2-(IO) - PO5-(7) - R.SW Max. IV Max. Ia 15-25V Min. IMa
92-78
0
Fill signal is not input and clutch slipping is displayed
* Measure the clutch oil pressure of the system where the abnormality is displayed. If the oil
pressure is normal, carry out the troubleshooting below.
b-l) Inspection of fill signal system
Remedy
See H-6, C)
(Clutch oil pressure)
Areresistance value
(female) and chassis,

and voltage between 2 YES Repair or
Defective SW (fill swtch)
*See Table 1. replace
Is voltagebetween
wiring
1) When measuring _ 0 SW (fill switch) _
harness
resistance, discon- F , (female) and
nect sc2. chassis normal?
*See Table 1. Defective winng harness in RE&W
*See Table 1. NO problem circuit
1) Same as Item 1. *See Table 1.
Connection of connector and fill switch Fill switch

Transmission
Abnormal Corresponding
controller Monitor When connected When released
display clutch Fill switch
connector and panel
pin number Voltage Resistance Voltage Resistance
X2-(20) - PO5-(1) - H.SW
92-79
0
8
X
TM4LSWPl41
F56103123
92-80
0
b-2) Transmission input shaft revolution signal system, check of Hi-Lo clutch system.
When pdg . k-$$ is displayed
b-3) Transmission output shaft revolution signal system, check of F, R clutch.
When pdqi - pdq is displayed
92-81
0
When fill. signal is not input (flow detector valve
Carry out diagnosis of A-12 b-l) Fill signal system.
Correspondences of indvzations are as follows.
_-
I_ 1 cc 1-i ,_I
_L_ ._
--
I- _l,,U 3
-I. _I I._1
I- I I III,
I
-_I. - - -1. -1
1:I-_-_ I l I--
1.1 I.1
I-- I-- - ‘-&

_l.l_l
1: -1 I I -1
_I. I- 7. I
I- l-l I I l-l
:l.l:l- - l.l_l
-
92-82
0
pressure control valve solenoid
11o Disconnection in pressure control valve solenoid

~$/-~$&tetn displayed
I CatJ*Z? Remedy
2 YES
Return ConnectOr to troubleshooting agam
YES original position. Is
- :o z:.o
1 displayed? -
IS reset
1) Delete abnormal NO
Is resistance value display memory.
of SC3 or SC4
(female) as shown in - ” Tur” staning
ytch OFF -
Table 1 and Table 2?
3 YES Defective contact. or disconnec Repair or
+r Measure pin no. tion in wiring harness between replace wiring
Is resistanceP$e
where abnormal problem SC3 or SC4 - TM3 or harness
between
display is given. Ng L/C.T. (ma 4 e) (1) - TM4 - 0 PS or L/C.T.
1) Turn starting and (2) as shown 8” (female)
switch OFF. 1
Table and Table Z?
Defective solenoid in problem Replace
2) Disconnect SC3
1) Turn starting NO circuit problem
or sc4.
switch OFF. *See Table 1. solenoid
2) ;iynnect 0
Disconnect L/C.T.
Table 1
/ Display 11 Measured item ormal value
1 2PS (I). (2) / ‘i2p’aces)

Min. IMa
92-83
0
Table 2
Display Measured item Normal value
Between SC3 (1) Resistance

LCT (I), (2)
(2) and (11) betweeen 30 - 80R
pins
(2) Resistance
between pin
and chassis Min. 1MfJ
ground (2
places)
RPS
LPS
SC4 (MIC 14)
ECMV L(-_)
ECMV R(-)
4PS
ECMV 4(-)
ECMV 3(-_)
ECMV 2(-)
ECMV 1(-)
ECMV L(+)
ECMV R(+)
ECMV 4(f)
ECMV 3(f)
ECMV 2(f)
ECMV I(+)
F56103124
92-84
0
TROUBLESHOOTING OF MONITOR
PANEL SYSTEM
P-l Monitor panel does not work at all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92- 87

a) Speedometer display does not work .................................... 92- 88
b) Speedometer display works, but other parts do not work .................... 92- 88
c) Suspension display does not work ..................................... 92- 88
d) (Mechatronics) caution, fuel gauge displays do not work .................... 92- 89
P-3 Automatic shift display (mechatronics) flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92- 90
P-4 Suspension (mechatronics) display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92- 90

a) Hard display does not light up ......................................... g2- 91
b) Medium display does not light up ...................................... g2- 91
c) Soft display does not light up ......................................... g2- 92
d) Suspension mode displays all light up ....... :. ......................... g2- g2

a) R display does not light up ............................................ g2- g3
b) N displaydoes not light up ........................................... g2- g3
c) D display does not light up ........................................... g2- g4
d) 5 display does not light up ............................................ g2- g4
e) 4 display does not light up ............................................ g2- 95
f) 3 display does not light up ............................................ g2- g5
g) L display does not light up ............................................ g2- 96
P-7 Shift limiter display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g2- g7
P-8 Lock-up display does not light up ......................................... 92- 97
P-9 Hi beam display does not light up ......................................... 92- 98
P-IO Abnormality in turn signal

a) Right turn signal lamp does not light up ................................. 9% gg
b) Left turn signal lamp does not light up .................................. 9% gg

a) When 1,2,4,6, R is displayed, display changes to E ....................... g2-100
b) When 3,5,7 is displayed, display changes to E ........................... g2-100
c) When 1 is displayed, display changes to E ............................... g2-101
d) When 2,3 is displayed, display changes to E ............................. g2-101
e) When 4,5 is displayed, display changes to E ............................. 92-102
f) When 6,7 is displayed, display changes to E ............................. 92-102
g) When R is displayed, display changes to E ............................... 92-103
92-85
0
P-l 2 Speedometer display does not work normally . . . . . ._. . . . . . . . . . . . . . . . . . . . . . . . . 92-104
P-13 Tachometer display does not work normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-104
P-14 Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-105
P-15 Odometer does not work . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-165

a) Caution display is flashing (lighted up), but alarm buzzer does not sound . . . . . . . 92-106
b) Alarm buzzer continues to sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-196

a) Caution display is flashing (lighted up), but warning lamp does not flash . . . . . . . 92-107
b) Warning lamp stays ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-167
P-l 8 Caution display does not flash (does not light up), but warning lamp flashes and
alarm buzzer sounds.
a) Warning lamp flashes and alarm buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . 92-108
b) Warning lamp flashes when engine stops
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-108
c) Warning lamp flashes when engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-108
P-l 9 Abnormality in pressure gauge

b) Display shows highest level and does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-109

a) No display given in display area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-I 10
b) Display shows lowest level and does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-I 10

b) Display shows lowest level and does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-l 11

b) Display shows lowest level and does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-I 12

b) Display shows FULL and does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-I 13
P-24 Abnormality in night lighting

a) None of panel lamps light up .......................................... 92-114
b) Service meter and odometer light up, but other parts do not light up ........... g2-115
c) Service meter and odometer do not light up .............................. g2-115
P-25 Engine (mechatronics) display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-116

a) High power display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-117
b) Economy display does not light up . . . . . . . . . . . . . . . . . . . . . . . , . . . , . . . . . . . . . 92-117
Related electrical circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g2_116
92-86
0
P-l Monitor panel does not work at all
Defective module (7831.31- R&S32

1 I

harness between PO9 clean or replace
(female)(l) - STZ(41. or
between 8T2 (3) - JO7
1) Turn starting
switch OFF.
2) Disconnect POS. L
NO disconnection in wiring inspection,
harness between PO9 clean or replace
lfemaleK2) - JO3 (8l- 30(9)
-earth
92-87
0
a) Speedometer display does not work.
Cause Remedy
2 YES
Defective module (7831.31-
YES Is voltage
between
c PO4(l)and(8)
normal?

lI14-zov NO disconnection in wiring inspection,
Is voltage between 2\ Turn starting harness between Pll (fel clean or replace
Pl 1 (1) and (8) l-l switch ON. (1). (8) and PO4 (female) (
*I
(8)

b) Speedometer display works, but other parts do not Iwork.
Defective module (7631-31- Replica
c) Suspension display does not work.

1 YES
Defective module (7831-31- RepbX.5
Is there continuty 7100) of monitor panel

between each pin
as shown in table
below?
1) Turn starting NO dtsconnection in wiring inspection,
switch OFF. harness in table below clean or replace
2) Disconnect Pl 1.
1 Pll (female) (1) - PO2 (female) (1)
1 Pll (female) (3) - PO2 (female) (3)
I Pll (female) (4) - PO2 (female) (4)
1 PI 1 (female) (8) - PO2 (female) (8)
92-88
0
d) (Mechatronics) caution, fuel gauge displays do not work.
Remedy
2 YES Defective module (7831.31. ReplaCe

Is there continuity
Y between PO2
(female) (2) and PO4
(female) (4)?
1 1) Turn starting disconnection in wiring inspection,
switch OFF. harness between PO2 (female1 clean or replace
2) Connect socket (2) and PO4 (female) (4)
adapter to PO4
(female).
3) Disconnect P02.
1) Turn starting
switch OFF.
2) Connect socket
adapter to PO4 Defective contact, or After
(female) disconnection in wiring inspection,
3) Disconnect Pl 1 harness in table below clean or replace
1 PI 1 (female) (4) - PO4 (female) (5) I

1 PI 1 (female) (5) - PO4 (female) (6) 1
I PI 1 (female) (7) - PO4 (female) (7) I
92-89
0
P-3 Automatic shift display (mechatronics).flashes
* Before carrying out troubleshooting, check that all the related connectors are properly inserted,
Remedy
YES
Defective module (7831.31- 3eplXX
Is voltage between
30ntro1ler
l)O-3v _ SC3 (femaleKl6) and
2) Turn starting ND chassis ground
switch ON. normal 7
1) 12-2ov NO jisconnection in wiring inspection,
2) Turn starting wrness between P12 clean or replace
switch ON. :femalei (2) -TMC (11) -
3) Disconnect SC3. SC3 (femaleHl6)
P-4 Suspension (mechatronics) display flashes
+ Before carrying out troubleshooting, check that all the

Sr Always connect any disconnected connectors before
going on to the next step.
YES
1 - 6100) of monitor panel
Is voltage between
~ See Troubleshootmg of
~ Is voltage between
l)O-3v _ SUl (female)(4) _
switch ON. normal?
1) 12--2ov NO disconnection in wiring rnspection.
switch ON. (3) - SU3 (9) - SUl (female)
3) Disconnect SUl. (41
92-90
0
a) Hard display does not light up.
Remedy
YES tepkxe
kfective module (7831~31-
1 j1CQ) of monitor panel
ISvoltage between
jee Troubleshooting Of
uspension controller
1) o-3v _ SUl (female) (18) _
2) Turn starting ~0 and chassis ground
switch ON. normal?
kfective contact, or wter
1) 12-2ov NO iisconnection in wiring nspection.
2) Turn starting ~rness between P12 (female) :1ean or replace
switch ON. 7) - su3 (12) - SUl
3) Disconnect SUl. female) (18)
b) Medium display does not light up.

YES
Is voltage between
. Is voltage between
l)O-3v _ SUl (fernale) _
switch ON. normal?
1) 12-2ov NO disconnection I” wiring inspection,
2) Turn startmg harness between PI2 (female) clean or replacl
switch ON. (8)-SU3(13)-SU1
3) Disconnect SUl. (female) (19)
92-91
0
c) Soft display does not light up.
ChUSEZ Remedy
Defective module (7831-31 ReplaCe


3) Disconnect SJl. (female) (20)
d) Suspension mode displays all light up.
See S-l 0 Trobleshooting of

92-92
0
a) R display does not light up.
YES
Defective module (7831-31 Replace
Is voltage between
PO8 (9) and chassis -
Is voltage between harness between PO8 (female) clean or replace
l)O-1v
- SF(3)andchassis - (9) and SF (female) (31
2) Turn starting
NO ground Norman?
switch ON.
IWU
b) N display does not light up.
YES
Replace
1r I Defective module (7831-31.
Defetive contact, or After

harness between PO8 (female1 clean or reDlace
(10) end SF (female) (4)

2j Turn starting harness between SF (male) (4) clean or replace
lever
92-93
0
c) D display does not light up.
CalIS=? Remedy
YES
1 Defective module (7831.31- RL?plXZ
I
Isvoltage between
POB(ll)a”d
chassis around l-l 2 YES
Defective ContaCt. Or After
inspectlo”.
clean or replace
After
inspection,
clean or replace
_._..___
1 o;‘defective transmission shift 1 I
d) 5 display does not light up.
YES
Defective module (7831-31. ReplXe
1r 5100) of monitor panel

disconnection in wiring Inspection.
(12) and SF (female) (6)
Defective contact, or AftW

Turn starting harness between SF (male) (6) clean or replace
switch ON. ~ and transmission shift lever.
IWU
92-94
0
e) 4 display does not light up.
YES
,
Is voltage between
PO8 (13) and
. Defective contact, or After
normal?
c 2
Is voltage between harness between PO8 (female) clean or rePlace
l)O-1v
2) Turn starting ND ground normal?
switch ON.
f) 3 display does not light up.
1 I
YES
1 Defective module (7831.31-
ReDlace
Is voltage between
POS(14)and
f Defective contact, or After
normal?
disconnection in wirmg inspection,
- Is voltage between harness between PO8 (female) clean or reDlace
l)O-1v
2) Turn starting NO ground
norma,?
switch ON.
1)4-3ov NO disconnection m wiring inspection,
2) Turn starting harness between SF (male1 (8) clean or replace
lever
92-95
0
g) L display does not light up.
CZlllSe Remedy
YES
Defective module (7831.31- RePlXe
IS voltagebetween
PO8 (15) and
normal?
disconnection in Wiring inspection,
Is voltage between harness between PO8 (female) clean or replace
l)O-1v
- SF(S)andchassis - (15) and SF (female) (9)
2) Turn starting
ND ground normal?
switch ON.
lever
8
X
z?
0
92-96
0
P-7 Shift limiter display does not light up
CaUSe Remedy
r
YES
between PO8
(female) (16) and
YES
2 I disconnection in wiring inspection,
switch ON. (16) - CNS (5) - SH (female)
Is there continuity
2) Disconnect P08. (4). or between SH (female) (2)
between SH (male)
P (4) and (2)? and chassis ground
1) Turn starting
switch OFF. Defective shift limit switch
2) Disconnect SH
P-8 Lock-up display does not light up
* Before carrying out troubleshooting, check that all the

* Always connect any disconnected connectors before YEI
disconnection in wiring After
going on to the next step. 4 harness between R24 inspection,
(female) (1) - TMC (4) - SC3 clean or replace
Is there continuity (female) (2). or defective lock-
Yl between R24 up relay. or see
(female) (2) and Troubleshooting of shift
chassis ground? CO”trOller
B
L-J
1) Remove lock-up
Is there continuity relay.
YES disconnection in wirina inspection,
between R24 2) Turn starting
harness between R24 - clean or replace
(female) (5) and switch OFF.
(femaleK2) - JO6 - earth
chassis ground? 3) Disconnect R24.
9
1) Remove lock-up
relay.
Is voltage between 2) Turn starting
R24 (female) (3) and switch OFF. Defective contact. or After
chassis ground 0 disconnection in wiring inspection,
3) Disconnect R24.
harness between R24 clean or replace
(female)(51 -TMBW - SC3
1)4-5v (4). or see Troubleshooting
of shift controller
2) Turn starting
[ ~z%Tup? 4) Remove lock-up ND

After
inspection,
r&v. harness between PO5 clean or replace
$“I&) (8) and R24 (female)
1) Connect PO5
(male) (8) to
chassis ground.
2) Turn starting
switch ON. : Defective module (7831-31-
NI3 5100) of monitor panel
92-97
0
P-9 Hi beam display does not light up
CaWS Remedy
kfective module (7831-31. Replace

ilOO) of monitor panel
YES
Is voltage
between kfective contact. or After
PO8 (6) and chassis iisconnection in wiring inspection,
wwzs between PO8 (female) clean or replace
6) and R06 (female) (5)
2) Turn starting
switch ON. Does Hi beam of left
YES
ToA
r
1) Turn Hi beam 3
switch ON.
2) Turn starting Isvoltage between
switch ON. - R06 (female) (3) and -
NO female normal?
4 YES
Iefective contact, or After
1)20-30V jisconnection in wiring inspection,
Is voltage between
2) Turn starting wrness between PO6 (female) clean or replace
CM (male) (2) and
switch ON. 3) and CM (female) (2)
chassis ground
3) Remove head No
normal?
lamp (Hi) relay.
4) Disconnect R06. Defective contact. or After
1)20-30V NO disconnection in wiring inspection.
2) Turn starting harness between CM (male) clean or replace
switch ON. - [2) and combination switch, or
3) Disconnect CM defective combination switch
2 YES Defective head lamp (Hi) relay. After

t
Is there continuity or defective contact. or inspection.
YES between R06 disconnection in wiring clean or replace
- (female)(2) and - harness between PO8 (female)
chassis ground? (6) and R06 (female) (5)
1 Defective contact. or After
1) Remove head NO disconnection in Wiring Inspection.
Is voltage between lamp (Hi) relay. clean or replace
From A - R06 (female) (1) and - 2) Turn starting (2) and chassis ground
chassis ground switch OFF.
normal? 3) Disconnect R06. 3 YES
1) 20-30V disconnection in wiring inspection,
Is voltage between
CM (male) (6) and
switch ON. chassis ground (1) and CM (female) (61
NO
3) Remove head normal?
lamp (Hi) relay.
4) Disconnect R06. NO
1) 20-30V disconnection in wiring inspection,
2) Turn starting harness between CM (female) clean or replace
switch ON. (6) and combination watch, or
3) Disconnect CM defective combination switch
92-98
0
a) Right turn signal lamp does not light up.
Remedy
2 YES
IIefective module (7831.31- Replace
between PO8
Yl
(female) (8) and -
chassis ground
1 normal?
1) Max 5n NO disconnection in wiring inspection.
Do front and rear 2) Turn starting harness between PO8 (female) clean or replace
turn signal lamps switch OFF. (8) and JO3 (male) (5)
work normally? 31 Disconnect P08.
El
1) operate t”r”
signal.
2) Turn starting See Troubleshooting of turn
switch ON. signal
b) Left turn signal lamp does not light up.
2 YES
Defective module (7831-31
ISresistance value 5100) of monitor panel
YE3 between PO8
- (female)(7) and -
chassis ground
1 normal?
Defective contact. Or After
1) Max. 5n NO disconnect in wiring harness inspection,
Do front and rear 2) Turn starting between PO8 (female1 (7) and clean or replace
turn signal lamps - switch OFF. JO3 (male) (3)
work normally? 3) Drsconnect P08.
&ii-FJ NO
See Troubleshooting of turn
switch ON. signal
92-99
0
a) When 1, 2, 4, 6, R is displayed, display changes to E.
CalAX Remedy
2 YES
shown in table
1 below?
?nYES
disconnection in wirina inspection,
harness between PO5 ifemale) clean or replace
(2) - TMA (8) - TM3
NO
(female) (6)
Shift controller abnormal disolav I I I Defective module (7831-31 Replace

1)Contact
PO5 NO 5100) of monitor panel
(male) (2) and (61
with chassis
ground.
2) Turn starting
switch ON.
3) Disconnect P05.
b) When 3, 5, 7 is displayed, display changes to E.

cO”trOller
1) Turn starting NC
Does automatic
switch ON.
shift display
lmechatronicsl
3 YES
FH--
Iefectlve contact, or After
1) Turn starting vJisconnection in wiring inspection.
switch ON. 1 harness between PO5 (female) clean or replace
:l) - TMA (9) - TM3
NO
:female) (3)
Shift controller abnormal display Defective module (7631-31. Replace

1) contact PO5 NO
0 I / , 5100) of monitor panel
3.2 4.2 5.2 9.2 (male) (1) and (5)
with chassis
ground.
3.3 4.3 5.3 9.3 2) Turn starting
switch ON.
3.4 4.4 5.4 9.4 3) Disconnect PO5
3.5 4.5 5.5 9.5
3.6 4.6 5.6 9.6
3.7 4.7 5.7 9.7

I I I
3.8 4.8 5.8 9.8
92-100
0
c) When 1 is displayed, display changes to E.
CalEE Remedy
2 ‘ES
L-t
; Is shift controller cO”trOller
YEE abnormal display as
shown in table
below?
1) Turn starting NC
switch ON.
(mechatronics)
3 YES
Defective contact, or discon- After
switch ON. Does shift indicator clean or replace
I display become
TMA (4) - TM4 (male) (3)
“1 “?

Shift controller abnormal display 1) Connect PO5 NO 5100) of monitor panel
(male) (2) and (6)
3.2 4.2 5.2 9.2 to chassis
ground.
3.3 4.3 5.3 9.3 2) Turn starting
switch ON.
4.4 3) Disconnect PD5.
3.4 5.4 9.4
3.5 4.5 5.5 9.5
3.6 4.6 5.6 9.6
3.7 4.7 5.7 9.7
3.8 4.8 5.8 9.8
d) When 2, 3 is displayed, display changes to E.

Is shift controller CO”trOller
r
show” in table
1 1 below?
1) Turn starting NO
Does automatic
switch ON.
shift display
(mechatronics) -
flash?
3 YES Defectwe contact, or discon- AftH
Does shift indicator between PO5 (female) (5) -
switch ON. TMA (5) - TM5 (male) (6) clean or replace
t display become -
NO “2°F

Shift controller abnormal display 5100) of monitor panel
mi k!Jy-
3.8 4.8 5.8 9.8
92-101
0
e) When 4, 5 is displayed, display changes to E. I
Cause
I
, 2, YES
I
controller
Is shift controller
YES. abnormal display as _
;lmww; in table
1
Does automatic
1) Turn starting
switch ON.
NO
shift display
(mechatronics) -
flash?
3 YES Defective contact, or discon- After
swttch ON. Does shift indicator clean or replace
TMA (6) - TM4 (male) (9)
r display become
NO “4”?
;hift controller abnormal display Defective module (7831-31- Replace

1 I connect
PO5 NO 5100) of monitor panel
3.5 4.5 5.5 9.5
3.6 4.6 5.6 9.6
3.7 4.7 5.7 9.7
3.8 4.8 5.8 9.8
f) When 6, 7 is displayed, display changes to E.
2 YES
c shown in table
below?
1
1) Turn startmg NO
Does atitomatic
switch ON.
shift display
(mechatronics)
flash?
3 YES
Defective contact. or discon- After
1) Turn starting nection in wring harness inspection,
switch ON. , Does shift indicator between PO5 (female) (3) - clean or replace
display become - TMA (7) - TM4 (male) (12)
NO “6”?

1) connect PO5 NO 5100) of monitor panel
(male) (2) and (3)
to chassis
Shift controller abnormal display ground.
2) Turn starting
switch ON.
3) Disconnect P05.
92-102
0
g) When R is displayed, display changes to E.
Cause Remedy

YES Is shift controller controller
abnormal display as
shown in table
below?
1
1) Turn starting NO
Does automatic
switch ON.
shift display
(mechatronics)
flash?
3 YES
1) Turn starting disconnection in wiring inspection,
switch ON. Does shift indicator harness between PO5 (female) clean or replace
‘. display become - (7) - TMA (3) - TM3
NO “R”? (female) (9)
I I I
1) Connect PO5 NO 5100) of monitor panel
(male) (2) and (7)
to chassis
ground.
2) Turn starring
Shift controller abnormal display switch ON.
3) Disconnect PO5.
1 3.2 / 4.2 1 5.2 1 9.2 1
92-103
0
P-l 2 Speedometer display does not work normally
Cause Remedy
Defective module (7831-31 3eplSX

L
Is resistance value
YES between PO8
- (female) (1) and (2) -
normal?
1 -
. 1) 5OOn-1 kfI
2) Turn starting Defective contact, or 4her
Is resistance value NO disconnection in wiring nspection,
switch OFF.
between N3 (male) _ harness between PO8 (female) :tean or replace
3) Disconnect P08.
(1) and (2) normal? (1). (2) - TMA (1). (2) - TM2
(5). (6) - N3 (female) (1). (2)
I
1)50021-l kfI
2) Turn starting
switch OFF.
3) Disconnect N3. NO Defective speed sensor Replace
P-l 3 Tachometer display does not work

normally
Before carrying out troubleshooting, checkthat all the related

Always connect any disconnected connectors before going
3 YES
Defective module (7831-31. Seplace
Is proximity 5100) of monitor panel
YES distance setting of
engine speed
sensor normal?
Defective mounting of engine Adjust
2 1) 0.5 - 1.75 mm NO speedsensor
Loosen the locknut
Is resistance value of engine speed
sensor, and turn
YES between PO8 the sensor clock-
- (female) (3) and (4) wise. If it contacts
normal? the gear within
1+1/6 turns, it is
l------------J --I within 1.75 mm. 1
- 1)5000-1 kR
2) Turn starting
Is resistance value switch OFF. Defective contact, or
between El 2 (male) - 3) Disconnect P08. _ disconnection in wiring After
(1) and (2) normal? NO inspection.
harness between PO8
(femaleH3).(4) - JO9(111.(12) clean or replace
_ E7 14),(5) - El2 (female!
1)5OOl7-1 krl
2) Turn starting 111.12)
switch OFF.
Defective engine speed
3) Disconnect El 2. NO
sensor 8
92-104
0
P-l 4 Service meter does not work
YES
Defective service meter Replace
‘) I

- PO1 (female) (1) and -
(4) normal?
3 YES
disconnection I” wiring inspection,
II * Is there continuity
harness between PO1 clean or reDlace
L-
I- - 1)20-30V _ between PO1
2) Start engine. (female)(l) - BT2 INo. 2) -
IS voltage between NO (female) (4) and
3) Disconnect PO1 JO7
alternator terminal chassis ground?
R and chassis Defective contact, or After
ground normal? 1)Turn starting NO disconnection in wiring inspection.
switch OFF. harness between PO1 (female) clean or replace
1) zo-3ov 2) Disconnect PO1 (4) and chassis ground
2) Start engine.
Defective alternator Replace

N”
P-l 5 Odometer does not work

2 YES
Defective odometer module Replace
(7831-31-9100)
Is voltage between
- P13 (female) (1). (3) -
- (2) normal?
Defectivev contact, or discon- After

1) Between (1) and ND nection in wiring harness inspection,
Is voltage between (2): 7 - 9v between PO4 (female) (2). (3). (8) clean or replace
PO4 (2). (3) - (8) Between (3) and and P13 (female) (1 I, (3). (2)
(2): 4 - 6V
2) Turn starting
switch ON.
1) Between (2) and 3) Disconnect P13.
(8): 7 - 9V
Between (3) and Defective module (7831.31. Fk?DlaCe
(8): 4 - 6V
2) Turn starting
switch ON.
92-105
0
* Before carrying out troubleshooting, check that $1 the related connectors are properly inserted.
a) Caution display is flashing (lighted up), but alarm buzzer does not sound.
CallSe Remedy
YES
Defective module (7831.31- leplace
1
Does buzzer sound? - YES

Defective contact, or vter
2 disconnection in wiring nspection,
harness between PO9 (female) :1ean or replace
(12) and BZ (female) (2)
1) Connect
PO9
(female) (12) to - Does buzzer sound? -
chassis ground. NO 3 YES
Defective buzzer ?eplSX
2) Turn starting
switch ON. - Is voltage between
3) Disconnect PO9. 1) connect BZ (2, to BZ (female) (1) and
chassis ground. N~ chassis ground
2) Turn starting normal?
switch ON. Defective contact. or wter
1)20-30V NO disconnection in wiring Inspection,

2) Turn starting harness between BZ (female) :l.%n or replace
switch ON. (1, and +24V
3) Disconnect BZ.
b) Alarm buzzer continues to sound
2 YES
Is there continuity with wiring harness between inspection,
YES between BZ PO9 (female) (12) and BZ repair or
(female) (2) and - (female) (2) replace
1 chassis ground?
1)Remove PO9. NO with wjring harness between inspection,
2) Turn starting 8Z (male) (2) and buzzer repair or
Does buzzer sound? switch OFF. replace
3) Disconnect BZ.
Defective module (7831-31. ReplaCe

92-106
0
a) Caution display is flashing (lighted up), but warning lamp does not flash.
Remedy
Defective module (7831-31

Doeslamp light up7 YES

After
2 disconnection in wiring inspection,
f harness between PO9 (female) clean or replace
1) Connect PO9 (11) and WL (female) (2)
(female) (11)to Does lamp light up? -
chassis ground. F 3 YES
Defective warning lamp
2) Turn starting
switch ON. 1 Is voltage between
3) Disconnect PO9. 1) Connect WL (2) _ WL (female) (1) and _
to chassis NO chassis ground
ground. normal?
2) Turn starting Defective contact. or After
switch ON. 1)20-30V NO disconnection in wiring inspection.
2) Turn starting harness between WI (female) clean or replace
3) Disconnect WL.
b) Warning lamp stays ON
2 YES Contact of chassis ground After

Is there continuity with wiring harness between inspection,
between WL PO9 (female) (11) and WL reparr or
(female)(2)and - (female) (2) replace
chassis ground?
1) Remove PO9. NO with warning lamp body, or inspection.
2) Turn starting contact of chassis ground repair or
switch OFF. with wiring harness between replace
3) Disconnect WL. warning lamp and WL(male)
(2)
1) Remove PO9.
2) Turn starting
switch ON. Defective module (7831.31. Redace
92-107
0
P-l 8 Caut on display does not flash (does not light up), but warning lamp
flash 2s and alarm buzzer sounds
a) Warning lamp flashes and alarm buzzer sounds
CalIS Remedy
kfective module (7831-31.

Is voltage
between
P12 (6) and chassis
ground normal?
1)15-3ov NO
machine caution monitor
2) Turn starting
switch ON.
b) Warning lamp flashes when engine stops.

61001 of monitor panel
between P12
(female) (10) and
chassis ground?
1
I Defective contact, or After
Is there continuity 1) Turn starting NO disconnection in wiring inspection.
between 20 (male) switch OFF. harness between P12 (female) clean or replace
(6) and chassis - 2) Disconnect P12. (10) - JO2 (2) - 20 (female)
ground?
(6)
1) Turn starting
switch OFF.
2) Disconnect 20.
Defective contact. Or After
NO
harness between 20 (male) (61 clean or replace
and engine oil pressure
sensor. or defective engine oil
pressure sensor
c) Warning lamp flashes when engine is running.
YES
11 Defective module (7831.31- Replace
PO9 (female) (9) and

Is voltage between disconnection in wiring inspection.
1)20-30V Alternator terminal _ harness between PO9 (female) clean or replace
2) Start engine. h > Rand chassis (9) - JO1 (1) - alternator
3) Disconnect PO9. ground normal? terminal R
1)20-30V NO
2) Start engine.
92-108
0
P-l 9 Abnormality in air pressure gauge
C3lE.e Remedy
Defective air pressure s?nsor Replace
Does air pressure

gauge display YES
FULL?
2 - 6100) of monttor panel

connector to DL _ between PO9
(female). No (female) (3) and (8)? 3 YES
switch ON. - Is there continuity disconnection in wiring inspection.
1) Connectshort between DL harness between PO9 (female) clean or replace
connector to DL Nz (female) (2) and - 1;; - RH4 (1) - DL(female)
(female). chassis ground?
switch OFF. 1) Turn starting NO disconnection in wiring inspection,
3)IDisconnect PO9. switch OFF. harness between PO9 (female) clean or replace
2) Disconnect DL. (8) - RHl (10) - DL (female)
(2)
b) Display shows highest level and does not move.
YES
Defective air pressure sensor Replace
1
Is whole display
area of air pressure -
gauge off? 2 YES
with wiring harness between inspection.
I Is there continuity
1) Remove DL. between PO9 PO9 (female) (3) - RH4 (1) - repair or
NC (female)(3)and - DL (female) (1) replace
2) Turn starting
1) Remove DL. NO 6100) of monitor panel
2) Turn starting
switch OFF.
3) Disconnect PO9.
92- 109
0
Remedy
YES :epklce
1 temperature sensor
Does coolant
temperature gauge
display lowest Hther
:ontact of chassis ground with
kW?l? nspection.
kring harness between PO9
~ Is there continuity :1ean or replace
between PO9
female) (4) - JO2 (1) - 7.0(5)
1) Remove 26.
NC (female)(4)and -
- 26 (female) (1)
2) Turn starting
Defective module (7831-31 kplace
2) Turn starting
switch OFF.
31 Disconnect PO9.
Defective engine water Replace

temperat”re sensor
1
Iswhole display
area of COOlant
YES Replace
temperature gauge Defecwe module (7831.31
Off? 2 6100) of monitor panel

connector to 26 L bewee” pOg
(female). NO (female) (4) and (8)? 3 YES
Defectwe contact, or After
switch ON. 1 Is there continuity clean or replaa
1) Connect short _ between 26
(4)---02(l)-20(5)-26
connector to 26 NO (female) (2) and
(female) (1)
(female). chassis ground?
2) Turn starting ‘ Defective contact. or After
switch OFF. NO disconnection in wiring inspection,
1) Turn starting
3) Disconnect PO9. switch OFF. harness between PO9 (female) repa,r or
21 Disconnect 26. (8) - JO2 (3) - 20 (9) - 26 replace
(female) (2)
92-110
0
CallSe Remedy
YES
kfective torque converter oil 7epkGe
1 emperature sen*or
Does torque
converter oil
temperat”re gauge -
2 YES
display lowest Defective of chassis ground \fter
IWd? with wiring harness between nspection,
_ Is there continuity
PO9 (female) (5) - TMC (8) - epair or
1) Remove TC.SE. between PO9
~6 (female) (5) and TM2 (7) - TCSE (female) (1) F+l%X
2) Turn starting
Defective module (7831.31- ReplaCe
1) Remove TCSE. NO 6100) of monitor panel
21 Turn startina
switch OFF.-
31 Disconnect PO9
2
z
0
Defective torque converter Oil Repl.XtZ
temperature sensclr
YES
Defective module (7831-31. RY&!pkXe
temperature gauge
1) Connect short
Cclnnec.tOr to between PO9
TC.SE (female). 1 (female) (5) and(B)? 3 YES
After
2) Turn starting
disconnection in wiring inspectlon.
switch ON. Is there continuity
1) Connect short between TC.SE
connector to NO (fH”ak) (2) and (5) - TMC (8) - TM2 (7) -
TC.SE (female). chassis ground? TC.SE (female) (1)
2) Turn starting After
Defective contact. Or
switch OFF. NO inspection,
1) Turn starting disconnection in Wiring
3) Disconnect PO9. repair or
switch OFF. harness between TC.SE
2) Disconnect (female) (2) - TM2 (8) - TMC r&XX
TC.SE. (5) - PO9 (female) (8)
92-111
0
r CalSe

temperature sensor
Does retarder oil

temperat”re gauge
display lowest 2 YES After
Contact of chassis ground
Isthere continuity with wiring harness between inspection,
1) Remove 64.
2) Turn starting (female) (6) and - 64 (female) (1) replace

Defective module (7831-31 Replace
2) Turn starting
switch OFF.
3) Disconnect PO9.

temperature sensor
area of retarder oil

YES
temperature gauge Defectwe module (7831-31. Replace

connector to 64 between PO9
(female). h (female) (6) and (S)? 3 YES
switch ON. Is there continuity disconnection in wiring inspection,
1) Connect short between 64 harness between PO9 (female) clean or replace
connector to 64 NO (fWIMk)(2) and - (6) - JO2 (10) - 64(female)
2) Turn starting After
switch OFF. 1)Turn starting NO inspection,
3) Disconnect PO9. switch OFF. repair or
2) Disconnect 64. (8) - JO2 (9) - 64 (female)
(21
92-112
0
(It takes 30 seconds for the fuel gauge to change one level, so remember this point when carrying
out troubleshooting.)
CZEZlXe Remedy
Defective fuel sensor kPlWS
Defective module (7831-31 ?eplace

Defective contact. or uter

switch ON. 1)4-100fl NO disconnection in Wiring nspection.
2) Turn starting harness between PO9 (female) :k?an or replace
switch OFF. (7) - JO2 (15) - 61 (female)
3) Disconnect PO9.
b) Display shows FULL and does not move.
YES
Defective fuel SensOr ReplaCe
11
Is whole display
area of fuel gauge -
Off? 2 YES
Is there continuity with wiring harness between inspection.
1) Remove 61. replace
N; (female)(7)and - 61 (female)
2) Turn starting
chassis ground
switch ON.
normal?
2) Turn starting
switch OFF.
3) Disconnect PO9.
92-113
0
P-24 Abnormality in night lighting (abnormality only in night lighting of
monitor panel)
a) None of panel lamps light up.
CZlUS2 Remedy
r-d
YES After
harness between PO1 (female) clean or reDlace
1
(3). PO3 (female) (2). PO6
ISvoltagebetween PlO (female) (2). P14 (female)
each pin in table (2) -chassis ground
below normal?
1) 20- 30V
2) Turn stertmg
switch ON. i Defective contact, or After
3) Turn light switch NO disconnection I” wiring inspectlo”.
ON. harness between LS (female) clean or replace
4) Disconnect POl, (1). PO1 (female) (2). P14
P14, and LS. (female)(l)
Between PO1 (female) (2) and chassis ground
Between P14 (female) (1) and chassrs ground
t Between LS (female) (1) and chassis ground
Note: If the night lighting for other devices (transmission shift

lever, etc.) does not light up, go to troubleshooting of
chassis (marker lamp relay system).
92-114
0
b) Service meter and odometer light up, but other parts do not light up.
Remedy

(2) - PO3 (female) (1). PO6
PlO(female)(l)
Defective rheostat Replace

(3) and chassis ground
Defective contact, or 4fter

3) Turn light switch NO disconnection I” wiring nspection.
ON. harness between LS (female) :kzan or replace
4) Disconnect LS. (1) and R07 (female) (5)
c) Service meter and odometer do not light up.
Defective contact, or r\fter

disconnection in wiring nspection,
harness between PO1 (female) :1ean or replace
(2). P14 (female)(l) - R07
(female) (5)
92-115
0
P-25 Engine (mechatronics) display flashes
Remedy
I
Y ES Defective module (7831-31
RWSX
Is voltage between
P12 (1) and chassis
ground normal7 2 YES See troubleshooting of engine
Controller
Is voltage between
l)O-3v EC1 (female) (5) and _
2) Turn starting r110chassis ground
switch ON. normal? Defective contact, or discon-
After inspec-
NO tion, clean or
between P12 (female)(l) -
1) 12-2ov k?plFN75
ECA (4) - EC1 (female) (5)
2) Turn starting
switch ON.
3) Disconnect ECl.
92-116
0
Related electrical circuit diagrams
P-l
PO9(04012) JO3(S16) 3O(SWP14)
(g @
Monitor panel
BT2
4 3
A To circuit
- braker
JO7
P-2
Module
Module
PO2 (0408)
Module
F56103146
P-3
PI2 (04016) TMC (Sl2) SC3 (MIC 171
Shift controller
F56103147A-K
P-4
Pl2(04016) SU3 (Sl6) SUI(MIC2ll

Suspension
controller
F56103148
92-l 18
0
P-5
Pl2(04016) SU3iSl6) SUI tMIC2I)
F56103149
P-6,
Transmission
F56103150
P-7
Shift limit switch

PO8tO4016)
F56103151
92-119
0
P-8
Lock-up relay
I-----J
+24V
GJ@@@)~
PO5(04012)
TMC(S12) SC3
TKHOCO39 8
3
k2
P-9
Head lamp relay (Hi)
PO8(04016)
Monitor panel
To head lamp
F56103153A-K
92- 120
0
P-IO
PO8 (04016) CM (SE) Combination switch

.@
Monitor
.@
JO3 (Sl6)
@ - To turn signal lamp (right)

@ - To turn signal lamp (left)
F56103154
P-II
PO5(04012) TMA(SI6) TM3 (SWP 14)
@ -0
@ @ -
@ @
@
To fill sensor
4
@ TM4tSWPl4)
@ -
F56103155-1
92-121
0
P-12
Output shaft
PO8(04016) TMA (Sl61 TM2 (SWPl4) speed sensor
F56103156
P-13
Speed sensor 6
PO8(04016) JO9 iSl2) E7CSWPl4) E12CX2)
@ @ 0
Monitor panel
12 -0 @
561 F03349A-K
P-14
PO1 (0405) BT2
4 3
” z=- To circuit braker
Monitor panel
5A JO7
(Service meter)
ER
TKH00040
P-15
Pl3(0404) PO4104081
Module.
PI I 10408)
Modulk
F56103159
92- 122
0
P-16
f24V
I
BZ CM21 Buzzer
PO9 (04012) 0
@@
F56103160
I P-17
t24v
WL(M2) Lamp
PO9(04012)
0
Resistor
F56103161
P-18
Pl2(040161 JO2 IS161 2O~SWP20)

Engine oil
pressure
sensor
F56103162
Alternator
PO9C64012) JOI (Sl6)
F56103163
92-123
0
P-19
PO9LO4012) PL (X2)
F56103164
P-20
Water
PO9 (04012) JO2 (Sl6) 2O(SWP20) 26 (X2)
@ @ @
O-0 0
F56103165
P-21
PO9(04012) TMC (53121 TM2 (SWPl4) TC,SE(XZl
@
Torque 8
@
converter oil X
@ 0 temperature 2
sensor
F56103166
P-22
PO9(04012) JO2 (SIB) 64(X2)
@ @
Retarder oil
temperature
B-0 seiisor
F56103167
P-23
P09(040121 JO2 (Sl6) 61 (XI)
Fuel sensor
F56103168
92-124
0
P-24
Marker lamp relay
PO I (0405)
v
PO3 (0402 1 I LS(M3) Rheostat
I
-0 +24V
0
output
I
@
0 GND
PO6iO402) ER
PO7 (0402)
PlO(O402)
P14CO402)
I=
fi z ER
F56103169-1
92-125
0
p-25
Pl2(04016) ECA (S 16) ECI(MICl7)
Engine
controller
561 F03347
P-26
En~lne controller ECA(S16)

ECZl(MIC21)
Mode select
SC2(MIC21)
To battery terminal (t) TKH00041
92-126
0
TROUBLESHOOTING OF IihAINTE-
NANCE MONITOR SYSTEM
M-l Maintenance monitor does not work . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . 92-128

a) When nothing works ........................................................ 92-l 28
b) When CHECK display does not work ......................................... 92-128
M-2 When engine is stopped, engine oil level display flashes ......................... 92-129
M-3 When engine is stopped, transmission oil level display flashes ................... 92-130
M-4 When engine is stopped, hydraulic oil level display flashes ....................... 92-131
M-5 When engine is stopped, retarder oil level display flashes ........................ 92-132
M-6 When engine is stopped, brake oil level display flashes .......................... 92-133
M-7 When engine is stopped, battery electrolyte level display flashes ................. 92-134
M-8 At neutral, retarder wear display flashes ........................................ 92-135
M-9 When engine is running, air cleaner clogging display flashes ............. :. ..... 92-136
M-10 When engine is running, full-flow filter clogging display flashes .................. 92-137
M-l 1 When engine is running, transmission filter clogging display flashes ............. 92-138
M-12 When engine is running, hydraulic filter clogging display flashes ................. 92-139
M-13 When engine is running, retarder
filter clogging display flashes .................. 92-140
M-14 Maintenance timer does not work ............................................... 92-141
M-15 Maintenance timer is not Oh or below, but maintenance item
lights up ........................................................................ 92-142
M-16 Abnormality in switch ........................................................... 92-142
does not work ............................................................... 92-142
b) Replacement switch,
misoperation cancel switch do not work ................ 92-l 42
M-17 Night lighting does not light up .................................................. 92-143

conditions.
Threrefore, always check the resistance value, voltage, etc. of the place giving the failure display,
that the problem occurred, and try to re-enact the failure conditioins when carrying out
troubleshooting.
92- 127
0
M-l Maintenance monitor does not work

on to the next step. Remedy
a) When nothing works

Is voltage
between Defective contact, or
.MMl (1)and (2) disconnection in wiring
harness between MM1 Repair wiring
YES
(female)(l) - MM7 (1) - harness or
BT2 (81, or between ST2 (7) re!Aace
1) 20-30V and JO7 or circuit braker
2) Turn starting Is there continuity
switch ON. between MM1
(female) (2) and
chassis ground?
1) Turn starting I harness between MM1 harness or
switch OFF. NO (female)(2) - MM712) - replace
2) Disconnect MM?. JO3W -earth
MM1 (04016) MM7(S16) BT2

\ I r \ I I 1
b) When CHECK display does not work
1 YES Defective module (7831-41.

Is there continuity monitor
between the pins in -
the table below?

1) Turn starting
switch OFF. between the pins given replace
2) Disconnect MM3
and MM4.
MM3(0408) MM4 (0408)

- n
Table 1
Maintenance monitor
module
MM3 (female) (5) - MM4 (female) (5) (7831-41-5100)

3 561 F03352
92-128
0
M-2 When engine is stopped, engine oil level display flashes
* Check the engine oil level again before starting troublestiooting.

CaUse Remedy
YES.
Is there continuity
YI
between MM1
(female) (4) and (2)!

switch OFF. - between MM1 (female) (4) - replace
between MM9 2) Disconnect MMl. MM8 (1) - MM9 (female) (1)
1) Turn starting
switch OFF.
2) Disconnect MM9.
between MM1 (female) (2) - r+XX
MM8 (12) - MM9 (female) (2)
1) Turn starting
switch OFF.
2) Disconnect MM9 Defective engine oil level
Se”SOr
MM I(O4016) MM8CSl2) MMS(X2)
0 Engine oil level

sensor
-_O
561 F03353
92-129
0
M-3 When engine is stopped, transmission oil level display flashes
* Check the transmission oil level again before starting troubleshooting.

* Before carrying out troubleshooting, check that alI the related connectors are properly inserted.
Jr Always connect any disconnected connectors before going on to the next step.
CaUSe Remedy
Defective module (7831.41. k?pbXe

Is there continuity
YI
between MM1
2
t 8 kpair wiring
Is there continuity ,arness or
switch OFF. between MM1 (female) (5) -
between MM1 6 eDlaCe
2) Disconnect MMl. MM8 (2) - MM1 6 (female) (1 I
Ifemale) (2) and
chassis ground?
I I
1) Turn starting
switch OFF.
2) Disconnect
MM16.
between MM1 (female) (2) -
MM8 (12) - MM1 6 (female)
(2)
1) Turn starting
switch OFF.
2) Disconnect
MM16.
Defective transmission oil
level sensclr
oil level sensor

MM I (04016)
Maintenance
monitor
561 F03354
92- 130
0
M-4 When engine is stopped, hydraulic oil level display flashes
* Check the hydraulic oil level again before starting troubleshooting.

Call% Remedy
YES
I)
kfective module (7831-41. ReplaCe
YES
1
r
Defective contact. or discon- Repar wiring
Is there continuity
1 nection in wiring harness harness or
between MM14 _ NO
&itch OFF. between MM1 (female) (6) - replaCe
(male) and chassis
2) Disconnect MMl. MM8(3)- MM14(female)
ground?
1) Turn starting
Defective hydraulic oil level ReDlace
switch OFF.
2) Disconnect NO Sensor
MM1 4.
MMI (04016) MM8(Sl2)
MM 14
Hydraulic oil level

sensor
561 F03355
92-131
0
M-5 When engine is stopped, retarder oil level display flashes
j, Check the retarder oil level again before starting troubleshooting.

r Cause Remedy


between MM2 (female) (6) - replaCe
ground? MM8 (10) - MM1 5 Ifemale)
I
1) Turn starting
switch OFF. Defective retarder oil level Replace
2) Disconnect sensrJr
MM1 5.
MM2(040121 MM8Ei2)
MM 15
IO
Reterder oil level
I
sensor
561 F03356
92-132
0
M-6 When engine is stopped, brake oil level display flashes
* Check the brake oil level again before starting troubleshooting.

* Before carrying out troubleshooting, check that all the’ related connectors are properly inserted.
CaKX Remedy
YES
Defective module (7831.41- Redace
HP
De’fective contact, or discon- Repair wiring

switch OFF. NO between MM1 (female) (7) -
Y between MM12 replace
2) Disconnect MMl. MM8 (4) - MM1 2 (female) (1)
chassis ground?
1
1) Turn starting
is there continuity switch OFF. Defective contact, or discon-
between MM12 2) Disconnect nection in wiring harness Repair wiring
(male1 (1) and (Z)? MM12 between MM1 (female) (2) - harness or
MM8 (12) - MM12 (female) replace
(2)
1) Turn starting
switch OFF.
2) Disconnect
Defective brake oil level ReplaCe
MM12.
B Se”SX
?z
z
MMI (04016) MM12
0 Brake oil level

@ SeWSOr
561 F03357
92- 133
0
M-7 When engine is stopped, battery electrolyte level display flashes
* Check the battery electrolyte level again before starting troubleshooting.

CaUSe Remedy
YES Defective module (7831.41.

I-----+
1 Defective contact. or discon-

1) Min. 4V 1 nection in wiring harness
2) Turn starting NO between MM1 (female) (11)
MM1 1 (male) and switch ON. _ MM8 (8) - MM1 1 (female)
31 Disconnect MMl.
1) M1n. 4V
2) Turn starting
switch ON. Defective battery electrolyte
3) Disconnect NO level sensor
MMll.
MM I (04016) MMB(Sl2)
MM Ii
Battery electrolyte
level sensor
561 F03358
92- 134
0
M-8 At neutral, retarder wear display flashes
* Check again that the retarder brake is not worn before starting troubleshooting.
Remedy
3 YES
Iefective module (7831.41. replace
j100) of maintenance monitor
YES Is there continuity
- between MM1
2 (female) (9) and (Z)?
Is there continuity To (A)

YES NO
_ between ~~19 - 1) Turn stanring
(male) (1) and(Z)? switch OFF.
1 2) Disconnect MM1
Is there contmuity 1) Turn startring Defective brake wear (rear Fi%?pl?KX

between MM20 - switch OFF. NO l&l sensor
(male) (1) and (2)’ 2) Disconnect
MM19.
1) Turn startring
switch OFF. Defective brake wear (rear Replace
2) Disconnect NO right) sensor
MM20.
YES
(female) (9) - MM8 (6) - replace
MM1 7 (2) - MM20 (female)
(1)
YES harness between MM20 harness or
!il
(female) (2) and MM19 WplXe
1) Turn startring (female) (2)
2, iii!!?’ NijFJ
Defective contact. Or
switch OFF NO (female) (2) - MM8 (12) - K3plXe
2) Disconnect MM17(3)-MMlS(female)
MMlS.
il)
561 F03359
92-135
0
M-9 When engine is running, air cleaner clogging display flashes
* Check clogging of air cleaner again before starting troubleshooting.

Cause Remedy
YES
Is there continuity
Y between MM1
(female) (10) and
1 chassis ground?
El
Defective contact. or Repair wiring
Is there continuity 1) Turn starting disconnection in wiring harness of
between MM1 3 switch OFF. NO harness between MM1 PJlaCe
(male) and chassis 2) Disconnect MMl. (female) (10) - MM8 (7) -
ground?
MM13 (female)
1) Turn starting
switch OFF.
0
. Defective air cleaner clogging
2) Disconnect sensor
MM13.
MM I (04016) MM8 (Sl2)
MM13
Maintenance
monitor Air cleaner
clogging sensor
561 FO3360
92-136
0
M-l 0 When engine is running, full-flow filter clogging display flashes
A Replace the full-flow filter before starting troubleshooting.

Cause Remedy
2 YES
7eplaCe
Isthere continurty 5100) of maintenance monitor
h
between MM1
(female) (12) and
chassis ground? Defective contact, or discon- kpair wiring
1
I I I rarness or
NO between MM1 (female) (12) eplace
Is there continuity 1) Turn starting
switch OFF. -MM8(9)-MM10
between MM10
@ensor end) and - 2) DiSCOnneCt MMi.
chassis ground?
1) Turn starting
switch OFF.
2) Disconnect Defective full-flow filter clog- 7wlace
NO
MMlO. ging sensor
MM I (04016) MM8(Sl21
MM IO
n
w Full-flow filter
sensor
561 F03361
92- 137
0
M-l 1 rayhntngine is running, transmission filter clogging display
j, Check clogging of transmission filter again before starting troubleshooting.

Remedy
YES
Defective module (7831-41. R+Xe
Is there continuity
YES between MM1
- (female)(l3) and -
chassis ground?
’ 1) Turn starting nection m wring harness harness or
Is there contmuity switch OFF. NO between MM1 (female) (13) reDlaCe
YES between 52 (female) _ 2) Disconnect MMI. MM7(11)-JO2(13)-52
,- (2) and chassis (female) (1)
ground?
II Turn
L (l)a”d(Z)? 1 NO between 52 (female) (2) and replace
JO3 (female) (8)
1) Turn starting
switch OFF.
2) Disconnect 52. Defective transmission filter Replace
NO clogging sensor
8
X
i%
0
MM I (04016) MM7(Sl6) JO2
Transmission filter
clogging sensor
561F03362A-K
92-138
0
M-l 2 When engine is running, hydraulic filter clogging display flashes
* Check clogging of hydraulic filter again before starting troubleshooting.

CaUSe Remedy
YES
Defective module (7831.41. k%pk%
d Is there continuity
51001 of maintenance nwnltw
YES between MM1

- (female) (14)and _-I
chassis ground?
Is there continuitv switch OFF. NO between MM1 (femaW(14) replace
2) Disconnect MM1 -MM7(12)-JO2(12)-54
(female) (1)
1) Turn starting
Is there continuifv switch OFF. 1
between 54 (male) 2) Disconnect 54.
NO between 54 (female) 12) and leDl%X
JO3 (female) (8)
1) Turn starting
switch OFF.
2) Disconnect 54. Defective hydraulic filter clog-
ging sensor
MM I (040 16) MM7(Sl6) JO2(S 16)
12 @ Hydraulic filter
clogging sensor
JO3(S 16)
- Toearth
561F03363A.K
92-139
0
M-l 3 When engine is running, retarder filter clogging display flashes
* Check clogging of retarder filter again before starting troubleshooting.

CaUSe Remedy
YES iepkw?
Is there co”tinuW
YES between MM2
(female) (7) and
chassis ground?
2 I I ,
Defective contact, or discon- 7epair wiring
1) Turn starting nection in wiring harness lanes* or
Is there continuity switch OFF. between MM2 (female) (7) - EplW3
YES between 53 (female) 2) Disconnect MM2. MM7 (13) - JO2 (14) - 53
- (2) and chassis (female) (1)
ground?
lP
1) Turn starting
Is there continuity switch OFF. Defective contact, or discon- kpair wiring
between 53 (male) - 2) Disconnect 53. nection in wiring harness ,arness or
(1) and(Z)? NO between 53 (female) (2) and ,epklce
JO3 (female) (8)
1) Turn starting
switch OFF.
2) Disconnect 53. Defective retarder filter clog Qplace
NO ging sensor
MM2(04012) MM7 (S 161 JO2(Sl6) 53(X2)
@ 14
0 Reterder filter
clogging sensor
.@
561 F03364A-K
92-140
0
M-l 4 Maintenance timer does not work (time does not advance)
Remedy

L-t
Is voltagebetween
MM2 (female) (5)
and chassis ground
normal? Defective contact. or discon- Repair wiring
YES
1) 20-30V between MM2 (female) (5) - replace
2) Start engine. MM7 (8) - JO1 (1) - alterna-
i
3) Disconnect MM2. , tor terminal R
Defective alternator ReplaCe
MM2(04012) MM7tS.16)
Altenator
561 F03365
M-l 5 Maintenance timer is not Oh or below, but maintenance item

lights up
A Before carrying out troubleshooting, check that all the related

connectors are properly inserted. CalXX Remedy

92-141
0
M-l 6 Abnormality in switch

CatIS? Remedy
does not work

b) Replacement switch, misoperation cancel switch

do not work
YES
Defective module (7831.41- ?ePlXe
5lW) of maintenance
monitor
1
Is voltage between
MM2 (female) (5)
and chassis ground
Contact of +24V with wiring Repair wirmg
normal? YES
harness between JO1 (female) harness or
2 (1) and alternator terminal R, replace
1) Max. 16V or defective alternator
switch ON. JO1 (male) (1) and
3) Disconnect MM2. NO ChaSSls ground
normal?
Contact of +24V with wiring Repair wiring

1) Max. 16V harness between MM2 harness or
2) Turn starting NO (female) (5) - MM7 (8) - JO1 replace
switch ON. (male)(l)
3) Disconnect JOl.
MM2(04012) MM7tSl6) JOI(S16)
Alternator
561 F03365
92- 142
0
M-17 Night lighting does not light up
(only lighting of maintenance monitor does not light up)
-SrBefore carrying out troubleshooting, check that all the related connectors are properly inserted.
RemedY

between MM5 (female) (1). I7epair wiring
YE
MM6 (female) (1) - MM7 tlarness or
(male) (91, or between MM5 r epkace
(female) (2). MM6 (female) (21
_ MM7 (male) (10). or blown
3 bulb
Isvoltage between
MM7 (female1 (9)
and (10) normal?
Defective contact, or discon- IGpair wiring

4 YE!
1) lo-3ov nection in wiring harness Inarness or
2) Turn starting between MM7 (female) (9) IreplaCe
switch ON. and LS (male) (2)
ON.
4) Disconnect MM7 Defective contact, or discon- fGzpair wiring
Is voltage
between 1 nection in wiring harness t,arness or
NC between MM7 (female) (10)
1 I Turn starting r eplZ%?
switch OFF. and chassis ground
2) Disconnect MM7.
1) lo-3ov
2) Turn starting
1 switch ON.
Is voltagebetween ON. Defective rheostat F7ePlace
LS (male) (1) and
chassis ground
normal?
Defective contact. or discon- fIepair wiring
1) zo-3ov nection in wiring harness t,arness or
2) Turn starting NO between LS (male) (3) and r‘eplaCe
g 1) Turn starting
switch ON. chassis ground
switch OFF.
g 2) Disconnect LS.
ON.
4) Disconnect LS Defective contact, or discon- Fkpair wiring
8
nection in wiring harness t larness or
between LS (male) (1) and @ace
R07 (female) (51
Note: If the lighting of other equipment (monitor panel,
shift lever, etc.) does also not light up, see
troubleshooting for the chassis (marker lamp relay
Marker lamp relay
+24V
R BTI
Coinbin,,nt 7 1% 1 [ LS(M3) , Rhreostat

switch
MM5 MM7 (S 161 0

@
Maintenance
monitor
MM6
561 F03366
92-143
0
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL.. ........................ .:. 30- 3 TORQUE CONVERTER CONTROL VALVE
PRECAUTIONS WHEN CARRYING OUT Removal ............................................................... 30-42
OPERATION ......................................................... 30- 4 Installation ........................................................... 30-42
SPECIAL TOOL LIST.. ............................................ 30- 6 Disassembly ........................................................ 30-44
TIGHTENING TORQUES AND Assembly ............................................................. 30-44
STANDARD VALUES TABLE.. ............................. 30- 8 TORQUE CONVERTER AND TRANSMISSION
WEIGHT TABLE ...................................................... 30-12 Disconnection ...................................................... 30-46
LUBRICANT AND COOLANT TABLE .................... 30-13 Connection .......................................................... 30-46
STARTING MOTOR TORQUE CONVERTER, PTO
ALTERNATOR PTO
ENGINE OIL COOLER TRANSMISSION
Removal ............................................................... 30-14 Disassembly .. ...................................................... 30-62
FUEL INJECTION PUMP (LEFT AND RIGHT) TRANSMISSION CONTROL VALVE (ECMV)
Removal ............................................................... 30-16 Removal ............................................................... 30-94
Installation ...........................................................30-16 Installation ........................................................... 30-94
AIR COMPRESSOR TRANSMISSION PUMP
Removal ............................................................... 30-16 Removal ............................................................... 30-94
WATER PUMP ECMV
Removal ............................................................... 30-18 Disassembly ..................................................... 30-95- 1
Installation ........................................................... 30-18 Assembly .......................................................... 30-95-I
AFTER-COOLER DIFFERENTIAL (For standard)
Removal ............................................................... 30-18 Removal ............................................................... 30-96
TURBOCHARGER Disassembly ........................................................ 30-98
Removal ...............................................................30-20 Assembly ........................................................... 30-102
Installation ........................................................... 30-20 DIFFERENTIAL (For with differential lock)
NOZZLE HOLDER Removal .......................................................... 30-I 1 l-l
Removal ............................................................... 30-20 Installation ...................................................... 30-I 1 l-l
Installation ........................................................... 30-20 Disassembly ................................................... 30-I 1 l-3
CYLINDER HEAD Assembly ........................................................ 30-I 1 l-7
Removal ............................................................... 30-22 CARRIER
Installation ........................................................... 30-24 Removal ............................................................. 30-I 12
ENGINE Installation ......................................................... 30-I 12
RADIATOR, TORQUE CONVERTER OIL COOLER FINAL DRIVE
OUTPUT SHAFT REAR WHEEL BRAKE
Removal ............................................................... 30-34 Removal ............................................................. 30-I 18
Installation ........................................................... 30-34 Installation ......................................................... 30-I 18
Disassembly ........................................................ 30-36 Disassembly ...................................................... 30-I 18
Assembly ............................................................. 30-36 Assembly ........................................................... 30-120
TORQUE CONVERTER, TRANSMISSION
Removal ............................................................... 30-38
Installation ........................................................... 30-40
93-1
0
PARKING BRAKE CALIPER FRONT BRAKE CHAMBER
Removal ............................................................. 30-122 Removal ............................................................. 30-174
Installation ......................................................... 30-I 22 Installation ......................................................... 30-174
Disassembly ...................................................... 30-122 Disassembly ...................................................... 30-176
Assembly ........................................................... 30-122 Assembly ........................................................... 30-180
PAKING BRAKE PAD REAR BRAKE CHAMBER
Removal ............................................................. 30-124 Removal ............................................................. 30-174
FRONT BRAKE CALIPER Disassembly ...................................................... 30-184
Installation ......................................................... 30-124 AIR GOVERNOR
Disassembly ...................................................... 30-I 26 Removal ............................................................. 30-192
FRONT FBRAKE CALIPER PAD Disassembly ...................................................... 30-192
Removal ............................................................. 30-126 Assembly ........................................................... 30-I 92
Installation ......................................................... 30-126 SLACK ADJUSTER
STEERING VALVE Removal ............................................................. 30-194
Removal (HD785-3) ........................................... 30-128 Installation ......................................................... 30-194
Removal (HD985-3) ........................................... 93- 2 Disassembly ...................................................... 30-194
Installation (HD785-3) ....................................... 30-128 Assembly ........................................................... 30-194
Installation (HD985-3) ....................................... 93- 2 BRAKE COOLING PUMP
FRONT WHEEL STEERING, HOIST PUMP
Removal ............................................................. 30-146 Removal ............................................................. 30-196
REAR WHEEL BRAKE COOLER
Removal.. ........................................................... 30-148 Removal ............................................................. 30-196
FRONT WHEEL HUB DEMAND VALVE
FRONT SUSPENSION Disassembly ...................................................... 30-200
Removal.. ........................................................... 30-156 Assembly ........................................................... 30-200
Installation ......................................................... 30-156 RELIEF VALVE
VARIABLE DAMPER VALVE Disassembly ...................................................... 30-200
Removal .......................................................... 30-157-I Assembly ........................................................... 30-200
Installation ...................................................... 30-157-I EMERGENCY STEERING MOTOR PUMP
VARIABLE DAMPER SELECTOR VALVE Removal ............................................................. 30-202
Assembly ........................................................ 30-157-3 STEERING CYLINDER
FIXED ATTENUATION VALVE Removal ............................................................. 30-202
Assembly ........................................................ 30-157-5 Disassembly ...................................................... 30-204
FRONT SUSPENSION CYLINDER Assembly ........................................................... 30-206
Disassembly ...................................................... 30-158 HOIST VALVE
Assembly ........................................................... 30-I 58 Removal ............................................................. 30-2 IO
REAR SUSPENSION CYLINDER Installation ......................................................... 30-210
Removal ............................................................. 30-160 Disassembly ...................................................... 30-212
Installation ......................................................... 30-160 Assembly ........................................................... 30-2 12
Disassembly ...................................................... 30-I 62 HOIST CYLINDER
PARKING BRAKE SPRING CYLINDER Installation ......................................................... 30-214
Removal ............................................................. 30-I 64 Disassembly ...................................................... 30-2 16
Installation ......................................................... 30-164 Assembly.. ......................................................... 30-218
Disassembly ...................................................... 30-166 BODY
BRAKE VALVE Installation ......................................................... 30-220
Removal ............................................................. 30-I 68 TRANSMISSION CONTROLLER
Installation ......................................................... 30-168 Removal ............................................................. 30-222
Disassembly ...................................................... 30-170 Installation ......................................................... 30-222
Assembly.. ......................................................... 30-172
93-l-l
0
REMOVAL OF STEERING VALVE REMOVAL OF STEERING VALVE
ASSEMBLY (A) ASSEMBLY (B)
* A& Loosen the oil filler cap slowly to release [If steering valve yoke (5) is stiff and cannot be
the pressure inside the hydraulic tank. removed easily from the input shaft.]
* With the method B for removal and instal-
Pass a rope through the yoke and secure
lation, removal is easy, but when installing
the yoke to the top to prevent the yoke
the steering valve, it is difficult to insert the
from falling out from the column shaft
spline, and it is necessary to align the spline
spline.
position, so normally method A should be
1. Remove yoke lock bolt (1). (See Fl) used for this operation.
* The lock bolt has a fine thread, so be * Make match marks to show the position of
careful not to lose it or to use force and insertion for the spline at the steering wheel
damage the thread. and yoke (5).
Sr Check that the yoke moves up and down * Match marks which made match marks
easily on the spline of the steering valve at factory are 2 teeth of the spline (60”)
input shaft, and that it comes off easily. discrepancy, so make a new match
* If the steering valve .input shaft is hit marks before removal of spline.
strongly, it may be deformed and cause (See F3)
problems.
1. Disconnect hoses (2). (See Fl )
2. Disconnect hoses (2). (See Fl) * Disconnect 5 hoses.
* Disconnect 5 hoses.
2. Removesteeringvalveassembly(3).(See Fl)
3. Removal steering valve assembly (3). m
(See Fl) * Remove the steering valve assembly from

the yoke and spline (4) of the steering
&?Ikg Steering valve assembly: For details, wheel end input shaft. (See Fl)
see Weight Table
* Lower it with a rope and be careful not

to drop it.
INSTALLATION OF STEERING INSTALLATION OF STEERING

VALVE ASSEMBLY (A) VALVE ASSEMBLY (B)
m
* Align the match marks for the insertion
position of the spline at yoke B and the
steering wheel end, and install the
steering valve assembly.
* If the position of the yoke is not correct,
it may cause variation in the rotation of
the steering wheel.
93-2
0
Fl F2
Make new
F56103485 F56103486A-I
F3
I The angle between

match marks is 60’
(2 teeth of spline)
Mutch marks
(When shipped at factory)
F56103486-1 K
93-3
0
40 MAINTENANCE STANDARD
Output shaft .................................................. 40- 2

Torque converter valve ................................ 40- 3
Torque converter .......................................... 40- 4
Transmission (HD785-3) .............................. .40- 6
Transmission (HD985-3) ............................... 94- 2
ECMV
(Electronic Control Modulation Valve). .... 40-I 1
Front axle ...................................................... 40-I 2
Rear axle support (HD785-3) ....................... .40-13
Rear axle support (HD985-3) ....................... .94- 7
Differential.. ................................................... 40-14
Final drive (HD785-3). .................................. .40-15
Final drive (HD985-3). ................................... 94- 8
Front brake .................................................... 40-I 6
Rear brake ..................................................... 40-17
Parking brake ............................................... .40-18
Steering linkage.. .......................................... 40-20
Front suspension cylinder.. .......................... 40-22
Rear suspension cylinder (HD785-3) .......... .40-23
Rear suspension cylinder (HD985-3). ......... .94- 9
Parking beake chamber.. ............................. .40-24
Slack adjuster.. .............................................. 40-25
Hydraulic pump (SAR4-160) ....................... .40-26
Demand valve ............................................... 40-28
Closs-over relief valve ................................. .40-28
Hoist valve .................................................... 40-29
Steering cylinder ......................................... .40-30
Hoist cylinder ................................................ 40-31
94- 1
0
94-2
0
Unit: mm
I ;,‘n’;;;d
Free length ‘nEc?d Free length Installed load
1 No.1 clutch spring
52.0 44.0 13.7 kg 48.9 11.0 kg
5 lNo.7 clutch spring 1 68.0 / 57.0 1 12.6 kg 1 63.9 1 10.1 kg 1
Replace
Wear Of No.1 Carrier, Width 4.0 -0.01 3.6

-0.03
16 No.3 clutch inner
drum seal ring Thickness 4.6 kO.12 4.35
Unit: mm
Width 4.0 -0.01 3.6

,7 Wear of No.2,3 clutch -0.03
collar seal ring
Thick-
ness 5.1 +0.12 4.85
Width 4.0 -0.01 3.6

18 Wear of No.4, 5 carrier -0.04
seal ring Thick-
ness 6.3 kO.15 6.05
Width 4.0 -0.0 1 3.6

-0.04
,9 Wear of No.6,7 carrier
seal ring Thick-
ness 4.0 +0.15 3.5
Width 4.0 -0.01 3.6

-0.04
2. Wear of No.6, 7 carrier
seal ring Thick-
ness 4.0 +0.15 3.75
Width 4.5 -0.0 1 4.1

2, Wear of No.6,7 carrier -0.03
seal ring Thick-
ness 5.8 f0.15 5.55
Width 3.0 -0.01 2.6

22 Wear of No.3 sun gear -0.03
seal ring Replace
Thick-
ness 4.0 kO.12 3.75

23 0.13 - 0.36
and planet gear
No.1 planet
0.15 - 0.39
25 Backlash between No.1 carrier

0.17 - 0.52
and No.2 clutch inner drum
26 Backlash between No.4 sun gear

0.13 - 0.38
and planet gear

0.16 - 0.41
gear and ring gear
28/gndBacklash between No.5 sun gear

I 0.13 - 0.38
2g Backlash between No.5 planet

3. Backlash between No.5 planet

0.16 - 0.41
gear and ring gear
31 Backlash between No.6 sun gear

0.13 - 0.37
and planet gear

0.14 - 0.40
gear and ring gear
Backlash between No.4, 5 carrier

33 0.18 - 0.55
and No.6 ring gear
94-4
0
Unit: mm
34 Backlash between No.7 sun

0.12 - 0.34

0.14 - 0.40 Replace
gear and ring gear
36 Deformation of inside teeth of

Repair limit: 0.3
disc

Replace
(N0.1~4, 5 planet gears) 2 kO.05 1.5
thrust
washer
3 +0.05 2.5
(No.6 and 7 planet gears)
Location Standard clearance Clearance limit

I I
No.1 gear train 0.30 - 0.80 1.5
Replace
No.4 gear train 0.30 - 0.80 1.5 thrust
washer, or
39 Planet gear side clearance
No.5 gear train 0.30 - 0.80 1.5 replace
carrier
No.6 gear train 0.30 - 0.80 1.5
No.7 gear train 0.30 - 0.80 1.5
Standard size Amount of wear

4. Stepped wear of seal ring
mating face
- 0.05 max.
Standard size Repair limit Replace
41 Oil seal contact surface of

output shaft 120 119.9
+0.097 0.5 -
0 0.797 0.88
If the surface
- has seizure
Inside 405 -0.135 +0.097 0.135 0.36 stripes or
-0.232 0 0.329
other damage,
No.2 - repair and
Clearance between cylinder and reuse if it is
42 Middle 275
I;:;;; +0.081
0 0.1100.272 0.30 within the
piston
clearance
Inside 180 -0.5 +0.063 0.5 - 0.84 limit.
-0.7 0 0.763 Replace if
I I I I 1 I 4there is mark-
4:;;; 1 +go.o81 /0.1;;-2 1 o.30 Ieddamage.
INGi?idle / 275 /
I I I I I I /
I
-
Inside 180 -0.5 +0.063 0.5 0.84
-0.7 0 0.763
No.2,3 -0.5 +0.081 0.5 -
‘Outside 300 -0.7 0 0.781 0.86
94-5
0
Unit: mm
If the surface
has seizure
stripes or
other damage,
repair and
reuse if it is
42 Clearance between cylinder and within the
piston clearance
limit. Replace
if there is
marked
damage.
Inside 0.29
I 410 I
I I ! I I I
I
No.7 -0.5 +0.063 0.5 -
Outside 470 -0.7 0 0.763 0.84
-
Inside 410 IL;“9; +0.063 0.135 0.29
0 0.261
94-6
0
REAR AXLE SUPPORT
8
X
E /’
2 2
c-c
B-B
561F03195-IK
Unit: mm
1
Standard Tolerance Standard Clearance
Clearance between rod mount- Shaft Hole
1
ing pin and bushing
80 -0.030 +0.046 0.030 - 0.3

-0.060 0 0.106
Clearance between inner 0.080 - Replace

2 and outer for bushing 115 0.150 0.5
Clearance between suspension

cylinder mounting pin and 80 -0.030 +0.046 0.030 -
3 frame or axle -0.060 0 0.106 0.3
Clearance between inner 0.080 -

4 and outer for bushing 115 0.150 0.5
94-7
0
FINAL DRIVE
56f6 tan
n\ fil 94.5flO kqn
’ 94.5flO kun
3 ll.Wl kwn 4
SKH00041
Unit: mm
Standard backlash Repair limit
4 Backlash between planet gear

I
and sun gear 0.26 - 0.58 1.2
Backlash between planet gear 0.30 - 0.78

2 1.0
and ring gear
Repair or
3 Curvature of drive shaft Repair limit: 1.5 TIR
replace
I
4 Thickness of spacer Replace

51 20.1 49
94-8
0
SKH00042
Unit: mm
I I
Tolerance Standard
Standard Clearance
Clearance between piston rod Shaft Hole
1
and bushing
-
200 -0.050 +0.246 0.05 0.4
-0.122 0 0.368
Replace
Clearance between piston rod -0.050 +0.246 0.05 -
2 0.4
and bushing 200 -0.122 0 0.368
-
Clearance between cylinder -0.050 +0.115 0.05 -
3 0.8
and wear ring 250 -0.260 0 0.375
94-9
0
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
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SEBM05610311

October 1997 Copyright 1997 Komatsu America International Company oo- 1

IO STRUCTURE AND FUNCTION ........................................................... IO-I

20 TESTING AND ADJUSTING ................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY .................................................... 30-1

40 MAINTENANCE STANDARD ............................................................... 40-1

90 OTHERS ................................................................._............................................. go-1

<Explanation of applicable serial numbers>

LIST OF REVISED PAGES

0 00-l IO-15 0 IO-51 IO-87 10-108-7

IO-142 20-20-I @ l 20-55 0 20-96-7 0 20-126

20-166-11 @ 20-204 @ 20-236 30-50 30-100 @

30-137 30-183 40-13 0 92-17 0 92-75

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Electrical volume: Each issued as one

. If a part cannot be smoothly removed from

A Slinging with one rope may cause

Wire ropes 4) Do not sling a heavy load with ropes form-

20 43.1 4.4 hanging angle. On the other hand, two

2) Sling wire ropes from the middle portion 150

Category omatsu code Part No. Main applications, features

l Used to prevent rubber gaskets, rubber

l Used in places requiring an immediately

l Features: Resistance to heat and chemi-

790-I 29-9060 Adhesive: l Used as adhesive or sealant for metal, glass

Holtz . Used as heat-resisting sealant for repair-

. Quick hardening type adhesive

l Quick hardening type adhesive

l Features: Resistance to heat, chemicals

l Used as adhesive or sealant for gaskets

. Features: Resistance to heat

l Features: Resistance to water, oil

l Used as sealant for various threads, pipe

nipples of hydraulic piping.

. Features: Silicon based, resistance to heat,

l Features: Silicon based, quick hardening

. Used as heat-resisting sealant for repairing

l Used as lubricant for sliding portion (to pre-

SYG24OOLI l General purpose type

l Used for normal temperature, light load

Molybdenum 400 g l Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Thread diameter Width

Thread diameter Width

TIGHTENING TORQUE OF HOSE NUTS

( Threaytmeter Width across flat Tightening torque

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Thread diameter 1 Width across flat 1 Tiahtenina toraue

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tightening torque