WA150-5 SEBM033805 Structure, Function & Maintenance

10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE MOUNT AND TRANSFER MOUNT 10- 2 3-GEAR PUMP UNIT....................................10-100

DAMPER........................................................ 10- 3 ACCUMULATOR (FOR PPC CIRCUIT) .......10-102
COOLING SYSTEM....................................... 10- 4 LOCK VALVE ...............................................10-103
POWER TRAIN.............................................. 10- 5 E.C.S.S. VALVE ...........................................10-104
POWER TRAIN SYSTEM DIAGRAM ............ 10- 6 ACCUMULATOR (FOR E.C.S.S.) ................10-107
DRIVE SHAFT (PROPELLER SHAFT) ......... 10- 8 HYDRAULIC PIPING OF
HST HYDRAULIC PIPING DIAGRAM ........... 10- 9 COOLING SYSTEM...............................10-108
HST PUMP .................................................... 10-10 COOLING FAN MOTOR...............................10-109
HIGH-PRESSURE RELIEF VALVE ............... 10-12 WORK EQUIPMENT CONTROL VALVE .....10-110
LOW-PRESSURE RELIEF VALVE................ 10-14 WORK EQUIPMENT PPC VALVE ...............10-123
HST CHARGE PUMP .................................... 10-15 WORK EQUIPMENT LINKAGE....................10-130
SPEED-RELATED VALVE (DA VALVE) ....... 10-16 BUCKET .......................................................10-132
HIGH-PRESSURE CUT-OFF VALVE............ 10-17 BUCKET POSITIONER AND
HST MOTOR ................................................. 10-18 BOOM KICK-OUT ..................................10-133
EP SERVO VALVE ........................................ 10-21 WORK EQUIPMENT CYLINDER .................10-139
HA SERVO VALVE ........................................ 10-22 AIR CONDITIONER......................................10-140
FORWARD-REVERSE SHUTTLE VALVE .... 10-23 MACHINE MONITORING SYSTEM .............10-141
TRANSFER.................................................... 10-24 MACHINE MONITOR ...................................10-151
CLUTCH SOLENOID VALVE ........................ 10-35 LIST OF ITEMS DISPLAYED
AXLE .............................................................. 10-36 ON MONITOR........................................10-152
DIFFERENTIAL ............................................. 10-38 ELECTRICAL SYSTEM
LIMITED-SLIP DIFFERENTIAL ..................... 10-44 (HST CONTROLLER SYSTEM) ............10-178
FINAL DRIVE ................................................. 10-48 HST CONTROLLER .....................................10-182
AXLE MOUNTING AND ENGINE START CIRCUIT............................10-183
CENTER HINGE PIN .............................. 10-50 ENGINE STOP CIRCUIT..............................10-185
STEERING PIPING ....................................... 10-55 PREHEATING CIRCUIT...............................10-186
STEERING COLUMN .................................... 10-56 PARKING BRAKE CIRCUIT.........................10-187
PRIORITY VALVE ......................................... 10-57 ELECTRONICALLY CONTROLLED
ORBIT-ROLL VALVE..................................... 10-60 SUSPENSION SYSTEM ........................10-190
STEERING CYLINDER ................................. 10-68 SENSORS ....................................................10-191
EMERGENCY STEERING PIPING ............... 10-70
EMERGENCY STEERING VALVE ................ 10-71
BRAKE PIPING.............................................. 10-74
BRAKE VALVE .............................................. 10-75
INCHING VALVE ........................................... 10-79
CHARGE VALVE ........................................... 10-80
ACCUMULATOR (FOR BRAKE) ................... 10-84
SLACK ADJUSTER ....................................... 10-85
BRAKE ........................................................... 10-88
PARKING BRAKE CONTROL ....................... 10-91
PARKING BRAKE.......................................... 10-92
HYDRAULIC PIPING ..................................... 10-94
WORK EQUIPMENT LEVER LINKAGE ........ 10-96
HYDRAULIC TANK........................................ 10-97
WA150-5 10-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE MOUNT AND TRANSFER MOUNT
ENGINE MOUNT AND TRANSFER MOUNT
10-2 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DAMPER
DAMPER
Unit: mm
No. Check item Criteria Remedy
Distance between HST pump Standard size Repair limit

1 Adjust
mounting face and end of hub 61.2 ± 0.8
2 Wear of flange and insert Repair limit: 1.0 Replace
3. Flange Outline
4. HST pump input shaft • The damper reduces the torsional vibration
5. Hub caused by fluctuation of the engine torque to pro-
6. Cover tect the drive system after the engine from the
7. Flywheel torsional vibration.
8. Insert • The power from the engine is transmitted through
flywheel (7) to flange (3), which absorbs the tor-
sional vibration, and then transmitted through
hub (5) to the HST pump.
WA150-5 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
1. Oil cooler 4. Reservoir tank

2. After cooler 5. Cooling fan
3. Radiator 6. Cooling fan motor
Specification
Radiator Oil cooler After cooler
Core type AL WAVE–4 CF40–1 AL WAVE
Fin pitch (mm) 3.5 / 2 3.5 / 2 4.0 / 2
Total heat radiating area (m 2) 22.0 5.72 5.75
Pressure valve opening pressure 68.6

— —
(kPa {kg/cm 2}) {0.7}
Vacuum valve opening pressure 0 – 4.9

— —
(kPa {kg/cm 2}) {0 – 0.05}
10-4 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Engine
2. Damper
3. HST pump
4. 3-gear pump unit
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle
WA150-5 10-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
POWER TRAIN SYSTEM DIAGRAM
10-6 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
1. Engine Outline
2. Damper • The power of engine (1) is transmitted to HST
3. HST pump pump (3) through damper (2) which is installed to
4. Work equipment and Steering pump the flywheel and which absorbs the torsional vi-
5. Brake and cooling fan pump bration of the power,
6. Transfer lubricating oil pump • The power of engine (1) is also transmitted to
7. High-pressure hose HST pump (3), HST charge pump built in HST
8. HST motor 1 pump (3), work equipment and steering pump (4)
9. HST motor 2 connected to HST pump (3), brake and cooling
10. Emergency steering valve (If equipped) fan pump (5), and transfer lubricating oil pump
11. Transfer (6).
12. Transfer clutch • HST pump (3) is equipped with the forward-re-
13. Parking brake verse shifting valve and servo piston, which
14. Front drive shaft changes the discharge direction and discharge
15. Front axle rate of HST pump (3) continuously by changing
16. Differential the swash plate angle.
17. Wet multiple disc brake • HST motors (8) and (9) are installed to transfer
18. Final drive (11) and connected to HST pump (3) by high-
19. Front tire pressure hose (7).
20. Rear drive shaft • The turning direction and speed of HST motors
21. Rear axle (8) and (9) are changed by the hydraulic power of
22. Differential HST pump (3) to control the travel direction and
23. Wet multiple disc brake travel speed of the machine.
24. Final drive • The power of HST motor 1 (8) is transmitted
25. Rear tire through transfer clutch (12) in transfer (11) to the
output shaft.
The power of HST motor 2 (9) is transmitted
through the gear in transfer (11) to the output
shaft.
• Parking brake (13) is installed on the rear side in
transfer (11). It operates the wet multiple disc
brake to stop the machine according to the oper-
ation of the parking brake lever.
• The power for the front side is transmitted
through front drive shaft (14) to front axle (15).
The power for the rear side is transmitted
through rear drive shaft (20) to rear axle (21).
• The power transmitted to axles (15) and (21) is
reduced in speed by the pinion gears of differen-
tials (16) and (22), and then transmitted through
the sun gear shaft to the sun gear.
• The power of the sun gear is reduced in speed by
the planetary mechanisms of final drives (18) and
(24), and then transmitted through the axle shaft
and wheels to tires (19) and (25).
WA150-5 10-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
1. Front axle Outline

2. Front drive shaft • The power from the output shaft of the transfer is
3. Transfer transmitted through front drive shaft (2) and rear
4. Rear drive shaft drive shaft (4) to front axle (1) and rear axle (5).
5. Rear axle • When the machine is articulated or it receives an
impact from the road during travel or a working
impact, the positions of the transfer and front and
rear axles change. The drive shafts can change
their angles and lengths by means of the univer-
sal joints and sliding joints so that the power will
be transmitted without damaging any part even
when the positions of the components change
because of the impacts.
10-8 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST HYDRAULIC PIPING DIAGRAM
HST HYDRAULIC PIPING DIAGRAM
1. Hydraulic tank
2. HST pump
3. Clutch solenoid valve
4. HST oil filter
5. HST motor 1
6. HST motor 2
WA150-5 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST PUMP
HST PUMP
a HST: Abbreviation for Hydro Static Transmission
1. Forward-reverse shifting solenoid valve Specifications

2. High-pressure cut-off valve
Model A4VG71DA
3. Speed-related valve (DA valve)
4. Charge pump Variable displacement swash
Type
5. Low-pressure relief valve plate-type piston pump
6. Servo cylinder Theoretical capacity
7. High-pressure relief valve 0 – 71
(cc / rev)
8. Control plate
9. Cylinder block Set pressure of high-pressure
43.2 {441}
10. Piston relief valve (MPa {kg/cm2})
11. Swash plate Set pressure of high-pressure Effective differential pressure
cut-off valve (MPa {kg/cm 2}) 40.2 {410}
Set pressure of low-pressure

2.5 {25}
relief valve (MPa {kg/cm2})
10-10 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST PUMP
Operation
Flow of power Flow of oil

• The HST pump is installed to the coupling which • As swash plate (11) of the HST pump slants, pis-
is installed to the engine flywheel. tons (10) in contact with its surface reciprocate
• The power of the engine is transmitted from the and work as pumps to suck and discharge the oil
flywheel through the coupling to the HST pump. in cylinder block (9).
• The HST pump is equipped with forward-reverse • As a result, high-pressure oil flows in a constant
shifting solenoid valve (1) and servo cylinder (6). direction into the HST motor.
If the operator operates for forward or reverse • If swash plate (11) slants in the opposite direc-
travel, forward-reverse shifting solenoid valve (1) tion, the sucking and discharging directions of the
operates and swash plate (11) in the HST pump oil are reversed, that is, the oil flows in the oppo-
slants to reverse the oil flow. site direction. While swash plate (11) is in neu-
• Cylinder block (9) and pistons (10) in it rotate to- tral, pistons (10) do not reciprocate, thus they do
gether with drive shaft (12) and the tips of pistons not discharge any oil.
(10) slide on swash plate (11) which does not ro- • The strokes of pistons (10) are changed to con-
tate. The pump has 9 pistons (10) in it. trol the travel speed by increasing or decreasing
inclination (angle) of swash plate (11).
• If the quantity of the oil in the low-pressure circuit
(the return circuit from the motor to the pump) be-
comes insufficient because of leakage from the
HST pump, HST motor, and control valve, the
charge pump adds oil through speed-related
valve (3) and check valve of high-pressure relief
valve (7).
WA150-5 10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE RELIEF VALVE
HIGH-PRESSURE RELIEF VALVE
1. Nut Function
2. Locknut • The high-pressure relief valve is installed to the
3. Poppet spring HST pump. If the oil pressure in the high-pres-
4. Check spring sure circuit between the HST pump and HST mo-
5. Main piston tor rises higher than the set pressure, the high-
6. Valve seat pressure relief valve drains the oil into the low-
7. Pilot poppet pressure circuit.
8. Adjustment screw The high-pressure relief valve controls the maxi-
mum pressure in the circuit to protect the circuit
with this function.
• If the quantity of the oil in the circuit becomes in-
sufficient, the high-pressure valve leads oil in
from the HST charge pump to prevent cavitation.
10-12 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE RELIEF VALVE
Operation
• Port A is connected to the high-pressure circuit of • If the oil pressure in port A and chamber B reach-
the HST pump and ports C and D are connected es the set pressure of poppet spring (3), pilot
to the low-pressure circuit of the HST pump. poppet (7) opens and the oil in chamber B flows
The oil fills chamber B through the orifice of main through chamber D to port C, and the oil pressure
piston (5). in chamber B lowers consequently.
Pilot poppet (7) is seated on valve seat (6). If the oil pressure in chamber B lowers, a pres-
sure difference is made between port A and
chamber B by the orifice of main piston (5). As a
result, main piston (5) is pushed open and the oil
in port A flows into port C to relieve the abnormal
pressure.
• The set pressure can be adjusted by increasing

or decreasing the tension of poppet spring (3).
To adjust the set pressure, remove the nut and
loosen the locknut. If the adjustment screw is
tightened, the set pressure is heightened. If the
former is loosened, the latter is lowered.
• If the oil pressure in port A lowers below that in
port C, check spring (4) pushes back main piston
(5) and the oil in port C flows through chamber D
into port A so that the quantity of the oil in port A
will not become insufficient.
WA150-5 10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LOW-PRESSURE RELIEF VALVE
LOW-PRESSURE RELIEF VALVE

Operation
• Port A is connected to the HST pump charge cir-
cuit and port B is connected to the drain circuit.
If the oil pressure is below the set pressure, the
oil does not flow into port B.
• If the pressure in port A reaches the set pressure
for some reason, piston (3) opens and the oil in
port A flows into port B, and the oil pressure in
port A lowers consequently.
• The set pressure can be adjusted by increasing
or decreasing the tension of spring (4).
To adjust the set pressure, loosen locknut (1) and
turn adjustment screw (2). If the adjustment
1. Locknut screw is tightened, the set pressure is height-
2. Adjustment screw ened. If the former is loosened, the latter is low-
3. Piston ered.
4. Spring
Function
• The low-pressure relief valve is installed to the
HST pump. If the oil pressure in the low-pressure
circuit between the HST pump and HST motor
rises higher than the set pressure, the low-pres-
sure relief valve drains the oil into the hydraulic
tank.
The low-pressure relief valve controls the pres-
sure in the HST pump charge circuit to protect the
circuit with this function.
10-14 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST CHARGE PUMP
HST CHARGE PUMP
1. Cover bolt Specifications

2. Pump gear
3. Key Gear pump
Type
4. Coupling (Inscribed type)
5. Drive shaft
6. Plate Theoretical capacity
19.6
7. Charge pump cover (cc/rev)
8. Crescent divider board
Function
Outline • The HST charge pump is connected to drive shaft
• The HST charge pump is built in the HST pump (5) of the HST pump and rotated by coupling (4).
and driven together with the HST pump to supply • The HST charge pump has pump gear (2) and
oil to the HST speed-related valve and low-pres- crescent divider board (8) in it and sucks and dis-
sure relief valve of the HST pump. charges the oil in the direction shown in the
• The HST charge pump sucks in oil from the hy- above figure.
draulic tank.
WA150-5 10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPEED-RELATED VALVE (DA VALVE)
SPEED-RELATED VALVE (DA VALVE)
1. Locknut
2. Adjustment screw
3. Poppet spring
4. Spring seat
5. Pilot poppet
Function
• The speed-related valve is installed to the HST
pump and used to divide the oil from the HST
charge pump into two parts. One part flows
through a throttle valve to the forward-reverse
shifting solenoid valve of the HST pump and the
other part flows to the low-pressure relief valve of
the HST pump.
Operation
• Port A is connected to the HST pump charge cir-
cuit. Port D is connected to the low-pressure re-
lief valve circuit. Port C is connected to the
forward-reverse shifting solenoid valve circuit.
• The oil from the HST charge pump always flow
through the throttle valve of pilot poppet (5),
chamber B, and port D to the low-pressure relief
valve.
As the hydraulic pressure from the HST charge
pump is applied a differential pressure is gener-
ated between port A and chamber B because of
the throttle valve of pilot poppet (5). Since this dif-
ferential pressure moves pilot poppet (5), the oil
flows from chamber B through port C to the for-
ward-reverse shifting solenoid valve.
• Pilot poppet (5), poppet spring (3), and spring
seat (4) are used as a set. To change the set
pressure, loosen locknut (1) and turn the adjust-
ment screw (2). If the adjustment screw is tight-
ened, the set pressure is lowered. If the former is
loosened, the latter is heightened.
10-16 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE CUT-OFF VALVE
HIGH-PRESSURE CUT-OFF VALVE
1. Adjustment screw
2. Locknut
3. Spring
4. Spool
5. Piston
6. Barrel
7. Shuttle spool
8. Valve seat
Function
• The high-pressure cut-off valve is installed to the
HST pump. If the oil pressure in the high-pres-
sure circuit between the HST pump and HST mo-
tor rises higher than the set pressure, the high-
pressure cut-off valve drains the oil from the ser-
vo cylinder circuit into the hydraulic tank to con-
trol the maximum pressure in the HST pump
circuit.
Operation
• Port A is connected to the high-pressure circuit
during reverse travel. Port B is connected to the
high-pressure circuit during forward travel. Port
Pc is connected to the speed-related valve, and
port T is connected to the drain circuit.
• If the pressure on the port A side rises high for
some reason, shuttle spool (7) is pushed down
and the circuit on port B side is closed. At the
same time, piston (5) is pushed up by the hydrau-
lic pressure on port A side and spring (3) is com-
pressed and spool (4) is also pushed up. Then,
ports Pc and T are opened and the hydraulic oil
in the speed-related valve circuit flows into the
drain port.
As a result, the oil pressure in port Pc lowers and
the swash plate angle of the HST pump reduces,
and consequently the discharge reduces and the
abnormal pressure in the HST pump circuit low-
ers.
WA150-5 10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST MOTOR
HST MOTOR
a HST: Abbreviation for Hydro Static Transmission
HST motor 1
1. Drive shaft Specifications

2. Piston
Model A6VM55EP
3. Cylinder block
4. Port plate Variable displacement bent
Type
axis type piston motor
5. EP servo valve
Theoretical capacity (cc/rev) 0 – 55
Set pressure of high-pressure
43.2 {441}
Set pressure of high-pressure Effective differential pressure
cut-off valve (MPa {kg/cm2}) 40.2 {410}
2.5 {25}
10-18 WA150-5
(5)
HST motor 2
1. Drive shaft Specifications

2. Piston
Model A6VM55HA
3. Cylinder block
4. Port plate Variable displacement bent
Type
axis type piston motor
5. HA servo valve
6. Forward-reverse shuttle valve Theoretical capacity (cc/rev) 28.5 – 55
Set pressure of high-pressure
43.2 {441}
Set pressure of high-pressure Effective differential pressure
cut-off valve (MPa {kg/cm2}) 40.2 {410}
2.5 {25}
WA150-5 10-19
(5)
Principle Operation
• Let's assume that a shaft of a disc is supported • The hydraulic oil sent from the HST pump flows
and the disc can rotate freely. If force F is applied in the inlet port of the HST motor and gives hy-
bias to this disc, it is divided into component force draulic pressure to the back side of pistons (2).
F1 at right angles to the disc and component Accordingly, drive shaft (1) rotates because of in-
force F2 in the peripheral direction of the disc. clination of pistons (2) and cylinder block (3).
Component force F2 rotates the disc to the right. • The oil from the HST pump flows between the for-
• If force F', not force F, is applied to the disc, it is ward-reverse shifting solenoid valve and servo
divided into component forces F1' and F2' simi- cylinder into forward-reverse shuttle valve (6) of
larly to the above and force F2' rotates the disc to the HST motor. The oil from the forward or re-
the left verse high-pressure discharge side of the HST
motor flows into forward-reverse shuttle valve
(6). If a load is applied to the motor connected to
servo valve (5) in the HST motor, the oil flows into
the servo cylinder of the HST motor because of
the pressure difference from forward-reverse
shuttle valve (6) side, thus cylinder block (3) is in-
clined more.
Structure
• There are 7 pistons (2) installed to the disc por-

tion of the drive shaft (1) as if they are spherical
joints. They are set in cylinder block (3) at a cer-
tain angle to drive shaft (1).
• As the external load on the HST motor is in-
creased by servo valve (5) and forward-reverse
shuttle valve (6), inclination of pistons (2) is in-
creased. As a result, the revolving speed is low-
ered but the torque is increased.
10-20 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EP SERVO VALVE
EP SERVO VALVE
1. Motor 1 solenoid valve Operation

2. EP servo valve • Suction force F1 of motor 1 solenoid valve (1)
3. Spring and force F2 of spring (3) are applied to EP servo
4. Servo cylinder valve (2).
• If the current given to motor 1 solenoid valve (1)
Function is little (F1 < F2), EP servo valve (2) leads the hy-
• The EP servo valve is installed to the rear part of draulic pressure of the motor high-pressure cir-
HST motor 1 and used to change the displace- cuit to the small diameter (S) side of servo
ment of the motor according to the current given cylinder (4) and releases the hydraulic pressure
to motor 1 solenoid valve (1). on the large diameter (L) side into the tank (motor
housing). As a result, servo cylinder (4) moves
toward the min side.
• If the current given to motor 1 solenoid valve (1)
is large (F1 > F2), EP servo valve (2) leads the
hydraulic pressure to the large diameter (L) side.
As a result, servo cylinder (4) moves toward the
max side because of the area difference between
the small diameter (S) side and large diameter (L)
side.
• The force of spring (3) changes according to the
position of servo cylinder (4) (the displacement of
the motor).
Accordingly, the displacement of the motor is
controlled by the current given to motor 1 sole-
noid valve (1) so that suction force F1 will be bal-
anced with spring force F2.
WA150-5 10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HA SERVO VALVE
HA SERVO VALVE
1. Motor 2 solenoid valve Operation

2. HA servo valve • When the load on the machine is small, HA servo
3. Servo cylinder valve (2) leads the hydraulic pressure on the side
selected by the forward-reverse shuttle valve to
Function the small diameter (S) side of servo cylinder (3)
• The HA servo valve is installed to the rear part of and releases the hydraulic pressure on the large
HST motor 2 and used to control the position of diameter (L) side into the tank (motor housing) to
servo cylinder (3) (the displacement of the motor) minimize the displacement of the motor.
to meet the motor output to the external load on • When a large load is applied to the machine on a
the motor. The displacement is controlled with uphill, etc., HA servo valve (2) leads the hydraulic
the hydraulic pressure in the circuit selected by pressure to the large diameter (L) side. As a re-
the forward-reverse shuttle valve. sult, servo cylinder (3) moves toward the max
side because of the area difference between the
small diameter (S) side and large diameter (L)
side. At this time, the displacement of the motor
becomes largest and the motor generates large
torque.
• If motor 2 solenoid valve (1) is energized, HA ser-
vo valve (2) leads the hydraulic pressure to the
large diameter (L) side and the displacement of
the motor becomes largest, regardless of the
load on the machine.
10-22 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FORWARD-REVERSE SHUTTLE VALVE
FORWARD-REVERSE SHUTTLE VALVE
1. Forward-reverse shifting solenoid valve Operation

2. Forward-reverse shuttle valve • The electric signals given to the forward-reverse
shifting solenoid valve of the HST pump are used
Function for forward-reverse shifting solenoid valve (1)
• The forward-reverse shuttle valve is installed to and linked to the forward-reverse shifting mecha-
the rear part of HST motor 2 and used to grasp nism.
and change the position of the forward-reverse • Forward-reverse shuttle valve (2) changes the
shifting solenoid valve to control where to lead hydraulic pressure applied to the HA servo valve
the hydraulic pressure for the HA servo valve. according to the forward-reverse shifting com-
Accordingly, shock made when the oil pressure mand.
changes for gear shifting are reduced.
WA150-5 10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER
TRANSFER
a. Clutch port Relationship between transfer clutch and transfer

b. Lubricating oil inlet port clutch pressure at each gear speed
c. Lubricating oil suction port
Gear
Transfer clutch Transfer clutch pressure
speed
1. Transfer
2. Parking brake lever 1st Engaged OFF
3. HST motor 2 mount
2nd Engaged OFF
4. HST motor 1 mount
5. Oil filler pipe Travel speed Travel speed Travel speed Travel speed
0 – 10km/h 10 – 20km/h 0 – 10km/h 10 – 20km/h
3rd
Outline Engaged Disengaged OFF ON
• The transfer is equipped with 2 HST motors. The
engine speed is changed to the forward 1st – 4th Travel speed Travel speed Travel speed Travel speed
0 – 10km/h 10 – 38km/h 0 – 10km/h 10 – 38km/h
and rear 1st – 4th gear speeds by combining the 4th
output and revolving direction of the HST motor Engaged Disengaged OFF ON
and the transfer clutch.
Note: The travel speed when tires of 16.9 – 24 size
are used is shown in the table.
10-24 WA150-5
1. HST motor 1 8. Motor 1 gear (Number of teeth: 43)

2. Input shaft 9. Sun gear (Number of teeth: 27)
3. Transfer clutch 10. Parking brake
4. Carrier 11. Rear coupling
5. Ring gear (Number of teeth: 66) 12. Output gear (Number of teeth: 50)
6. Planetary gear (Number of teeth: 19) 13. Output shaft
7. Planetary shaft 14. Front coupling
WA150-5 10-25
Input shaft portion
Unit: mm
Standard Tolerance Standard Clearance

Clearance between input shaft size Shaft Hole clearance limit
1
and bearing (F)
++0.011 +0 -0.023 –
45 –
+-0.005 -0.012 0.005
Clearance between input shaft ++0 ++0.013 -0.006 –
2 75 –
bearing and cage (F) -0.013 -0.006 0.026
Clearance between input shaft +0.011 +0 -0.023 – Replace
3 45 –
and bearing (M) -0.005 -0.012 0.005
Clearance between input shaft +0 ++0.013 -0.006 –
4 75 –
bearing and ring gear (M) -0.013 -0.006 0.026
Clearance between input shaft +0.011 +0 -0.023 –
5 40 –
and bearing (R) -0.005 -0.012 0.005
Clearance between input shaft +0 +0.013 -0.006 –
6 68 –
bearing and carrier (R) -0.013 -0.006 0.026
10-26 WA150-5
Clearance between press-fit +0.033 +0 -0.045 –

7 40 –
shaft and bearing +0.017 -0.012 -0.017
Clearance between press-fit +0 -0.014 -0.033 –
8 80 –
shaft bearing and motor 1 gear -0.016 -0.033 0.002
Clearance between piston and -0.085 +0.040 0.085 –
9 150 –
spacer -0.125 +0 0.165
Clearance between piston and -0.550 +0.046 0.550 –
10 187 –
cage -0.650 +0 0.696
Clearance between clutch +0.055 +0.040 -0.055 –
11 180 –
housing and front case +0.015 +0 0.025
Standard size Tolerance Repair limit
Thickness of separator plate
12 1.8 ±0.06 1.6
Distortion of separator plate – 0.05 0.15
±0.05
Thickness of friction plate 3.0 2.55
13 -0.10
Distortion of friction plate – 0.07 0.25
Load on wave spring 902 N ±90 N 765 N
14
(Height: 2.2 mm) {92 kg} {±9.2 kg} {78 kg}
Inside diameter of contact face +0.021
25 25.1
of seal ring +0
+0.15
Width of groove of seal ring 2.5 2.8
15 +0.10 Replace
-0.01
Width of seal ring 2.5 2.3
-0.03
Thickness of seal ring 1.2 ±0.1 1.05
60 60.1
of seal ring +0
+0.15
16 +0.10
-0.01
-0.03
95 95.5
of seal ring +0
+0.15
17 +0.10
+0
-0.05
Backlash between motor 1 gear
18 0.170 – 0.439
and output gear
Side clearance of planetary
— 0.35 – 0.80
gear (on both sides)
WA150-5 10-27
Output shaft portion
10-28 WA150-5
Unit: mm

Clearance between output size Shaft Hole clearance limit
1
shaft and bearing (F)
+0.030 +0 -0.045 –
60 –
+0.011 -0.015 -0.011
Clearance between output +0 -0.015 -0.040 –
2 95 –
shaft bearing and cage (F) -0.018 -0.040 0.003
Clearance between output +0.030 +0 -0.045 –
3 55 –
shaft and bearing (R) +0.011 -0.015 -0.011
Clearance between output +0 -0.015 -0.040 –
4 100 –
shaft bearing and rear case (R) -0.018 -0.040 0.003
Clearance between oil seal and +0.170 +0.054 -0.170 –
5 100 –
cage (F) +0.080 +0 -0.026 Replace
Clearance between dust seal +0.400 +0.054 -0.400 –
6 100 –
and cage (F) +0.200 +0 -0.146
Clearance between oil seal and +0.170 +0.054 -0.170 –
7 100 –
cage (R) +0.080 +0 -0.026
Clearance between dust seal +0.400 +0.054 -0.400 –
8 100 –
and cage (R) +0.200 +0 -0.146
Inside diameter of sliding sur-
9 0
face of coupling oil seal (F) 75 74.8
-0.074
Inside diameter of sliding sur- 0
10 75 74.8
face of coupling oil seal (R) -0.074
Standard Clearance
Clearance between cage and Standard size
11 clearance limit
front case
0.9 0.35 – 1.45 – Adjust shim
Free rotation torque of output
12 2.9 – 4.9 Nm {0.3 – 0.5 kgm}
shaft
WA150-5 10-29
10-30 WA150-5
1. HST motor 2
2. Motor 2 gear (Number of teeth: 43)
3. Strainer
4. Drain plug
5. Speed sensor
Unit: mm

Clearance between input shaft size Shaft Hole clearance limit
6
and bearing
+0.025 +0 -0.037 –
50 –
+0.009 -0.012 -0.009
Replace
Clearance between input shaft +0 +0.018 -0.012 –
7 80 –
bearing and cage -0.013 -0.012 0.031
Backlash between motor 2 gear
8 0.170 – 0.439
and output gear
WA150-5 10-31
Operation of clutch
When clutch is ON (fixed) When clutch is OFF (released)
• If the oil from the clutch solenoid valve is shut off, • The oil sent from the clutch solenoid valve is sent
piston (2) is moved to the right by the tension of by pressure to the back side of piston (2) and it
spring (1). pushes back spring (1) and piston (2) moves to
Plates (3) and discs (4) are fixed to each other the left. The friction force of plates (3) and discs
and rotation of discs (4) is stopped by their friction (4) is lost and ring gear (5) is set in neutral.
force and ring gear (5) meshed with the internal • Wave springs (6) installed between plates (3) re-
teeth is fixed. turn piston (2) quickly and separate plates (3) and
discs (4) to prevent increase of slip loss when the
clutch is disengaged.
10-32 WA150-5
Low-speed mode
Operation
• In the low-speed mode, transfer clutch (1) is fixed
and the power of both HST motor 1 (2) and HST
motor 2 (3) is transmitted to output shaft (11).
• The power of HST motor 1 (2) is transmitted
through input shaft (4), sun gear (5), planetary
gear (6), carrier (7), motor 1 gear (8), and output
gear (10) to output shaft (11).
through motor 2 gear (9) and output gear (10) to
output shaft (11).
WA150-5 10-33
High-speed mode
Operation
• In the high-speed mode, transfer clutch (1) is re-
leased and HST motor 1 (2) stops. Accordingly,
the power of only HST motor 2 (3) is transmitted
to output shaft (11).
through motor 2 gear (9) and output gear (10) to
output shaft (11).
10-34 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLUTCH SOLENOID VALVE
CLUTCH SOLENOID VALVE
P: From HST charge pump Operation

A: To transfer clutch • When the current of the input signal is large, the
T: To drain port hydraulic oil of the transfer clutch is drained.
• As the current of the input signal is reduced, the
1. Clutch solenoid valve hydraulic pressure of the transfer clutch is height-
2. Plunger ened.
3. Coil • After the current of the input signal is reduced un-
4. Push pin til the hydraulic pressure of the transfer clutch
5. Spring reaches the hydraulic pressure sent from the
6. Spool HST charge pump, the hydraulic pressure of the
7. Body transfer clutch is kept at the hydraulic pressure
sent from the HST charge pump even if the cur-
rent of the input signal is reduced further.
WA150-5 10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
AXLE
FRONT AXLE
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Shaft
8. Oil filler port / level plug
9. Slack adjuster
10. Oil temperature sensor
11. Draing plug
10-36 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
REAR AXLE
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port / level plug
8. Slack adjuster
9. Draing plug
WA150-5 10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
1. Pinion gear (Number of teeth: 9)

2. Shaft
3. Bevel gear (Number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 9)
6. Side gear (Number of teeth: 12)
10-38 WA150-5
Unit: mm
7 Backlash of differential gear 0.15 – 0.35 Replace

8.82 – 27.44 N {0.9 – 2.8 kg}
8 Starting force of bevel gear Adjust
(At outside surface of bevel gear)
9 Pinion gear washer thickness
3 ± 0.08 2.8 Replace
10 Side gear washer thickness 2 ± 0.05 1.8
Thickness of shim at differential
11 0.50 – 1.35
side bearing carrier (Each side) Adjust
12 Backlash of bevel gear 0.18 – 0.28
13 End play of bevel pinion 0 – 0.151 Replace
14 0.35 – 1.4 Adjust
housing and gauge assembly

size Shaft Hole clearance limit
Clearance of differ- Outer +0 -0.024 -0.059 –
15 105 —
ential side bearing race +0.020 -0.059 -0.004
Inner +0.051 +0 -0.066 –
65 —
race +0.032 +0.015 -0.032
Outer +0 -0.041 -0.076 –
Clearance of bear- race 110 —
-0.015 -0.076 -0.026
16 ing on gear side of
pinion shaft Inner +0.039 +0 -0.051 –
50 —
race +0.025 -0.012 -0.025
Outer +0 -0.041 -0.076 –
-0.015 -0.076 -0.026
17 ing on coupling
side of pinion shaft Inner +0.039 +0 -0.051 – Replace
55 —
race +0.025 -0.012 -0.025
Clearance between pinion gear -0.13 +0.02 0.11 –
18 25.18 —
and spider -0.18 +0.02 0.2
Clearance of piston fitting por-
-0.100 +0.072 0.100 –
19 tion of differential housing 214 —
-0.172 + 0 0.244
(Housing and piston)
-0.100 +0.072 0.100 –
20 tion of bearing carrier (Piston 194 —
-0.172 +0 0.244
and carrier)
Clearance Outer +0 +0 -0.035 –

90 —
between drive race -0.015 -0.035 0.015
21
shaft and bearing Inner +0.018 +0 -0.030 –
of cage 40 —
race +0.002 -0.012 -0.002
WA150-5 10-39
REAR DIFFERENTIAL
1. Pinion gear (Number of teeth: 9)

2. Shaft
3. Bevel gear (Number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 9)
6. Side gear (Number of teeth: 12)
10-40 WA150-5
Unit: mm
7 Backlash of differential gear 0.15 – 0.35 Replace

8.82 – 27.44 N {0.9 – 2.8 kg}
8 Starting force of bevel gear Adjust
(At outside surface of bevel gear)
9 Pinion gear washer thickness
3 ± 0.08 2.8 Replace
10 Side gear washer thickness 2 ± 0.05 1.8
11 0.50 – 1.35
side bearing carrier (Each side) Adjust
12 Backlash of bevel gear 0.18 – 0.28
13 End play of bevel pinion 0 – 0.150 Replace
14 0.35 – 1.4 Adjust
housing and gauge assembly

size Shaft Hole clearance limit
Clearance of differ- Outer +0 -0.024 -0.059 –
15 105 —
ential side bearing race -0.020 -0.059 -0.004
Inner +0.051 +0 -0.066 –
65 —
race +0.032 -0.015 -0.032
Outer +0 +0.041 -0.076 –
-0.015 -0.076 -0.026
16 ing on gear side of
pinion shaft Inner +0.039 +0 -0.051 –
50 —
race +0.025 -0.012 -0.025
Outer +0 -0.038 -0.073 – Replace
-0.015 -0.073 -0.023
17 ing on coupling
side of pinion shaft Inner +0.033 +0 -0.045 –
40 —
race +0.017 -0.012 -0.017
Clearance between pinion gear -0.13 +0.02 0.11 –
18 25.18 —
and spider -0.18 -0.02 0.2
-0.100 +0.072 0.100 –
19 tion of differential housing 214 —
-0.172 +0 0.244
(Housing and piston)
-0.100 +0.072 0.100 –
20 tion of bearing carrier (Piston 194 —
-0.172 +0 0.244
and carrier)
WA150-5 10-41
Outline When turning

• The power transmitted to the front and rear axles • When turning, the rotating speed of the left and
is turned by 90 degrees and reduced in speed, right wheels is different, so pinion gear (4) and
and then transmitted through pinion gear (4) to side gear (3) inside the differential transmit the
sun gear shaft (2). power of carrier (6) to sun gear shaft (2) while ro-
• The power of the sun gear is further reduced by tating in accordance with the difference between
the planetary gear type final drive and is transmit- the left and right rotating speeds.
ted to the axle shaft and wheels.
When traveling in a straight line

• When traveling in a straight line, the rotating
speed of the left and right wheels is the same, so
pinion gear (4) inside the differential assembly
does not rotate. The power of carrier (6) passes
through pinion gear (4) and side gear (3), and is
transmitted equally to the left and right sun gear
shafts (2).
10-42 WA150-5
Torque proportioning differential Travel on soft ground (When the road resistances
under both tires are different)
Outline • When the tires slips on soft ground, the side gear
• A 4-wheel-drive wheel loader, as a construction of the tire on the less road resistance side turns
machine, must naturally work on places where forward. As a result, the meshing points of pinion
the ground condition is bad. If its tires slip in such gear (4) and the side gears change.
places, its function lowers and the lives of the • If left side gear (7) turns forward a little, distance
tires are shortened. To solve this problem, the "a" from the pinion gear to the meshing point of
torque proportioning differential is used. the left side gear becomes longer than distance
• Differential pinion gear (4) of this differential has "b" to the meshing point of the right side gear,
an odd number of teeth. The meshing points of and then "a" and "b" are balanced at a point
pinion gear (4) and side gears (3) change accord- where a x TL = b x TR. The ratio of a:b changes
ing to the difference of the road resistance. Con- up to 1:1.38, depending on the meshing condi-
sequently, the traction forces of the tires on both tion.
sides change. • Accordingly, the pinion gear does not run idle and
the drive force is transmitted to both side gears
and the tires do not slip until the ratio of a:b be-
comes 1:1.38, or the difference between the road
resistances under both tires becomes 38%.
• The lives of the tires are lengthened 20 - 30% and
the working capacity is increased by the above
effect.
Operation
Straight travel (When the road resistances under

both tires are the same)
• When the road resistances under the both tires
are the same, distance "a" from differential pinion
(4) to the meshing point of left side gear (7) and
distance "b" to the meshing point of right side
gear (3) are the same.
• Accordingly, left traction force TL and right trac-
tion force TR are balanced.
WA150-5 10-43
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIMITED-SLIP DIFFERENTIAL
LIMITED-SLIP DIFFERENTIAL
1. Plate
2. Disc
3. Pinion (Number of teeth:12)
4. Washer
5. Side gear(Number of teeth:24)
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Bevel gear
10. Case
10-44 WA150-5
Unit: mm

11 Plate thickness 3
± 0.02 2.9
3.1
+0.04
12 Disc thickness 2.5 2.45
-0.03
13 Washer thickness 2 ± 0.05 1.8
Clearance between disc and
14 0.20 – 0.6
plate (Total of both sides)
End play (one end ) of side Replace
15 0.13 – 0.36
gear in axial direction
Backlash between case and
16 0 – 0.5
plate
Backlash between side gear
17 0.13 – 0.32
and disc

Clearance between spider and size Shaft Hole clearance limit
18
differential pinion gear
-0.110 +0.05 0.110 –
22 —
-0.160 +0 0.210
WA150-5 10-45
Operation of limited-slip differential When traveling in a straight line
1. When there is no imbalance between drive

The power is transmitted from bevel gear (9) to case
force of left and right wheels [Road surface
(10), pressure ring (8), shaft (7), pinion (3), and side
condition (friction coefficient) and load for left
gear (5), and is divided to the left and right shafts.
and right wheels are uniform and load on bucket
The brake system, consisting of discs (2) and plates
is centered exactly]
(1) is installed at the rear face of side gear (5). A
The power is divided equally to the left and right
brake torque is generated that is proportional
by the differential gear. In this case, the wheel
to the torque transmitted from pressure ring (8) to
slip limit of the left and right wheels is the same,
shaft (7).
so even if the power from the engine exceeds
This brake torque acts to limit the rotation in relation
the wheel slip limit, both wheels will slip and the
to side gear (5) and case (10), so it is difficult for left
differential will not be actuated.
and right side gears (5) to rotate mutually and the op-
There is no load on the brake at the rear face of
eration of the differential is limited.
the side gears.
Brake torque generation mechanism of left and
right side gears (5).
Shaft (7) is supported at the cam surface cut into the
facing surfaces of left and right pressure rings (8).
The power (torque) transmitted from pressure rings
(8) to shaft (7) is transmitted at the cam surface, but
force Fa separating left and right pressure rings (8)
is generated in proportion to the torque transmitted
according to the angle of this cam surface.
This separation load Fa acts on the brake at the rear
face of left and right side gears (5) and generates the
brake torque.
10-46 WA150-5
2. When there is imbalance between drive force Difference in wheel drive force for each type of differ-
of left and right wheels [Road surface condition ential when wheel on one side slips
(friction coefficient) and load for left and right Wheel drive force
wheels are not uniform and it is easier for wheel (Ratio when slipping wheel is
on one side to slip] set to 1)
Example 1. When digging, and wheel on one Slipping Locked Total
side is on soft surface wheel wheel (ratio)
Example 2. When clearing snow, and wheel on Limited-slip differential 1 2.64 3.64
one side is on snow and wheel on other side is (option) (1.53)
on asphalt Torque proportioning 1 1.38 2.38 (1)
Example 3. When traveling on slope, and there differential (standard)
is imbalance between load on left and right Normal differential 1 1 2 (0.84)
wheels
The power from transfer is divided equally to the
left and right by the side gear. However, when On road surfaces where the wheel on one side is like-
the drive force exceeds the wheel slip limit on ly to slip, the limited-slip differential increases the
the side where the wheel is slipping, the amount drive force by 1.53 times more than the torque pro-
of the force exceeding the wheel slip limit portioning differential.
passes through the brake and case at the rear
face of the side gear and is transmitted to the When turning
brake on the opposite side (locked side) and is The differential gears built into a limited-slip differen-
sent to the wheel on the locked side. tial are the same as the gears used in a normal differ-
If this excess portion of the drive force becomes ential, so the difference in rotation between the inside
greater than the braking force, the differential and outside wheels when turning the machine can be
starts to work. generated smoothly.
WA150-5 10-47
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
1. Planet gear (No. of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (No. of teeth: 69)
5. Sun gear shaft (No. of teeth: 15)
10-48 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
Tolerance
Standard Standard Clearance
Clearance between pinion gear size Clearance limit
6 Shaft Hole
bearing and shaft
Replace
+0.025 +0.013 -0.025 –
33.338 +0.013 0 0 —
Clearance between axle housing +0.100 +0.100 -0.100 –
7 and ring gear 255 +0.030 0 +0.070 —
Clearance between oil seal and
8 housing Max. 0.2 Adjust
+0.50 +0.063 -0.5 –
Housing 130 +0.25 0 -0.187 —
9 Press-fitting portion
of axle shaft seal 0 -0.25 -0.45 –
Shaft 93.5 -0.054 -0.45 -0.196 —
+0.025 -0.013 -0.076–
Clearance at press- Outer race 127 0 -0.051 -0.013 —
10 fitting portion of axle
housing bearing +0.063 +0.025 -0.063 –
Inner race 77.788 +0.038 0 -0.013 — Replace
+0.025
112.713 0 —
Outer race -0.077 – —
+0.038 -0.014
Clearance at press- 112.661 — +0
11 fitting portion of axle
housing bearing 0
69.9 -0.25 —
Inner race -0.05 – —
+0.013 -0.012
69.85 — +0
End play of axle shaft 0 – 0.098
12 Adjust
Starting torque of axle shaft Max. 3.2 Nm {0.33 kgm}
13 Clearance of guide pin 8 +0.080 +0.036 +0.080 – — Replace

+0.116 +0 +0.152
Outline
• The final drive finally reduces the speed of the
power transmitted from the HST motor through
the transfer to the axle and increases the drive
force.
• Ring gear (4) is press fitted to the axle housing
and is fixed in position by a pin.
• The power transmitted from the differential and
passing through sun gear shaft (5) has its speed
reduced by the planetary gear mechanism and
the drive force increased.
The increased drive force passes through plane-
tary carrier (2) and axle shaft (3) and is transmit-
ted to the wheels.
WA150-5 10-49
AXLE MOUNTING AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER HINGE PIN
AXLE MOUNTING AND CENTER HINGE PIN

.
10-50 WA150-5
AXLE MOUNTING AND
1. Front axle Outline

2. Tension bolt • Since front axle (1) receives forces directly during
3. Front frame work, it is fixed to front frame (3) directly with ten-
4. Center hinge pin sion bolts (2).
5. Rear axle • Rear axle (5) rocks at the center of rear frame (6)
6. Rear frame so that each tire will keep in contact with ground
7. Additional counterweight (If equipped) even when the machine travels on soft ground.
8. Counterweight • Front frame (3) and rear frame (6) are connected
by center hinge pin (4) with the bearing between
them. The steering cylinders on both sides con-
nect front frame (3) and rear frame (6) and move
to adjust the bending angle, or the turning radius.
WA150-5 10-51
AXLE MOUNTING AND
10-52 WA150-5
AXLE MOUNTING AND
Unit: mm

Clearance between upper size clearance limit
Shaft Hole
1 hinge pin and rear frame
(small) -0.038 +0.100 0.038 –
50 –
-0.068 +0 0.168
Clearance between upper -0.038 +0.250 0.038 –
2 50 –
hinge pin and spacer -0.068 +0 0.318
Clearance between upper -0.038 +0 0.026 –
3 50 –
hinge pin and bearing -0.068 -0.012 0.068
Clearance between upper -0.073 0.023 –
4 66 ±0.050 –
hinge pin and rear frame (large) -0.103 0.153
Replace
Clearance between front frame +0 -0.020 -0.120 –
5 105 –
and upper hinge bearing -0.015 -0.120 -0.005
Clearance between lower hinge -0.050 +0.067 0.077 –
6 69.85 –
pin and rear frame bushing -0.060 +0.027 0.127
Clearance between lower hinge -0.050 +0.053 0.078 –
7 69.85 –
pin and bearing -0.060 +0.028 0.113
Clearance between front frame +0 -0.050 –
8 88.9 ±0.050 –
and lower hinge bearing -0.020 0.070
Clearance between rear frame +0.084 +0.054 -0.084 –
9 80 –
and bushing +0.059 +0 -0.005
10 Height of upper hinge spacer
23 ±0.1 –
Standard shim thickness of
11 1.3
upper hinge and retainer
Adjust
12 0.8
upper hinge and retainer
Tightening torque for upper 3.92 – 5.88 Nm {0.4 – 0.6 kgm} (When adjusting shim)
13
hinge retainer mounting bolt 59 – 74 Nm {6.0 – 7.5 kgm} (Final value)
WA150-5 10-53
AXLE MOUNTING AND
Unit: mm

1 Thickness of thrust plate 0
10 –
-0.15
+0.3
2 Thickness of thrust washer 5 –
-0.1
Standard Tolerance Standard Clearance Replace

Clearance between hole and size Shaft Hole clearance limit
3
shaft at front support end
-0.043 +0.550 0.093 –
150 –
-0.106 +0.050 0.656
Clearance between hole and -0.043 +0.550 0.093 –
4 150 –
shaft at rear support end -0.106 +0.050 0.656
5 0.2 –
thrust cap
10-54 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING PIPING
STEERING PIPING
1. Steering cylinder (right)

2. Orbit-roll valve
3. Hydraulic oil tank
4. Priority valve
5. Work equipment and steering pump
6. Steering cylinder (left)
WA150-5 10-55
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
1. Steering wheel
2. Steering column
3. Orbit-roll valve
4. Tilt lever
Unit: mm

Clearance between steering size Shaft Hole clearance limit
5 Replace
shaft and column bushing
+0 +0.15 0.05 –
19 0.4
-0.08 +0.05 0.23
10-56 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
P: From steering pump LS: From orbit-roll valve

CF: To orbit-roll valve T: To hydraulic tank
EF: To work equipment control valve
1. Relief valve body 7. Plug

2. Spring seat 8. Valve body
3. Spring 9. Spool
4. Poppet 10. Spring
5. Seat 11. Plug
6. Screen
Unit: mm
Standard size Repair limit
Free length Installed Installed Free length Installed

12 Control spring length load load
Replace
63.4 47.6 187 N 63.4 ± 1 187 ± 14.7 N
{19.1 kg} {19.1 ± 1.5 kg}
13 Relief spring 31 27.8 83 N – 83 ± 14.7 N

{8.5 kg} {8.5 ± 1.5 kg}
WA150-5 10-57
Outline Operation
• The priority valve is in the circuit between the
work equipment and steering pump and the orbit- 1. Steering wheel at neutral
roll valve. It acts to divide the flow of oil from the When the engine is stopped, spool (3) is pushed
steering pump and send it to the orbit-roll valve or fully to the left by the tension of spring (4). The
oil cooler circuit. It also sets the oil pressure in the circuit between ports M and N is fully open, while
circuit from the priority valve to the orbit-roll valve the circuit between ports M and Q is fully closed.
to 18.6 MPa {190 kg/cm2} to protect the circuit. In this condition, if the engine is started and the
steering pump is rotated, the oil from the pump
goes from the port M to port N, and then enters
port A to the orbit-roll valve.
When this happens, the oil passing through ori-
fice m in spool (3) enters port P. It then com-
presses spring (4), and moves spool (3) to the
right in the direction of the arrow.
This stabilizes the condition so that the circuit
between ports M and Q is almost fully open and
the circuit between ports M and N is almost fully
closed. Therefore, the oil from the pump almost
all flows to the work equipment circuit.
10-58 WA150-5
(3)
2. Steering wheel turned to left 3. Steering cylinder at end of stroke

When the steering wheel is turned to the left, an If the operator tries to turn the steering wheel fur-
angle variation is generated between the spool ther when the steering cylinder has reached the
and sleeve of the orbit-roll valve, and the oil flow end of its stroke, the circuit from port M through
is switched. (For details, see ORBIT-ROLL port N to port S is kept open and the pressure
VALVE.) rises.
The oil from the pump flows from port M to port When this pressure rises above requirement
N, and enters port A. The degree of opening of pressure relief valve (10) opens and the oil is
the sleeve (port A) and spool (port B) creates a relieved to the hydraulic tank. Because of this
difference between the pressure up to port A flow of oil, a differential pressure is created on
and the pressure beyond port B. Some of the oil both sides of orifice r. Therefore, the balance is
from port B flows to the Girotor, and then goes to lost between the load of spring (4) and the pres-
the front right cylinder. The remaining oil passes sure up to port A and the pressure beyond port
through orifice b, flows to port J, and then enters B. As a result, the pressure up tp the port A
port R. becomes relatively higher.
When this happens, spool (3) stabilizes at a For this reason, the pressure at port P moves
position where the differential pressure between spool (3) even further to the right from the condi-
the circuit up to port A and circuit beyond port B tion in Item 2. It stabilizes the condition at a posi-
(pressure of port P - pressure of port R) and the tion where the circuit between ports M and N is
load of the spring (4) are balanced. It adjusts the almost fully closed, and the circuit between ports
degree of opening from port M to ports N and Q, M and Q is almost fully open.
and distributes the flow to both circuits.
The ratio of this distributed flow is determined by
the degree of opening of port A and port B, in
other words, the angle variation between the
sleeve and spool of the orbit-roll valve. This
degree the opening is adjusted steplessly by the
amount the steering is turned.
WA150-5 10-59
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
P: From steering pump LS: To priority valve

L: To steering cylinder T: To hydraulic tank
R: To steering cylinder
1. Ground 8. Drive shaft

2. Valve body 9. Sleeve
3. Check valve 10. Spool
4. Gerotor 11. Center pin
5. Spacer 12. Centering spring
6. Cover 13. Anti-cavitation valve
7. Spacer 14. Over-load relief valve
10-60 WA150-5
Outline Structure
• The orbit-roll valve is connected directly to the • Top (A) of spool (3) is connected to the drive
shaft of the steering wheel. It switches the flow of shaft of the steering column and further connect-
oil from the steering pump to the left and right ed to sleeve (5) through center pin (4) (which is
steering cylinders to determine the direction of not in contact with the spool while the steering
travel of the machine. wheel is in neutral) and centering spring (12).
• The orbit-roll valve, broadly speaking, consists of • Top (B) of drive shaft (6) is engaged with center
the following components: rotary type spool (3) pin (4) and combined with sleeve (5) in one body,
and sleeve (5), which have the function of select- and the bottom is engaged with the spline of rotor
ing the direction, and the gerotor set (a combina- (8) of the gerotor set.
tion of rotor (8) and stator (9)), which acts as a • Valve body (2) has 5 ports, which are connected
hydraulic motor during normal steering opera- to the pump circuit, tank circuit, left steering cir-
tions, and as a hand pump (in fact, the operating cuit, right steering circuit, and LS circuit respec-
force of the steering wheel is too high, so it can- tively. The ports on the pump side and tank side
not be operated) when the steering pump or en- are connected by the check valve in the body. If
gine have failed and the supply of oil has the pump or engine fails, the oil can be sucked
stopped. through this check valve directly from the tank
side.
WA150-5 10-61
(3)
Operation
1. Steering wheel at neutral
10-62 WA150-5
• While the steering wheel is in neutral, spool (3)

and sleeve (5) are fixed at a place where center
pin (4) is set to the center of the oblong hole of
spool (3) by centering spring (12).
At this time, port A of sleeve (5) from the pump,
port E to gerotor, port F of the right steering cir-
cuit, port G of the left steering circuit, and vertical
grooves B, C, and D of spool (3) are shut off.
Orifice b of port J to the priority valve is con-
nected to vertical groove B of spool (3).
Port K of sleeve (5) connects port L of spool (3)
to vertical groove M.
• As a result of above connection and disconnec-
tion of the ports and vertical grooves, the oil
which has been set to the pilot pressure of the pri-
ority valve is drained through port J, orifice b, ver-
tical grooves M and K, and port L into the
hydraulic tank.
WA150-5 10-63
2. Steering wheel turned (turning left)
10-64 WA150-5
• If the steering wheel is turned to the left, spool (3) 3. Steering wheel stopped
connected by the drive shaft of the steering col- Wh en th e o pe ra t io n o f s te er in g w hee l i s
umn turns to the left. stopped, the difference in rotation between the
At this time, since spool (3) and sleeve (5) are spool (3) and sleeve (5) is returned to the neutral
connected by centering spring (12), spool (3) condition by the reaction of centering spring
compresses centering spring. (12).
Accordingly, an angular displacement is made
between spool (3) and sleeve (5) by the com-
pression of centering spring (12).
Then, port A is connected to vertical groove B
first. Next, vertical groove B is connected to port
E, and then port E is connected to vertical
groove C, and vertical groove C is connected to
port G of the left steering circuit at last.
Orifice b of port J to vertical B and priority valve
is kept connected, but port K of sleeve (5) dis-
connects vertical groove M and port L gradually.
When port A is connected to vertical groove B,
port F of the right steering circuit is connected to
vertical groove D.
• As a result of above connection and disconnec-
tion of the ports and vertical grooves, the oil from
the pump flows through port A to the vertical
groove B, and then flows to port E to rotate the
gerotor. The oil discharged from the gerotor flows
through port E, vertical groove C, and port G to
the head side of the left steering cylinder.
The hydraulic pressure in vertical groove M is
transmitted through orifice b to port J and used
as the pilot pressure of the priority valve.
The oil from the head side of the right steering
cylinder is drained through port F, vertical groove
D, and port H into the hydraulic tank.
WA150-5 10-65
CONNECTION BETWEEN HAND PUMP AND SLEEVE
• The diagrams above show the connections with Therefore, the amount of oil discharged is
the sleeve ports used to connect the suction and directly proportional to the amount the steering
discharge ports P of the gerotor. wheel is turned.
• If the steering wheel has been turned to the right,
ports a, c, e, g, i, and k are connected by the ver-
tical grooves in the spool to the pump side. At the
same time, ports b, d, f, h, j, and l are connected
to the head end of the right steering cylinder in
the same way.
In the condition in Fig. 1, ports 1, 2, and 3 are the
discharge ports of the gerotor set.
They are connected to port l, b, and d, so the oil
is sent to the steering cylinder.
Ports 5, 6, and 7 are connected and the oil flows
in from the pump.
If the steering wheel is turned 90°, the condition
changes to the condition shown in Fig. 2. In this
case, ports 2, 3, and 4, are the suction ports, and
are connected to ports k, a, and c. Ports 5, 6,
and 7 are the discharge ports, and are con-
nected to ports d, f, and h.
• In this way, the ports acting as the discharge
ports of the gerotor are connected to the ports go-
ing to the steering cylinder, while the ports acting
as the suction ports are connected to the pump
circuit.
• Adjustment of discharge according to amount
steering wheel is turned.
For each 1/7 turn of the steering wheel, the
inside teeth of the gerotor advance one tooth,
and the oil from the pump is discharged in an
amount that matches this movement.
10-66 WA150-5
(3)
Role of centering spring

• Center spring (12) is composed of 4 X-shaped
leaf springs and 2 flat leaf springs and installed
between spool (3) and sleeve (5) as shown in the
figure.
• If the steering wheel is turned, spool (3) com-
presses centering spring (12) and an angular dis-
placement is made between spool (3) and sleeve
(5).
As a result, the ports of spool (3) and sleeve (5)
are connected and the oil is sent to the steering
cylinder. When the steering wheel stops turning,
the gerotor also stops turning. Then, the oil is
not sent to the steering cylinder and its pressure
rises. To prevent this, when the steering wheel
stops turning, it is returned by the reaction force
of centering spring (12) toward the neutral posi-
tion by the angular displacement of spool (3) and
sleeve (5).
WA150-5 10-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit: mm
Tolerance
Clearance between mounting pin size Clearance limit
1 and bushing at connection of Shaft Hole
frame and cylinder rod
30 -0.020 +0.117 0.100 – —
-0.053 +0.080 0.170
Clearance between mounting pin -0.020 +0.117 0.100 –
2 and bushing at connection of 30 -0.053 +0.080 0.170 — Replace
frame and cylinder bottom
Width of boss Width of hinge Standard clearance

(a + b)
3 Connection of steering cylinder
and front frame Max. 0 – 1.0
40 43 (after adjusting shim)
4 Connection of steering cylinder 40 43 Max. 0 – 1.0

and rear frame (after adjusting shim)
10-68 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER
Unit: mm
Tolerance
Clearance between piston rod size Clearance limit
1 Shaft Hole
and bushing
30 -0.020 +0.133 0.013 – 0.505 Replace pin,

-0.072 +0.007 0.205 bushing
Clearance between piston rod -0.020 +0.117 0.100 –
2 support shaft and bushing 30 -0.053 +0.080 0.170 1.0
Clearance between cylinder bot- -0.020 +0.117 0.100 –

3 tom support shaft and bushing 30 -0.053 +0.080 0.170 1.0
4 Tightening torque of cylinder head 412 ± 41.2 Nm {42 ± 4.2 kgm}
Tightening torque of cylinder pis-

5 ton 343 ± 34.3 kNm {35 ± 3.5 kgm} (Width across flats: 32 mm) Tighten
Tightening torque of nipple plug

6 on cylinder head side 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
WA150-5 10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY STEERING PIPING
EMERGENCY STEERING PIPING

(If equipped)
1. Orbit-roll valve
2. Priority valve
3. Pressure switch (for detecting drop of steering oil pressure)
4. Steering pump
5. HST motor 2
6. Emergency steering valve
7. Pressure switch (For detecting operation of emergency steering)
8. Check valve
10-70 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY STEERING VALVE
EMERGENCY STEERING VALVE

(If equipped)
PP: From steering pump 1. Check valve body

A: To port A of HST motor 2 2. Check valve
B: To port B of HST motor 2 3. Valve body
Y: To orbit-roll valve 4. Pressure reducing valve
S: To hydraulic tank 5. Selector valve
G: To pressure switch
WA150-5 10-71
Operation
When engine and steering pump are normal
• While the engine and steering pump are operat-

ing normally, the oil sent from the steering pump
flows into the orbit-roll valve to steer the machine.
• At this time, the oil from the steering pump flows
in port PP and pushes spool (1) to the left to shut
off the circuit from the HST motor to the orbit-roll
valve.
10-72 WA150-5
When engine or steering pump is abnormal
• If the engine or steering pump has a trouble and

the steering pump does not supply oil sufficiently
to the orbit-roll valve during travel, the discharge
pressure of the steering pump lowers and spool
(1) is pushed back to the right by the reaction
force of spring (2).
• At this time, the oil from the HST motor is set high
by check valves (3) and (4). Then, the oil is re-
duced in pressure by pressure reducing valve (5)
to a proper level for the steering circuit and it
flows through spool (1) and port Y to the orbit-roll
valve. As a result, the machine can be steered.
• If the quantity of the oil in the HST circuit be-
comes insufficient because of oil leakage into the
steering circuit, etc., check valves (6) and (7) add
oil to the HST circuit.
a Check valves (3) and (4) work so that the emer-

gency steering system will operate regardless of
the travel direction.
WA150-5 10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING
BRAKE PIPING
1. Hydraulic tank 7. Accumulator (for front)

2. Brake valve 8. Accumulator (for rear)
3. Brake and cooling fan pump 9. Charge valve
4. Slack adjuster (for right rear) 10. Strainer
5. Rear brake 11. Slack adjuster (for left front)
6. Slack adjuster (for left rear) 12. Front brake
13. Slack adjuster (for right front)
10-74 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
P1: From HST pump A: To rear brake

T1: To hydraulic tank PB: From accumulator (Front side)
T2: To steering pump (Suction side) B: To front brake
PA: From accumulator (Rear side)
1. Rod 5. Brake valve body (for rear)

2. Inching valve spool 6. Brake valve spool (for front)
3. Inching valve body 7. Brake valve body (for front)
4. Brake valve spool (for rear)
Unit: mm

Clearance between inching size Shaft Hole clearance limit
8
valve spool and body
-0.022 +0.033 0.020 –
22.4 0.096
-0.053 +0 0.086
Clearance between inching -0.022 +0.033 0.020 –
9 22.4 0.096
valve guide and body -0.053 +0 0.086
Clearance between inching -0.050 +0.050 0.050 –
10 12 0.157
valve spool and guide -0.093 +0 0.143
Replace
Free Installed Installed Free Installed
11 Inching valve control spring length length load length load
24.5 N 20.8 N
34.7 16.7 –
{2.5 kg} {2.1 kg}
12 Brake valve control spring 35.6 24.0 113 N – 96 N

{11.5 kg} {9.8 kg}
13 Inching valve return spring 50.0 49.5 19.6 N – 16.7 N

{2.0 kg} {1.7 kg}
14 Brake valve return spring 114.9 52.4 147 N – 125 N

{15.0 kg} {12.7 kg}
WA150-5 10-75
Outline
• The brake valve is installed under the front of the
operator's seat. If either brake pedal is pressed,
oil flows to the brake piston to operate the brake.
• Both brake pedals are connected mechanically to
each other. If either of them is pressed, the other
moves, too.
• The brake valve has an inching valve in it to con-
trol the control pressure of the HST pump.
Operation
1. When brake pedal is pressed
• If brake pedal (1) is pressed, the pressing force is When only either brake operates (When either
transmitted through rod (2), spool (3), and spring brake fails)
(4) to spool (5). • Even if only either brake operates because of oil
• If spool (5) is pushed to the right, port Ta is closed leakage, etc. in the front or rear brake system, the
and the oil from the pump flows through the accu- pressing force of brake pedal (1) moves spools
mulator, port PA, and port A to the rear brake pis- (5) and (6) mechanically to the right.
ton to operate the rear brake. Accordingly, the oil from the pump flows normally
• At the time when spool (5) is pushed to the right, to the brake piston of the normal system to oper-
spool (6) is also pushed to the right to close port ate the brake and stop the machine. With this
Pb. As a result, the oil from the pump flows mechanism, safety is heightened.
through the accumulator, port PB, and port B to
the front brake piston to operate the front brake.
10-76 WA150-5
2. When balanced
• If the rear brake piston is filled with oil and the oil • The oil pressure in the rear brake circuit (on port
pressure between ports PA and A rises, the oil A side) is balanced with the pressing force of the
flowing through orifice c of spool (5) into chamber brake pedal. The oil pressure in the front brake
E pushes back spool (5) to the left against spring circuit (on port B side) is balanced with the oil
(4) and close ports PA and A from. Since port Ta pressure in the rear brake circuit (on port A side).
is kept closed at this time, the oil which flowed If spools (5) and (6) move to the right stroke end,
into the brake piston is held and the brake is kept the pas ses b e twe en p or ts PA and A a nd
operated. between ports PB and B are fully open and the
• At the time when spool (5) is pushed to the left, oil pressure in the rear and front brake circuits is
the front brake piston is filled with oil and the equal to the oil pressure from the pump. Accord-
pressure between ports PB and B rises. As a re- ingly, the operator can adjust the braking force
sult, the oil which flowed through orifice d of spool with the brake pedal until spool (5) and (6) move
(6) into chamber F pushes back spool (6) to the to the right stroke end.
left by the moving distance of spool (5) to close
ports PB and B. Since port Tb is kept closed, the
oil which flowed into the brake piston is held and
the brake is kept operated.
WA150-5 10-77
3. When brake pedal is released
• If brake pedal (1) is released, the pedal pressing

force applied to spool (5) is lost.
• Spool (5) is pushed back to the left by the back
pressure of the rear brake piston and reaction
force of spring (7). Consequently, port PA is
closed and the oil in the rear brake piston flows
through ports A and port Ta into the hydraulic
tank and the rear brake is released.
• At the time when spool (5) moves to the left,
spool (6) is also pushed back to the left by the
back pressure of the front brake piston and reac-
tion force of spring (7). Consequently, port PB is
closed and the oil in the front brake piston flows
through ports B and Tb into the hydraulic tank
and the front brake is released.
10-78 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD INCHING VALVE
INCHING VALVE
P1: From port Y of HST pump Outline

T2: To steering pump (Suction side) • The inching valve is built in brake valve (2). It re-
duces the control oil pressure of the HST circuit
1. Brake pedal to reduce the capacity of the HST pump accord-
2. Brake valve ing to stroke (S) of spool (3).
3. Spool
4. Body
WA150-5 10-79
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CHARGE VALVE
CHARGE VALVE
10-80 WA150-5
P: From brake and cooling fan pump

T: To hydraulic tank
A: To cooling fan motor
ACC1: To accumulator (Rear side)
ACC2: To accumulator (Front side)
S: Brake operation sensor port
G: Gauge port
1. Valve body
2. Inverse shuttle valve
3. Plunger
4. Unload relief valve
5. Flow control valve
6. Unload valve
7. Relief valve
Unit: mm

Clearance between inverse size Shaft Hole clearance limit
8
shuttle valve spool and body
-0.006 +0.011 0.006 –
12 0.029
-0.014 +0 0.025
Clearance between plunger -0.005 +0.009 0.005 –
9 8 0.024
and body -0.012 +0 0.021
Clearance between flow control
-0.006 +0.011 0.006 –
10 valve, unload valve spool and 18 0.032
-0.017 +0 0.028
body
Free Installed Installed Free Installed Replace
Inverse shuttle valve return
11 length length load length load
spring
9.8 N 8.3 N
21.6 18.3 –
{1.0 kg} {0.85 kg}
Unload relief valve return spring 188 N 160 N
12 35.9 30.0 –
(inside) {19.2 kg} {16.3 kg}
13 Unload relief valve return spring 39.8 27.5 137 N – 116 N

(outside) {14.0 kg} {11.8 kg}
Flow control valve, unload 49 N 42 N
14 valve spool return spring 51.6 45.0 {5.0 kg} – {4.3 kg}
4.9 N 4.2 N
15 Check valve return spring 11.5 9.0 {0.5 kg} – {0.43 kg}
Function
• The charge valve keeps the oil pressure from the
pump to the set pressure and stores it in the ac-
cumulator.
• If the oil pressure rises above the set pressure,
the oil from the pump is led to the drain circuit to
reduce the load on the pump.
WA150-5 10-81
Operation 2. When oil is supplied to accumulator

1. When oil is not supplied to accumulator 1) Cut-in state
(Cut-out state) • If the accumulator pressure lowers, the
• Plunger (1) is moved by the pressure of the pressure in port E lowers and plunger (1)
accumulator to the left to keep unload relief moves to the right and unload relief valve
valve (2) pushed open. (2) closes the drain circuit.
• The oil in the spring chamber of unload valve • Accordingly, the oil pressure in port F
(3) flows through port F, unload relief valve and the spring chamber of unload relief
(2), and port T into the hydraulic tank. valve (3) rises and unload relief valve (3)
• Since the oil pressure in port F lowers, un- moves to the right.
load valve (3) is moved by the oil pressure in • As a result, ports C and B are connected
chamber B to the left. to each other and the oil from the pump
• Accordingly, ports C and D are connected to flows to port B.
each other and almost all the oil from the • If the oil pressure in port B exceeds the
pump flows through ports P, C, D and A to set pressure of check valve (4), it pushes
the cooling fan motor. check valve (4) open and flows to port E
to start heightening the pressure in the
accumulator. The supply pressure for
the accumulator is decided by the set
pressure of check valve (4).
• A set quantity of oil is supplied to the ac-
cumulator, regardless of the engine
speed, and the excessive oil flows
through port A to the cooling fan motor.
• The oil flowing to port E is supplied first
to the accumulator having the lowest
pressure by inverse shuttle valve (5).
10-82 WA150-5
2) Cut-out state 3. When input pressure to valve rises above set

• If the pressure in port F reaches the set pressure
pressure (cut-out pressure) of unload re- • If the oil pressure in chamber B reaches the
lief valve (2), the oil in the spring cham- set pressure of relief valve (6), the oil flowing
ber of unload valve (3) flows through port from the pump through port P to chamber B
F, unload relief valve (2), and port T to pushes relief valve (6) open and flows
the hydraulic tank. through port T into the hydraulic tank.
• Plunger (1) is moved to the left by the As a result, the maximum pressure in the
pressure of the accumulator to keep un- brake circuit is limited to protect the circuit.
load relief valve (2) pushed open.
• Since the oil pressure in port F lowers,
unload valve (3) is moved by the oil pres-
sure in chamber B to the left.
• Accordingly, ports C and D are connect-
ed to each other and almost all the oil
from the pump flows through ports P, C,
D and A to the cooling fan motor.
WA150-5 10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)
ACCUMULATOR (FOR BRAKE)

1. Cylinder
2. Piston
Function
• The accumulator is installed between the charge
valve and brake valve. The space between its
cylinder (1) and free piston (2) is filled with nitro-
gen gas. The brake oil pressure is stored in this
space by utilizing the compressibility of the nitro-
gen gas and used as the pressure source to drive
the brake.
Specifications
Gas used: Nitrogen gas
Amount of gas: 500cc
Charge pressure: 3.43 ± 0.1 MPa {35 ± 1.0 kg/cm2}
(at 20°C)
10-84 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
A: From brake valve

B: To brake piston
1. Body
2. Check valve
3. Piston
Unit: mm

Clearance between piston and size Shaft Hole clearance limit
4
body
-0.065 +0.052 0.065 –
30 0.163
-0.098 +0 0.150
Clearance between check -0.013 +0.015 0.013 –
5 10 0.048
valve and body -0.028 +0 0.043
Replace
Free Installed Installed Free Installed
6 Piston return spring length length load length load
11.8 N 9.8 N
87.5 48.2 –
{1.2 kg} {1.0 kg}
7 Check valve return spring 21.7 19.25 53.9 N – 46.1 N

{5.5 kg} {4.7 kg}
WA150-5 10-85
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
Function
• The slack adjuster is installed to the brake oil line
from the brake valve to the brake piston and used
to fix the time lag of operation of the brake.
Operation
When brake is applied When brake is released
• The oil from the brake valve flows to port A and • The oil kept between piston (1) and brake piston
moves piston (1) to the right. The oil kept be- pushes back piston (1) to the left. Oil of quantity
tween piston (1) and brake piston drives the equivalent to the moving distance of piston (1) is
brake. returned through port A to the brake valve and
• Since the oil kept between piston (1) and brake drained into the hydraulic tank.
piston drives the brake, the brake piston stroke is
fixed and the time lag of operation of the brake is
reduced.
• If the quantity of the oil between piston (1) and
brake piston becomes insufficient because of
wear of the brake disc, etc., check valve (2) is
pushed open and oil is added.
10-86 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE
BRAKE
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Discs (x2)
10-88 WA150-5
Unit: mm

10 Thickness of inner ring
6 ± 0.1 5.5
Thickness of brake disc 5.2 ± 0.15 4.4
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.8 (Min.) —

Replace
Standard size Tolerance Wear limit
12 Wear of brake outer ring disc
contact surface
25.0 ± 0.1 0.3
13 Spring load Installed height Installed load Installed load
6.0 1,225 N {125 kg} 980 N {100 kg}
Outline
• The rear brake has a wet-type multiple-disc
structure, and consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
assembled in it.
Inner ring (5) and outer ring (8) are joined to the
spline portion of differential housing (1).
• Disc (9) has a lining stuck to both sides. It is as-
sembled between inner ring (5) and outer ring
(8), and is joined by the spline of sun gear shaft
(6).
WA150-5 10-89
Function
When brake is applied When brake is released
• When the brake pedal is depressed, pressure oil • When the oil pressure is released, piston (2) is re-
P goes from the hydraulic tank through the turned to its original position by the force of
pump and brake charge valve. It acts on the pis- spring (8), a gap is formed between inner ring (3)
ton inside the brake cylinder and the piston (2) and outer ring (5), and discs (4) become free.
slides. Lattice shape grooves are cut into the lining
Therefore, piston (2) stops the rotation of discs stuck to disc (4), and when disc (4) is rotating,
(4) fitted between inner ring (3) and outer ring oil flows in the grooves and carries out cooling of
(5), and applies the brake to the machine. the lining.
10-90 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
1. Parking brake lever 4. Control cable

2. Lowest switch of parking brake lever 5. Transfer
3. Intermediate switch of parking brake lever 6. Multiple-disc brake lever
Outline
• The mechanical parking brake is built in transfer • If parking brake lever (1) is returned, multiple-
(5). If parking brake lever (1) is operated, multi- disc brake lever (6) connected by control cable
ple-disc brake lever (6) is operated to "apply" or (4) is pushed down and the parking brake is "re-
"release" the parking brake. leased"
• If parking brake lever (1) installed on the opera- • While the parking brake is "applied", the current
tor's seat is pulled, multiple-disc brake lever (6) to the forward-reverse solenoid valve of the HST
connected by control cable (4) is pulled up and pump is shut off and the swash plate of the HST
the parking brake is "applied". pump is kept in neutral.
WA150-5 10-91
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
1. Lever 5. Plate
2. Housing 6. Disc
3. Ball 7. Wave spring
4. Piston 8. Output shaft
Unit: mm

Thickness of plate
9 2.6 ± 0.06 2.5
Distortion of plate — 0.05 0.6

Replace
Thickness of brake disc 4.7 ± 0.08 4.5
10
Distortion of brake disc — 0.07 0.25
Load on wave spring 229 N ± 23N 195 N

11 (Height: 4.7 mm) {23.4 kg} {± 2.3 kg} {19.9 kg}
Outline
• The parking brake is a wet multiple-disc brake
which mechanically brakes transmission output
shaft (8).
• Lever (1) is connected to the control cable. If the
parking brake lever is pulled, ball (3) between pis-
ton (4) connected to lever (1) and housing (2)
moves on the inclined surface of the piston
groove. As a result, piston (4) presses plates (5)
and discs (6) to brake output shaft (8).
10-92 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING
HYDRAULIC PIPING
10-94 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING
1. Work equipment control valve Outline

2. Bucket cylinder • The hydraulic system consists of the HST, steer-
3. Hydraulic tank ing, work equipment, brake, cooling fan, and
4. Work equipment PPC valve transfer lubricating circuit. Work equipment cir-
5. Lock valve cuit controls the operation of the lift arm and
6. Oil cooler bucket.
7. Cold relief valve • The oil in hydraulic tank (3) is sent by the work
8. 3-gear pump unit equipment pump of 3-gear pump unit (8) to work
• Work equipment and steering pump equipment control valve (1). If both spools of the
• Brake and cooling fan pump lift arm and bucket of work equipment control
• Transfer lubricating oil pump valve (1) are held, the oil flows through the drain
9. Accumulator (for PPC circuit) circuit of work equipment control valve (1) and is
10. Accumulator (for E.C.S.S.) (If equipped) filtrated by the return filter installed to hydraulic
11. Lift cylinder tank (3) and returns to hydraulic tank (3).
12. E.C.S.S. valve (If equipped) • If the work equipment control lever is operated,
the spool of the lift arm or bucket of work equip-
ment PPC valve (4) operates.
• The oil from the PPC valve hydraulically operates
each spool of work equipment control valve (1)
and flows to lift cylinder (11) or bucket cylinder (2)
to move the lift arm or bucket.
• The maximum pressure in the hydraulic circuit is
controlled by the relief valve in work equipment
control valve (1). The bucket cylinder circuit has
a safety valve (safety-suction valve) to protect it-
self.
• Accumulator (for PPC circuit) (9) is installed to
the PPC pilot circuit so that the work equipment
can be lowered to the ground even if the engine
stops.
• Hydraulic tank (3) is pressurized, enclosed, and
equipped with a breather which has a relief valve
and which is also used as an oil filler cap. The
breather pressurizes the tank and prevents gen-
eration of negative pressure and cavitation.
WA150-5 10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE

Joystick type
1. Work equipment control lever

2. Wrist rest
3. Lock valve
4. Safety lock lever
5. Work equipment PPC valve
6. Wrist rest height adjustment lever
10-96 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Oil filler cap / Breather Specifications

2. Return filter
3. Hydraulic tank Tank capacity (l) 65
4. Drain plug Oil quantity inside the tank (l) 47
5. Sight gauge
6. Return filter bypass valve Bypass valve setting pressure 0.2
(MPa{kg/cm2}) {2.04}
WA150-5 10-97
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
Breather
1. Oil filler cap

2. Case
3. Unlocking knob
4. Sleeve
5. Poppet
6. Filter element
Prevention of negative pressure in tank

• Since the hydraulic tank is pressurized and en-
closed, negative pressure can be generated
when the oil level in the tank lowers. At this time,
sleeve (4) is opened by the pressure difference
from the atmospheric pressure and the atmo-
sphere flows in the tank to prevent generation of
negative pressure.
(Set pressure of air intake valve:
3.0 ± 0.3 kPa {0.03 ± 0.003 kg/cm2})
Prevention of rise of pressure in tank

• While the hydraulic circuit is in operation, the
pressure in the hydraulic tank rises when the oil
level in the hydraulic tank rises according to the
operation of the hydraulic cylinders and when the
temperature rises. If the pressure in the tank ris-
es above the set pressure, poppet (5) operates to
release the pressure from the tank.
(Set pressure of exhaust valve:
0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})
10-98 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 3-GEAR PUMP UNIT
3-GEAR PUMP UNIT

(Work equipment and steering / Brake and cooling fan / Transfer lubricating oil)
SAR(3)63 + SBR(1)10 + 6
1. Work equipment and steering pump Outline

2. Brake and cooling fan pump • The 3-gear pump unit is installed to the HST
3. Transfer lubricating oil pump pump and driven through its shaft to supply hy-
draulic oil to the work equipment, steering, brake,
cooling fan, and transfer.
10-100 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 3-GEAR PUMP UNIT
Unit: mm
Type Standard clearance Clearance limit

SAR(3)63
4 Side clearance
SAR(1)10 0.10 – 0.15 0.19
SBR(1) 6
SAR(3)63 0.083 – 0.144
Clearance between inside
5 diameter of plain bearing and SAR(1)10 0.20
0.068 – 0.115 Replace
outside diameter of gear shaft
SBR(1) 6
Type Standard size Tolerance Repair limit
SAR(3)63 14 +0
6 Diving depth of pin SBR(1)10 10 -0.5
–
+0.5
SBR(1) 6 7
+0
7 Spline rotating torque 13.8 – 28.5 Nm {1.4 – 2.9 kgm}
Discharge Standard Discharge
Speed pressure discharge amount
Type (MPa {kg/
(rpm) amount limit
Discharge amount –
cm2} (l/min) (l/min.)
– Oil: SAE10W
Oil temperature: 45 - 55°C SAR(3)63 145 134
SBR(1)10 2,500 20.6 {210} 23 21
SBR(1) 6 14 13
WA150-5 10-101
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR (FOR PPC CIRCUIT)
ACCUMULATOR (FOR PPC CIRCUIT)

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
• The accumulator is installed between the HST
charge pump and work equipment PPC valve.
Even if the engine stops with the work equipment
raised, the pressure of the compressed nitrogen
gas in the accumulator sends the pilot oil pres-
sure to the work equipment control valve to oper-
ate the valve so that the work equipment will
lower by its weight.
Specifications
Amount of gas: 300 cc
Charge pressure: 1.18 MPa {12 kg/cm2}) (at 80°C)
Max. using pressure: 6.86 MPa {70 kg/cm2}
10-102 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LOCK VALVE
LOCK VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The lock valve is installed between the HST
charge pump and work equipment PPC valve. If
the safety lock lever is set in the LOCK position,
the lock valve operates to shut off the oil in the
PPC circuit so that the work equipment cannot be
operated.
WA150-5 10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD E.C.S.S. VALVE
E.C.S.S. VALVE
(If equipped)
(E.C.S.S.: Electronically Controlled Suspension System)
P: From work equipment hydraulic pump

A: From lift cylinder bottom side
B: From lift cylinder head side
SP: To accumulator (for E.C.S.S.)
10-104 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD E.C.S.S. VALVE
1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve
WA150-5 10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR (FOR E.C.S.S.)
ACCUMULATOR (FOR E.C.S.S.)

(If equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
• The accumulator is installed to the lift cylinder
bottom circuit. The space between its cylinder (3)
and free piston (4) is filled with nitrogen gas. The
nitrogen gas absorbs the oil pressure pulses gen-
erated on the lift cylinder bottom side during trav-
el for higher travel performance and operating
performance by utilizing its compressibility.
Specifications
Amount of gas: 2,000 cc
Charge pressure: 2.5 ± 0.1 MPa {25 ± 1.0 kg/cm2}
(at 20°C)
10-106 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING OF COOLING SYSTEM
HYDRAULIC PIPING OF COOLING SYSTEM
1. Cooling fan motor Outline

2. Brake and cooling fan pump • Cooing fan motor (1) installed to the radiator is
3. Hydraulic tank driven hydraulically by brake and cooling fan
4. Charge valve pump (2).
WA150-5 10-107
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR
COOLING FAN MOTOR
P1: From charge valve Specifications

P2: To hydraulic tank
Dr: To hydraulic tank Model MSF-12-10
Type Fixed displacement swash

1. Port block plate-type piston motor
2. Valve plate
3. Piston Theoretical capacity
9.9
4. Shoe (cc/rev)
5. Thrust plate Rated speed
6. Output shaft 1,350
(rpm)
7 Case
8. Cylinder block Rated capacity
13.4
9. Center spring (l/min)
10. Check valve
11. Check valve spring
10-108 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR
Function
• This hydraulic motor is a swash plate-type axial
piston motor, which converts the pressure of the
hydraulic oil sent from the hydraulic pump into
revolution.
Principle of operation
• The oil sent from the hydraulic port flows through
valve plate (7) into cylinder block (5).
This oil can flow on only one side of the Y-Y line
connecting the top dead center and bottom dead
center of the stroke of piston (4).
• The oil sent to one side of cylinder block (5)
pressed pistons (4) (2 or 3 pieces) and generates
force F1 (F1 kg=P kg/cm² x x/4 D2 cm²).
• This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of Eo degrees
to the output shaft (1), the force is divided into
components F2 and F3.
• The radial components F3 generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
• The resultant of this torque [T = (F3 x ri)] ro-
tates the cylinder block (5) throught the piston.
• Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output shaft
(1) revolves to transmit the torque.
WA150-5 10-109
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
WORK EQUIPMENT CONTROL VALVE

1. 2-Spool valve
A. PA1 : To work equipment PPC valve P2 F. B2 : To lift cylinder bottom

B. PA2 : To work equipment PPC valve P4 G. B1 : To bucket cylinder bottom
C. A1 : To bucket cylinder head H. P : Pump
D. A2 : To lift cylinder head J. PB1 : To work equipment PPC valve P1
E. T : Drain K. PB2 : To work equipment PPC valve P3
10-110 WA150-5
1. Main relief valve 4. Check valve

2. Bucket spool 5. Safety-suction valve
3. Lift arm spool 6. Suction valve
Unit: mm
Free
length x Installed Installed Free Installed
Lift arm raise and bucket tilt
7 Outside length load length load
spool return spring
diameter
92.2 N 87.3 N Replace spring if
42.5 x 27.5 41 40.4
{9.4 kg} {8.9 kg} damaged or
Lift arm lower spool return 55.9 N 53 N deformed
8 58.9 x 26.3 57.3 56
spring {5.7 kg} {5.4 kg}
9 Lift arm float spool return spring 53.4 x 12 38.5 110.8 N 50.7 105 N
{11.3 kg} {10.7 kg}
10 Bucket dump spool return 42 x 27.5 41 72.5 N 39.9 68.6 N

spring {7.4 kg} {7 kg}
WA150-5 10-111
2. 3-Spool valve
A. PA1 : To service PPC valve P1 H. B3 : To lift cylinder bottom

B. PA2 : To work equipment PPC valve P2 J. B2 : To bucket cylinder bottom
C. PA3 : To work equipment PPC valve P4 K. B1: To service cylinder
D. A1 : To service cylinder L. P : To pump
E. A2 : To bucket cylinder head M. PB1 : To service PPC valve P2
F. A3 : To lift cylinder head N. PB2 : To work equipment PPC valve P1
G. T : To drain P. PB3 : To work equipment PPC valve P3
10-112 WA150-5
1. Main relief valve 5. Check valve

2. Service spool 6. Suction valve
3. Bucket spool 7. Safety-suction valve
4. Lift arm spool
Unit: mm
Free
length x Installed Installed Free Installed
Lift arm raise and bucket tilt
8 Outside length load length load
spool return spring
diameter
92.2 N 87.3 N Replace spring if
42.5 x 27.5 41 40.4
{9.4 kg} {8.9 kg} damaged or
Lift arm lower spool return 55.9 N 53 N deformed
9 58.9 x 26.3 57.3 56
spring {5.7 kg} {5.4 kg}
110.8 N 105 N
10 Lift arm float spool return spring 53.4 x 12 38.5 50.7
{11.3 kg} {10.7 kg}
Bucket dump spool return 72.5 N 68.6 N
11 42 x 27.5 41 39.9
spring {7.4 kg} {7 kg}
WA150-5 10-113
3. Relief valve
• When the hydraulic pressure inside the port A
and the port B reaches the set pressure of the pi-
lot poppet spring (4), the pilot poppet (3) opens to
let the hydraulic pressure of the port B flow from
the port D to the port C and the pressure of the
port B drops.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjusting screw
Function • When the pressure at the port B drops, pressure

• The relief valve is installed to the inlet of the work difference occurs between the port A and the port
equipment valve. When the oil pressure rises B by the orifice of the main valve (1) and the main
above the specified level, this valve drains the oil valve shall be pushed open to let the oil of the
into the hydraulic tank to limit the maximum pres- port A to pass through the port C to flow into the
sure of the work equipment circuit and protect the drain circuit, to release the abnormal pressure.
circuit. • The preset pressure can be changed by increas-
ing or decreasing the tension of the pilot poppet
Operation spring (4).
• The port A is connected to the pump circuit and • To change the preset pressure, remove the cap
the port C is connected to the drain circuit. The oil nut to loosen the lock nut. After that, screw-in the
passes through the orifice of the main valve (1) to adjust screw (5) to raise the preset pressure and
fill the port B. The pilot poppet (3) is contacting loosen the adjust screw (5) to lower the preset
(seated) to the valve seat (2). pressure.
10-114 WA150-5
4. Safety-suction valve
1. Piston • If abnormal pressure generated in port A reaches

2. Main valve the set pressure of spring (6), poppet (5) opens
3. Piston spring and the hydraulic oil in port C is drained through
4. Valve seat port D and periphery a of suction valve (7).
5. Poppet
6. Poppet spring
7. Suction valve
8. Suction valve spring
9. Adjustment screw
Function
• The safety-suction valve is in the bucket cylinder
circuit in the work equipment valve. When the
work equipment valve is in neutral, if any impact
is applied to the cylinder and abnormal pressure
is generated, that pressure is released through
this valve to protect the cylinder.
• If negative pressure is generated in the cylinder
circuit, this valve works as a suction valve. • If poppet (5) opens, the pressure in port C lowers
and piston (1) moves to the right. Piston (1)
Operation comes in contact with the tip of poppet (5) and the
(1) Operation as safety valve hydraulic oil is drained through throttle b and port
• Ports A and B are connected to the cylinder cir- D.
cuit and drain circuit respectively.
• The hydraulic oil in port A flows through the hole
of piston (1) to port C. Since d2 < d3, main valve
(2) is seated on the left side.
• The order of the diameters (areas) of the sections
is d5 > d4 > d1 > d3 > d2.
WA150-5 10-115
5. Suction valve
• Since the pressure in port C is lower than that in
port A, main valve (2) moves to the right and the
hydraulic oil flows through port A to port B, thus
generation of abnormal pressure is prevented.
• Even if abnormal pressure is generated, suction
valve (7) having a large section diameter does
not operate since d1 < d4.
1. Main poppet
2. Sleeve
3. Spring
Function
• The suction valve prevents generation of nega-
tive pressure in the circuit.
(2) Operation as suction valve
• If negative pressure is generated in the cylinder Operation
circuit, the pressure in ports A and C becomes • If negative pressure is generated in port A (lift cyl-
negative since those ports are connected. The inder head) (If the pressure in port A is lower than
hydraulic pressure equivalent to the area differ- the pressure in the tank circuit port B), main pop-
ence between d4 and d1 is applied to suction pet (1) opens because of the area difference be-
valve (7). tween d1 and d2 and the oil flows from tank port
• If the pressure difference between ports B and A B into cylinder port A.
increases above the set pressure, it moves suc-
tion valve (7) to the right. Accordingly, hydraulic
oil flows from port B to port A to prevent genera-
tion of negative pressure in port A.
10-116 WA150-5
6. Operation of the work equipment control valve
(1) Neutral position of the lift arm and bucket spools
Operation
• The hydraulic oil flows through pump (1) and pri-
ority valve to port A and its maximum pressure is
controlled by relief valve (2).
• The bypass circuit of bucket spool (3) is open
since bucket spool is in neutral.
• Since lift arm spool (4) is in neutral, its bypass cir-
cuit is open. Accordingly, the hydraulic oil in port
B returns through the periphery of the spool, port
C of the drain circuit, and filter into the tank.
WA150-5 10-117
(2) RAISE position of the lift arm spool
Operation
• If the work equipment control lever is pulled, lift
arm spool (4) is pulled out to the RAISE position.
• The hydraulic oil flows through pump (1) and by-
pass circuit of bucket spool (3) to the bypass cir-
cuit of lift arm spool (4).
• Since the bypass circuit is closed by the spool,
the hydraulic oil from port B pushes check valve
(5) open.
• The hydraulic oil from port B flows through port D
to the cylinder bottom side.
• On the other hand, the hydraulic oil on the cylin-
der head side returns through port E and drain
port C into the tank. Accordingly, the lift arm ris-
es.
10-118 WA150-5
(3) LOWER position of the lift arm spool
Operation
• If the work equipment control lever is pushed, lift • On the other hand, the hydraulic oil on the cylin-
arm spool (4) is pushed in to the LOWER posi- der bottom side returns through port D and drain
tion. port C into the tank. Accordingly, the lift arm low-
• The hydraulic oil flows through pump (1) and by- ers.
the hydraulic oil from port B pushes check valve
(5) open.
• The hydraulic oil from port B flows through port E
to the cylinder rod side.
WA150-5 10-119
(4) FLOAT position of the lift arm spool
Operation
• If the work equipment control lever is pushed fur- • While the bucket is in contact with the ground, it
ther from the LOWER position, lift arm spool (4) can move up and down according to the uneven-
is pushed in to the FLOAT position. ness of the ground.
• The hydraulic oil flows through pump (1) and by-
• The hydraulic oil in the bypass circuit flows into
the drain circuit because of the spool and cannot
push check valve (5) open.
• Since both of RAISE circuit D and LOWER circuit
E of the lift cylinder are connected to the drain cir-
cuit, the lift arm is lowered by its weight.
10-120 WA150-5
(5) TILT position of the bucket spool
Operation
• If the work equipment control lever is pulled,
bucket arm spool (3) is pulled out to the TILT po-
sition.
the hydraulic oil from port A pushes check valve
(7) open.
• The hydraulic oil from port G flows to the cylinder
bottom side.
der rod side returns through port H and drain port
C into the tank. Accordingly, the bucket tilts.
WA150-5 10-121
(6) DUMP position of the bucket spool
Operation
• If the work equipment control lever is pushed,
bucket arm spool (3) is pushed in to the DUMP
position.
the hydraulic oil from port A pushes check valve
(7) open.
• The hydraulic oil from port H flows to the cylinder
rod side.
der bottom side returns through port G and drain
port C into the tank. Accordingly, the bucket
dumps.
10-122 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
WORK EQUIPMENT PPC VALVE

Mono-lever type
a Do not disassemble. If it is disassembled, its set pressure must be adjusted.
P: From HST charging pump

P1: To bucket TILT valve
P2: To bucket DUMP valve
P3: To lift arm RAISE valve
P4: To lift arm LOWER (FLOAT) valve
WA150-5 10-123
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Rod 10. Piston
5. Disc 11. Body
6. Nut (for connecting lever)
10-124 WA150-5
Operation
1. When in NEUTRAL
(1) PPC valve for bucket (2) PPC valve for lift arm
• Ports PA and PB of the bucket control valve and • Ports PA and PB of the lift arm control valve and
ports P1 and P2 of the PPC valve are connected ports P3 and P4 of the PPC valve are connected
through fine control hole f of spool (1) to the drain through fine control hole f of spool (1) to the drain
chamber D. chamber D.
WA150-5 10-125
2. When in fine control

(NEUTRAL o Fine control)
• If rod (4) and piston (10) are pushed by disc (5),

retainer (9) is pushed and spool (1) is also
pushed down through metering spring (2).
• Accordingly, fine control hole f is disconnected
from drain chamber D and connected to pump
pressure chamber PP almost simultaneously,
and then the pilot oil of the main pump flows from
port P1 to port PB.
• If the pressure in port P1 rises, spool (1) is
pushed back and fine control hole f is discon-
nected from pump pressure chamber PP and
connected to drain chamber D almost simulta-
neously to release the pressure in port P1.
• As a result, spool (1) moves up and down to bal-
ance the force of metering spring (2) with the
pressure in port P1.
The positional relationship between spool (1) and
body (11) (where fine control hole f is between
drain chamber D and pump pressure chamber
PP) does not change until retainer (9) comes in
contact with spool (1).
• Since metering spring (2) is compressed in pro-
portion to the stroke of the control lever, the pres-
sure in port P1 rises in proportion to the stroke of
the control lever.
• Accordingly, the control valve spool moves to a
position at which the pressure in the chamber PB
(equal to the pressure in port P1) is balanced with
the force of the control valve spool return spring.
10-126 WA150-5
3. When in fine control 4. When lever is operated to stroke end

(When control lever is returned)
• If disc (5) begins to return, the force of centering • If disc (5) and rod (4) push down piston (10) and
spring (3) and the pressure in port P1 push up retainer (9) pushes down spool (1), fine control
spool (1). hole f is disconnected from drain chamber D and
• As a result, fine control hole f is connected to connected to pump pressure chamber PP.
drain chamber D and the oil in port P1 is re- • Accordingly, the pilot oil from the main pump
leased. flows through fine control hole f and port P1 into
• If the pressure in port P1 lowers too much, spool chamber PB and pushes the control valve spool.
(1) is pushed down by metering spring (2) and • The oil returning from chamber PA flows through
fine control hole f is disconnected from drain port P2 and fine control f' into drain chamber D.
chamber D and connected to pump pressure
chamber PP almost simultaneously. Then, the
pump pressure is applied until the pressure in
port P1 is restored to the level corresponding to
the position of the lever.
• When the control valve spool returns, the oil in
drain chamber D flows in through fine control hole
f' of the valve which is not in operation and then
flows through port P2 into chamber PA.
WA150-5 10-127
5. When lift arm is FLOATED 6. When FLOAT state of lift arm is cancel
• If rod (4) and piston (10) on the LOWER side of • Disc (5) is returned from the FLOAT position by
port P4 are pushed down by disc (5), the internal pushing it down with a force greater than the at-
mechanism of body (11) starts to operate the de- tractive force of solenoid.
tent in the middle of the stroke. • The FLOAT state also can be canceled and the
• If rod (4) is pushed up and the current flows into lever can be returned to the neutral position by
the solenoid in body (11), an attractive force is turning off the current in solenoid (demagnetizing
generated. the solenoid).
• Accordingly, rod (4') is kept pushed up and the
FLOAT state is kept even if the lever is released.
• At the same time, the control valve is also moved • The lift arm RAISE and bucket TILT operations
to the FLOAT position and kept at that position. are carried out similarly to the above.
10-128 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
10-130 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
1. Bucket
2. Tilt lever
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
Tolerance
Clearance between bushing and size clearance limit
7 pin at each end of joint of bucket Shaft Hole
link
50 -0.025 +0.148 0.105 – 1.0
-0.064 +0.080 0.206
8 Clearance between bushing and 50 -0.025 +0.148 0.105 – 1.0

pin of joint of lift arm and bucket -0.064 +0.080 0.206
9 Clearance between bushing and 60 -0.030 +0.174 0.130 – 1.0

pin of joint of lift arm and frame -0.076 +0.100 0.250
Clearance between bushing and -0.025 +0.148 0.105 – Replace
10 pin of joint of bucket cylinder bot- 50 -0.064 +0.080 0.206 1.0 (Replace if pin
tom and frame has scuff mark)
Clearance between bushing and -0.025 +0.148 0.1050 –
11 pin of joint of bucket cylinder rod 50 1.0
and tilt lever -0.064 +0.080 0.206

12 pin of joint of tilt lever and lift arm 65 -0.076 +0.100 0.250 1.0

13 pin of joint of lift cylinder rod and 55 1.0
lift arm -0.076 +0.080 0.218

14 pin of joint of lift cylinder bottom 55 -0.076 +0.100 0.250 1.0
and frame
Width of boss Width of hinge

Standard
Standard Standard clearance
15 Joint
frame
of bucket cylinder and
size Tolerance size Tolerance Adjust clearance
on each side to
80 -0 83 ± 1.5 1.5 – 5.0 1.5 mm or less
-0.5
+3.0
16 Joint of lift arm and frame 84 — 88 +0 4.0 – 7.0
17 Joint of lift arm and bucket 84 — 88 +3.0 4.0 – 7.0

+0 Adjust clearance
on each side to
+3.0 0.5 mm or less
18 Joint of bucket link and bucket 83 — 88 +0 5.0 – 8.0
-0 +3.0 Adjust clearance

19 Joint of lift cylinder and frame 85 -0.5 88 +0 3.0 – 6.5 on each side to
1.5 mm or less
20 Joint of tilt lever and bucket link 83 — 88 ± 1.5 3.5 – 6.5 Adjust clearance
on each side to
21 Joint of tilt lever and lift arm 143 ± 0.5 146 — 2.5 – 3.5 0.5 mm or less
22 Joint of bucket cylinder and tilt 85 0 88 ± 1.5 1.5 – 5.0 Replace

lever -0.5
Adjust clearance
23 Joint of lift arm and lift cylinder 84 — 89 ± 0.8 4.2 – 5.8 on each side to
2.0 mm or less
WA150-5 10-131
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BUCKET
BUCKET
1. Bucket 3. Bucket tooth (If equipped)

2. Bolt-on cutting edge 4. Adapter (If equipped)
Unit: mm
5 Wear of cutting edge (Thickness) Turn over or
22 15.5 replace
6 Wear of cutting edge (Length) 62 5
Tooth 29 15.5
7 Wear of bucket tooth Replace
Tip tooth 36 24
8 Clearance of adapter mount Max. 0.5 — Adjust or
replace
10-132 WA150-5
(5)
BUCKET POSITIONER AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
1. Bucket positioner proximity switch 4. Bucket cylinder

2. Boom kick-out proximity switch (If equipped) 5. Boom
3. Plate 6. Plate (If equipped)
Unit: mm
7 Clearance of bucket positioner

proximity switch 3–5
Adjust
8 Clearance of boom kick-out prox- 3–5
imity switch
WA150-5 10-133
OUTLINE
Bucket positioner
• The bucket positioner is driven electrically.
When the bucket is returned to an angle from the
DUMP position toward the TILT position, the
bucket positioner returns the work equipment
(bucket) control lever from the TILT position to
the HOLD position to automatically stop the
bucket at a proper digging angle.
• Plate (3) is bolted to the rod of bucket cylinder (4).
Proximity switch (1) is bolted to the cylinder.
• If the work equipment (bucket) control lever is
moved from the DUMP position to the TILT posi-
tion, the rod of bucket cylinder (4) moves toward
the front of the machine. When plate (3) parts
from proximity switch (1) at a point, proximity
switch (1) operates to return the work equipment
(bucket) control lever to the HOLD position.
Boom kick-out
• The boom kick-out is driven electrically. When
the lift arm is raised to an angle before the maxi-
mum position, the boom kick-out returns the work
equipment (lift arm) control lever from the RAISE
position to the HOLD position to automatically
stop the lift arm at the current position.
• Plate (6) is fixed to lift arm (5). Proximity switch
(2) is fixed to the front frame.
• If the work equipment (lift arm) control lever is
moved from the LOWER position to the RAISE
position, lift arm (5) rises. When plate (6) parts
from proximity switch (2), proximity switch (2) op-
erates to return the work equipment (lift arm) con-
trol lever to the HOLD position.
10-134 WA150-5
OPERATION OF PROXIMITY SWITCH

When bucket is tilted
• While the bucket is dumping more than the set • If the work equipment (bucket) control lever (7) is
position of the bucket positioner, plate (2) is over moved to the TILT position, bucket dump spool
the sensing face of proximity switch (1), the lamp (8) moves up and is held at that position by the
of which is lighting up. coil magnetized by detent solenoid (6). As a re-
At this time, bucket positioner relay (4) is turned sult, work equipment (bucket) control lever (7) is
on and a current flows in detent solenoid (6) of held at TILT position and the bucket tilts.
work equipment PPC valve (5) to magnetize the
coil.
WA150-5 10-135
• If the bucket tilts and parts from the set position FUNCTION OF PROXIMITY SWITCH
of the bucket positioner, or if plate (2) parts from
over the sensing face of proximity switch (1), the When object of sensing is over sensing face of
lamp of proximity switch (1) goes off and bucket proximity switch
positioner relay (4) is turned off. Accordingly, the
circuit of detent solenoid (6) of work equipment Lamp of proximity switch ON
PPC valve (5) is turned off to demagnetize the Bucket positioner relay switch circuit Made
coil.
Bucket dump spool (8) held at the TILT position Work equipment PPC valve detent
Made
receives the reaction force of spring (9) and solenoid circuit
returns work equipment (bucket) control lever (7) Work equipment PPC valve detent
to the HOLD position. Magnetized
solenoid
When object of sensing is apart from over sens-

ing face of proximity switch
Lamp of proximity switch OFF
Bucket positioner relay switch circuit Broken
Work equipment PPC valve detent

Broken
solenoid circuit

Demagnetized
solenoid
10-136 WA150-5
When lift arm is raised • If the work equipment (lift arm) control lever (7) is
• While the lift arm (3) is lower than the set position moved to the RAISE position, boom lower spool
of the boom kick-out, plate (2) is over the sensing (8) moves up and is held at that position by the
face of proximity switch (1), the lamp of which is coil magnetized by detent solenoid (6). As a re-
lighting up. sult, work equipment (lift arm) control lever (7) is
At this time, boom kick-out relay (4) is turned on held at RAISE position and the lift arm rises.
and a current flows in detent solenoid (6) of work
equipment PPC valve (5) to magnetize the coil.
WA150-5 10-137
• If the lift arm (3) rises and parts from the set po- FUNCTION OF PROXIMITY SWITCH
sition of the kick-out, or if plate (2) parts from over
the sensing face of proximity switch (1), the lamp When object of sensing is over sensing face of
of proximity switch (1) goes off and boom kick- proximity switch
out relay (4) is turned off. Accordingly, the circuit
of detent solenoid (6) of work equipment PPC Lamp of proximity switch ON
valve (5) is turned off to demagnetize the coil. Boom kick-out relay switch circuit Made
Lift arm raise spool (8) held at the RAISE posi-
tion receives the reaction force of spring (9) and Work equipment PPC valve detent
Made
returns work equipment (lift arm) control lever (7) solenoid circuit
to the HOLD position. Work equipment PPC valve detent
Magnetized
solenoid
When object of sensing is apart from over sens-

ing face of proximity switch
Lamp of proximity switch OFF
Boom kick-out relay switch circuit Broken

Broken
solenoid circuit

Demagnetized
solenoid
10-138 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

LIFT CYLINDER
BUCKET CYLINDER
Unit: mm
Tolerance
Name of Standard Standard Clearance
cylinder size clearance limit
Clearance between Shaft Hole
1 piston rod and bush- Replace
-0.030 +0.163 0.036 – bushing
ing Lift 60 0.567
-0.104 +0.006 0.267
Bucket 55 -0.030 +0.163 0.036 – 0.567

-0.104 +0.006 0.267
Tightening torque of Lift 932 ± 93.2 Nm {95 ± 9.5 kgm}
2
cylinder head Bucket 863 ± 86.3 Nm {88 ± 8.8 kgm}
Lift 1,770 ± 177 Nm {180 ± 18.0 kgm} Retighten

Tightening torque of (Width across flats:60 mm)
3 cylinder piston nut
Bucket 1,770 ± 177 Nm {180 ± 18.0 kgm}
(Width across flats:60 mm)
WA150-5 10-139
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
(If equipped)
AIR CONDITIONER PIPING
1. Air outlet duct 8. Compressor

2. Fresh air inlet filter 9. Hot water return piping
3. Fresh air inlet duct 10. Hot water take-out piping
4. Recirculating air filter 11. Refrigerant piping
5. Recirculating / Fresh air selector damper 12. Air conditioner unit
6. Receiver tank 13. Floor duct
7. Condenser
10-140 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
MACHINE MONITORING SYSTEM

Outline
• The machine monitor system uses the sensors • Normal mode indications are those which are
and other devices installed to various parts of the usually being made for ordinary use by the ma-
machine to observe the condition of the machine. chine operators. The description below applies to
It processes this information swiftly and displays the contents of the main indications.
it on the monitor panel to inform the operator of
the condition of the machine. 1. Items which are always indicated
• The indications of the machine monitor will be • Meters (Travel speedometer)
made under the normal mode and under the ser- • Gauges (Engine cooling water temperature
vice mode. gauge, HST oil temperature gauge and fuel
• The machine monitor has ON/OFF output func- level gauge)
tion of automatic preheating which assists with • Pilot indications
the starting of the engine. • Service meter
• The machine monitor has the relay ON/OFF out-
put function to cut the output to the HST solenoid 2. Items which will be indicated only when some ab-
when the HST controller has a trouble. normality occurs
• Cautions
• Action code indications (When the machine
monitor panel mode selector switch (>) is de-
pressed and released while the action code
is being indicated, the failure code (6 digits)
will be indicated.)
3. When the time comes to change the filter or oil,

necessary items for the filter change or oil
change will be indicated on the character display.
(Maintenance monitoring functions)
4. In addition to the above, this system is equipped

with the functions to indicate the travel distance
integrating meter (odometer), to reset the filter/oil
changing time, and to select the language by use
of the character display and the machine monitor
panel mode selector switch which is the opera-
tion switch of the character display.
WA150-5 10-141
• This machine monitoring system is equipped with • Also, the service mode is equipped with the fol-
the service mode function to facilitate the trouble- lowing functions necessary when replacing the
shooting work for respective controllers (includ- machine monitor.
ing the machine monitor itself) on the network. • The machine monitoring system consists of the
The description below applies to the contents of machine monitor proper, buzzer, and switches
the main functions. that are used for inputting data to the machine
monitor proper, sensors, respective controller on
1. Electric fault history the network, and relevant switches and sensors.
This function will indicate the electric fault history
data of respective controllers being memorized
by the machine monitor. Also, it can be used to
delete the aforementioned data.
2. Machine fault history

This function will indicate the machine fault histo-
ry and machine fault history data of respective
controllers being memorized by the machine
monitor.
3. Real time monitor

This function will make real time indications of the
inputting data and outputting data being recog-
nized by respective controllers on the network.
4. Maintenance monitor
This function is to be used for revisions of the pre-
set filter and oil changing time. (Revision of the
time for the maintenance monitor operation)
5. Selection of optional items

This function is used to set the machine model,
tier size, and optional equipment.
6. Controller initializing function

This function is being used to effect the settings
of this machine monitor before shipment from our
factory.
10-142 WA150-5
(4)
Individual circuit diagrams of the machine monitor
Starting and lighting
10-144 WA150-5
1. Starting switch Connection table of connector pins of machine moni-

2. Alternator tor
3. Emergency flasher switch
4. Flasher unit Symbol Connector pin No.
5. Turn signal lever a CNL23-3
6. Turn signal lamp (Left)
7. Turn signal lamp (Right) b CNL23-1
8. Head lamp relay
c CNL23-12
9. Lamp switch
10. Dimmer switch d CNL22-11
11. Head lamp (Lo)
e CNL23-17
12. Head lamp (Hi)
13. Clearance lamp, tail lamp relay f CNL21-12
14. Clearance lamp, tail lamp
15. License plate lamp g CNL22-12
16. Working lamp relay h CNL23-9
17. Tachograph lamp (If equipped)
WA150-5 10-145
(3)
Power supply and network
1. Monitor panel mode selector switch 1 "U" Connection table of connector pins of machine moni-
2. Monitor panel mode selector switch 1 "u" tor
3. Monitor panel mode selector switch 2 "<"
4. Monitor panel mode selector switch 2 ">" Symbol Connector pin No.
5. HST controller a CNL23-11
b CNL21-2
c CNL21-1
d CNL21-4
e CNL21-5
f CNL22-6
g CNL22-2
h CNL21-3
i CNL21-7
j CNL21-15
k CNL23-14
10-146 WA150-5
Sensing
1. Alarm buzzer Connection table of connector pins of machine moni-

2. HST filter clogging sensor tor
3. Steering oil pressure sensor (If equipped)
(Machines equipped with emergency steering) Symbol Connector pin No.
4. Emergency steering oil pressure sensor a CNL21-11
(Machines equipped with emergency steering)
(If equipped) b CNL23-6
5. Coolant level sensor
c CNL22-3
6. Brake oil pressure sensor
7. Engine oil pressure sensor d CNL22-5
8. Parking brake not applied signal
e CNL23-8
9. Parking brake indicator signal
10. Fuel level sensor f CNL23-19
11. HST oil temperature sensor
12. Coolant temperature sensor (for monitor) g CNL23-10
13. Axle oil temperature sensor h CNL21-13
i CNL23-18
j CNL23-13
k CNL21-14
l CNL21-16
m CNL21-8
WA150-5 10-147
HST safety control
1. Directional lever Connection table of connector pins of machine moni-

2. HST safety relay tor
3. Motor 1 solenoid valve
4. Clutch solenoid valve Symbol Connector pin No.
5. HST controller a CNL22-8
b CNL22-10
c CNL22-9
d CNL22-6
e CNL22-2
f CNL21-3
g CNL23-15
10-148 WA150-5
Automatic preheating
1. Coolant temperature sensor (for preheating) Connection table of connector pins of machine moni-
2. Automatic preheater relay tor
3. Engine heater relay
4. Ribbon heater Symbol Connector pin No.
a CNL21-6
b CNL22-4
WA150-5 10-149
(3)
CAN input
Machine monitor HST controller
CAN output
Directional lever signal HST control
Machine monitor Model selection Model selection
HST function selection HST control
Travel speed pulse Travel speedometer
Gear speed signal Indication of 1, 2, 3, or 4

HST controller
Error Indication of characters
Input/Output state signal Real-time monitor
10-150 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITOR
MACHINE MONITOR
a Monitor lamps 17 and 18 do not operate on this machine.
1. HST oil temperature gauge 17. Engine oil level caution lamp
2. HST oil temperature caution lamp 18. Air cleaner clogging caution lamp
3. Engine water temperature gauge 19. Maintenance caution lamp
4. Engine water temperature caution lamp 20. Radiator water level caution lamp
5. Speedometer 21. HST oil filter clogging caution lamp
6. Turn signal pilot lamp (Left) 22. Engine oil pressure caution lamp
7. Head lamp beam pilot lamp 23. Battery charge circuit caution lamp
8. Turn signal pilot lamp (Right) 24. Character display
9. Meter indication pilot lamp 25. Steering oil pressure caution lamp
10. Fuel level caution lamp (Machine equipped with emergency steering)
11. Fuel level gauge 26. Emergency steering pilot lamp
12. Centralized warning lamp (Machine equipped with emergency steering)
13. Parking brake pilot lamp 27. Preheater pilot lamp
14. Brake oil pressure caution lamp 28. Gear speed selector switch position pilot lamp
15. Parking brake not applied caution lamp 29. Directional lever position pilot lamp
16. Axle oil temperature caution lamp
WA150-5 10-151
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIST OF ITEMS DISPLAYED ON MONITOR
LIST OF ITEMS DISPLAYED ON MONITOR

Condition for judging running of engine: When running judgment A or B is satisfied, it is judged that the engine
is running.
1. Input is given to alternator terminal R (24 V).
2. Engine oil pressure is normal (Open).
3. Signal of terminal C has been input at least once after IGN_BR, and then it has been turned OFF at least
once.
Judgment of operation
A: After 1 and 2 are established simultaneously, it is judged that the engine is running until IGN_BR is turned
OFF.
B: If 1 and 3 are established simultaneously or 2 and 3 are established simultaneously, it is judged that the en-
gine is running. If both signals of 1 and 2 are lost, however, it is judged that the engine is stopped even if
IGN_BR is turned ON.
Pri-
Lamp Period of lamp Buzzer Condition for operation Period of buzzer
ority
Warning for dangerous Period: 1,600 msec

w: ON and OFF condition ON: 800 msec
Q: ON – 1
continuously (When error indication OFF: 800 msec
or caution is turned on) (DUTY 50%)
Period: 1,600 msec Caution for wrong oper-

Period: 240 msec
ON: 800 msec ation, etc. (When abnor-
w: Flash A: Intermittent ON 1: 80 msec 2
OFF: 800 msec mal operation is
OFF: 160 msec
(DUTY 50%) performed)
Period: 240 msec Cancellation of calibra-

E: Cancellation
A: Intermittent ON 1: 80 msec tion, etc. (When opera- ON: 1,000 msec (Once) 3
sound
OFF: 160 msec tion is not accepted)
ON: 1,000 msec.

E: Condition is Completion of calibra-
e: Completion OFF: 160 msec.
set sepa- – tion, etc. (When com- 4
sound ON: 1,000 msec (Once)
rately pleted normally)
10-152 WA150-5
Operation
Engine is stopped Engine is running
Centralized warning
Centralized warning
Individual indication
Indication of failure
Condition for Indication
Warning buzzer
Warning buzzer
Division No. Item Device Remarks
code message
code message
operation color
Backup When clear-

– Backup lamp Bulb for night ance lamp is – – – – – – – – Orange
lamp light ON
Indication of km/h or MPH
Unit 9
meter
LED – Q – – – Q – – Green (Selected by setting
monitor)
Conversion of If there is error in
Pointer: travel speed communication, con-
5 Travel speed Movement pulse into – – – – – – – – – dition is held until key
travel speed is turned OFF.
Other than
– – – – – – – – –
below
HST oil tem- Pointer: Alarm: Above
1 perature/HST Movement 110°C w Q Q B@CRNS w Q Q B@CRNS Red White range: 50 - 110°C
2 oil tempera- Indicator: Red range: 110 - 135°C
ture caution LED HST oil tem-
perature: – – – DGH1KX – – – DGH1KX –
Above 150°C
Other than – – – – – – – – –
below
Engine water Alarm: Above
Pointer: 102°C – Q – – – Q – – Red
3 temperature/ Movement White range: 50 - 102°C
4 Engine water Indicator: Alarm: Above Red range: 102 - 135°C
temperature 105°C w Q Q B@BCNS w Q Q B@BCNS Red
Gauge/ LED
Meter caution
Engine water
temperature: – – – DGE2KX – – – DGE2KX –
Above 150°C
Pointer: Other than – – – – – – – – –
Fuel level / below
10 Fuel level Movement
11 caution Indicator: Above 110z
LED (Below 5%) – Q – – – Q – – Red
Conversion of
travel speed
Odometer pulse into – – – – – – – – –
travel dis-
tance
24 LCD Operates
when charge
is normal.
Service meter Corresponds – – – – – – – – –
to clock time
in 1:1.
Other than Lamp is turned ON by
below – – – – – – – – – each controller and
12 Centralized Bulb message is indicated
warning lamp When error is on character display.
made E E E E E E E E Red Lamp is turned ON by
caution.
Oil pressure
is normal – – – – – – – – –
(GND) *1: For 30 sec just
Brake oil Oil pressure after key is turned ON
pressure and engine is started
14 (Accumulator Bulb is abnormal – Q – – w Q Q – Red *2: 30 sec after
oil pressure) (OPEN) (*1) engine is started
Oil pressure (after *1)
is abnormal – – – – w Q Q 2G42ZG Red
(OPEN) (*2)
Caution Other than – – – – – – – – – Lamp lights up and
lamp below warning buzzer
Prevention of sounds when engine
omitting to When appli-
15 Bulb cation of is stopped and park-
apply parking ing brake is released
brake parking brake A Q Q – – – – – Red
is omitted (or when key is turned
(24 V) OFF).
Oil tempera-
– – – – – – – – –
ture is normal *3: oil temperature
Oil tempera- above 120°C is
ture is abnor- w Q Q B@C7NS w Q Q B@C7NS Red detected for continu-
Axle oil tem- mal (*3) ous 5 seconds or oil
16 perature Bulb temperature above
Brake oil tem- 115°C is detected for
perature: – – – DGR1KX – – – DGR1KX – continuous 5 seconds
Above 150°C and the travel speed
Detection of is above 35 km/h
error – – – DGR1KB – – – DGR1KB –
WA150-5 10-153
Operation
Centralized warning
Centralized warning
Warning buzzer
Warning buzzer
code message
code message
operation color
Oil level is If error is detected

normal (GND) – – – – – – – – – when IGN_C signal is
turned ON. Error is
not detected while
Engine oil engine is running. (If
17 Bulb abnormality is
temperature Oil level is detected when key is
low (OPEN) – Q – B@BAZK – – – – Red
turned ON, alarm is
kept turned ON until
normal oil level is
detected.)
Normal – – – – – – – – –
Clogging of (OPEN) Error is detected only
18 air cleaner Bulb while engine is run-
Clogging ning.
(GND) – Q – – – Q – AA1ANX Red
Mainte- Normal – – – – – – – – –
19 Bulb 30 h before
nance maintenance – Q – E – Q – E Red
Water level is – – – – – – – – –
Caution normal (GND) Error is judged when
20 Radiator Bulb it is detected for 30
lamp water level Water level is – Q – B@BCZK – Q – B@BCZK Red sec.
low (OPEN)
Normal
Clogging of (OPEN) – – – – – – – – – Error is judged when
21 Bulb HST oil temperature
HST oil filter Clogging – Q – 15BONX – Q – 15BONX Red is above 50°C.
(GND)
Oil pressure
is normal – – – – – – – – –
(OPEN)
Oil pressure Error is detected 15
22 Engine oil Bulb is low (GND) – Q – – w Q Q B@BAZG Red sec after engine is
pressure
When abnor- started.
mality is
detected – – – DHE4L6 – – – – Red
(OPEN)
Normal volt-
age (24 V) w – Q AB00L6 – – – – Red
Battery
23 charge circuit Bulb
Defective
charge (0 V) – Q – – w Q Q AB00MA Red
When turn Interlocked with turn
signal lever is signal lever. Oper-
6 Turn signal turned ON
Bulb (while key is – Q – – – Q – – Green ates when hazard
8 lamp lamp switch is turned
turned OFF, ON.
too)
When beam
of head lamp
Beam of head is turned ON Interlocked with lamp
7
lamp
Bulb (When both – Q – – – Q – – Blue switch and dimmer
head lamp switch.
and beam are
turned ON)
Parking brake Lamp lights up when
is released – – – – – – – – – parking brake is
(OPEN) applied.
Parking Parking brake Operation of forward-
13 Bulb is applied – Q – – – Q – – Red reverse (F-R) lever is
Pilot lamp brake (GND) prohibited and warn-
Prevention of ing buzzer is turned
dragging of A Q Q – A Q Q – Red ON while parking
parking brake brake is applied.
Steering oil Oil pressure
is normal – – – – – – – – –
pressure (OPEN)
25 (Machines Bulb
equipped with Oil pressure
emergency is low (GND) – Q – – w Q Q DDS5L6 Red
steering)
Emergency Oil pressure
– – – – – – – – –
is lost (GND)
steering
26 (Machines Bulb Oil pressure
equipped with is normal – Q – – – Q – – Green
emergency (OPEN)
steering)
a Monitor lamps 17 and 18 do not operate on this machine.
10-154 WA150-5
Operation
Centralized warning
Centralized warning
Warning buzzer
Warning buzzer
code message
code message
operation color
Other than Lamp lights up when

below – – – – – – – – – automatic preheater
is turned ON.
Automatic Output is turned OFF
27 Bulb When engine when IGN_C signal is
preheating is preheated – Q – – – Q – – Orange turned ON.
(postheated) Postheater is turned
ON after IGN_C sig-
nal is turned OFF.
When F is
Direc- F selected – Q – – – Q – – Green
tional When N is
29 N LED selected – Q – – – Q – – Orange
lever
Pilot lamp When R is
position R – Q – – – Q – – Green
selected
When 1st
1 gear speed is – Q – – – Q – – Green
received Indicator lamp lights
Gear When 2nd up when CAN signal
2 gear speed is – Q – – – Q – – Green is received from HST
speed controller.
received
28 selector LED Indicator lamp does
When 3rd not light up when
switch 3 gear speed is – Q – – – Q – – Green CAN communication
position received is defective (All lamps
When 4th go off).
4 gear speed is – Q – – – Q – – Green
received
WA150-5 10-155
Service mode functions
1. Outline
1) Electrical equipment system failure history 2) Machine system failure history
This function is used to check the electrical This function is used to check the machine
equipment system failure history of each system failure history of each controller
controller saved in the machine monitor. For saved in the machine monitor. For the fail-
the failure codes displayed in the electrical ure codes displayed in the machine system
equipme nt sy stem failu re his tory, se e failure history, see TROUBLESHOOTING.
TROUBLESHOOTING. After each failure is The contents of the machine system failure
repaired and the normal operation is con- history displayed on the character display
firmed, delete the failure history. are as follows.
The contents of the electrical equipment
system failure history displayed on the char-
acter display are as follows.
*1: Displayed alternately every 3 seconds
***: The order in which the subject failure

*1: Displayed alternately every 3 seconds occurred
######: Failure code
***: The order in which the subject failure $$$: Frequency of occurrence of the subject
occurred failure
######: Failure code %%%%%: The service meter value of the
$$$: Frequency of occurrence of the subject first occurrence of the subject
failure failure
%%%%%: The time elapsed since the sub- @@@@@: The service meter value at the
ject failure occurrence for the occurrence of the latest failure
first time (it is determined by The fai lu re c ode fai lure of a currently
subtracting the service meter detected failure flashes. Up to several
value of the first occurrence from machine system failure codes are saved.
the current service meter value)
@@@@@: The time elapsed since occur-
rence of the latest failure (it is
determined by subtracting the
service meter value at the latest
occurrence from the current ser-
vice meter value)
The fai lure code failure o f a currentl y
detected failure flashes. Up to 20 failure
codes are saved.
10-156 WA150-5
3) Real-time monitor Any 2 items can be displayed simultane-

This function is used to check the input and ously by specifying their ID Nos. In this
output signals, etc. recognized by each con- case, they are displayed on the character
troller on the network. display as shown below.
The contents of the real-time monitor dis-
played on the character display are as fol-
lows.
#####: Specified ID Nos.

*1: Changed after 3 seconds %%%: Data. If a unit is used, it is displayed
on the right of the data.
***: Item name
######: ID No. given to each item
%%%: Data. If a unit is used, it is displayed
on the right of the data.
WA150-5 10-157
4) Maintenance monitor
This function is explained in "Operation man-
ual, Operation, Character display, Display of
replacement periods of filters and oils". It is
used to change the replacement periods of
the filters and oils.
5) Selection of options
With this function, you can display installa-
tion of an optional device and change the
setting of that device. Use this function after
any optional device is installed or removed.
6) Initialize
This function is used only in the factory. Do
not use it.
10-158 WA150-5
(4)
2. Operating method
WA150-5 10-159
Items Related to the Fault History of Electric System

1) Selection of displaying and clearing the fault history of electric system
The fault history is displayed in the order of occurrence with the new fault first.
A current fault is displayed prior to the restored ones.
Pressing the > SW displays the next older fault.
Pressing the < SW displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the tSW changes the screen to the [Select displaying abnormalities in electric system] screen
on the first layer.
Pressing the USW changes the screen to the [Clear individually the fault history of electric system] or
[Clear the fault history of electric system] screen.
2) Selection of displaying the fault history of electric system (first layer)

Pressing the > SW changes the screen to the [Select the initializing function] screen.
Pressing the < SW changes the screen to the [Select displaying the fault history of vehicle system]
screen.
Pressing the tSW changes the screen to the ordinary or alert screen.
Pressing the USW changes the screen to the [Display abnormalities in electric system] screen.
10-160 WA150-5
3) Selection of displaying the fault history of electric system and clearing the entire fault history of electric
system (second layer)
A current fault is displayed piror to the restored ones.
Pressing the tSW changes the screen to the [Select displaying abnormalities in electric system] screen
on the first layer.
Pressing the USW changes the screen to the [Clear individually the fault history of electric system] or
[Clear the fault history of electric system]screen.
* If the history consisted of one fault, pressing the switch does not change the screen to that for all-out
clearing (but change the screen to that for individual clearing).
1. [Display the electrical equipment system failure history] screen

2. [Display the electrical equipment system failure history] screen (When there is not history)
3. [Select clearing entirely the electrical equipment system failure history] screen
***: The order in which the subject failure occurred

######: Unified failure code (6 digits)
$$$: Frequency of occurrence of the subject failure
%%%%%: The time elapsed since the subject failure occurrence for the first time (it is determined by
subtracting the service meter value of the first occurrence from the current service meter
value)
@@@@@: The time elapsed since occurrence of the latest failure (it is determined by subtracting the
service meter value at the latest occurrence from the current service meter value)
WA150-5 10-161
4) Clearing individually the fault history of electric system, and clearing the entire fault history of electric
system (the third layer)
Select YES or NO with the < or > SW.
Cursor (_) blinks on the selected item. Pressing the tSW changes the display as follows, with the his-
tory reset if YES was selected, or not if NO was selected:
a. If No (cancel) was selected, the display returns to the [Display the fault history of electric
system] screen of the relevant fault (i.e., the screen before entering the [Clearing individually
(entirely) the fault history of electric system] screen).
b. If YES (clear ) was selected, the display returns to the [Display the fault history of electric
system] screen of a fault next to the relevant fault. If the fault history to be shown exhausts, the
screen returns to the [Select displaying the fault history of electric system] screen.
By default, the cursor is on NO (no reset) to prevent resetting by error.
A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
If a fault was cleared, peeps sound (on for 0.1 sec. - off for 0.1 sec. - on for 0.1 sec.) to notify that the
operation has been accepted.
If the entire history was cleared, it is considered to have been cleared even if it consisted of only one
fault .
1. [Clear individually the electrical equipment system failure history] screen

2. [Clear entirely the electrical equipment system failure history] screen
10-162 WA150-5
(3)
Items Related to the Fault History of Machine System

1) Display of the fault history of vehicle system
Pressing the tSW changes the screen to the [Select displaying abnormalities in machine system]
screen on the first layer.
2) Selection of displaying the fault history of machine system (first layer)

Pressing the > SW changes the screen to the [Select the real-time monitor functions] screen.
Pressing the < SW changes the screen to the [Select displaying the fault history of machine system]
screen.
Pressing the tSW changes the screen to the ordinary or alert screen.
Pressing the USW changes the screen to the [Display abnormalities in electric system] screen.
WA150-5 10-163
3) Display of the fault history of vehicle system (second layer)

The fault history is displayed in the order of occurrence with the newest fault first.
The fault history is displayed in the order of occurrence with the newest fault first.
Pressing the > SW displays the next newer fault.
Pressing the < SW displays the next older fault.
Pressing the tSW changes the screen to the [Select displaying abnormalities in vehicle system]
screen.
1. [Display the machine system failure history] screen

2. [Display the machine system failure history] screen (When there is not history)
***: The order in which the subject failure occurred

######: Unified failure code (6 digits)
$$$: Frequency of occurrence of the subject failure
%%%%%: The service meter value of the first occurrence of the subject failure
@@@@@: The service meter value at the occurrence of the latest failure
10-164 WA150-5
Real-time monitor function
The real-time monitor function displays the information saved in the HST controller and machine monitor mount-
ed on the machine in real time.
This function is used for testing, adjusting, and troubleshooting in the normal display mode or 2-item display
mode for displaying 2 data simultaneously.
1) Selection/Display of real-time monitor item

Pressing the > SW changes the screen in the order of No. 1, No. 2, No. 3 --- Select display of 2 items.
Pressing the < SW changes the screen in the order of Select of display of 2 items, No. 13, No. 12, No.
11 ---.
Pressing the tSW changes the screen to the [Select real-time monitor function] screen.
In [Display of real-time monitor]: Pressing the USW holds the displayed data. Pressing it again returns
the displayed data into the active state.
In [Select display of 2 items]: Pressing the USW changes the screen to the [Select 2 items] screen.
2) Selection of real-time monitor function (first

layer)
Pressing the > SW changes the screen to
the [Select maintenance monitor function]
screen.
Pressing the < SW changes the screen to
the [Select display of machine system failure
history] screen.
Pressing the tSW change the screen to the
normal screen or alarm screen.
Pressing the USW change the screen to the
[Display of real-time monitor] screen.
WA150-5 10-165
3) Display of real-time monitor and selection of display of 2 items (second layer)

Pressing the > SW displays the next data.
Pressing the < SW displays the previous data.
Pressing the tSW changes the screen to the [Select real-time monitor function] screen.
In [Display of real-time monitor]: Pressing the USW holds the displayed data. Pressing it again returns
the displayed data into the active state.
In [Select display of 2 items]: Pressing the USW changes the screen to the [Select 2 items] screen.
*1: Changed after 3 seconds
1. [Display of real-time monitor] screen

2. [Select display of 2 items] screen
***: Real-time monitor item name

$$$$$: ID of item
%%%: Data and unit (SI unit)
4) Selection of 2 items (third layer)

How to input ID
a. When the screen appears, the cursor (_)
is blinking at the highest position of
"00000".
b. Each time the > SW or the < SW is
pressed, the digit changes by 1 between
0 and 9.
c. Select a necessary digit and press the
USW.
d. The cursor moves to the 2nd position.
Select the digits for the all positions by
performing steps b. and c. above.
e. After selecting the digit for the lowest po-
sition, press the USW.
f. If the ID is entered, the screen changes to
the [Display 2 items] screen.
g-1. If you press the tSW before finishing
entering the ID, the cursor moves to the
highest position.
g-2. If you press the tSW while the cursor is
at the highest position, the screen re-
turns to the [Select display of 2 items]
screen.
10-166 WA150-5
5) Display of 2 items (fourth layer)

Pressing the tSW changes the screen to the [Select 2 items] screen.
Pressing the USW holds the displayed data. Pressing it again returns the displayed data into the
active state.
$$$$$: ID of item
%%%%: Data and unit (SI unit)
a The first item and second item are displayed alternately every 3 seconds
a If an item ID that cannot be displayed is selected on the [Select 2 items] screen, the data & unit dis-
play box (%%%) is left blank.
Real-time Monitoring Items

Component Terminal
Item ID Real-time monitoring item Item displayed Display unit Displayed range Remarks
detected No.
All the items are shown A value out of the range
Abridged due to SI unit system so
even if some of them are displayed is shown as
limitation of long as the val-
not equipped depending the lowest (highest)
number of letters. ues have units
on models and options. value in the range.
20200 Monitor ROM No. MONITOR ROM --- --- Monitor ---
40000 Travel speed SPEED 1 km/h 0 – 50 HST L41-13
04202 Fuel level FUEL SENSOR 1% 0 – 100 Monitor L23-13
04101 Engine water temperature COOLANT TEMP 1 °C 24 – 131 Monitor L21-16
Engine water temperature
04103 COOLANT Lo 1 °C -31 – 91 Monitor L21-6
low
30100 HST oil temperature HST TEMP 1 °C 24 – 131 Monitor L21-14
30202 Axle oil temperature BRAKE TEMP 1 °C 24 – 131 Monitor L21-8
HST con-
01005 Engine speed ENG SPEED 1 rpm 0 – 3000 HST L42-4
troller CAN
HST con-
32600 HST oil pressure HST PRESS 0.1 MPa 0.0 – 100.0 HST L41-3
troller CAN
Motor 1 solenoid feed- HST con-
80000 MOTOR SOL 1 mA 0 – 1000 HST L41-6
back current troller CAN
Clutch solenoid feedback HST con-
80100 CLUTCH SOL 1 mA 0 – 1000 HST L41-14
current troller CAN
HST con-
50302 Potentiometer voltage SPEED POT 1% 0 – 100 HST L41-1
troller CAN
HST con-
80200 HST traction force TRACTION --- STD/LIMIT HST L42-3
troller CAN
WA150-5 10-167
(Reference) Inspection with real-time monitor
Example) Measurement of engine speed

Measure the engine speed under the following condition.
Cooling water temperature: Within operating range
HST oil temperature: 45 - 55°C
First, check this condition with the real-time monitor.
Condition Real-time monitor item Component ID
Cooling water temperature COOLANT TEMP Machine monitor 04101
HST oil temperature HST TEMP Machine monitor 30100
After checking the above items with the real-time monitor, check the engine speed.
Condition Real-time monitor item Component ID
Engine speed ENG SPEED HST controller 01005
10-168 WA150-5
Maintenance functions
1) Selection/Display of maintenance monitor item

Pressing the > SW changes the screen in the order of No. 1, No. 2, No. 3 ---.
Pressing the < SW changes the screen in the order of No. 13, No. 12, No. 11 ---.
Pressing the tSW changes the screen to the [Select maintenance monitor function] screen.
Pressing the USW changes the screen to the [Change maintenance interval time].
2) Selection of display of maintenance monitor function (first layer)

Pressing the > SW changes the screen to the [Select OPT function] screen.
Pressing the < SW changes the screen to the [Select real-time monitor function] screen.
Pressing the tSW change the screen to the normal screen or alarm screen.
Pressing the USW change the screen to the [Select maintenance monitor item] screen.
WA150-5 10-169
3) Selection of maintenance monitor (second layer)

The contents of this display are the same as those of the maintenance monitor of the function opened
to the operator. Maintenance caution lamp does not light up, however.
Pressing the tSW change the screen to the [Select maintenance monitor function] screen.
Pressing the USW change the screen to the [Change maintenance monitor interval time] screen.
1. [Select maintenance item] screen

2. Example) When the data is HST oil filter
##: ID No. of each maintenance item

***: Each maintenance item
10-170 WA150-5
4) Change of maintenance interval time (third layer)

The maintenance interval time can be set freely to 0 - 9999 h.
If you press the tSW, the time is not changed but the screen changes to the [Select maintenance item]
screen.
At this time, the operation cancel sound (1-second peep) is heard.
How to input interval

a. When the screen appears, the cursor (_) is blinking at the highest position.
b. Each time the > SW or the < SW is pressed, the digit changes by 1 between 0 and 9.
c. Select a necessary digit and press the USW.
d. The cursor moves to the 2nd position. Select the digits for the all positions by performing steps (b.)
and (c.) above.
e. After selecting the digit for the lowest position, press the USW.
f-1. If the input interval time is acceptable, the screen changes to the check screen.
f-2. If the input interval time is not acceptable, the time does not change but the screen changes to the
[Select maintenance item] screen. At this time, the operation cancel sound (1-second peep) is
heard.
g. If you have input a wrong value, press the tSW to return to the [Select maintenance item] screen and
repeat the above steps from the first.

***: Each maintenance item
%%%%: Current interval time (4 digits)
If there is not a digit in a position of the interval time, input "0". Example: "0012"
WA150-5 10-171
5) Check of change of maintenance interval time (fourth layer)

Select YES or NO with the < or > SW. The cursor (_) blinks on the selected item. Pressing the tSW
returns the screen to the [Select maintenance item] screen with the change done if YES was selected,
or not if NO was selected.
By default, the cursor is on NO (the change not done) to prevent resetting by error.
When the change of the set time is finished, the operation acceptance peeps (on for 0.1 sec o off for
0.1 sec o on for 0.1 sec) are heard.

%%%%: Interval time (4 digits) to be changed
The maintenance interval time is set as shown in the following table, when shipped.
Item Replacement interval time (h) Displayed item name ID No.
Engine oil 500 ENG OIL 01
Engine oil filter 500 ENG FILT 02
Fuel filter 500 FUEL FILT 03
Transfer oil 1,000 TRANSF OIL 25
HST oil filter 1,000 HST FILT 26
Hydraulic oil filter 2,000 HYD FILT 04
Hydraulic oil 2,000 HYD OIL 10
Axle oil 2,000 AXLE OIL 15
10-172 WA150-5
Setting required when optional device is installed
When any of the following optional devices is added or replaced, adjust the sensors, etc. to the initial values with
the machine monitor.
Added or replaced optional device Adjustment item
Tire size, machine monitor Model selection, tire size selection, tire deviation selection
Function of selecting optional device

1) Selection and display of optional item
Pressing the > SW or < SW changes the selected optional items in order.
Pressing the tSW changes the screen to the [Select function of selecting optional device]
In [Model selection item]: Pressing the USW changes the screen to the [Select model] screen.
In [Select each optional device]: Pressing the USW updates the items of each optional device.
2) Selection of function of selecting optional

device (fourth layer)
Pressing the > SW changes the screen to
the [Select initializing function] screen.
Pressing the < SW changes the screen to
the [Select maintenance monitor function]
screen
Pressing the tSW changes the screen to
the normal screen or alarm screen.
Pressing the USW changes the screen to
the [Model selection item] screen.
WA150-5 10-173
3) Model selection item and selection of optional device (second layer)

Pressing the > SW or < SW changes the selected optional items in order.
In [Model selection item]: Pressing the USW changes the screen to the [Select model] screen.
In [Select each optional device]: Pressing the USW updates the items of each optional device.
1. [Model selection item] screen

2. [Select tire deviation] screen
Selection of tire deviation

Pressing the USW selects deviation from the standard tire between -12% and +12% (at intervals of 2%). (@@
is the deviation selected when shipped.)
(+00/+02/+04/+06/+08/+10/+12/-02/-04/-06/-08/-10/-12)
When selection is finished, the operation acceptance peeps (on for 0.1 sec o off for 0.1 sec o on for 0.1 sec)
are heard.
1) Selection of model (third layer)

Pressing the >SW or <SW selects a model.
(100/150/200/250/320)
Pressing the tSW changes the screen to the [Model selection item] screen.
If you press the USW to finish selection, the operation acceptance peeps (on for 0.1 sec o off for 0.1
sec o on for 0.1 sec) are heard and the screen changes to the [Select tire size] screen.
a Select "150" for this machine.
10-174 WA150-5
5) Selection of tire size (fourth layer)

Pressing the > SW or < SW selects a tire size.
(13.0/14.0/15.5/16.9/17.5/18.4/20.5)
If you press the USW to finish selection, the operation acceptance peeps (on for 0.1 sec o off for 0.1
sec o on for 0.1 sec) are heard and the screen changes to the [Model selection item] screen.
a Since "150" was selected on the "Select model" screen, "14.0" "15.5" "16.9" or "17.5" can be selected.
(Other tire sizes are not displayed.)
WA150-5 10-175
AMP040-16P [CN-L21]
Pin No. Specification I/O Type of use Signal name WA150-5 Remarks
SW for operating
1 D_IN (NSW +24V) I D/I+24V Service SW t SW input
machine monitor
SW for operating
2 D_IN (+24V) I D/I+24V Service SW U SW input
machine monitor
3 GND I GND CAN shield GND
SW for operating
4 D_IN (GND) I D/IGND Increment SW < SW input
machine monitor
SW for operating
5 D_IN (GND) I D/IGND Decrement SW > SW input
machine monitor
Engine water temperature Engine water temperature
6 A_IN I A/I sensor (For automatic pre- sensor (For automatic pre-
heating) heating)
7 GND I GND Sensor GND GND
Brake oil temperature sen- Brake oil temperature sen-
8 A_IN I A/I
sor sor
9 N.C. – – --- ---
10 N.C. – – --- ---
D_OUT Buzzer Buzzer
11 O D/O sink
(+24 V, sink: 200 mA) (Machine monitor) (Machine monitor)
Lamp switch Lamp switch
12 D_IN (+24V) I D/I+24V
(Clearance lamp) (Clearance lamp)
Parking brake omission pre- Parking brake omission pre-
13 D_IN (NSW +24V) I D/I+24V
vention vention
14 A_IN I A/I HST oil temperature sensor HST oil temperature sensor
15 GND I GND GND GND
Engine water temperature Engine water temperature
16 A_IN I A/I
sensor sensor
10-176 WA150-5
AMP040-12P [CN-L22]
1 N.C. – – --- ---
Machine monitor – HST con-
2 CAN- I/O CAN CAN-
troller
3 D_IN (GND) I D/IGND Emergency steering operation Emergency steering operation (If equipped)
D_OUT
4 O D/O sink Automatic preheater relay Automatic preheater relay
(+24 V, sink: 200 mA)
5 D_IN (GND) I D/IGND Emergency steering normal Emergency steering normal (If equipped)
Machine monitor – HST con- CAN+
6 CAN+ I/O CAN
troller
7 N.C. – – --- ---
8 D_IN (+24V) I D/I+24V Direction R Direction R
9 D_IN (+24V) I D/I+24V Direction N Direction N
10 D_IN (+24V) I D/I+24V Direction F Direction F
11 D_IN (+24V) I D/I+24V Turn signal lamp left Turn signal lamp left
12 D_IN (GND) I D/IGND Dimmer switch Dimmer switch
AMP040-20P [CN-L23]
1 D_IN (NSW+24V) I D/I+24V IGN BR IGN BR
2 N.C. – – --- ---
3 D_IN (+24V) I D/I+24V IGN C IGN C
4 N.C. – – --- ---
5 N.C. – – --- ---
6 D_IN (GND) I D/IGND HST filter clogging HST filter clogging
7 D_IN (GND) I D/IGND (Air cleaner clogging) ---
8 D_IN (GND) I D/IGND Engine water level Engine water level
9 D_IN (+24V) I D/I+24V Lamp switch (Head lamp) Lamp switch (Head lamp)
10 D_IN (GND) I D/IGND Engine oil pressure Engine oil pressure
NSW power supply Power supply
11 I NSW power supply (+24 V) NSW power supply (+24 V)
(+24 V) +24 V
12 D_IN (GND) I D/IGND Alternator R Alternator R
13 A_IN I A_I Fuel level sensor Fuel level sensor
14 GND I GND GND GND
D_OUT
15 O D/O sink HST solenoid cut-out relay HST solenoid cut-out relay
(+24 V, sink: 200 mA)
16 N.C. – – --- ---
17 D_IN (+24V) I D/I+24V Turn signal lamp right Turn signal lamp right
18 D_IN (+24V) I D/I+24V Parking brake Parking brake
19 D_IN (GND) I D/IGND Brake oil pressure Brake oil pressure
20 D_IN (GND) I D/IGND (Engine oil level) ---
WA150-5 10-177
ELECTRICAL SYSTEM
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD (HST CONTROLLER SYSTEM)
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)

System diagram
10-178 WA150-5
ELECTRICAL SYSTEM
Control function
1. Speed changing function
The HST controller calculates the maximum speed matched to the selected gear speed and controls the
HST according to the gear speed signal and travel speed adjustment signal.
1. HST controller a. CNL41-10: Travel speed adjustment potentiome-

2. Gear speed selector switch ter power supply
3. Travel speed adjustment dial b. CNL41-1: Travel speed adjustment signal
4. Shift control relay c. CNL41-2: Travel speed adjustment potentiome-
5. Traction control switch ter GND
d. CNL42-12: Gear speed signal
e. CNL42-3: Traction control signal
Travel speed
Travel speed Traction con-
Selected gear Traction Clutch sole- Motor 1 sole- Motor 2 sole- adjustment
range trol switch
speed control noid output noid output noid output signal input
(km/h) signal
voltage (V)
0 – 13 (Set
–
with travel
1st (Normally Unlimited ON MAX – MID MAX. fixed 1.0 – 4.0
speed adjust-
OFF)
ment signal)
Standard
Unlimited
(OFF)
2nd 0 – 13 ON MAX – MID MAX. fixed 1.0 – 4.0
Limited
Limited
(ON)
Standard
Unlimited
(OFF)
3rd 0 – 20 ON, OFF MAX – 0 MAX. fixed 0
Limited
Limited
(ON)
Standard
Unlimited
(OFF) MAX. fixed -
4th 0 – 38 ON, OFF MAX – 0 0
Limited Variable
Limited
(ON)
Note: The travel speed range shown above is for the tire size of 16.9-24.
2. Traction control function

The HST controller can limit the output torque
according to the traction control signals when
the selected gear speed is 2nd - 4th.
WA150-5 10-179
ELECTRICAL SYSTEM
3. Travel speed adjustment function (Variable shift control system)

If the gear speed selector switch is set to the 1st position, the maximum speed can be limited to 4 - 13 km/h
with the travel speed adjustment signal.
4. Motor 1 overrun prevention function

While the machine is traveling at high speed (15 km/h or higher) with the gear in the 3rd or 4th position, if
the gear is shifted to the 1st or 2nd position, the clutch is engaged at high speed and motor 1 speed
exceeds the allowable limit.
To prevent motor 1 from overrunning in this case, the HST controller prohibits shifting the gear from 3rd or
4th position to the 1st or 2nd position while the travel speed is above 10 km/h.
If the gear cannot be shifted, the action code (E00) is displayed on the machine monitor and the alarm
buzzer is turned ON.
The error condition is reset when the travel speed lowers below 9 km/h or the gear speed selector switch is
set in a gear speed position at which the gear can be shifted.
Gear shifting operation Action after gear shifting

Travel speed at
Switch position Switch position Actual gear speed Display of action
gear shifting Remarks
before gear shifting after gear shifting after gear shifting code
(km/h)
2nd 2nd Gear can be
1st 0– 3rd 3rd Not displayed shifted regardless
4th 4th of travel speed.
1st 1st Gear can be

2nd 0– 3rd 3rd Not displayed shifted regardless
4th 4th of travel speed.
1st 1st
0 – 10 2nd 2nd Not displayed Gear can be
4th 4th shifted to 1st or
3rd 2nd only when
1st 3rd travel speed is
Displayed (E00)
10 – 2nd 3rd below 9 km/h.
4th 4th Not displayed
1st 1st
0 –10 2nd 2nd Not displayed Gear can be
3rd 3rd shifted to 1st or
4th 2nd only when
1st 3rd travel speed is
Displayed (E00)
10 – 2nd 3rd below 9 km/h.
3rd 3rd Not displayed
Note: The travel speed range shown above is for the tire size of 16.9 – 24.
10-180 WA150-5
ELECTRICAL SYSTEM
5. Travel speed limiting function

When the machine travels down a slope at high speed, the axle speed and engine speed exceed the allow-
able limit, and the travel speed exceeds the allowable limit consequently.
To limit the travel speed in this case, the HST controller limits the output of motor 2 while the travel speed is
above 40 km/h.
If the travel speed is limited, the action code (E00) is displayed on the machine monitor and the alarm
buzzer is turned ON.
The error condition is reset when the travel speed lowers below 39.5 km/h.
WA150-5 10-181
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST CONTROLLER
HST CONTROLLER
Input and output signals
AMP 1-963217-1-16P [CN-L41]

Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
Travel speed adjustment potenti- 9 NC –
1 Input
ometer signal Travel speed adjustment potenti-
10 Output
Travel speed adjustment potentiometer (+5 V)
2 –
ometer GND 11 NC –
3 HST pressure sensor signal Input 12 HST pressure sensor (+5 V) Output
4 HST pressure sensor GND – 13 Travel speed signal A (Pulse) Input
5 Motor 2 solenoid Output 14 Clutch solenoid Output
6 Motor 1 solenoid Output 15 NC –
7 Power supply (+24 V) Input 16 GND –
8 Power supply (+24 V) Input
AMP 2-963217-1-16P [CN-L42]

Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
1 NC – 9 NC –
2 Checker H Input and output 10 NC –
3 Traction control signal Input 11 Engine speed sensor GND –
4 Engine speed signal Input 12 Gear speed signal Input
Travel speed signal B (Revolving 13 NC –
5 Input
direction) 14 Checker D Input and output
6 NC – 15 Checker B Input and output
7 Checker C Input and output 16 CAN-H Input and output
8 CAN-L Input and output
10-182 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE START CIRCUIT
ENGINE START CIRCUIT
a For details of the directional lever relay, see Electrical circuit diagram.
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to secure
3. Starting switch the safety when the engine is started.
4. Directional lever • The engine does not start if the directional le-
5. Neutral safety relay ver is not in the N (Neutral) position.
6. Starting motor safety relay
7. Starting motor
8. Alternator
9. Fuel cut-out solenoid
10. Fuel solenoid pull relay
11. Fuel cut-out solenoid timer
12. Machine monitor
13. Short connector
14. Directional lever relay
WA150-5 10-183
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE START CIRCUIT
Operation
1. When starting switch is ON 3. When starting switch is turned to START position
• If the starting switch is turned ON, terminals • If the starting switch is turned to the START
B and BR of the starting switch are closed position, terminals B and C of the starting
and the current flows from the battery switch are closed and the current flows from
through the starting switch and battery relay short connector terminal 7 through terminal 8
coil to the ground and the contacts are and neutral safety relay terminals 3 and 5 to
closed. As a result, the power is supplied to starting motor safety relay terminal S, and
each circuit of the machine. then the contacts are closed to start the start-
At this time, if the signal from terminal ACC ing motor and engine.
of the starting switch flows in the timer relay, • If the directional lever is not in the N (Neutral)
the relay contacts are closed for 3 seconds position, the neutral safety relay does not op-
and the current flows into the coil on the pull erate and the engine does not start.
side of the fuel cut-out solenoid.
The current from terminal ACC of the start-
ing switch flows into the coil on the hold side
of the fuel cut-out solenoid to hold the sole-
noid so that the fuel will be supplied even
after the coil on the pull side is energized.
The engine is now ready to start.
2. Neutral safety circuit

• If the directional lever is set in the N (Neutral)
position, the current flows from contact N of
the forward-reverse lever to the multi-func-
tion selector relay circuit. At this time, multi-
function selector relay circuit supplies a cur-
rent as the N signal to the neutral safety relay
coil to connect neutral safety relay terminals
3 and 5.
10-184 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT
1. Battery Operation
2. Battery relay • The current from ACC terminal of starting switch
3. Starting switch to hold side coil of fuel cut solenoid is cutoff when
4. Directional lever starting is turned off. Fuel supply to engine is shut
5. Neutral safety relay off.
6. Starting motor safety relay When the fuel supply is stopped, the engine re-
7. Starting motor duces its speed and stops. Then, the power gen-
8. Alternator eration of the alternator stops to shut off voltage
9. Fuel cut-out solenoid supply from the terminal L of the alternator. In
10. Fuel solenoid pull relay addition, the current from the terminal BR of start-
11. Fuel cut-out solenoid timer ing switch is shut off. Consequently, the battery
12. Machine monitor relay contact opens to shut down the power sup-
13. Short connector plied to every circuit of the machine.
14. Directional lever relay
WA150-5 10-185
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PREHEATING CIRCUIT
PREHEATING CIRCUIT
(AUTOMATIC PREHEATING SYSTEM)
1. Battery Operation
2. Battery relay • When the starting switch is turned ON, the ma-
3. Starting switch chine monitor is started up. At this time, if the
4. Automatic preheating relay coolant temperature is 0°C or less, the machine
5. Engine heater relay monitor makes to contact the coil of the preheat-
6. Ribbon heater ing relay to the earth and the preheating relay op-
7. Machine monitor erates to let the engine heater relay operate to
8. Coolant temperature sensor (For preheating) start preheating by the electric intake air heater.
• The operating time of the preheating process is
Outline as shown below
• The automatic preheating system is being in-
stalled to improve the engine starting capability in
cold weather areas. This system is capable of
shortening the preheating time and, at the same
time, it is capable of making automatic setting of
the preheating time matching the current coolant
temperature, by merely turning the starting
switch.
• When the starting switch is turned ON, the pre-
heating pilot lamp on the machine monitor lights
and the electric intake air heater starts preheat-
ing the intake air.
As for the preheating time, the coolant tempera-
ture is detected by the coolant temperature sen-
sor and the controller being built into the machine
monitor carries out the preheating time setting.
• While the pilot lamp is lighting, preheating is in
progress and keep the starting switch at the ON
state. If the starting switch is turned to the START
position, the preheating process is cancelled.
10-186 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
PARKING BRAKE CIRCUIT
1. Parking brake lever intermediate switch 14. Directional lever relay

2. Parking brake lever bottom switch 15. Forward relay
3. Parking brake relay 16. Reverse relay
4. Parking brake selector connector (CNL20) 17. Neutral safety relay
5. Parking brake selector connector (CNL18) 18. HST pump forward solenoid valve
6. Parking brake pilot lamp relay 19. HST pump reverse solenoid valve
7. Parking brake drag prevention relay 20. Motor 1 solenoid valve
8. Machine monitor 21. Clutch solenoid valve
9. Alarm buzzer 22. Motor 2 solenoid valve
10. HST controller power hold relay 23. HST motor directional selector solenoid valve
11. HST controller
12. HST safety relay
13. Directional lever
WA150-5 10-187
Operation
1. When parking brake lever is returned (ON o OFF)
Position of starting switch OFF ON
State of engine Stopped Running
Position of parking brake

Lock Mid-Free Free Lock Mid-Free Free Lock Mid-Free Free
lever
Intermediate switch (1) Open Close Open Close Open Close
Bottom switch (2) Open Close Open Close Open Close
Parking brake ON ON
reminder caution lamp OFF (Reset) (Oper- OFF (Reset) (Oper- OFF (Reset)
(Alarm buzzer) ated) ated)
Parking brake pilot lamp OFF ON OFF ON OFF
1) When parking brake lever is in Lock position • The parking brake pilot lamp goes off re-
• When the parking brake is applied, both gardless of the state of the parking
intermediate switch (1) and bottom brake. Parking brake reminder caution
switch (2) are open. lamp lights up and the alarm buzzer
• The parking brake pilot lamp lights up sounds only when the engine is stopped.
only while the starting switch is in the ON • Then, the HST controller power hold re-
position and goes off regardless of the lay operates and the current flows in the
state of the parking brake reminder cau- HST controller to hold the operation of
tion lamp. the motor solenoid and clutch solenoid
• The parking brake is applied. and prevent the machine from moving
down on a slope, etc.
2) When parking brake lever is moved from • The parking brake is released.
Lock position to Mid position
• If the parking brake lever is returned a lit-
tle, intermediate switch (1) is closed but
the contacts of the parking brake relay
are kept open.
• The parking brake pilot lamp and parking
brake reminder caution lamp operate as
in step 1).
• The parking brake is kept applied.
3) When parking brake is set in Free position

• If the parking brake lever is returned to
the end, bottom switch (2) is closed.
• At this time, the coil flows in the coil of the
parking brake relay to close the contacts,
and then the parking brake pilot lamp re-
lay operates.
• Since the current flows in the coil of the
parking brake drag prevention relay, the
forward-reverse solenoid circuit is closed
and the machine can travel forward or in
reverse and the parking brake reminder
caution signal is input to the machine
monitor.
10-188 WA150-5
2. When parking brake lever is pulled (OFF o ON)
Position of starting switch OFF ON
State of engine Stopped Running
Position of parking brake

Free Free-Mid Lock Free Free-Mid Lock Free Free-Mid Lock
lever
Intermediate switch (1) Close Open Close Open Close Open
Bottom switch (2) Close Open Close Open Close Open
Parking brake
OFF OFF
reminder caution lamp ON (Operated) ON (Operated) OFF (Reset)
(Reset) (Reset)
(Alarm buzzer)
Parking brake pilot lamp OFF OFF ON OFF ON
1) When parking brake is set in Free position

• When the parking brake is released, both • Since the current to the coil of the park-
intermediate switch (1) and bottom ing brake drag prevention relay is cut
switch (2) are closed. out, the forward-reverse solenoid circuit
• The parking brake pilot lamp goes off re- is opened. Accordingly, the machine
gardless of the state of the parking does not move forward or in reverse
brake. Parking brake reminder caution even if the directional lever or the direc-
lamp lights up and the alarm buzzer tional selector switch is operated.
sounds only when the engine is stopped. • The parking brake pilot lamp lights up
• Then, the HST controller power hold re- only while the starting switch is in the ON
lay operates and the current flows in the position and goes off regardless of the
HST controller to hold the operation of state of the parking brake reminder cau-
the motor solenoid and clutch solenoid tion lamp.
and prevent the machine from moving • The parking brake is applied.
down on a slope, etc.
• The parking brake is released.
2) When parking brake lever is moved from

Free position to Mid position
• If the parking brake lever is pulled a little,
bottom switch (2) is opened but the con-
tacts of the parking brake relay are kept
closed.
• The parking brake pilot lamp and parking
brake reminder caution lamp operate as
in step 1).
• The parking brake is kept released.
3) When parking brake lever is in Lock position

• If the parking brake lever is pulled to the
end, intermediate switch (1) is opened.
• At this time, the current to the coil of the
parking brake relay is cut out and the
contacts are opened and the parking
brake pilot lamp relay is turned OFF.
WA150-5 10-189
ELECTRONICALLY CONTROLLED
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION SYSTEM
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM

Electronically Controlled Suspension System (Abbreviation: ECSS)
(If equipped)
1. ECSS controller
2. ECSS relay
3. ECSS switch
4. ECSS solenoid
5. Speed sensor
Function
• The controller controls the ECSS solenoid valve automatically to turn the accumulator charged with high-
pressure gas ON and OFF to damp the vertical movement of the work equipment and reduce the jolts of the
machine during high-speed travel. Consequently, the operator comfort is improved, the material spills less,
and the working efficiency is increased.
System operation table

Travel speed
ECSS switch ECSS solenoid output State of ECSS
(km/h)
OFF 0 – MAX OFF OFF
0 – 4.8 OFF OFF
Turn system ON
4.8 – MAX ON ON
ON
MAX – 3.8 ON ON
Turn system OFF
3.8 – 0 OFF OFF
Note: The travel speed range shown above is for the tire size of 16.9 – 24.
10-190 WA150-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS
SENSORS
Engine speed sensor
1. Wire 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
• The engine speed sensor is installed to the ring
gear of the flywheel housing. As the gear re-
volves, the engine speed sensor generates a
pulse voltage.
Speed sensor
1. Connector 3. O-ring
2. Sensor 4. Bolt
Function
• The speed sensor is installed to the transfer
case. As the gear revolves, the speed sensor
generates a pulse voltage and a revolving direc-
tion signal (Counterclockwise: ON).
WA150-5 10-191
Engine oil pressure sensor
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
• This sensor is mounted to the engine block. The
diaphragm detects oil pressure, and when it
reaches below the specified value, the switch is
turned ON.
Fuel level sensor
1. Connector 3. Arm
2. Variable resistor 4. Froat
Function
• This sensor is mounted to the side surface of the
fuel tank. The float moves vertically depending
on the remaining quantity of the fuel.
The movement of the float operates the variable
resistor through the arm and sends a signal to the
machine monitor to indicate the remaining quan-
tity of the fuel.
10-192 WA150-5
Coolant temperature sensor (For monitor)

HST oil temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
• The coolant temperature sensor (for monitor) is
installed to the engine cylinder block and the HST
oil temperature sensor is installed to the hydrau-
lic piping of motor 2. They generate thermistor
resistance change signals as temperature
change signals.
Coolant temperature sensor (For preheating)
1. Connector
2. Plug
3. Thermistor
Function
• The coolant temperature sensor (for preheating)
is installed to the engine coolant piping. It gener-
ates thermistor resistance change signals as
temperature change signals.
WA150-5 10-193
Axle oil temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
• The axle oil temperature sensor is installed to the
front axle. It generates thermistor resistance
change signals as temperature change signals.
HST oil pressure sensor
1. Sensor
2. Lead wires
3. Connector
Function
• The HST oil pressure sensor is installed to the
solenoid block of motor 2. It measures the oil
pressure in the HST circuit and generates signals
of that pressure.
10-194 WA150-5
Steering oil pressure sensor

(If equipped)
Emergency steering oil pressure sensor
(If equipped)
1. Retainer 5. Case
2. Piston 6. Switch
3. Body 7. Connector
4. Push rod
Function
• The steering oil pressure sensor is installed to the
block of priority valve port P. It measures the oil
pressure in the steering circuit and generates sig-
nals of that pressure.
• The emergency steering oil pressure sensor is in-
stalled to the emergency steering valve. It mea-
sures the oil pressure in the emergency steering
circuit and generates signals of that pressure.
HST filter clogging sensor
1. Terminal
2. Plug
Function
• The HST oil filter clogging sensor is installed to
the HST oil filter. It senses the oil pressures be-
fore and after the filter. If the difference between
the measured pressures exceeds the set level,
the switch is turned ON.
WA150-5 10-195
Coolant level sensor
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
• This sensor is mounted to the sub-tank in the
bulkhead. The float lowers to turn off the switch
when the coolant level reaches below the speci-
fied level.
10-196 WA150-5

WA150-5 SEBM033805 Structure, Function & Maintenance

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10 STRUCTURE, FUNCTION AND

ENGINE MOUNT AND TRANSFER MOUNT 10- 2 3-GEAR PUMP UNIT....................................10-100

ENGINE MOUNT AND TRANSFER MOUNT

Distance between HST pump Standard size Repair limit

1. Oil cooler 4. Reservoir tank

Radiator Oil cooler After cooler

Core type AL WAVE–4 CF40–1 AL WAVE

Fin pitch (mm) 3.5 / 2 3.5 / 2 4.0 / 2

Total heat radiating area (m 2) 22.0 5.72 5.75

Pressure valve opening pressure 68.6

Vacuum valve opening pressure 0 – 4.9

POWER TRAIN SYSTEM DIAGRAM

1. Front axle Outline

HST HYDRAULIC PIPING DIAGRAM

1. Forward-reverse shifting solenoid valve Specifications

Set pressure of low-pressure

Flow of power Flow of oil

HIGH-PRESSURE RELIEF VALVE

• The set pressure can be adjusted by increasing

LOW-PRESSURE RELIEF VALVE

HST CHARGE PUMP

1. Cover bolt Specifications

SPEED-RELATED VALVE (DA VALVE)

HIGH-PRESSURE CUT-OFF VALVE

1. Drive shaft Specifications

1. Drive shaft Specifications

• There are 7 pistons (2) installed to the disc por-

1. Motor 1 solenoid valve Operation

1. Motor 2 solenoid valve Operation

FORWARD-REVERSE SHUTTLE VALVE

1. Forward-reverse shifting solenoid valve Operation

a. Clutch port Relationship between transfer clutch and transfer

1. HST motor 1 8. Motor 1 gear (Number of teeth: 43)

Input shaft portion

Standard Tolerance Standard Clearance

No. Check item Criteria Remedy

Clearance between press-fit +0.033 +0 -0.045 –

Output shaft portion

Standard Tolerance Standard Clearance

Standard Tolerance Standard Clearance

When clutch is ON (fixed) When clutch is OFF (released)

CLUTCH SOLENOID VALVE

P: From HST charge pump Operation

1. Pinion gear (Number of teeth: 9)

7 Backlash of differential gear 0.15 – 0.35 Replace

Standard Tolerance Standard Clearance

Clearance Outer +0 +0 -0.035 –

1. Pinion gear (Number of teeth: 9)

7 Backlash of differential gear 0.15 – 0.35 Replace

Standard Tolerance Standard Clearance

Outline When turning

When traveling in a straight line

Straight travel (When the road resistances under

Standard size Tolerance Repair limit

Standard Tolerance Standard Clearance

Operation of limited-slip differential When traveling in a straight line

1. When there is no imbalance between drive

1. Planet gear (No. of teeth: 26)

13 Clearance of guide pin 8 +0.080 +0.036 +0.080 – — Replace

AXLE MOUNTING AND CENTER HINGE PIN