the best service repair manual

1. CEBMWI 8020
SHOP
MANUAL
KOMKtkSU
WA2504 LC
WHEEL LOADER
MACHINE MODEL SERIAL NUMBERS
WA25011 LC A65001 and up
It is our policy to improve our products whenever it is possible and practical to do so. We
reserve the right to make changes or add improvements at any time without incurring any
obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be
made to this publication. It is recommended that customers contact their distributor for
information on the latest revision.
FEB 92

2. CONTENTS
No. of page
10 ENGINE
12 TESTING AND ADJUSTING .................................................. 12-l
13 DISASSEMBLY AND ASSEMBLY .............................................. 13-1
20 POWER TRAIN
21 STRUCTURE AND FUNCTION ................................................ 21-l
22 TESTING AND ADJUSTING .................................................. 22-l
23 DISASSEMBLY AND ASSEMBLY .............................................. 23-l
24 MAINTENANCE STANDARD ................................................. 24-l
40 STEERING SYSTEM
41 STRUCTURE AND FUNCTION ................................................ 41-l
42 TESTING AND ADJUSTING .................................................. 42-l
43 DISASSEMBLY AND ASSEMBLY .............................................. 43-l
44 MAINTENANCESTANDARD ................................................. 44-l
50 BRAKE AND AIR SYSTEM
51
52
53
54
STRUCTURE AND FUNCTION ................................................ 51-l
TESTING AND ADJUSTING .................................................. 52-1
DISASSEMBLY AND ASSEMBLY .............................................. 53-l
MAINTENANCE STANDARD ................................................. 54-l
60 WORK EQUIPMENT SYSTEM
61 STRUCTURE AND FUNCTION ................................................ 61-l
62 TESTING AND ADJUSTING .................................................. 62-l
63 DISASSEMBLY AND ASSEMBLY .............................................. 63-l
64 MAINTENANCE STANDARD ................................................. 64-l
80 ELECTRIC AND ELECTRONIC SYSTEM
81 STRUCTURE AND FUNCTION ................................................ 81-l
82 TESTING AND ADJUSTING .................................................. 82-1
83 DISASSEMBLY AND ASSEMBLY .............................................. 83-l
90 OTHERS
91
93
97
99
STRUCTURE AND FUNCTION ................................................ 91-l
DISASSEMBLY AND ASSEMBLY .............................................. 93-l
GEAR PUMP ............................................................ 97-l
METRIC CONVERSION TABLE ............................................... 99-l
00-l

3. SAFETY
A
WARNING! IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and
repair techniques recommended and described in this manual are both effective and safe methods of
operation. Some of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbol shown is used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may
possibly arise, first consider safety, and take the necessary actions to deal with the situation.
SAFETY
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read
the Operation and Maintenance Manual carefully BE-
FORE operating the machine.
1.
2.
3.
4.
5.
6.
Before carrying out any greasing or repairs, read all
the precautions given on the decals which are fixed
to the machine.
When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
-Always wear safety glasses when hitting parts with
a hammer.
-Always wear safety glasses when grinding parts
with a grinder, etc.
If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other
clothes suited for welding work.
When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on the
controls in the operator’s compartment.
Keep all tools in good condition and learn the
correct way to use them.
Decide a place in the repair workshop to keep tools
and removed parts. Always keep the tools and parts
in their correct places. Always keep the work area
clean and make sure that there is no dirt or oil on
the floor. Smoke only in the areas provided for
smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If this
is not possible, insert the safety pin or use blocks
to prevent the work equipment from falling. In
addition, be sure to lock all the control levers and
hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide
safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
Before disconnecting or removing components of
the oil, water or air circuits, first remove the
pressure completely from the circuit.
12. The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying
out any work on the oil or water circuits.
00-2

4. SAFETY
13. Before starting work, remove the leads from the
battery. Always remove the lead from the negative
(-) terminal first.
14. When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are free
from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part. Do not
work with any part still raised by the hoist or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides. Slowly
release the pressure, then slowly loosen the bolts to
remove.
16. When removing components, be careful not to
break or damage the wiring, Damaged wiring may
cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately. Fuel or oil on the floor can
cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal places.
Replace any damaged part with new parts.
l When installing hoses and wires, be sure that
they will not be damaged by contact with
other parts when the machine is being oper-
ated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when install-
ing tubes for high pressure circuits. Also check
that connecting parts are correctly installed.
21. When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be partic-
ularly careful to check that they are installed
correctly.
22. When aligning two holes, never insert your fingers
or hand. Be careful not to get your fingers caught
in a hole.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24. Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either end
of the track.
00-3

5. FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make
judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop.
For ease of understanding, the manual is divided into chapters for each main group of components; these
chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to ‘Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
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00-4

6. ENGINE
12 TESTING AND ADJUSTING
STANDARDVALUETABLE .......................................................... 3
ENGINE ON TEST BENCH ........................................................ 3
ENGINEON CHASSIS ........................................................... 4
TOOLLlST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VALVECLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUELINJECTIONTIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINEOILPRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINEOILTEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BLOW-BYPRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EXHAUSTGAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATING FORCE 10
OPERATINGANGLE.::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: 11
+ The following precautions are necessary when using the Standard Value Tables to make judgements during
troubleshooting or during testing and adjusting.
1. The values in these tables are based on the values for new machines leaving the plant, so they should
be used as target values when repairing or when estimating wear after a period of use.
2. The standard values in these tables for judgement when troubleshooting are estimated values based on
the standard values for the machine when shipped from the plant, and on the results of various tests.
Therefore, they should be used as reference in combination with repair and operating records when
making judgements.
3. These standard value tables must not be used for standard values when judging claims. In addition, do
not use these values alone to make simple judgements.
12-1

7. TESTING AND ADJUSTING
A When carrying cut testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
bar on the frame, lower the bucket to the ground, and stop the engine.
Then apply the parking brake and block the tires.
A Do not allow unauthorized persons near the machine.
A When measuring the engine speed, one worker should measure the engine speed while the another person
sits in the operator’s seat to operate the controls. Always check that the operation is safe, and use agreed
upon signals.
A Be careful not to get caught in rotating parts.
A When installing or removing gauges, loosen the oil filler cap slowly to release the pressure inside the
hydraulic tank. Then operate the control levers several times to release the remaining pressure in the
hydraulic piping.
A When taking measurements, do not allow unauthorized persons near the machine.
A The oil in the circuit is hot, so be careful not to get burnt.
12-2

8. TESTING AND ADJUSTING STANDARD VALUE TABLES
STANDARD VALUE TABLE
l ENGINE ON TEST BENCH
Engine
Category Rem
Performance
tzIG&GY
Intake resistance
Exhaust pressure
Exhaust temperature
Intake and exhaust
system
Exhaust gas color
Valve clearance (When engine
is cold)
Engine body Blow-by pressure
Oil pressure (Oil temperature
min. 80°C) SAElOW-30 oil
Lubrication system
Oil consumption ratio
Fuel system
I
Fuel injection timing
Radiator pressure valve func-
Cooling system
Fan belt tension
610T
Condition, etc
I I
Unit Standard Permissible
value value
Intake valve
Exhaust valve
At rated output, oil
temperature min.
60°C SAElOW30 oil
At rated idling
At low idling
Whole speed range
(inside oil oanl
mm 0.254
mm 0.508
mmh20 Max 178 Max 730
(New limit) (worn limit)
kg/cm2 Min 2.1 2.1
kg/cm2 Min 0.7 0.7
“C 120
At continuous rated
horsepower (propor-
tion of fuel consump-
tion)
% 0.3
Before top dead
center
1 mm 1 1.5 1
12-3

9. TESTING AND ADJUSTING STANDARD VALUE TABLES & TOOL LIST
l ENGINE ON CHASSIS
Engine 61OT
Exhaust color Sudden acceleration
TOOL LIST
No. Check item Tool Part number Remarks
1 Engine speed Multi-Tachometer 799-203-8000 Digital display L: 60 - 2,OOOrpm
H: 60 - 19,OOOrpm
2 Water, oil, and intake Thermistor kit 799-101-6000 o-2Ou’C
temperature
3 Oil pressure Pressure measuring kit 799-203-2002 0 - 25kg/cm2
4 Blow-by pressure Blow-by checker (pipe tee) 3822476 Cummins part
5 Valve clearance Feeler gauge 795-125-1330 mm
6 Exhaust color Smoke checker 7992019001 Discoloration 0 - 70%, with standard color
(Discoloration % x l/10% z Bosch index)
A
A
A
A
When carrying out testing, adjusting, or troubleshooting, stop the engine on level ground, install the safety
bar on the frame, lower the bucket,to the ground, and stop the engine. Then apply the parking brake.
Do not allow unauthorized persons near the machine.
When measuring the machine speed, one worker should measure the engine speed while the other sits in
the operator’s seat to operate the controls. Always check that the operation is safe, and use agreed signals.
Be careful not to get in rotating parts.
12-4

10. TESTING AND ADJUSTING VALVE CLEARANCE & FUEL INJECTION TIMING
VALVE CLEARANCE
* Condition: Engine is cold
+ Adjust clearance between valve and rocker lever as
follows.
*
Remove engine side covers and engine center
hood.
Remove air cleaner and air cleaner bracket
Remove muffler
Adjust valve clearance.
For details of adjusting valve clearance, see engine
shop manual.
FUEL INJECTION TIMING
t Measurement condition
l Coolant temperature: Inside operating range.
1. Remove bracket (1).
2. Testing and adjusting fuel injection timing.
+ For details of adjusting fuel injection timing, see
engine shop manual.
12-5

11. TESTING AND ADJUSTING ENGINE OIL PRESSURE
+ Measurement condition.
l Coolant temperature: inside operating range.
Low idling 7.0 kg/cm2 7.0 kg/cm2
Special Tool
1
A WARNINGI When measuring, be careful not to
get caught in rotating parts.
A WARNINGI Install and remove the plug and oil
pressure gauge with the engine stopped.
* Measure the engine oil pressure when the oil
temperature is at the specified temperature.
1. Remove plug (1).
2. Install oil pressure gauge (A) 25 kg/cm2.
3. Start engine and measure oil pressure.
L12AH013
12-6

12. TESTING AND ADJUSTING ENGINE OIL TEMPERATURE
ENGINE OIL TEMPERATURE
* Measurement condition.
l Coolant temperature: Inside operating range.
Special Tool
I I I
1 Part number I Part name I Ch.
A 7go4oo-1300 Thermistor 1
or temp. gauge
794101-6Kxl
1. Remove dipstick.
2. Insert sensor or thermistor temperature gauge in the
dipstick guide. Connect sensor to thermistor tem-
perature gauge (A) and measure temperature of oil
in the oil pan.
12-7

13. TESTING AND ADJUSTING BLOW-BY PRESSURE
t Measurement condition.
l Coolant temperature: Inside operating range.
l Valve clearance: Standard value.
l Engine speed: Rated idling.
I O.V. Engine 1 730 mmH,O
Soecial Tool
Part number Part name QtY
B 3822476 Blow-bv tool 1
A WARNING! When taking measurements, be
careful not to touch the exhaust muffler, or to
get caught in rotating parts.
Measuring blow-by
1. When measuring the blow-by, warm the engine up
thoroughly (oil temperature: min. 6O’C)
2. Stop engine and install pipe tee (B) of blow-by
checker on engine breather hose (1).
3. Connect adapter and pressure gauge (A) 0 - 1000
mmH,O with hose.
4. Run engine at rated idling and measure blow-by
pressure.
Precautions when measuring blow-by
it Blow-by may vary according to condition of the
engine, so if there is any abnormality in the mea-
sured value, check for any problem related to
defective blow-by, such as excessive oil consump-
tion, defective exhaust gas color, early deterioran-
tion or contamination of the oil.
Hose Heater mow-by 1
I- Plug with
-Orifice n
Manometer
12-8

14. TESTING AND ADJUSTING EXHAUST GAS COLOR
EXHAUST GAS COLOR
t Measurement condition.
l Coolant temperature: Inside operating range.
l Valve clearance: Standard value.
Special tool
a
A WARNINGI When measuring the exhaust color,
be careful not to touch the exhaust pipe.
*
1.
2.
3.
4.
5.
6.
7.
When measuring exhaust color, warm the engine
thoroughly (Oil temperature min. 60” C).
Insert probe hose (1) in outlet of exhaust pipe and
secure to exhaust pipe with clip.
Connect probe hose, connector of accelerator
switch and air hose (2) to smoke meter (A).
+ The air supply pressure should be under 15
kg/cm;!
Connect power cord to socket, making sure the
power switch is in off position.
Loosen cap nut of suction pump and insert filter
paper (insert filter paper securely to prevent exhaust
gas leakage).
Turn the power switch on.
Accelerate the engine suddenly. At the same time
depress the accelerator pedal, operate the relief
valve, and catch the exhaust gas color on filter
paper.
Lay the used filter paper on top of unused filter
paper (10 sheets or more) inside the filter paper
holder, and read indicated value.

15. TESTING AND ADJUSTING ACCELERATOR PEDAL
ACCELERATOR PEDAL
OPERATING FORCE
* Measurement condition.
l Coolant temperature: Inside operating range
Snecial tools
1. Measuring procedure.
4
b)
Put push-pull scale (A) in contact with the
accelerator pedal at point 150mm from pedal
fulcrum “a”. (The center of push-pull scale A
must be in contact with a point 150mm from
the pedal fulcrum).
Start the engine, push the pedal in the direction
of operation and measure the maximum value
when pushing from idling to the end of the
pedal travel (high idling).
2. Testing adjusting.
4
b)
d
*
Stop the engine.
Disconnect the accelerator cable (1) at the
bottom of the pedal, and check that the linkage
and ball joint at the bottom of the pedal move
smoothly.
Connect the cable at the bottom of the pedal,
then disconnect at the connection for the
injection pump, and check that the cable (1)
moves smoothly.
When carrying out the this inspection, adjust or
replace parts as necessary. Measure the oper-
ating force again and check that it is within the
standard value.
a
12-10

16. TESTING AND ADJUSTING ACCELERATOR PEDAL
OPERATING ANGLE
ttem Standard
value
Operating angle of accelerator
pedal
Installed height of accelerator
pedal stopper
a,
a,
L
45”
26 + 2”
47mm
1. Measuring.
a) Stop the engine.
b) Put angle gauge (1) in contact with the ac-
celerator pedal and measure the angle of
movement a = a, -a, from low idling (a,) to
high idling (a2).
2. Adjusting.
4
b)
c)
4
4
*
Remove the cover at the bottom of the cab,
open the engine hood and apply the safety
lock.
Loosen nut (1) and adjust with bolt (2) so that
installed height L of the accelerator pedal
stopper is 47mm.
Loosen locknut (3) and adjust the length of the
cable so that the injection pump governor lever
contacts the high idling stopper when the
accelerator pedal is fully depressed (high
idling).
Check that the injection pump governor lever
contacts the low idling stopper when the accel-
erator pedal is released (low idling).
Adjust the travel of the governor lever at joint
(4).
After performing the above adjustments, mea-
sure all parts again to check that the dimen-
sions are within the standard value.

17. ENGINE
13 DISASSEMBLY AND ASSEMBLY
NOZZLEHOLDERASSEMBLY .......................................................... 2
REMOVAL ...................................................................... 2
INSTALLATION ................................................................... 2
CYLINDER HEADASSEMBLY.. ......................................................... 3
REMOVAL ...................................................................... 3
INSTALLATION.. ................................................................. 4
RADIATOR ......................................................................... 5
REMOVAL ...................................................................... 5
INSTALLATION ................................................................... 7
ENGINE.. ......................................................................... 9
REMOVAL ...................................................................... 9
INSTALLATION.. ................................................................ 14
FUELTANK ....................................................................... 18
REMOVAL ..................................................................... 18
INSTALLATION.. ................................................................ 19
+ Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling
cylinders, pumps and piping.
1. Start engine, keep idling.
2. Operate hydraulic cylinder 4 - 5 cycles, but do not exceed beyond 100 mm of stroke end.
3. Continue to operate cylinder 3 - 4 cycles until stroke end.
4. After finishing above steps, keep normal engine speed.
NOTE: After long storage, same procedure is required.
13-1

18. DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
NOZZLE HOLDER ASSEMBLY
REMOVAL
A WARNING! Disconnect the cable from the
negative (-) terminal of the battery.
1. Side cover hood.
a) Remove left and right engine side covers.
b) Remove exhaust pipe (1) then remove hood
(2).
2. Connector hose.
a) Disconnect connector hose.
3. Air cleaner assembly.
a) Remove air cleaner assembly (4) and air clean-
er bracket (5).
4. MufRer and exhaust manifold assembly.
a) Disconnect the drain pipe, then remove the
muffler and exhaust manifold together (6).
5. Remove the nozzle holder assembly.
+ For details of the engine, see the Engine Shop
Manual.
INSTALLATION
1. Install the nozzle holder assembly.
t For details of the engine, see the Engine Shop
Manual.
2. Muffler and exhaust manifold.
a) Fi gaskets and install muffler and exhaust
manifold assembly (6) as one unit, then con-
nect the drain pipe.
3. Air cleaner assembly.
a) Install the air cleaner bracket (5).
b) Install the air cleaner assembly (4) and secure
with band.
4. Connector hose.
a) Install connector hose (3).
5. Hood and engine side covers.
a) Install the hood (2), then install the exhaust pipe
(1).
b) Install the left and right engine side covers.
13-2

19. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD ASSEMBLY
REMOVAL
A WARNING! Disconnect the cable
negative (-) terminal of the battery.
from the
1. Drain water.
a) Remove radiator drain plugs (1) and (2), and
drain coolant.
Drain 38P of coolant.
t If the coolant contains antifreeze, dispose
of lt correctly.
2. Engine hood and side covers.
a) Remove left and right engine side covers.
b) Remove exhaust pipe (3) then remove hood
(4).
3. Connector hose.
a) Disconnect connector hose (5).
4. Air cleaner assembly.
a) Remove air cleaner assembly (6).
b) Remove air cleaner mounting bracket (7).
5. Muffler and exhaust manifold assembly.
a) Disconnect the drain pipe, then remove the
muffler and exhaust manifold together (8).
6. Remove the cylinder head assembly.
+ For details of the engine, see the Engine Shop
Manual.
1 LOBAH

20. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
INSTALLATION
+ Check to make sure there is no dirt or foreign
material on the cylinder head mounting face, or
inside the cylinder.
1. Install the cylinder head assembly.
+ For detail of engine, see the Engine Shop
Manual.
2. Muffler and exhaust manifold assembly.
a) Fff gaskets and install the muffler and exhaust
manifold assembly (8) as one unit, then con-
nect the drain pipe.
3. Air cleaner assembly.
a) Install the air cleaner bracket (7).
b) Install the air cleaner assembly (6) and secure
with band.
4. Connector hose.
a) Install connector hose (5).
5. Hood and engine side covers.
a) Install hood (4) then install the exhaust pipe
(3).
b) Install the left and right engine side covers.
6. Refilling with coolant.
a) Replace drain plugs (1) and (2) and add cool-
ant through radiator filler neck to the specified
level.
%aAdd 38P of coolant
+ Run the engine to circulate the coolant
through the system, Then check the cool-
ant level again.
n
i L06AH033
13-4

21. DISASSEMBLY AND ASSEMBLY RADIATOR
RADIATOR
REMOVAL
a WARNING! Park the machine on level ground,
set the safety bar on the frame, lower the
bucket to the ground, stop the engine, apply
the parking brake, and place blocks under the
tires.
1. Draining the coolant.
Remove drain plugs (1) and (2) and drain the
coolant.
Drain 38P of coolant.
+ If the coolant contains antifreeze, dispose
of it correctly.
2. Hood.
a) Open left and right engine side covers (2A).
b) Remove mounting bolts (4) on radiator side of
engine center hood (3).
+ Loosen mounting bolts on hydraulic oil tank
side.
c) Remove exhaust pipe (5). Place block @
between engine and center hood (3) and muf-
fler (6).
+ Leave about a 30mm space between the
engine center hood and the radiator guard.
d) Remove the left and right engine side panels
(7).
e) Remove radiator guard (8).
+ Disconnect the rear lamp connector (9).
3. Fan guard.
a) Remove fan guard (10) and radiator support
(11).
1 LOBAH
' t L06AROOi

22. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
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click on it.

23. DISASSEMBLY AND ASSEMBLY RADIATOR
4. Electric wiring.
a) Disconnect wiring (12) of radiator coolant level
sensor from connector.
5. Radiator hoses.
a) Disconnect radiator hose (13) from the engine.
b) Disconnect radiator hose (14) from both the
radiator and the engine.
c) Disconnect radiator hoses (15) and (16) from
radiator.
t Loosen lower hose clamp (17).
d) Disconnect radiator drain hose from radiator.
6. Cooler piping.
a) Disconnect oil cooler hoses (18) and (19).
7. Radiator.
a) Sling radiator (20), remove mounting bolts, and
lift radiator.
+ When removing the radiator, move it to-
wards the counterweight to prevent the
radiator core from coming near the fan.
&I
Radiator: 130 kg.
13-6

24. INSTALLATION
1. Radiator.
4 Sling radiator (20) and place at mounting
position. tighten the mounting bolts.
b) Insert radiator upper hose (15) into the radiator.
* Be careful not to damage the radiator core.
l Insert the radiator carefully from the counter-
weight side.
* Install so that the clearance from the fan is
uniform.
+ After connecting the hoses, tighten the clamps.
Mounting bolts: 28.5 + 3.0 kgm.
2. Cooler piping.
a) Connect oil cooler hoses (18) and (19).
+ Be careful not to twist the hoses.
l Hose width across the flats: 41 mm.
3. Radiator hoses.
a) Connect drain hose to the radiator.
b) Connect radiator hoses (15) and (16) to the
radiator.
* Tighten lower hose clamp.
c) Connect radiator hose (14) to engine and
radiator.
d) Connect radiator hose (13) to the engine.
4. Electric wiring.
a) Connect wiring (12) of radiator coolant level
sensor to the connector.
DISASSEMBLY AND ASSEMBLY RADIATOR

25. DISASSEMBLY AND ASSEMBLY RADIATOR
5. Fan guard.
a) Install fan guard (10) and radiator supports (11).
6. Hood.
4
b)
c)
d)
Set radiator guard (8) in position, then tempo-
rarily tighten the mounting bolts.
Install left and right engine side panels (7).
Close engine side hood (2A), then adjust the
latches.
Remove block @ and tighten mounting bolts of
engine center hood (3) then install exhaust
pipe (6).
+ The final tightening of all mounting bolts is
done.
* Connect rear lamp connector (9).
7. Refilling wfth coolant.
a) Install radiator drain plugs and add coolant
through the radiator filler neck (21) to the
specified level.
t Run the engine to circulate the coolant
through the system. Then check the cool-
ant level again.
&la Coolant: 384.
13-8