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В настоящее время вы находитесь на странице с руководствами Kubota экскаватор. Выберите один из продуктов, чтобы сразу перейти к руководству по этому продукту. Не можете найти Kubota ? Тогда попробуйте вбить в поле поиска Kubota и модель, чтобы найти нужное руководство Kubota. На ManualsPDF.ru в настоящее время имеется 12 руководств Kubota . Самые популярные Kubota экскаватор:

• Kubota KX018-4
• Kubota U27-4G
• Kubota KX080-4S

Последнее добавленное руководство Kubota было добавлено 2022-08-02, и это Kubota KX080-4.

WORKSHOP MANUAL
KUBOTA EXCAVATOR
U15-3
Code No.97899-61270
Record of Revisions
Symbol
1
2
3
4
Date
Main Revised Points & Corrective Measures
Person-in-charge
ss
CONTENTS
I Product engineering section
II Service engineering section
WSM U15-3
I Product engineering section
A.Developing concept and feature . . . . . . . . . . . . . . . . . . . . . .I-3
a.
b.
c.
d.
e.
Objective and Concept of Development . . . . . . . . . . . . . . . . . . . . . . . I-3
Main Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3
Major Selling Points and Improvements . . . . . . . . . . . . . . . . . . . . . . . I-4
Evaluation of Competitive Power with Competitors . . . . . . . . . . . . . . I-8
Actual performance comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-11
B.Machine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-12
a. Major dimensions and working range (with rubber crawler) . . . . . . . I-12
b. Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-13
c. Performance and lifting capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-14
I-1
WSM U15-3
I-2
WSM U15-3
A.Developing concept and feature
a. Objective and Concept of Development
1 Objective of Development
Development of products which go ahead of competitive companies in terms of reduced manufacturing
costs while reinforcing the performance in horizontal operability, workability, durability, comfort and
safety.
2 Product Concept
Integration of the world's best actual performance of backhoe and the spirit of innovation.
b. Main Specifications
model
Brand
Type
Engine
Output
Displacement
Machine weight
Excavating capacity
Hydraulic pump
P1, P2
P3
U15-3
U-15
KUBOTA
KUBOTA
D782-EBH-4
D782-BH
PS/rpm
13/2300
12/2100
kW/rpm
9.6/2300
8.8/2100
cm3
778
778
kg
1600
1450
Bucket
kN (kgf)
15.2 (1550)
12.5
Arm
kN (kgf)
8.8 (900)
8.5
220
210
2
Relief pressure
kg/cm
Pump discharge rate
L/min
16.6
15.1
Relief pressure
kg/cm2
190
210
Pump discharge rate
L/min
10.4
9.5
I-3
WSM U15-3
c. Major Selling Points and Improvements
1. Quick chart
Inner package of hoses for all attachments
Max. excavation capacity
increased by 22%
Max. excavation depth
increased by 10%
4-port ROPS specification
Engine start control
High-positioned boom cylinder
Flat steps
Travel lock function
Theft-proof version (EU - option)
Standard equipped with SC valve
I-4
WSM U15-3
2. Wrist arm control lever
3. Enlarged foot space
U-15 (Previous model)
U15-3 (New model)
330mm
460mm
4. Upper positioned boom cylinder
5. Inner package of hoses for front attachments
I-5
WSM U15-3
6. Engine start control, Travel lock function
Unloading lever : UP
Engine start
:
Front attachment,
traveling
:
Engine start
:
Front attachment,
traveling
:
Unloading lever : DOWN
7. 4-post ROPS
The equipment is of European specifications.
I-6
WSM U15-3
8. Machine equipped with theft-proof device (Future EU option)
Antenna unit
Starter key set
9. Side-opening type full-open hood
U-15 (Previous model)
U15-3 (New model)
Paint color and equipment are of European specifications.
I-7
WSM U15-3
d. Evaluation of Competitive Power with Competitors
1. Workability
U15-3
Current
U-15
Increase in engine output
9.6
8.8
11.2
8.5
11.3
{
Max. excavation capacity
increased by 22%
15.2
12.5
14.2
13.7
14.4
{
Max. excavation depth
increased by 10%
2310
2100
2155
2100
2170
{
Max. vertical depth
increased by 11%
1900
1720
1870
1750
1720
{
Max. excavation radius
increased by 5%
3900
3720
3900
3720
3800
{
Travel 2-speed traction force
increased by 5%
-
-
-
-
{
Travel 2-speed speed
increased by 8%
2.0/4.0
2.3/4.3
2.1/4.3
2.3/4.0
{
Swiveling force increased by
12%
-
-
-
-
Item
Offence
Defense
{
2.2/4.3
KOMATSU YANMAR
PC15MR
Vio15
SCM
301.5CR
Appealing point in sales
We will appeal such a
point that the max. excavation capacity and max.
excavation depth which
are the basic performances of excavating
machine take a lead over
those of our existing
machines as well as
competitive companies'
machines.
2. Durability
KOMATSU YANMAR
PC15MR
Vio15
SCM
301.5CR
Item
U15-3
Current
U-15
{
Boom cylinder Protection of
cylinder by high-positioning
{
x
x
x
x
{
Protection by inner package
of hoses for all attachments
{
'
'
x
x
{
Standard equipped with tension spring
{
x
{
{
{
{
Double-grouser type iron
crawler <For domestic market only>
{
x
-
-
{
{
Introduction of high-back
and integrated seat
{
x
{
{
{
{
Prevention of water entry by
enclosed hydraulic oil tank
{
x
-
-
-
{
Equipped with starter automatic release function
{
x
-
-
-
{
Boom cast steel members
{
x
{
x
x
{
High-tensile brass bush
{
x
{
-
-
Offence
Defense
I-8
Appealing point in sales
As the greatest differentiation from competitive
companies' products, we
will appeal such a point
that loading work can be
performed without hassle. This is because the
machine can be brought
close to a 2-ton dump
truck without damage to
the boom cylinder during
loading work. Such job is
found often with
machines of this class.
We will also appeal such
a point that the machine
is equipped with the
inner package of hoses
for all attachments which
gives no damage to cylinder.
WSM U15-3
3. Operability
Item
Offence
U15-3
Current
U-15
Defense
KOMATSU YANMAR
PC15MR
Vio15
SCM
301.5CR
{
Horizontal operation
{
x
{
{
{
{
Starter key used also for
higher-ranked models
{
x
-
-
-
{
Equipped with auto-glow
indicator
{
x
-
-
-
{
Right and left pedaling for
swing
{
x
{
{
{
U15-3
Current
U-15
Appealing point in sales
We will appeal the comfort and operability of
horizontal operation to
users of current U-15.
We will also appeal to
rental users that the
starter key can be used
also for higher-ranked
models.
4. Comfort
Item
Offence
Defense
KOMATSU YANMAR
PC15MR
Vio15
SCM
301.5CR
{
Ample getting-on/off space
{
Front
operation
'
'
'
{
Flat steps
{
x
{
{
{
U15-3
Current
U-15
Appealing point in sales
We will appeal the
ampleness of getting-on/
off space.
5. Maintainability
Item
Offence
Defense
KOMATSU YANMAR
PC15MR
Vio15
SCM
301.5CR
{
Theft-proof specification
{
x
x
x
x
{
Standard equipped with SC
valve
{
'
-
-
{
Rotary joint O-ring
{
x
-
-
-
{
Side-opening full-open hood
{
x
x
x
x
{
Split-type dozer hose
{
{
x
{
x
Item
U15-3
Current
U-15
{
Travel lock function, Unlock
{
x
x
x
{
{
Engine start control
{
x
x
x
{
Compatible with ROPS
{
x
x
x
x
Appealing point in sales
We will appeal to rental
uses that the machine
can be equipped with a
new system theft-proof
device as well as the
improved operability of
SC valve and 4P multivalve.
6. Safety
Offence
Defense
{
I-9
KOMATSU YANMAR
PC15MR
Vio15
SCM
301.5CR
Appealing point in sales
We will appeal such a
point that the machine
assures the Japan's topclass safety.
WSM U15-3
7. Working Range
mm
U15-3
U-15
Difference
Max. excavation depth
2310
2100
+210
Max. vertical excavation depth
1900
1720
+180
Max. excavation radius
3900
3720
+180
Max. excavation height
3540
3740
-200
Max. dumping height
2440
2600
-160
Max. floor excavation radius
3840
3610
+230
1200
1270
-70
8. Outline of Hydraulic System (Travel straight function)
䊑䊷䊛
Boom
䉰䊷䊎䉴
Service
ᣓ࿁
Swivel
Bucket
䊋䉬䉾䊃
䉝䊷䊛
Arm
䊄䊷䉱
Dozer
Travel
Left
⿛ⴕᏀ
Travel
⿛ⴕฝ
Right
䉴䉟䊮䉫
Swing
䌐1䋱
P
䌐2䋲
P
䌐3䋳
P
21.6 MPa
16.6 L/min
21.6 MPa
16.6 L/min
18.6 MPa
10.4 L/min
Travel straight function is possible only together with boom operation.
I-10
WSM U15-3
e. Actual performance comparison
1. On-site Excavation Test
-Test Conditions1 m trench excavation, 45-deg. discharge of soil
Excavation work for 10 min., (5-min. rotation)
The equipment is of European specifications.
U15-3
U-15
Increasin
g rate
PC15MR-1
Vio15-2
301.5CR
*24.3
*26.3
*25.9
Volume of soil discharged per hour
m3/h
31.4
25.0
+26%
Cycle time
sec
8.3
9.8
+15%
Fuel consumption
cc/10min
Volume of soil discharged per liter of fuel
3/L
m
400
390
13.1
10.7
+22%
* Actual measurement
2. Comparison of Operating Speed
1. Attachment operated 3 times
2. Boom
(Ground level to top)
sec
UP
DOWN
sec
U15-3
U-15
difference
47.3
48.9
+3.4%
2.3
2.9
+26.1%
2.5
2.4
-4.0%
3. Swiveling speed
rpm
9.0
7.8
+13.3%
4. Combined operation
sec
29.7
29.9
-0.20
* Actual measurement
3. Comparison of Stability
Tipping load
U15-3
U-15
Dynamic Front
*148
*148
Dynamic Side
*138
*127
Static Front
*194
*213
Static Side
*181
*177
* Actual measurement
I-11
WSM U15-3
B.Machine specifications
a. Major dimensions and working range (with rubber crawler)
Unit
U15-3
3570
1
Overall length (at transport)
mm
2
Overall height (at transport)
mm
2250
3
Overall width
mm
1240/990
4
Minimum road clearance
mm
145
5
Dozer outer width x height
mm
1240/990 x 261
6
Tumbler-to-tumbler distance
mm
1230
7
Crawler center distance
mm
1010/760
8
Crawler shoe width
mm
230
9
Crawler height
mm
360
10
Swivel structure rear end height
mm
422
11
Overall crawler length
mm
1587
12
Approach angle
deg.
30.1
13
Maximum digging height
mm
3540
14
Maximum digging radius
mm
3900
15
Maximum digging depth
mm
2310
16
Maximum dumping height
mm
2440
17
Maximum vertical digging depth
mm
1910
18
Minimum front turning radius
mm
1430/1207
19
Minimum tail turning radius
mm
620
20
Ground contact pressure
kPa
(kgf/cm2)
25 (0.25)
21
Swing angle left/right
deg.
63/58
22
Bucket lift angle
deg.
180
23
Maximum ground digging radius
mm
3840
24
Minimum ground finishing radius
mm
1320
25
Radius at maximum digging height
mm
2015
26
Radius at maximum dumping height
mm
2012
27
Maximum bucket bottom height with
arm vertical
mm
1200
28
Overall height with arm crowded and
minimum front swivel radius
mm
1430
Remarks
Front/swing
Arm vertical or fully crowded
from operator’s manual
I-12
WSM U15-3
b. Dimensional drawings
from operator’s manual
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
410 485 990 620 980 990 3540 2440 2310 1910 1430 2250 2630 265 180 2750 825 3570 3840 3900
1240
1240
I-13
(mm)
WSM U15-3
c. Performance and lifting capacity
1. Performance
Unit
U15-3
m3
0.04
Maximum digging force, arm
KN(kgf)
8.8 (900)
Teeth bottom
Maximum digging force, bucket
KN(kgf)
15.2 (1550)
Teeth bottom
sec/cycle
10.8
Standard bucket capacity
Cycle time
Digging performance
Dozer capacity
heaped
3/h
Remarks
CECE
33.4
m
m3
0.067
without extention blade
Digging performance, cycle time conditions:Dig 1m depth with Standard bucket and dump soil on the
ground after 45° swivel.
I-14
WSM U15-3
2. Lifting capacity
Lifting posture
Dozer
Maximum lifting capacity
(standard arm)
Unit
(kgf)
U15-3
Crawler extended
Remarks
crawler retracted
60
Up
kgf
215 (T)
215 (T)
Down
kgf
280 (R)
280 (R)
Up
kgf
100 (T)
185 (T)
Down
kgf
135 (T)
195 (T)
Up
kgf
475 (R)
475 (R)
Down
kgf
475 (R)
475 (R)
Up
kgf
275 (T)
475 (R)
Down
kgf
315 (T)
475 (R)
Lifting capacity
The machine can lift the loads listed above when the hydraulic pressure is as specified. But the actual measurements are based on "n = 1", which means some fluctuations are expected.
Measuring conditions:
(1) Hydraulic oil temperature: 50 ± 5 °C, riding operator (about 60 kg), engine at maximum rpm.
(2) The boom is inched until the other end of the machine comes off the ground or the boom circuit gets
relieved. Then the loads are measured.
Note:The loads also vary depending on the ground surface condition, dozer's ground-contact status,
operator's weight, remaining fuel and other factors.
(3) The boom swing position is set at the center.
(The machine may turn over if it is set off the center.)
*The above figures show the machine that is about to life a load.
In the above table, (T) means that the machine may turn over if the load is heavier. And (R) means that the
boom circuit gets relieved if the load is heavier.
I-15
WSM U15-3
I-16
WSM U15-3
II Service engineering section
A.Maintenance specifications . . . . . . . . . . . . . . . . . . . . . . . . . II-3
a.
b.
c.
d.
List of oil and water quantities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-4
Quality specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-6
Operating noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-11
B.Machine body structure and function . . . . . . . . . . . . . . . . II-13
a.
b.
c.
d.
Overall Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control levers and linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Under carriage components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II-13
II-23
II-28
II-34
C.Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-44
a.
b.
c.
d.
e.
f.
g.
h.
Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine servicing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II-44
II-45
II-46
II-47
II-48
II-49
II-52
II-54
D.Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-55
a. Main pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-55
b. Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-61
c. Swivel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-69
d. Travel motor (Wheel motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-73
e. Pilot valve (Remote control valve). . . . . . . . . . . . . . . . . . . . . . . . . . II-83
f. Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-87
g. Swivel Joint (Rotary joint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-92
h. Unload valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-96
i. Selector valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-98
j. Accessaries of hydraulic compornents . . . . . . . . . . . . . . . . . . . . . . II-99
h. Hydraulic system flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-103
l. Service port system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-108
m. Hydraulic components layout : U15-3 . . . . . . . . . . . . . . . . . . . . . . II-111
n. Hydraulic circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-112
II-1
WSM U15-3
E.Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-113
a. New Functions of Electric System . . . . . . . . . . . . . . . . . . . . . . . . . II-113
b. Battery circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-114
c. Key switch (Engine starter switch). . . . . . . . . . . . . . . . . . . . . . . . . II-115
d. Safty lever lock switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-116
e. Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-118
f. Travel hi-speed control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-120
g. Meter panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-127
h. Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-133
i. Auto glow circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-134
j. Auto release control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-144
k. Water temp. sensor & gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-151
l. Fuel control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-153
m. Engine stop solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-154
n. coil commander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-156
o. Fuel sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-158
p. Engine oil pressure sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . II-161
q. Engine electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-162
r. Horn circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-164
s. Charging system (Alternator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-167
t. Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-171
u. Route of Electric Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-174
v. Electrical component layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-181
w. Electric Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-182
x. Electrical Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-187
II-2
WSM U15-3
A.Maintenance specifications
a. List of oil and water quantities
Unit
U15-3
Radiator soft water
L
2.7
Reserve tank soft water
L
0.6
Crankcase engine oil
(at filter replacement)
L
3.5
Remarks
Kubota LLC-N-50F
Class CC
10W30
Hydraulic tank oil
L
13
ISO 46
Total hydraulic oil
L
22
ISO 46
Wheel motor gear oil
L
0.25
Swivel reducer gear oil
L
-
Track roller gear oil
cc
40
Carrier roller
(upper track roller)
cc
-
Front idler
cc
30
Engine Oil SAE 30 Class CD
Fuel tank light oil (full)
L
18
Diesel light oil No. 3
II-3
SAE 90 (API, GL-4)
Engine Oil SAE 30 Class CD
Grease EP2
WSM U15-3
b. Tightening torque
1. Machine
Unit: N·m (kgf·m)
Loctite
U15-3
Travel wheel motor
{
60.8 ~ 70.6 (6.2 ~ 7.2)
Control valve
{
Sprocket
{
60.8 ~ 70.6 (6.2 ~ 7.2)
Track roller
{
103 ~ 117.7 (10.5 ~ 12)
Carrier roller
48.1 ~ 55.9 (4.9 ~ 5.7)
Plate (idler)
77.5 ~ 90.2 (7.9 ~ 9.2)
Grease cylinder nipple
Remarks
Slide plate
98.0 ~ 108.0 (9.0 ~ 11.0)
Swivel bearing
{
103 ~ 117.7 (10.5 ~ 12)
Swivel motor
{
367.7 ~ 431.5 (37.5 ~ 44.0)
Return filter
19.6 ~ 29.4 (2.0 ~ 3.0)
Engine bracket/engine support
{
Engine anti-vibration rubber
{
39.2 ~ 45.1 (4.0 ~ 4.6)
{
107.9 ~ 125.5 (11.0 ~ 12.8)
Engine anti-vibration rubber
Counterweight
Nut
39.2 ~ 45.1 (4.0 ~ 4.6)
Coupling
48.1 ~ 55.9 (4.9 ~ 5.7)
Main pump
77.5 ~ 90.2 (7.9 ~ 9.2)
Rotary joint
Oil tank
48.1 ~ 55.9 (4.9 ~ 5.7)
Rotary joint stopper
48.1 ~ 55.9 (4.9 ~ 5.7)
{
Muffler flange
23.5 ~ 27.5 (2.4 ~ 2.8)
Control valve through bolt
13.7 ~ 14.7 (1.4 ~ 1.5)
2. General bolt/nut tightening torque
Unit: N·m (kgf·m)
4T
7T
9T
M6
7.8 ~ 9.3 (0.8 ~ 0.95)
9.8 ~ 11.3 (1.0 ~ 1.15)
12.3 ~ 14.2 (1.25 ~ 1.45)
M8
17.7 ~ 20.6 (1.8 ~ 2.1)
23.5 ~ 27.5 (2.4 ~ 2.8)
29.4 ~ 34.3 (3.0 ~ 3.5)
M10
39.2 ~ 45.1 (4.0 ~ 4.6)
48.1 ~ 55.9 (4.9 ~ 5.7)
60.8 ~ 70.6 (6.2 ~ 7.2)
M12
62.8 ~ 72.6 (6.4 ~ 7.4)
77.5 ~ 90.2 (7.9 ~ 9.2)
103.0 ~ 117.7 (10.5 ~ 12.0)
M14
107.9 ~ 125.5 (11.0 ~ 12.8)
123.6 ~ 147.1 (12.6 ~ 15.0)
166.7 ~ 196.1 (17.0 ~ 20.0)
M16
166.7 ~ 191.2 (17.0 ~ 19.5)
196.1 ~ 225.4 (20.0 ~ 23.0)
259.7 ~ 304 (26.5 ~ 31.0)
M18
245.2 ~ 284.4 (25.0 ~ 29.0)
274.6 ~ 318.7 (28.0 ~ 32.5)
343.2 ~ 402.1 (35.0 ~ 41.0)
M20
333.4 ~ 392.3 (34.0 ~ 40.0)
367.7 ~ 431.5 (37.5 ~ 44.0)
519.8 ~ 568.8 (53.0 ~ 58.0)
II-4
WSM U15-3
3. Hydraulic pipe tightening torque
Steel pipe size (mm)
(O.D. x I.D. x Thickness)
Tightening torque
N·m (kgf·m)
Wrench width (mm)
[Reference]
I8 x 6 x t1
29.4 ~ 39.2 (3.0 ~ 4.0)
*17
I10 x 7 x t1.5
39.2 ~ 44.1 (4.0 ~ 4.5)
*19
I12 x 9 x t1.5
53.9 ~ 63.7 (5.5 ~ 6.5)
*21
I16 x 12 x t2
88.3 ~ 98.1 (9.0 ~ 10.0)
*29
I18 x 14 x t2
127.5 ~ 137.3(13.0 ~ 14.0)
*32
I27.2 x 21.6 x t2.8
235.4 ~ 255.0(24.0 ~ 26.0)
*41
Remarks
* Ihara-made sleeve nuts
4. Hydraulic hose tightening torque
Tightening torque N·m (kgf·m)
Thread size
(piping thread)
Wrench width
[Reference]
Union nut
Taper thread
1/8”
7.8 ~ 11.8 (0.8 ~ 1.2)
19.6 ~ 29.4 (2.0 ~ 3.0)
*17
1/4”
24.5 ~ 29.4 (2.5 ~ 3.0)
36.3 ~ 44.1 (3.7 ~ 4.5)
*19
3/8”
37.2 ~ 42.1 (3.8 ~ 4.3)
68.6 ~ 73.5 (7.0 ~ 7.5)
*22
1/2”
58.8 ~ 63.7 (6.0 ~ 6.5)
83.4 ~ 88.3 (8.5 ~ 9.0)
*27
3/4”
117.7 ~ 127.5 (12.0 ~ 13.0)
166.6 ~ 181.3 (17.0 ~ 18.5)
*36
Remarks
Note: * Wrench width may vary depending on the manufacturer, thread diameter and other factors.
5. Engine
N·m (kgf·m)
Engine model
D782
Cylinder head cover
4.9 (0.5)
Nozzle holder
58.8 (6.0)
Rocker arm bracket nut
10.8 (1.1)
Cylinder head cover
40.2 (4.1)
Connecting rod bolt
28.4 (2.9)
Flywheel
56.9 (5.8)
Bg case bolt 1
14.7 (1.5)
Bg case bolt 2
28.4 (2.9)
Bearing case cover bolt
10.8 (1.1)
Hose clamp (threaded type)
Part code
N·m (kgf·cm)
Applicable diameter (mm)
Tightening torque
09318-89016
12 ~ 16
2.5 ~ 3.4
(25 ~ 35)
09318-89039
31 ~ 40
2.5 ~ 3.4
(25 ~ 35)
09318-89045
36 ~ 46
2.5 ~ 3.4
(25 ~ 35)
RB101-63631
13 ~ 20
3.4 ~ 4.4
(35 ~ 45)
RC101-64581
15 ~ 25
4.9 ~ 5.9
(50 ~ 60)
68311-72821
26 ~ 38
4.9 ~ 5.9
(50 ~ 60)
RC411-63181
40 ~ 55
4.9 ~ 5.9
(50 ~ 60)
RC401-63191
50 ~ 60
4.9 ~ 5.9
(50 ~ 60)
69284-63171
77 ~ 95
4.9 ~ 5.9
(50 ~ 60)
RD411-63821
32 ~ 44
4.9 ~ 5.9
(50 ~ 60)
II-5
WSM U15-3
c. Quality specifications
No
Q1
1
2
Specificatios Items
1
Total length (Transport)
mm
3575 ± 71
2
Total width
mm
1240/990 ± 12
3
Total height (Canopy)
mm
2300 ± 23
4
Total height (Cabin)
mm
-
1
Machine size
Weight
1
Performance
2
5
Machine weight (Canopy)
kg
1600 ± 32
Machine weight (Cabin)
kg
-
Swivel speed
rpm
8.7 ± 0.9
Travel speed F1
km/h
2.2 ± 0.2
3
F2
km/h
4.0 ± 0.4
4
R1
km/h
2.2 ± 0.2
5
R2
km/h
4.0 ± 0.4
deg
30 <
6
4
Gradeability
1
Rear end min. turning radius
mm
620 ± 12
2
Swivel frame rear ground clearance
mm
422 ± 8
3
Tambler center distance
mm
1230 ± 37
4
Crawler total length
mm
1587 ± 48
5
Crawler total width
mm
1240/990 ± 26
6
Crawler shoe width
mm
230 ± 5
7
Min. ground clearance
mm
145 ± 4
1
Engine,
2
Model name
Rated output DIN 70020
D782-BH-4
kw
9.6 ± 0.2
ps
13.0 ± 0.3
3
Rated speed
rpm
2300
4
Displacement
L
0.778
cc
6
U15-3
Remarks
Main Speed JIS A8404
2
3
Unit
1
Hydraulic pump type
2
Pump delivery
3
Main relief pressure
(Bench set)
L
P1,P2
P3
P4
7
1
Swivel motor type
8
1
Under carrage
3
778
Variable x2 +gear
16.6 x 2, 10.4, 6.2
Mpa
21.6 -0.5
kgf/cm2
220 -5
Bar
216 -4.9
Mpa
18.6 -0.5
kgf/cm2
190 -5
Bar
186 -4.9
Mpa
3.9 -0.5
kgf/cm2
40 -5
Bar
39 -4.9
+1.0
+10
+9.8
+1.0
+10
+9.8
+1.0
+10
+9.8
Travel motor type
Variable displacement pump
Crawler shoe type
Rubber
II-6
Fuel tank
Rated engine RPM, K=100%
WSM U15-3
No
9
1
Specificatios Items
Front attachment
11
2
3
Bucket width
mm
456 ± 10
4
Swing angle L
deg
63 ± 2
5
R
deg
58 ± 2
mm
3901 ± 59
Max. digging radius
m3
0.04 ± 0.002
7
Ground level Max. digging radius mm
3843 ± 58
8
Ground level Min. finish radius mm
1320 ± 26
9
Max. digging depth
mm
2306 ± 46
10
Max. vertical digging depth
mm
1911 ± 38
11
Max. digging height
mm
3536 ± 71
12
Max. dump height
mm
2443 ± 49
14
Mini. turning radius
mm
1426 ± 43
15
Mini. turning radius
(Left swing)
mm
1207 ± 36
16
L
mm
510 ± 15
17
Off-set
amount
R
mm
385 ± 12
18
Max. digging force
kgf
1.55
N
15.2
1
Width
mm
1244/990 ± 5
2
Height
mm
261 ± 5
4
Max. lift above GL
mm
263 ± 13
5
Max. below GL
mm
182 ± 9
Fuel
Tank
L
17.5 ± 0.9
Hydraulic oil Tank
L
13 ± 0.7
4
Dozer
Water & oil
5
Q2
1
CECE
U15-3
Bucket
heaped
capacity
6
10
Unit
Bucket tooth slaggish
mm
73 ± 93
2
Decline of front attachment
mm
0 ± 10
3
Dozer's declination
mm
0 ± 10
3
3
Min. clearance of bucket teeth to boom cylinder protector mm
4
1
Approach angle
deg
30.1 ± 3.0
5
1
Crawler height
mm
360 ± 7
2
Max. crawler height
mm
360 ± 7
Q3
2
3
Without side cutter
Bucket bottom horizontal
Main Specs JIS A8404
1
1
Remarks
37
+34
-16
Engine performance
1
1
Max. engine torque
4.52/1750
N•m/rpm
44.3/1750
no load
rpm
2
1 pump relief
rpm
3
2 pump relief
rpm
2300 <
4
3 pump relief
rpm
2300 <
rpm
1200 + 150/-0
1
Max, engine rpm
kgf•m/rpm
Idling rpm
II-7
2600 >
Include grouser on the sprocket
WSM U15-3
No
Q4
Specificatios Items
Unit
U15-3
Travelling performance
1
1
Travel motor block performance, L/R
mm
2
1
Max, Traction force
kgf•m
1255 ± 126
kN•m
12.8 ± 1.3
kgf•m
637 ± 64
kN•m
6.5 ± 0.7
2
3
4
1
F1
F2
F1
mm
600 >
F2
mm
600 >
3
Dozer F1
mm
600 >
4
Dozer R1
mm
600 >
1
Travel straightness
Q5
Track shoe sag distance Iron
Rubber
2
Arm digging force
3
Bucket digging force
1
6
1
25 ~ 30
10 ~ 15
kgf
824<
K=65%
10m distance
Dozer up & down 10m distance
1
8
1
8.4<
kgf
1412<
kN
14.4<
sec
2.2 ± 0.3
Machine stance to JIS bucket tooth
root
up
down
sec
2.5 ± 0.3
Oil temp. 50 ± 5°C
Arm speed
crowd
sec
3.5 ± 0.3
Oil temp. 50 ± 5°C
extend
sec
2.4 ± 0.3
Oil temp. 50 ± 5°C
crowd
sec
2.8 ± 0.3
Oil temp. 50 ± 5°C
dump
sec
1.9 ± 0.3
Oil temp. 50 ± 5°C
up
sec
1.4 ± 0.3
Max. down to max. up
down
sec
1.9 ± 0.3
Max. up to max. down
2
7
kN
Bucket tooth root
Boom speed
3
Bucket speed
2
Dozer speed
2
Oil temp. 50 ± 5°C
Max. heiht to ground
1
Max. digging height radius
mm
2015 ± 202
2
Max. dump height radius
mm
2012 ± 121
at bucket pin
4
Bucket bottom height at arm vertical
mm
1200 ± 36
Bucket horizontal
5
Bucket wrist angle
degree
180 ± 3
kgf•m
217 <
kN•m
2.1 <
kgf•m
217 <
kN•m
2.1 <
Q6
1
mm
mm
20 deg, 10 min
Work performance
5
13
300 >
2
2
4
Remarks
Swivel, swing performance
1
Swivel torque
2
L
R
2
1
Swivel capable angle at slope
3
1
Swivel block performance
5
1
Swivel start-up speed
7
1
Swing speed
8
1
2
Swing Lock
L/R
deg
18 <
deg
30 >
sec
2.1 ± 0.2
Left
sec
4.6 ± 0.3
Right
sec
3.7 ± 0.3
Swivel R&L
mm
II-8
6>
Arm extend,show/Quick
Bucket load=JIS heaped x 1.8
0 ~ 90 deg swivel
90 deg-swivel, 100 times actual
digging cylinder dislocation
WSM U15-3
No
Q7
1
Specificatios Items
1
Relief pressure setting
P3
4
P4
220 -5
Remarks
MPa
21.6 -0.5
bar
215.8 -4.9
+10
+1.0
+9.8
kgf/cm2
220 -5
MPa
21.6 -0.5
bar
215.8 -4.9
+10
+1.0
+9.8
kgf/cm2
190 -5
MPa
18.6 -0.5
bar
186.3 -4.9
+10
+1.0
+9.8
40 -5
MPa
3.9 -0.5
bar
39.2 -4.9
Boom
mm
25 >
2
Arm
mm
15 >
3
Bucket
mm
10 >
4
Dozer
mm
25 >
30°C
sec
3>
50°C
sec
1
1
Cylinder block performance
Boom cushioning performance
3
1
Q8
1
kgf/cm2
kgf/cm2
2
8
P1
P2
3
6
U15-3
Hydraulic performance
2
5
Unit
Service port flow
+10
+1.0
+9.8
Arm extend, bucket
Hydraulic oil temp. 50 ± 5°C
height 1m, 10 min.
Bucket load : Heaped
Soil gravity : 1.8
0.5 to 1.5
80°C
sec
0.3 <
No load/load
L
27
Lever operating force & stroke
1
Boom lever operating force
4
Arm lever
kgf
1.4 ± 0.5
kN
13.7 ± 4.9
kgf
1.4 ± 0.5
N
13.7 ± 4.9
5
Bucket lever
kgf
1.4 ± 0.5
N
13.7 ± 4.9
6
Swivel (Swing) lever
kgf
1.4 ± 0.5
N
13.7 ± 4.9
kgf
3.1 ± 0.5
7
Dozer lever
8
Travel lever
L/R
N
30.0 ± 4.9
kgf
1.5 ± 0.5
N
15.0 ± 4.9
Measured 20 mm below the grip
end.
9
Accelerator lever (up/down)
kgf
3.4 ± 1.5
N
35.0 ± 14.7
Measured 30 mm below the grip
end.
10
Swing pedal
kgf
10.0 ± 1.0
Measured Step end.
N
98.0 ± 9.8
up
kgf
2.0 ± 1.0
N
20.0 ± 9.8
down
kgf
3.0 ± 1.0
N
30.0 ± 9.8
11
Safety lock lever, L&R
II-9
WSM U15-3
No
1
2
13
1
Specificatios Items
Service port pedal
Boom lever stroke
2
5.0 ± 1.0
N
51.0 ± 10
up
mm
72 ± 10
down
mm
72 ± 10
mm
72 ± 10
4
Bucket lever stroke (crowd/dump)
mm
74 ± 10
5
Swivel lever stroke
mm
74 ± 10
6
Dozer lever up & down
mm
80 ± 10
7
Travel lever, L & R, F & R
L
mm
75 ± 10
R
mm
75 ± 10
9
Swing pedal stroke
mm
6 ± 10
10
Service port pedal stroke (LH & RH)
mm
12 ± 10
Standard arm, Dynamic Bucket load Side, dozer up
operation load limit
to 10 degrees
tipping
Over end,
dozer up
kgf
-
N
-
kgf
-
N
-
Bucket load Side, dozer up
to tipping,
track frame
Over end,
extended
dozer up
kgf
121 <
N
1187 <
kgf
130 <
N
1275 <
Bucket load Side, dozer up
to tipping,
track frame
Over end,
retracked
dozer up
kgf
63 <
Remarks
L/R
Measured grip end
Measured Step end
Stability
1
3
1
N
618 <
kgf
130 <
N
1275 <
Standard arm, Static Bucket load Side, dozer up
operation load limit
to tipping,
track frame
Over end,
extended
dozer up
kgf
162 <
N
1589 <
kgf
175 <
N
1716 <
Bucket load Side, dozer up
to tipping,
track frame
Over end,
retracked
dozer up
kgf
95 <
2
Q10
1
kgf
Arm lever stroke (crowd/dump)
2
2
U15-3
3
Q9
1
Unit
N
932 <
kgf
175 <
N
1716 <
arm extended, bucket crowd, swing
0 degree, exclude bucket weight
37Kg.
front level crowd, swing 0 degree,
exclude bucket weight 37Kg.
Load is added at the top of arm.
Comfortability
1
At operator’s Canopy
ear LPA
Cab
db(A)
78 >
2
Noise level
db(A)
-
3
Noise source; LWA
db(A)
92 >
II-10
Cab door close
WSM U15-3
d. Operating noise
Unit
U15-3
At ear level (Canopy)
db(A)
78 >
Around the machine
db(A)
Acoustic power level
db(A)
Remarks
92 >
Low-noise specified number
Ultra-low noise specified number
Emission control specified
Standard operation
Energy tax system
(The noise at ear level is measured with the average energy output under no load at maximum rpm.)
60 dB(A):
Sleeping
peacefully
80 dB(A):
Awakened
and weeping
Microphones
1.5 to 4 m
Simulated digging is made at maximum engine rpm, and the then operating noise is measured within 10 m
in radius from the machine (imaginary hemispherical space with the machine length from 1.5 to 4 m).
II-11
WSM U15-3
e. Machine weight and parts weight
*
The weights in the table below are approximate.
Unit
U15-3
kg
1600
Body weight
kg
1340
Maximum breaker weight
kg
90
Backhoe overall
kg
177
Swing bracket and boom cylinder not
included
Upper swivel structure
kg
816
Canopy/cabin
Lower travel structure
kg
577
Rubber crawler
Track frame
kg
61/83/61
Left/center/right
Swivel frame
kg
150
Swing bracket
kg
28
Boom
kg
67
Arm
kg
30
Bucket
kg
29
Dozer
kg
67
Counterweight
kg
205
Iron crawler
kg
89
Rubber crawler
kg
56
Unit
U15-3
Engine
kg
64
Dry weight
Hydraulic tank
kg
13
With filter
Fuel tank
kg
1.6
Swivel bearing
kg
17
Battery
kg
13
Track roller
kg
4
Upper track roller
kg
-
Sprocket
kg
5
Idler
kg
18
Canopy roof
kg
9
Post (support)
kg
21
Machine weight
Pump assembly
kg
14
Wheel motor
kg
17
Swivel motor
kg
15
Control valve
kg
14
Boom cylinder
kg
15
Arm cylinder
kg
12
Bucket cylinder
kg
11
Swing cylinder
kg
9
Dozer cylinder
kg
7
Rotary joint
kg
13
Radiator
kg
2
II-12
Remarks
450-400
Remarks
Sprocket included
Without joint
Offset
WSM U15-3
B.Machine body structure and function
a. Overall Arrangement
(7)
(1)
(8)
(9)
(2)
(10)
(11)
(12)
(3)
(4)
(13)
(14)
(5)
(6)
(15)
Vertical Operation
(1)
Service port pedal
(9)
Fuel tank
(2)
Control valve
(10) Swivel motor
(3)
Oil cooler
(11) Swivel joint
(4)
Battery
(12) Oil tank
(5)
Radiator
(13) Unloading valve
(6)
Suction pipe
(14) Pump
(7)
Swing pedal
(15) Engine
(8)
Selector valve
Note : For the export model, the travel Hi - Low control switch is located on the dozer lever grip.
II-13
WSM U15-3
2. Arrangement of Control Levers
(1)
Travel lever (left)
(2)
Control lever for front attachments (left)
(3)
Lock lever for attachment control
(4)
Service port pedal
(5)
Travel lever (right)
(6)
Control lever for front attachments (right)
(7)
Two travel speed switch
(8)
Control lever for dozer or track width
(9)
Boom swing pedal
(10) Throttle lever
(11) Track width change / dozer select lever
II-14
WSM U15-3
(1)
Horn switch
(2)
Starter switch
(3)
Malfunction indicator (Quick Diagnosis)
(4)
Fuel meter
(5)
Hour meter
(6)
Working light switch
Adoption of Meters
Hour meter, oil level gauge and Easy checker
(oil lamp, charge lamp, glow lamp and fuel level
alarm lamp) for various indications.
II-15
WSM U15-3
Direction of accel lever : EU - version
PP - version
(Machine front)
Idle
Max
Idle
(1)
Starter Switch
(A)
“STOP“
(B)
“RUN“
(C)
“START“
(1)
Max
(Machine fronto )
(2)
(4)
(5)
(3)
(1)
Hood Left
(4)
Oil cooler
(2)
Hood Rear
(5)
Radiator
(3)
Wing nut
The oil cooler and the radiator can be checked and cleaned by opening the left hood.
Engine oil can be refilled by opening the inspection
door after lifting up the seat.
(1)
(1) Oil filler port
II-16
WSM U15-3
(2)
(1)
(3)
(4)
(5)
(1)
Fuel level gauge
(2)
Fuel cap cover
(3)
Air vent
(4)
Hydraulic oil filler port
(5)
Cap
(6)
Gauge
(6)
• Adoption of fuel level gauge makes it possible to check the remaining oil amount.
• A gauge is mounted at the side of the fuel filler port. When fuel is nearly filled up, the pointer of the gauge
starts moving and about 2 liters of fuel oil is filled up.
• A hydraulic oil filler port is provided also at the side of the fuel filler port.
(2)
(3)
(4)
(5)
(1)
(1)
Fuel filter cartridge
(2)
Water separator
(3)
Water separator handle
(4)
Indication line
(5)
Float (Red)
(6)
Cup
(7)
Retainer ring
(7)
(6)
Like in the models of KX91-3S·D and KX121-3S·D Series, the fuel filter has been separated from the water
separator.
II-17
WSM U15-3
3. Press-fitting of Bushes
Positions where bushes and dust seals are inserted (except for the parts finished with bush insertion).
(6)
(1)
(5)œ
(2)
(4)
(3)
Both bush and dust seal
œBush only
(1)
Bucket link 1 side
(2)
Arm end
(3)
Bucket link 1 side
(4)
Arm boss side
(5)
Arm boss side
(6)
Tensile brass
(7)
(5)
(1)
(2)
(6)
(4)
(3)
(9)
(7)
(11)
(8)
(10)
(1)
(Dust seal magnified view)
(7)
Dust seal
(2)
Bush side
(8)
Bush inserting direction
(3)
Outside
(9)
Bush
(4)
Bush
(10) Bush inserting direction
(5)
Insert
(11) Dust seal
(6)
Reinforcing plate
II-18
WSM U15-3
4. Front Equipment
Rectify the boom inside.
(3) (2) (1) (4)
(10)
(28)
(11)
(12)
(19)
(13)
(15)
(17)
(16)
(22) (20)(20)(21)(22)
(7)
(27)
(5)
(18)
(24)
(25)
(6)
(26)
(14)
No.
Part Name
(9)
Q'ty
No.
(8)
Part Name
Q'ty
(1)
Bracket (SP)
2
(6)
Cushion (1)
1
(2)
Bolt
4
(7)
Cushion (2)
1
(3)
Plug
2
(8)
Plate (lower)
1
(4)
Pipe joint
2
(9)
Jam nut
2
(5)
Clamp
1
(10) Grommet (boom)
2
Part No.
RB237-6652'
(11) Assemble the pipe joint (4) and the bracket (SP) (1) in
parallel.
(20) White
(12) Put the marking (tape) to the front (for both bucket and
SP).
(21) Red
(13) Pay attention to the direction of the cushion (6).
(22) Black
(14) Fix the hoses (for both bucket and SP) so that they
should face up forwards.
(23) Color of hose tape
(15) Thin
(24) Left side
(16) Thick
(25) Right side
(17) Front
(26) As viewed from rear
(18) Rear
(27) Working light should be in parallel with the bottom plate.
(19) Magnified view of the clamp
(28) Pay attention to the direction of the bracket (10).
Apply adhesive to the grommet.
II-19
WSM U15-3
5. Greasing (1)
(14)
(15) (16)
(17)
(1)
(18)
(2)
(8)
(3)
(4)
(7)
(9)
(5)
(11)
(12)
(10)
(6)
(13)
(1)
Type A (Boss greasing)
Swing supporting points (upper and lower)
(10) Type A (Pin greasing)
(2)
Type A (Boss greasing)
(11) Type C (Boss greasing)
(3)
To swivel bearing balls
(12) Type A (Pin greasing)
(4)
To swivel bearing teeth
(13) Type A (Pin greasing)
(5)
Type A (Boss greasing)
(14) As viewed from front of the swivel frame
(6)
Type A (Pin greasing)
(15) Swing cylinder bottom
(7)
Type A (Boss greasing)
(16) Swivel bearing (teeth)
(8)
Type A (Boss greasing)
(17) Swivel bearing balls
(9)
Type A (Boss greasing)
(18) Grease the swivel bearing balls and teeth
respectively at 6 positions while turning the
bearing by 90 deg. each.
The balls and teeth may be greased before
assembling.
II-20
WSM U15-3
6. Greasing (2)
(1)
(3)
(5)
(4)
(2)
(1)
Type A (Boss greasing)
(2)
Type B (Boss greasing)
(3)
Type B (Boss greasing)
(4)
Type B (Boss greasing)
A-type: Straight type
(06611-15010)
B-type: 67°C
(06616-25010)
C-type: 90°C
(06616-35010)
II-21
WSM U15-3
7. Cleaning and greasing the Track Frame Slide Pipes
When the slide pipes of the track frame are clogged or adhered with soil or sand, clean the slide pipes in the
following manner according to need.
WARNING
To avoid the personal injury or death:
• Place the machine on even ground when cleaning the track frame slide pipes.
1.
2.
3.
4.
First lift the machine off the ground using the dozer blade and boom functions.
Switch the track width change / dozer select lever to the “Track width change” position.
Push the control lever forward, and expand the track width to 1240 mm.
Remove soil and sand adhered to the slide pipes, then put grease evenly around the pipes. Make sure
all 4 slide pipes are greased.
5. Retract and expand the track width repeatedly for a few times by moving the control lever, so that the
grease is spread adequately.
6. Switch the track width change / dozer select lever to the “Dozer” position.
7. Place the machine down on the ground carefully by moving the dozer blade and the boom.
(1) Track frame slide pipes
II-22
WSM U15-3
b. Front attachment
1. Bucket dimensions
Unit
U15-3
Remarks
(1)
mm
400
Lip outside width
(2)
mm
456
Side cutter outside width
(3)
mm
60.5 x 6
(4)
mm
139.5
(5)
mm
95.5
(6)
mm
16
(7)
mm
22
(8)
mm
47.75
(9)
mm
I49
(10)
mm
I60
(11)
mm
I30
(12)
mm
I30
(13)
mm
457
(14)
mm
380.5
(15)
mm
I48.5
(16)
mm
126.5
(17)
mm
88.5
(18)
mm
16.5
Ixt
Arm end width
II-23
WSM U15-3
2. Bucket fixture dimensions
Unit
U15-3
A
mm
45.3
B
mm
2 x M12 x 1.25
C
mm
45.3
D
mm
45.3
E
mm
16.5
F
mm
3.95
G
mm
865
H
mm
2
I
mm
180
J
mm
167.5
K
mm
104.5
L
mm
735
M
mm
173
N
mm
175
O
mm
85
Remarks
II-24
WSM U15-3
3. Bucket link pin
[Unit : mm]
Parts name
Specifications
(1)
Bucket link 1
I30 x 95.5
(2)
Bush A
I30 x I38 x W35
(3)
Pin A dia
I30 x 192.5
(5)
Bucket link 2, 3
I30 - I30
(6)
Arm boss
I55 x I38 x L125.5
(7)
Bush B
I30 x I38 x W35
(8)
Pin B dia
I30 x 192.5
(10)
Bucket cylinder L/S (stroke)
529 / 802 (269)
II-25
WSM U15-3
4. Front pins and bush
[Unit : mm]
*
Location No.
Pin diameter x length
Bush inner dia. x outer dia. x length
(1)
I35 x 257
I35 x I45 x 45
(2)
I35 x 160
I35 x I45 x 35, 44
(3)
I35 x 160
I35 x I45 x 45
(4)
I30 x 112.5
I30 x I40 x 35
(5)
I30 x 96
I30 x I40 x 35
(6)
I50 x 109
I50 x I60 x 37, 28, 40
(7)
I50 x 109
I50 x I60 x 37, 28, 40
(8)
I30 x 160
I30 x I40 x 35
(9)
I30 x 142
I30 x I40 x 35
(10)
I30 x 191
I30 x I38 x 35
(11)
I30 x 142
I30 x I40 x 45
(12)
I30 x 192.5
I30 x I40 x 35
(13)
I30 x 192.5
I30 x I38 x 35
(14)
I30 x 182
I30 x I38 x 35
(15)
I30 x 182
I30 x I38 x 35
The working limits of the pins are 1.0 shorter than the reference on new vehicle.
Outside
diameter
Length
Outside
diameter
Length
(New pin and bush tolerance)
-0.05
-0.05
-0.05
pin : I25 --0.05
0.08 , I30 -0.07 , I35 -0.07 , I50 -0.07
+0.130
+0.130
+0.090
bush : Inner dia. I25 +0.100 , I30 +0.100 , I35 +0.130
+0.100 , I50 +0.060
+0.100
+0.100
+0.100
Outer dia. I38 +0.070
+0.040 , I40 +0.070 , I45 +0.070 , I60 +0.070
II-26
Remarks
WSM U15-3
5. Swing bracket
(7)
(11)
(12)
(8)
(9)
(10)
(1)
Swing bracket
(2) ~ (6) Bushing
(7)
After installing the bush, pin of I34.9 goes through smoothy.
(8)
Dimension before bushing.
(9)
Side of the bush (3) should flash the face.
(10) After installing the bush, pin of I34.9 goes through smoothy.
(11) Side of the bush (2) should behind the surface.
(12) After installing the bush, pin of I49.95 goes through smoothy.
(1)
(4)
(1)
Bushing end to be fitted to boss end
(2)
Bush (506040)
(3)
Bush (506040)
(4)
Bushing end to be fitted to boss end
II-27
WSM U15-3
c. Control levers and linkage
1. Lever strokes and operating forces
Reference on new vehicle
Unit
U15-3
mm
72
N(kgf)
13.7 (1.4)
Play
mm
2>
=
Stroke
mm
72
Stroke
Boom lever
Arm lever
Bucket lever
Swivel lever
Operating force
Operating force
N(kgf)
13.7 (1.4)
Play
mm
2>
=
Stroke
mm
74
N(kgf)
13.7 (1.4)
Play
mm
2>
=
Stroke
mm
74
N(kgf)
13.7 (1.4)
Play
mm
2>
=
Stroke
mm
75
Operating force
Operating force
Operating force
Travel lever
Acceleration lever
Dozer lever
Remarks
Measured at the grip end
Measured 20 mm below the grip end
Measured at the grip end
Measured 20 mm below the grip end
Measured at the grip end
Measured 20 mm below the grip end
Measured at the grip end
Measured 20 mm below the grip end
Measured at the grip end
N(kgf)
15.0 (1.5)
Clearance LH/RH lever
at neutral position.
mm
5
Longitudinal direction
Clearance LH/RH lever
at most forward and
backward position.
mm
10
Longitudinal direction
Clearance LH/RH lever
mm
2~5
N(kgf)
35.0 (3.4)
Operating force
Stroke
Operating force
mm
80
N(kgf)
30.0 (3.1)
Lock lever, up
Operating force
20 (2.0)
Lock lever, down
Operating force
30 (3.0 )
Swing pedal
Operating force
N(kgf)
98.0 (10.0)
Travel high SW
Operating force
N(kgf)
-
II-28
Measured 20 mm below the grip end
Lateral direction
Measured 30 mm below the grip top
Measured at the grip end
Measured 20 mm below the grip end
Measured at the grip end
WSM U15-3
2. Accelerator Lever
Set the automatic release function at more than 1200 rpm by idling.
(17)
(18)
No.
Part Name
(1)
Bracket (Operation, R)
(2)
Lever assembly (Accelerator)
Lever (Accelerator)
Bush
(3)
Lever grip 2
(4)
Plain washer
(5)
Plain washer
(6)
Disc spring
(7)
Nut
(8)
Seal (Lever, blade)
Q'ty
1
1
1
2
1
1
2
2
2
1
No.
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Part Name
Q'ty
Remarks
Bolt
2
Nut
2
Cable (Accelerator)
1
Headed pin
1
Snap pin 6
1
Plain washer
1
Support (Accelerator)
1
Bolt
2
M8 7T
Put them together and assemble beforehand.
Dimensions in the parenthesis show the design values.
Intermediate stroke (115) (on both sides)
119 (17 equally spaced)
Tighten up the hex nuts
(4 locations)
Hexagonal, 12 across
II-29
WSM U15-3
3. Dozer Lever
(6)
No.
(1)
Part Name
Q'ty
Lever assembly (Blade)
1
Lever (Blade)
1
Bush
2
(2)
Grip
1
(3)
Seal (Lever, blade)
1
(4)
Cable (Blade)
1
Plain washer
1
Snap pin
1
(5)
Bracket (Cable, blade)
1
(6)
Dimensions in the parentheses show the design values.
1
II-30
Remarks
WSM U15-3
4. Dozer Cables (Route)
RA221-6573'
Cable (Blade)
Pass the cable behind the welded member
of the bracket (muffler).
Pass the cable along the inside of the
welded member of the swivel frame.
Pass the cable through the 2 holes
of the vertical ribs at the left side of
the swivel frame.
Pass the cable under the control valve.
II-31
WSM U15-3
5. Swing Pedal
(273.5) Reference value
(4)
(7)
(65) Reference value
(8)
(5)
(6)
No.
(1)
Part Name
Q'ty
Lever assembly (Swing)
1
Lever (Swing)
1
Bush
2
(2)
Plain washer
(3)
(4)
No.
(5)
Part Name
Q'ty
Plain washer
1
Snap pin
1
Lever assembly (Swing pedal)
1
1
Lever (Swing pedal)
1
Snap pin
1
Bush
2
Rod (Swing)
1
Pedal
1
Rod end right-hand screw
1
Bolt
1
Nut
2
Plain washer
2
Spring washer
1
Jam nut
1
Plain washer
1
Snap pin
1
(6)
(7)
(8)
Assemble so that the pedal upper side should be
level at neutral.
II-32
WSM U15-3
6. Swing Pedal
(4)
(103) Reference value
(2)
(1)
(3)
No.
(1)
(2)
(3)
Part Name
(5)
Q'ty
Lever assembly (SP pedal)
1
Lever (SP pedal)
1
Bush
2
Pedal
1
Bolt
1
Plain washer
1
Jam nut
1
Rod (SP)
2
Rod end right-hand screw
1
Nut
Spring washer
1
Plain washer
1
Snap pin
(4)
Assemble so that the pedal upper side should be level at neutral.
II-33
WSM U15-3
d. Under carriage components
1. Swivel bearing
(4)
(1)
(2)
(3)
(1) Seal B
(2) S-mark
(3) Seal A
(4) Rp 1/8, for grease nipple
Apply the nylon plug in position.
1) Number of teeth = 73
Details of the grease fitting
2) Backlash = 0.05 ~ 0.35 mm
(0.002 ~ 0.014 inch)
3) P.C.D. = I328.5
4) Induction-harden the inner and outer ring
raceways as well as the tooth flank and
bottom.
Raceway surface hardness: 50 ~ 60 HRC
Tooth flank and bottom surface hardness:
52 ~ 60 HRC
Machine front
(See the Gear Specifications for gear
hardening details.)
5) Inner ring’ “S” marking and outer ring’s
stopper on the soft zone.
When installing the bearing, position the
soft zone where there is the least load.
6) Radial clearance (Measuring load) (0.03
~ 0.25)
Axial clearance (Measuring load) (0.03 ~
0.15)
II-34
Plug outer soft zone
Inner soft zone S - mark
WSM U15-3
2. Truck Frame (Adjustment of Play)
Play adjusting setbolts
at 2 positions on the
machine backside.
Magnified view of adjusting portion
or less
(Set bolt)
No.
Part Name
Q'ty
(1)
Set bolt (RA221-21161)
2
(2)
Nut
1
Play adjusting procedure
1. Tighten the play adjusting setbolts until they reach the left and right sides of the frame.
2. Loosen the play adjusting setbolts by 1/4 turns when they have reached the frame.
3. Lock the adjusting setbolts by nuts.
II-35
WSM U15-3
3. Structure of Track Roller
No.
Part Name
Q'ty
Remarks
(1) Track roller
1
FCD600
(2) Shaft (Track roller)
1
S45C-D
(3) Ball bearing
2
(4) Bracket (1)
1
FCD450-10
(5) Bracket (2)
1
FCD450-10
(6) O-ring
2
(7) Seal (Floating)
2
(8) Shaft circlip
2
(9) Plug (R1/8)
1
(1) Packing, NBR
(2) Spring
(3) Reinforce, ring
(4) Sleeve
(5) Fill grease
Lub oil :Engine oil SAE #30CD class 40 cc
Plug :Apply screw lock agent and tightening
torque, 0.8 kg·m
Notes:
1. Fill the bearing with oil (40 cm3).
2. Use Engine genuine oil SAE30 class CD or equivalent.
3. Use care not to confuse the sides of the shaft circlip.
(Rolled-over side to be fitted in the groove is inner side, while the burred (sharp) side is the outer side)
4. The roller should be turned smoothly after it has been assembled completely.
5. Dimensions of assembling jigs for seal etc. and the assembling procedure are equivalent to those of
RA211-2170'.
II-36
WSM U15-3
4. Tension Device
Both iron and rubber springs can be used compatively.
No.
Part Name
Q'ty
(1)
Idler assembly
2
(2)
Cylinder assembly (Left)
1
Cylinder assembly (Right)
1
Nipple (Grease cylinder)
2
(3)
In the case of rubber roller, adjust it so that the
joint mark (f) should come to the upper center position (as shown in the figure below).
Seam
II-37
WSM U15-3
5. Idler and tension spring
[mm]
473
23
6
L
(1) Support 1
(5) Floating seal
(9) Wire
(13) Retainer
(2) Support 2
(6) Bushing
(10) Plug, R 1/8
(14) Nut
(3) shaft
(7) O-ring
(11) Yoke
(15) Split pin
(4) Idler
(8) Spring pin
(12) Spring
(16) Bolt
OK
NO
1) Pre-set length of spring : L=130 mm (5.12 inch)
2) Bolt(16) tightening torque : 77.5 ~ 90.2 N·m
(7.9 ~ 9.2 kgf·m)
3) Lub oil : Engine oil SAE30 CD. Apply screw lock agent.
(Locktite 271).
30cc
(Spring roll pin direction)
II-38
WSM U15-3
6. Idler and sprocket
(A) Reference on new vehicle
(B) Allowable limit
Unit
U15-3
Remarks
202/196
Rubber Crawler
196/190
Steel Crawler
Idler
(a) Outside diameter
(A)/(B)
mm
(b) Guide width
(A)/(B)
mm
27/23
(c) Idler width
(A)/(B)
mm
60/55
Sprocket
(d) Outside diameter
(A)/(B)
mm
290/284
Sprocket
(e) Wheel width
(A)/(B)
mm
23/18
(c)
(e)
(a)
(d)
(b)
II-39
WSM U15-3
7. Rubber track
Spec items
Type
230 x 35 x 96
Lug height
23.0 mm
Iron core pitch
96.0 mm
Circunference
3360 ± 10 mm
Number of steel cords
48 ± 4
Steel cords lap length
260 mm
Steel cords strength
3.92 KN (400 kgf) or more
Thickness of crawler main part
23.0 mm
Ditto joint parts
26.5 mm
Core metal
FCD450 (Equiv.)
Number of core metal (Links)
35
II-40
WSM U15-3
8. Track shoe
(A) Reference on new machine
(B) Allowable limit
Crawler width
Unit
U15-3
360/370
(a)
Length (A)/(B)
mm
(b)
Wheel tread height (A)/(B)
mm
56/51
(c)
Collar outside diameter
mm
22/20.5
(d)
Collar inside diameter
mm
14/16
(e)
Master pin outside diameter
mm
14/12.5
Grouser height (A)/(B)
mm
16.5/8
Crawler width x No. of links
mm
230 x 37
Crawler tension
mm
25 ~ 30
(f)
(D)
Roller outer collar to plate
(d)
(b)
(e)
(For 4 kinks)
Code
Including plate
(c)
(f)
(a)
Remarks
(B)
(A)
Wire center line
(C)
II-41
(D)
WSM U15-3
9. Iron track shoe
(Link)
(Bushing)
Over 25
(when assembled)
(Bushing)
(Link)
(Pin)
(Inside)
(Outside)
(Common for both ends)
(Inside)
(Outside)
(Common for both ends)
Rubber pad
Tighten hex nuts to torque of 70-100 N·m.
II-42
WSM U15-3
9. Dozer
Unit
U15-3
Remarks
(1)
Pin outside dia. - Length
mm
I30-102.5
(2)
Outside diameter - Length
mm
I30-84.5
(3)
Outside diameter - Length
mm
I30-84.5
(4)
Outside diameter - Length
mm
I30-95
Track cylinder mounting pin
(5)
Outside diameter - Length
mm
I25-133
Extension blade mounting pin
A
Width
mm
1244/990
B
Height
mm
261
C
Length
mm
710
D
Tip wear thickness
mm
t9
E
Distance between supports
mm
434
Movement above ground/below ground
mm
263/182
Dozer capacity
m
3
0.067
II-43
w/o Extention blade
WSM U15-3
C.Engine
a. Main specification
Main specifications of the D782-BH-4 high-speed diesel engine
Type
4-cycle, vertical, 3-cylinder, water-cooled diesel engine
No. of cylinders - Cylinder bore x Stroke
mm
3 - I67 x L73.6
Piston displacement
I
0.778
Rated net output/rpm
kW / rpm
9.6 (13.1PS) / 2300
Maximum engine speed
rpm
Engine idling speed
rpm
2600 >
=
1200 +150 / -0
Type of combustion chamber
E-TVCS
Type of fuel injection pump
Bosch MD mini-pump
Type of governor
Centrifugal mechanical governor
Type of injection nozzle
DN4PD52 mini-nozzle
Fuel injection timing
deg
BTDC14 ~ 16 (15p ~ 17p : pressure feed type)
Fuel injection pressure
MPa
13.7 (140 kgf/cm2)
Compression ratio
24
Cooling system
Pressure radiator type, 0.088 MPa (0.9 kgf/cm2)
Forced circulation by cooling water pump
Starting system
V, kW
Self-starter (12,1.2)
Charging system
V, W
Alternator type (12,480)
Fuel used
Diesel light oil
Battery used
Weight
Application
50B24 R or equivalent
kg
About 64
Mini-excavator U15-3
II-44
WSM U15-3
b. Performance curves
II-45
WSM U15-3
c. Engine electrical data
Unit
U15-3
Fuel system
Bosch MD (NC), Mini-Pump
Injection P type
Fuel tank capacity
Fuel consumption rate
Fuel consumption
L
18
g/kWh
286
L/hr
19.3 (2.0)
Calculated 0.85,
0.6(actual measurement)
DN4PD62
Denso
Type of nozzle
Injection pressure
Electrical system
Charging generator
Denso-specified type
2
Mpa (kgf/cm )
13.8 ~ 14.7 (140 ~ 150)
V-W
12-480
Part code/ electricals
V10505-B-AEBI-1
Charging current
A
40
Regulator-adjusted voltage
V
14.2 ~ 14.8
Type of battery
5-hour rated capacity
55B24R
Ah
1.28 ± 0.01
V-W
Yuasa
20 °C
12-1.2
Maker-specified type
Glow plug
5000 rpm, 10A, 25 °C
36
Electrolyte specific gravity
Self-strat motor
Remarks
228000-0951
1.5 ± 0.15
(DC11V applied for 6 seconds)
II-46
Denso
Cold resistance 0.9 :
WSM U15-3
d. Engine servicing data
(A) Reference on new vehicle
(B) Allowable limit
Unit
U15-3
Engine model
D782-BH-4
Cylinder head distortion limit
mm
Top clearance
Cylinder bore
(A)/(B)
Cylinder liner wear limit
Clearance with piston ring
groove
Piston ring fitting clearance
0.05
mm
0.50 ~ 0.65
mm
67.000 ~ 67.019 / +0.15
mm
+0.15
Oil ring
(A)/(B)
mm
0.02 ~ 0.06 / 0.15
Compression ring
(A)/(B)
mm
0.085 ~ 0.115 / 0.15
Oil ring
(A)/(B)
mm
0.15 ~ 0.30 / 1.2
Compression ring
(A)/(B)
mm
0.15 ~ 0.30 / 1.2
Top
Compression ring
(A)/(B)
mm
0.30 ~ 0.45 / 1.2
Second
mm
I67
(A)/(B)
mm
0.041 ~ 0.124 / 0.15
(A)/(B)
(kgf/cm2)
Piston outside diameter
Timing gear backlash
Compression pressure
Mpa
3.0 ~ 3.4 (31~35) / 2.5 (25)
%
10 >
=
Crank pin out. diameter
mm
33.959 ~ 33.975
Side clearance
mm
0.15 ~ 0.31/0.5
Valve guide inside diameter
mm
6.010 ~ 6.025
Valve stem outside diameter
mm
5.968 ~ 5.980
Difference among compression pressure cylinders
Crankshaft
Clearance between valve stem and valve guide
Pressure at radiator water pressure test
Cap opening valve pressure
Thermostat
Remarks
(A)/(B)
(A)/(B)
mm
0.030 ~ 0.057 / 0.1
2)
kPa (kgf/cm
kPa
Working temperature
(kgf/cm2)
°C
II-47
137 (1.4)
88 (0.9) o 59 (0.6)
69.5 ~ 72.5
In 10 seconds
71°C
WSM U15-3
e. Engine Mount
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(1)
Vibration-proof rubber
(2)
Cover (Rubber sheet)
(3)
Rounded part
(4)
Bracket (Engine, rear)
(5)
Stopper (Engine)
(6)
Bracket (Engine, rear)
(7)
Vibration-proof rubber
II-48
WSM U15-3
f. Fuel System
1. Fuel System (1)
Type of pipe clip
Route of fuel hose
(11)
(10)
(12)
* mark
14911-42751
# mark
14971-42751
(13)
(14)
(15)
(16)
(17)
Can be operated for 8 hours
by 18 liters of fuel oil.
(18)
Details of A
(19)
(20)
No.
Q'ty
Tube length (mm)
Fuel tube
1
L = 1280
(10) Pump assembly (Fuel)
Tube (1)
1
L = 1150
(11) Pipe joint (T-S)
(2)
Fuel tube
1
L = 220
(12) T-pipe joint
(3)
Fuel tube
1
L = 520
(13) Engine fuel injection pump
Tube (420)
1
L = 420
(14) Engine fuel return port
(4)
Fuel tube
1
L = 280
(15) Joint (Fuel drain)
(5)
Fuel tube
1
L = 140
(16) Fuel tank assembly
(6)
Fuel tube
1
L = 140
(17) Filter assembly (Fuel)
(7)
Fuel tube
1
L = 150
(18) Pump assembly (Fuel)
(8)
Fuel tube
1
L = 550
(19) Straight pipe joint
Tube (470)
1
L = 470
(20) Fuel pipe assembly
Fuel tube
1
L = 80
(1)
(9)
Part Name
II-49
WSM U15-3
2. Fuel System (2)
(3)
(9)
(1)
(2)
(10)
(4)
(7)
(6)
(11)
(5)
(8)
(12)
(13)
(16)
(17)
(14)
(18)
(15)
(1)
Water separator
(10) Engine fuel return port
(2)
Filter assembly (Fuel)
(11) Pass it through this hole.
(3)
Pump assembly (Fuel)
(12) Fuel tank upper part
(4)
Fuel tank (Upper)
(13) Clamp
(5)
Fuel tank (Lower)
(14) Pass it under the cover (tank, return).
(6)
Clamp
(15) Fuel tank lower part
(7)
Water separator
(16) Clamp
(8)
Fuel tank
(17) Pass it over the dozer cable.
(9)
Engine fuel injection pump
(18) Pass it along inner side of fuel tank L member.
II-50
WSM U15-3
3. Fuel tank
(7)
(8)
(9)
(1)
Fuel tank
(2)
Cap assembly (fuel)
S
Cap (fuel)
Sponge
Packing
(3)
Fuel filter assembly
Fuel filter
Packing
(4)
Sensor (fuel)
(5)
Machine screw with spring
(6)
Fuel level gauge assembly
(7)
Tightening torque
(8)
Fuel level 15.2L
(9)
Fuel level 2.2L
II-51
Note:
No leak is allowed under air pressure of 29.4 kPa
(0.3 kg/cm2) in following conditions.
Fluid in use: Light oil
Ambient operating temperature: -17 to 70 °C
WSM U15-3
g. Cooling system
1. Structure
Clamp
Cap (pressure)
Cap
Hole
Through
II-52
WSM U15-3
2. Radiator specifications
Diy
Performance specifications
Heading
Condition
Air flow
Vater flow
Temp difference
m/s
8
L/min
40
°C
60
kW
20.7 (17853 kcal/h)
Air resisyance
Pa
132.3 (13.5 mmAg)
Water resistance
kPa
Press
kPa
Vacuum
kPa
Test pressure
Vibration durability
kPa
Acceleration
(
mmHg)
147 (1.5 kgf/cm2)
147 (1.5 kgf/cm2)
6G
Direct
Up/down
Cycle
22.3 Hz
Cycle
10°
Core type
Core size
CF29-2
Wide
mm
351
Height
mm
325
Thickness
mm
36
mm
4.5/2
Fin
m2
3.78
Tube
m2
0.89
Total
m2
4.67
Front area
m2
0.132
Water passage area
cm2
12.7
L
1.3
kar
2.4
Fin pitch
Radiation area
Water duantity
Dry weight
Surface treatment
Remarks
(Conventional unit)
Radiator capacity
Valve opening pressure
Structural specifications
Unit
Louver-less
II-53
WSM U15-3
(Case outer dia.)
(Element inner dia.)
h. Air cleaner
129 (Element draw-out allowance)
55 (Cap draw-out allowance)
Item
Specifications
Unit
Standard
Conditions
Air flow resistance
kPa
(mmAg)
Below 2.747
(below 280)
Cleaning efficiency
%
Rated air flow rate: 2.0 m3/min.
Test dust: JIS Z8901, Class 8 powder
Dust concentration: 1 g/m3
Air flow resistance: 2.94 kPa (300 mmAg)
Full life for an increase
Dust containment
Filtering area
Initial
Full life
Above 99
Above 99.9
g
Above 50
m2
0.45 (effective)
Other conditions
As per JIS D1612
Heat-resistant temperature
-30 °C ~ 90°C
II-54
WSM U15-3
D.Hydraulic system
a. Main pump
1. Outer view
(1)
(2)
(4)
(3)
(4)
(5)
(4)
(4)
(1) Suction port
(2) 4 - M10
(3) Oil inlet
(4) Discharge port
(5) Rotation direction, Clockwise
Two Point Pitch
2. Pump coupling
II-55
WSM U15-3
3. Pump hose adapter
P1 and P2 are common.
No.
Part Name
Q'ty
(1)
Pump assembly (Piston)
1
(2)
Pipe joint (L, G3/8 - G3/8)
1
(3)
Pipe joint (L, G3/8 - G3/8)
1
(4)
Pipe joint (L, G3/8 - G3/8)
1
(5)
Pipe joint (L, G3/8 - G1/4)
1
(6)
O-ring
1
(7)
Plug
4
(8)
Flange (Suction)
1
(9)
Bolt
4
Remarks
R1/8 P1, P2, P3, P4
For 3/8
M10 x 1.5 7T
(10)
O-ring
1
S35
(11)
Bolt
2
M12 x 1.25 7T
II-56
WSM U15-3
4. structure
(1) Body S
(10) Swash plate
(21) Rod G
(35) Snap ring
(62) Seal washer
(2) Body H
(11) Needle
(24) Retainer
(39) O - ring
(65) Gear pump
(3) Shaft
(12) Swing pin
(25) Stopper pin
(40) O - ring
(66) Coupling
(4) Cylinder barrel
(13) Packin
(27) Pin
(44) Hex bolt
(67) Collar
(5) Valve plate
(14) Spring C
(30) Ball bearing
(49) Hex plug
(68) Bolt
(6) Piston
(15) Spring T
(31) Needle bearing
(51) Plug
(69) O - ring
(7) Shoe
(18) Spring holder
(32) Oil seal
(56) Spring pin
(70) Washer
(8) Shoe holder
(19) Spring guide
(33) Belleville spring
(60) Hex screw
(71) O - ring
(9) Barrel holder
(20) Pin
(34) Snap ring
(61) Nut
(72) O - ring
II-57
WSM U15-3
Discharge: q1=q2 (cc/rev)
5. P-Q performance curve
Pressure: P1+P2 (kgf/cm2)
Test condition
Remark
Oil
ISOVG46
3.44 kgf·m
Oil temp
50 ± 5 °C
(at P3=5 kgf/cm2)
RPM
2300 rpm
3.44 kgf·m
Direction
Clockwise
q3
4.5 cc/rev
q4
2.7 cc/rev
P4
40 kgf/cm2
Pump intake torque
(at P3=190 kgf/cm2)
II-58
WSM U15-3
6. Pump Specifications, Type : PVD-00B-14P-5G3-4552A, code NO. : RA221-6111
1.Capacity
P1, P2: 7.2 x 2 cm3/rev
P3: 4.5 cm3/rev
2.Pressure
P1, P2: 21.6 MPa
P3: 18.6 MPa
at bench
(220
kgf/cm2
P4: 2.7 cm3/rev
P4: 3.9 MPa
2
)
(40 kgf/cm2)
(190 kgf/cm )
3.Speed
Rated Speed: 2300 min-1
Max. Speed: 2600 min-1
4.Suction pressure
-0.02 ~ +0.04 MPa (-0.2 ~ +0.4 kgf/cm2)
5.Oil
ISO VG 32, 46, 68 Anti - Wear hydraulic fluid
6.Oil temp
Temp range : -20 ~ +100 °C
7.Control
Constant torque control
8.Torque
at P3= 0.49 MPa T=37.0 N·m
at P3= 20.6 MPa T=39.0 N·m
9.Pump discharge
P1, P2: 16.56 l/min x 2
(4.37 us gal/min)
Rotation Direction: Clockwise
P3: 10.35 l/min
(2.73 us gal/min)
P4: 6.21 l/min
(1.64 us gal/min)
7. Discharge rate
Unit
U15-3
P1/P2 maker-specified type
Remarks
PVD-00B-14P-5G3-4552A(F)
Pp maker-specified type
Service port flow rate
L/min
27/2)
Rated load pressure
P1/P2
Mpa(kgf/cm
21.6 (220)
Rated load pressure
P3/Pp
Mpa(kgf/cm2)
18.6(190)
Theoretical discharge rate
P1/P2/P3/Pp
cc/rev
7.2/7.2/4.5/2.7
Theoretical discharge rate at rated
output
P1/P2
L/min
16.6/16.6
P3/Pp
L/min
10.4/6.2
P1/P2
L/min
14.1/14.1
P3/Pp
L/min
8.8/5.3
P1/P2
L/min
13.3/13.3
P3/Pp
L/min
8.3/5.0
85% of theoretical discharge rate
80% of theoretical discharge rate
II-59
without load / with load
WSM U15-3
8. Function
1) Outline
Discharge groove P2
This compact, lightweight hydraulic pump has a
mechanism that provides for the performance of
two variable pumps. Yet it needs as small a space
as for just one conventional pump. This pump is
also equipped with a pilot gear pump.
The pump features a constant horsepower control
function for making most of the engine power. The
greater the pump load becomes, the lesser the
discharge rate becomes. As a result, when the
pump discharge pressures P1 and P2 have risen
and the resultant force of the piston higher, the
swash plate exceeds the spring force and tilts
from the oscillating center of the oscillating pin. In
this way, the discharge rate can be kept low.
Suction groove (1)
Suction groove (2)
Discharge groove P1
(a) Valve plate
Discharge groove
P1 and opening
Discharge groove
P2 and opening
2) Function
An even number of pistons are used in this swash
plate variable piston pump. This is to produce the
performance of two same-capacity pumps in one
pump casing.
Conventional valve plates have one suction
groove and one discharge groove, as shown in
Fig. 4. The new system, on the other hand, is provided with two suction grooves and two discharge
grooves, as shown in Fig. 3. The discharge
grooves P1 and P2 are located in the outer and
inner sides, respectively. Every other piston chamber of cylinder barrel gets open to either of these
discharge grooves in the valve plate. In other
words, both the inner and outer suction grooves
behave just the same way, whereas the inner and
outer discharge grooves work independently from
each other.
In this design with an even number of pistons, the
same number of pistons gets open outward and
inward of the valve plate. Because all the pistons
are of the same diameter, located in a same-pitch
circle and slide over the same swash plate, the
discharge rates of the discharge grooves P1 and
P2 are the same.
There is another advantage in employing just a
single swash plate. Even though the swash plates
tilting angle varies according to the variable control, the discharge rates of P1 and P2 ports change
accordingly and equally.
(b) Cylinder barrel
Fig. 3 Operating principle
Suction groove
Discharge groove
(a) Valve plate
(b) Cylinder barrel
Fig. 4 Conventional swash plate piston pump
II-60
WSM U15-3
b. Control valve
1. Relife valve specifications
Type of valve: CP CV NSC10-KP11-2
Manufacturer: Nabco
1) Bench set pressure specifications
No.
(1)
Mpa (kgf/cm2)
Product name
Main relief valve
P1 · P2 : 21.6
+1.0
+1.0
-0.5
Remarks
MRV-P1 · MRV-P2 · MRV-P3
+10
(220 -5 )
+10
P3 : 18.6 -0.5 (190 -5 )
(2)
Unti-void valve
(3)
Port relief valve
17.7 (180)
At swing cylinder rod ACV-B1
At boom cylinder bottom CRV-B8 b1
(4)
Port relief valve
27.5 (280)
At boom cylinder rod CRV-b2
(5)
Port relief valve
23.5 (240)
Arm & bucket CRV-5A, CRV-B5, CRV-B9
(6)
2) List of pressures
Unit
U15-3
Remarks
Mpa(kgf/cm2)
(230 ± 10)
Main relief valve
Machine set pressure
P
P2
P3
Pp
Working part
Bucket
2)
Bench set pressure
Mpa(kgf/cm
Machine set pressure
Mpa(kgf/cm2)
Working part
+10
21.6 (220 -5 )
(225 ± 10)
Arm
2)
Bench set pressure
Mpa(kgf/cm
Machine set pressure
Mpa(kgf/cm2)
Working part
+10
21.6 (220 -5 )
(200 ± 10)
Dozer
Bench set pressure
Mpa (kgf/cm2)
18.6 (190 -5 )
Machine set pressure
Mpa (kgf/cm2)
(45 ± 5)
Working part
+10
-
Bench set pressure
Mpa (kgf/cm2)
3.9 (40 -0 )
Pilot secondary pressure
Mpa (kgf/cm2)
21.5 (22)
Boom rod/bottom (b1, b2)
Mpa (kgf/cm2)
27.5 (280)/17.7 (180)
Arm rod, bottom, bucket bottom (b3, b4, b5)
Mpa (kgf/cm2)
23.5 (240)
Swivel (C1)
Mpa (kgf/cm2)
13.2 (135)
Boom bottom (b1)
Mpa (kgf/cm2)
Boom rod (b2)
Mpa (kgf/cm2)
Arm rod, bottom, bucket bottom
Mpa (kgf/cm2)
Swivel (C1)
Mpa (kgf/cm2)
+2
On the machine
At bench test
Overload relief valve
II-61
Bucket dump
WSM U15-3
2. Control Valve (1)
No.
(1)
Part Name
Control valve, assembly
Q'ty
No.
1
Part Name
(17) Elbow pipe joint (G3/8-13)
Q'ty
2
(2)
Bolt
4
(18) Straight pipe joint (3-3-35)
1
(3)
Shouldered elbow
2
(19) T-pipe joint (F2)
2
(4)
Pipe joint (L. G1/4-G1/4)
3
(20) Pipe joint (Bushing G1/4)
1
(5)
Pipe joint (L. G1/8-G1/4)
5
(21) Pipe joint (S, G3/8-G3/8)
1
(6)
Pipe joint (L. G1/8-G1/4)
3
(22) Pipe joint (S, G1/8-G1/4)
3
(7)
Pipe joint (S. G1/4-G1/4)
3
(23) Pipe joint (S, G3/8-G3/8)
1
(8)
Pipe joint (S. G3/8-G3/4)
2
(24) Pipe joint (L, G3/8-G3/8)
6
(9)
Pipe joint (L. G1/2-14)
1
(25) Pipe joint (S, G1/4-G1/4)
3
(10) Valve, assembly (Check)
1
(26) Pipe joint (S, G2-G2)
1
(11) Stay
1
(27) Pipe joint (S, G1/4-G1/4)
1
(12) Poppet
1
(28) Pipe joint (S, G3/8-G3/8)
1
(13) Spring
1
(29) O-ring
13
(14) Washer
1
(30) O-ring
14
(15) Hole circlip
1
(31) O-ring
8
(16) Pipe joint (L, G1/4-G1/4)
10
Bucket
Travel Right
Swivel
Boom
Arm
Blade
Travel Left
Service
Swing
II-62
WSM U15-3
3. Control Valve (2)
Front
Rear
II-63
Check valve cover
II-64
Swivel
Confluence
Service
Arm
Setting
Travel
ID marking
provided
Travel
Boom
(A4 and B4 are plugs.)
Plug PF 1/4
(2 locations) Setting
Supply
"Side E"
Pump port
"Side E"
Actuator port
Tank port
Setting
"Side E"
Thread depth 12
Actuator port
ID marking
provided
Pilot port
Bucket Discharge
Setting
Tightening torque
T=13.7 14.7N m
{1.4 1.5kgf m}
Pilot pressure
Unload confluence valve
4 mm stroke
6 6 travel left & right
Dozer
Setting
"Side E"
ID marking
provided
Setting
Stroke Swing, dozer, service,
Swing
Check valve C
Check valve spring
Tank port
Stamp product code (214749-01)
and serial No. on nameplate.
Caution:
No wrong
assembling Plug PF 3/8 (2 locations)
WSM U15-3
4.Control Valve (3)
Stroke (mm)
WSM U15-3
5. Control Valve (4)
Swing
Dozer
Swivel
Confluence
Service
Arm
Travel left
Supply
Travel right
Boom
Bucket
Discharge
Valve specifications
• Rated pressure: 22.6 MPa {230 kgf/cm2}
(Under condition of 4 million boost-up actions)
• Rated flow rate: 15 L/min
• Relief valve set pressure level
: 4.30 ~ 24.5 MPa {50 ~ 250 kgf/cm2}
• Overload valve set pressure level
: 4.30 ~ 24.5 MPa {50 ~ 250 kgf/cm2}
• Spool length spring force (manual control)
[Travel] At neutral:
98.1 N {10 kgf}
At stroke end: 131 N {13.4 kgf}
[Others] At neutral:
83.4 N {8.5 kgf}
At stroke end: 103 N {10.5 kgf}
• Maximum pilot operating pressure
: 4.90 MPa {50 kgf/cm2}
• Allowable tank pressure
: Below 0.98 MPa {10 kgf/cm2}
• Oil in use: General mineral hydraulic oil
• Operating oil temperature range
: -20 ~ +90 °C (100 °C )
• Oil contamination level: Within Class NAS9
Operating conditions
• Relief valve set pressure
MPa {218 +50 kgf/cm2 at 16.6 L/min}
P1·P2: 21.4 +0.49
0
MPa {188 +50 kgf/cm2 at 10.4 L/min}
P3: 18.4 +0.49
0
• Operating flow rate
P1·P2: 16.6 L/min
P3: 10.4 L/min
• Service port flow rate (P2+P3): 27.0 L/min
• Overload valve set pressure
MPa {238 +50 kgf/cm2 at 5 L/min}
A5·B5·B9: 23.3 +0.49
0
MPa {278 +50 kgf/cm2 at 5 L/min}
A8: 27.3 +0.49
0
MPa {178 +50 kgf/cm2 at 5 L/min}
B8: 17.5 +0.49
0
• Spool leak amount
Leak amount from A1, A8, B1 to i: Below 3 cm3/min
Leak amount from others to i: Below 7 cm3/min
(* 9.8 MPa {100 kgf/cm2}) (Oil viscosity 37 cSt)
• Spool operating pressure with pilot on (See Characteristics Chart.)
: 0.37 ~ 1.96 MPa {3.6 ~ 20 kgf/cm2}
Po port pilot pressure: 3.50 MPa {35.7 kgf/cm2}
• Operating oil temperature range
: -20 ~ +90 °C (100 °C )
Figures in { } are just for your reference.
II-65
WSM U15-3
6. Control valve sectional view
1) Swing section : A-A, RB238-70011
4) Confluence section : D-D, RA221-70911
Setting: 18.4
+0.49
0
MPa {188
+5
0
kgf/cm2}
at 10.4 L/min
Tightening torque T= 3.92 N·m {T= 0.4 kgf·m}
Tightening torque 39.2 N·m
{4.0 kgf·m}
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
2) Dozer section : B-B, RA221-70021
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
5) Service port section : E-E, RA221-70041
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
3) Dozer section : C-C, RA221-70031
6)Arm section : F-F, RA221-70051
Setting: 23.3 0 MPa {238 0 kgf/cm2}
at 5 L/min
Tightening torque T= 3.92 N·m {T= 0.4 kgf·m}
+0.49
Setting: 23.3
+0.49
0
MPa {238
+5
0
kgf/cm2}
at 5 L/min
Tightening torque T= 3.92 N·m {T= 0.4 kgf·m}
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
II-66
+5
WSM U15-3
7) Travel R section : G-G, RA221-70061
10)Boom section : J-J, RA221-70071
Setting: 17.5
Setting: 27.3
+0.49
0
MPa {278
+5
0
+0.49
0
MPa {178
+5
0
kgf/cm2}
at 5 L/min
Tightening torque T= 39.2 N·m {T= 4.0 kgf·m}
kgf/cm2}
at 5 L/min
Tightening torque T= 3.92 N·m {T= 0.4 kgf·m}
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
8) Inlet section : H-H, RB238-70941
11) Bucket section : K-K, RB238-70081
Setting: 21.4 0 MPa {218 0 kgf/cm2}
at 18.8 L/min
Tightening torque T= 39.2 N·m {T= 4.0 kgf·m}
+0.49
+5
Setting: 23.3
+0.49
+5
+0.49
0
MPa {238
+5
0
kgf/cm2}
at 5 L/min
Tightening torque T= 3.92 N·m {T= 0.4 kgf·m}
Setting: 21.4 0 MPa {218 0 kgf/cm2}
at 18.8 L/min
Tightening torque T= 39.2 N·m {T= 4.0 kgf·m}
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
12)Outlet : L-L, RB238-70971
9) Travel L section : I-I, RA221-70091
Drilled ID hole
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}
Apply Loctite #242 to avoid looseness.
II-67
WSM U15-3
7. Inner sectional view
Tightening torque T= 13.7 ~ 14.7 N·m
{T= 1.4 ~ 1.5 kgf·m}
II-68
WSM U15-3
c. Swivel motor
1. Swivel system specifications
(A) Reference on new vehicle
Unit
Maker
U15-3
Eaton Fluid Power Ltd.
Type
2-200DOS-E3888
Capacity
cc/rev
195
Mpa
(kgf/cm2)
13.2
(135)
Locked
L/min
1.0
Rotating
Brake V
Pressure
Drain spec.
Remarks
L/min
0.5
Swivel speed
rpm
8.7 ± 0.9
Swivel speed (Three times rotation)
sec.
20.8
Swivel startup
sec.
2.1 ± 0.2
Front horizontal, heaped, engine at
max. rpm, 0 to 90° swivel
Swivel block performance
mm/min
120
Front horizontal, heaped, 15°, engine
at stop
Allowable slope angle for swivel
deg. (kg)
18 =
>
Front horizontal, heaped, engine at
max. rpm
mm
73+20
Play at bucket tip
(How to measure the play at bucket tip)
1. Dump the arm and crowd the bucket. Position the bucket 1 m above the ground.
2. Push the bucket tip with a force of 5 kgf or so. Take this position as "0", and push the bucket tip in the opposite direction with
a force of 30 kgf.
3. Measure the displacement of the bucket tip.
4. Take the above steps more than 5 times, but without swing.
(How to measure the swivel block performance)
1. The swivel block performance must be checked with a hydraulic oil temperature of 45 ± 5°C on a 15-degree slope.
II-69
WSM U15-3
2. Component of swivel motor
No.
Part Name
010
Assy motor,swivel
020
030
Q'ty
Remarks
1
Include A ~ R and 020 ~ 220
Assy gear
1
Include A ~ D and 030 ~ 060
Bearing,ball
1
040
Bearing,ball
1
050
Plug
1
060
Retainer
1
070
Plate
1
080
Plate,valve
1
090
Valve
1
100
Plate
1
110
Spring
2
120
Pin
2
130
Drive
1
140
Gear,roller
1
150
Valve,drive
1
160
Assy valve
1
170
Ball
2
180
Plug
2
190
Spring
2
200
Plug
3
210
Bolt
4
220
Kit seal
1
230
Bolt
4
Include k, 170, 180, 190, 200
Include C ~ Q
II-70
WSM U15-3
3. Cross-sectional View of Swivel Motor
No.
1
2
3
4
5
{6
7
{8
{9
10
{11
12
{13
14
15
16
{17
18
19
20
21
22
23
24
25
Part Name
Q'ty
Bearing housing
Pinion gear
Ball bearing
Ball bearing
Piug
X-ring
1
1
1
1
1
1
Retaining ring
O-ring
1
1
Remarks
No.
26
27
28
{ 29
30
31
6308 LLU
6207
R1/8
AS568-041
32
33
Q'ty
Remarks
Relief cartridge
Steel ball
Plug
O-ring
Spring
Prug
Part Name
(2)
(2)
(2)
(2)
(2)
(3)
Include 32 ~ 44
Cartridge
Screw guide
(2)
(2)
Shaft face seal
1
34
O-ring
(2)
Wear plate
O-ring
1
2
AS568-041
35
36
Needle valve
Spring washer
(2)
(2)
Valve plate
O-ring
1
1
AS568-038
37
38
Spring presser
Orifice plate
(2)
(2)
Valve
Balancing plate
Spring
Inner face seal
1
1
2
1
39
{ 40
{ 41
42
Spring
O-ring
O-ring
Hexagon socket setscrew
(2)
(2)
(2)
(2)
2
1
1
1
3
1
1
(1)
43
{ 44
45
46
47
Hexagon nut
O-ring
Nameplate
Rivet
Hexagon bolt
(2)
(2)
1
2
4
Pin
Outer face seal
2K drive
Gear roller
Valve drive
O-ring
Valve housing assembly
Valve housing
AS568-011
Include 25 ~ 44
{
II-71
Pinion gear assembly
Seal kit
1BP14
R1/8
1BP16
1BP18
1BP5
1BP12
Include 1 ~ 8
Include { items
WSM U15-3
4. Swivel Motor fittings
The outer diameter is same as that of current model. Relief pressure differs.
Control valve Front (A3)
Control valve Rear (B3)
Control valve Rear (T1)
Mounting direction
Machine front side
No.
Part Name
Q'ty
Remarks
(1)
Motor assembly (Swivel)
1
(2)
Pipe joint (S, G3/8-G1/4)
1
A
(3)
Pipe joint (L, G1/4-G1/4)
1
For 3/8 A
(4)
Pipe joint (L, G3/8-G1/4)
1
B
(5)
Pipe joint (S, G3/8-13)
1
T
O-ring
1
T
(6)
Pipe joint (L, G3/8-G3/8)
1
For 3/8 A, B
(7)
Bolt
4
M14 x 1.5 T
II-72
II-73
Outlet
A
B
Inlet
B
A
Counterclockwise
Clockwise
Turning direction
Turning direction (when viewed from output side)
2 x G3/8 lube oil filler/discharge port
9 x M10 x 1.5 (through)
(9 equally spaced)
Hydraulic circuit
G1/8 (PP port)
18 countersunk
Stop plug (2 locations right and left)
8 x M10 x 1.5 (through)
(8 equally spaced)
2 x G3/8 (A and B ports)
28 countersunk
2 x G1/4 (Drain port)
24 countersunk
WSM U15-3
d. Travel motor (Wheel motor)
1. Overview (RA221-61291)
WSM U15-3
2. Specifications
(1) Motor type ID mark
PHV - 120 - 37 - 9 - 8411A
R & D No.
Paint class
Reduction ratio
Nominal output torque
NACHI travel motor PHV series
(2) Motor specifications
Max. theoretical output torque
Gear box
Motor
Others
1st/2nd
1443 N·m (147 kgf·m) / 730N·m (75 kgf·m)
Max. output speed
39.4 / 77.4 min-1 at 16.6 l/min
Reduction ratio
1 / 36.96
Displacement
11.36 / 5.79 cm3/rev
Max. pressure
21.6 MPa (220 kgf/cm2)
Max. speed
1461 / 2867 min-1
Max oil flow
16.6 l/min
Hi - Low change pressure
0.5 MPa (5 kgf/cm2)
Equivalent capacity for one turn of motor assy.
419.9 / 214.0 cm3/rev
Operating oil
ISO - VG46 or equivalent
Temperature
-20 ~ 100 °C
Filtering
10 Pm
Gear box oil
SAE -90 (API, Class : GL5), Gear oil
Gear box oil amount
250 cm3
Weight
17 kg
II-74
WSM U15-3
(3) Travel performance specifications
Unit
Type
U15-3
Remark
PHV-120-37-9-8411A
>
Climbing performance
% / deg.
58 / 30 =
Maximum traction force
KN(kgf)
12.8 ± 1.3 (1255 ± 126)
mm / 10m
>
300 =
km/h
2.2 ± 0.2 / 4.0 ± 0.4
First speed
sec / 10m
16.1
Rubber crawler
Second speed
sec / 10m
8.8
Rubber crawler
Crawler speed
sec / turn
5.7 / 3.0
Travel straightness
mm / 10m
600 >
=
Locked
l / min
4.0 >
Rotating
l / min
0.5 >
Locked
cc / min
90 ~ 180 / 180 ~ 420
1F / 2F actual measurement sample data
Rotating
cc / min
5 ~ 20 / 20 ~ 45
1F / 2F actual measurement sample data
Travel block performance
Travel speed
Drain amount
Drain
(machine body raised)
1.
2.
3.
1F
Travel posture, 20°, 10 minutes, engine at
stop, bucket : empty
1F / 2F Rubber crawler
1F / 2F
Travel position, 10 minutes, engine at
max. rpm
0:1 temp. 50 °C ± 5,
For one minutes
New machine’s drain specifications
Measurement conditions
(1) Hydraulic oil temperature: 50 ± 5°C, Machine front at travel position
How to measure the travel block performance
(1) Travel the machine over a distance of 1 m or more on a 20° slope. Test it more than 3 times.
(2) Mark the lower travel structure and the crawler to measure the displacement in the 10-minute time span.
(3) Test it more than two times and record the greater displacement.
Crawler speed
(1) Raise the machine body and mark the crawler. Run the crawler half a turn in advance. Measure the running speed twice
or more.
II-75
WSM U15-3
3. Piston motor installation
Motor (Left)
Motor (Right)
No.
Part Name
Q'ty
(1)
Drive Sprocket
2
(2)
Hex socket bolt
18
(3)
Motor, assembly (Wheel)
2
(4)
Hex socket bolt
16
(5)
Spring washer
16
(6)
Pipe joint (S, G1/4-G1/4)
2
(7)
Pipe joint (S, G1/8-G1/4)
2
(8)
Adaptor
2
(9)
O-ring
2
(10) Straight pipe joint
2
(11) O-ring
2
II-76
WSM U15-3
4. Structure
b1
(1)
b2
S2
(2)
S1
(3)
a1-a2
(5)
(4)
(1)
(1)
(2)
(5)
(1) Counter balance valve
(4) Selector valve
(2) HI - Lo change valve
(5) Hi - Lo piston
(3) Selector valve
II-77
(4)
WSM U15-3
4. Principle of operation
(1) Operating principle of wheel motor
(1)
(2)
(6)
(7)
(5)
(3)
(5)
(4)
(1) Stationary part
(5) Hydraulic motor
(2) Rotating part
(6) Symple planetary gear reducer (two - step)
(3) Counter balance valve
(7) Carrier 2
b1 : four planet gears,
(8)
b2 : three planet gears
(4) Two - speed spool
Description of operation
The PHV series travelling motor has a stationary main body composed of a hydraulic motor and hydraulic valve and a rotating main body composed of a simple planetary gear reducer.
II-78
WSM U15-3
(2) Reducer
1) Function
The PHV series travelling motor reducer, which is a simple two-step planetary gear reducer, converts
the high-speed revolution of the hydraulic motor to low-speed high torque to obtain case rotation.
2) Description of operation
In the figure shown to the right, the gear S2 is
spline-coupled with the hydraulic motor output
shaft (or they are combined). The revolution
of the gear S2 is single-reduced through the
gears (S2, b2, a2). This single-reduced revolution is double-reduced through the gears
(S1, b1, a1) spline-coupled with the carrier 2.
The reduced revolution is transmitted to the
rotating main body through the annular gears
a1 and a2, providing travelling driving force.
The reduction ratio of a simple two-step planetary gear reducer is generally expressed as
shown below.
R=
(1)
(2)
(4)
Zs1
Zs2
×
Zs1 + Za1 Zs2 + Za2
Where
Zs1, Zs2: Number of teeth of gears s1 and s2
Za1, Za2: Number of teeth of gears a1 and a2
Because the PHV series travelling motor is of
the main body rotating type, the reduction ratio
is expressed as shown below.
1
R’ =
1-1/R
(3)
(1) Stationary part
(2) Rotating part
(3) Symple planetary gear reducer (two - step)
(4) Carrier 2
II-79
WSM U15-3
(3) Hydraulic motor
1) Function of motor
The hydraulic motor, which is an axial piston motor (rotating cylinder and swash plate type), converts
the hydraulic energy supplied from the pump to revolving movement.
2) Structure of motor and operating principle (See the figure below.)
(4) Cylinder barrel
(a) The motor shaft and gear S2 are combined or coupled through splines
(5) Valve plate
(b) Port A
(6) Piston
(c) Port B
(7) Swash plate
(8) Shaft
The pressure oil flowing in through the hydraulic valve is supplied to the valve plate (5). When the
pressure oil is supplied to the port A, the oil flows into the cylinder port, which corresponds to the port
A, in the cylinder barrel (4) and presses the piston (6). This pressing force is converted to turning
force through the swash plate (7) and the resulting turning force is transmitted to the shaft (3) splinecoupled with the cylinder barrel (4). The return oil in the cylinder port flows out through the port B of
the valve plate (5).
In the case of reverse rotation, the pressure oil flows in through the port B and flows out through the
port A.
II-80
WSM U15-3
3) Operating principle of two-speed motor
The swash plate has two faces I and II on the surface opposite to the shoe-sliding surface and supported by the two balls fixed in the body 2 .
The ball is positioned eccentrically above the central axis. In the 1st speed state, therefore, the face
II is pressed against the body 2 by hydraulic oil force applied to the piston and the spring force in the
cylinder barrel and the swash plate angle becomes D. At this time, the motor is of large capacity.
When the speed selector lever is switched to the g2nd speed position, the operating pressure is conducted through the two-speed spool to the control room and the control piston moves until the face II
of the swash plate touches the body 2, fixing the swash plate angle at E. At this time, the motor is of
small capacity.
When the engine is stopped, the control room is connected to the drain port through the two-speed
spool and the swash plate is returned to the 1st speed position by the spring force. At the time of
starting, therefore, the motor is always in the 1st speed state.
(1) Swash plate
(7) Body 2
(2) Shoe
(8) Face II
(3) Piston
(9) Face I
(4) Spring
(10) Control room
(5) Cylinder barrel
(11) Control piston
(6) Ball
(12) Operating pressure
II-81
WSM U15-3
(4) Hydraulic valve (counter balance valve)
When the pressure oil is supplied through the port A, the pressure oil pushes open the check valve (3)
and flows into the inlet-side port A’ of the hydraulic motor. At the same time, the pressure oil flows
through the choke hole C into the room D and slides the spool valve (2) to the right, overcoming the force
of spring (4). As a result, the hydraulic motor return oil flows in through the port B’, passes through the
opening E of the main body (1) and spool valve (2) and returns to the port B. These processes make the
hydraulic motor rotate. When the pressure oil is supplied through the port B, the above-mentioned processes are reversed and the hydraulic motor rotates reversely.
When the pressure oil supplied through the port A is made unpressurized, the spring force works to
return the spool valve to the left. At this time, the oil in the room D controls the speed at which the spool
valve returns to the left, utilizing the choking effect of the choke hole C. Even if the pressure oil supplied
through the port A is made unpressurized, the hydraulic motor continues rotating using an inertial force.
At this time, the return oil is gradually controlled through the sliding speed of the spool valve and the
helix shape, thus stopping the hydraulic motor smoothly.
II-82
WSM U15-3
e. Pilot valve (Remote control valve)
1. Structure
Maker : Kawasaki Precision Machinery Ltd.
Type : PV 48 M 2043 A
Code No. : RA221-61721
1) Control diagram
Single-operating angle
Double operating angle
Lean center position
Adjust nut (width across flat 22)
Fix the adjust nut with a spanner
when mountting the lever,
and tighten the lock nut
(customor's supply)
with 41.2 2.9N m {420 30kgf cm}.
Stamping of model
name & serial No.
To be marked wit "Yellow
circle"paint for ident fication
No.2 port
(Outer DIA. of the port - part)
No.3 port
T port
P port
6-G1/4 Thread depth 12
(O-ring seal to JIS B 2351)
Spot facing DIA. 24 depth 1
Tightening torque 29.4 2.0 N m
{300 20kgf cm}.
No.1 port
No.4 port
II-83
WSM U15-3
2) Specifications
1.
2.
3.
4.
5.
6.
7.
8.
9.
Max primary pressure: 6.9 MPa {70 kgf/cm2}
Max. back pressure: 0.3 MPa {3 kgf/cm2}
Rated flow: 15 L/min
Secondary pressure characteristics: Refer to the ‘Control diagram’ shown right
Operating torque: Refer to the ‘Control diagram’ shown right
Max allowable external torque: Refer to the ‘Max. allowable external torque’ shown right
Hydraulic oil: mineral hydraulic oil
Oil temp. range: -20 °C ~ +90 °C
Filter: A filter of 40 mesh and over should be applied at the entrance of port P for proventing the
spool sticking.
3) Operating specifications
1. Primary pressure: 3.9MPa {40 kgf/cm2}
32.4 N·m {330 kgf·cm}
88.3 N·m {900 kgf·cm}
Torsional torque
20.6 N·m {210 kgf·cm}
30.9 N·m {315 kgf·cm}
Single-operating torque
Secondary
pressure
Push - rod stroke (mm)
Operating angle (deg.)
II-84
Operating torque (kgf cm)
Bending torque
Secondary pressure (MPa)
Intermittent
Secondary pressure (kgf/cm2)
Rated
Operating torque (N m)
4) Max. allowable external torque
WSM U15-3
2. Sectional view
Htdraylic symbol
Grease is applied on each rotational
part of the universal joint.
Pay attention to the direction of
assembling the universal joint.
Grease is applied on
each top part.
No.
101
Part name
Casing
151
Plate
201
Spool
211
Pulg
212
Rod, push
213
Seal
214
O - ring
216
Seat, spring
217
Washer 2
221
Spring
241
Spring
301
Joint
302
Plate, circular
312
Nut, adjusting
501
Bellows
Shim for adjusting secindary
pressure 1 sheet with designed
thickness T = 0.4
II-85
WSM U15-3
3. Adaptors
P/V (both right and left)
(8)
(7)
(6)
(Quick coupler)
Front
(5)
Rear
Left pilot valve
No.
Right pilot valve
Position for use
Color of hose tape
(2)
Arm dumping
Blue
(2)
Boom lowering
Light blue
(3)
Swivel Right
Yellow
(3)
Bucket dumping
Brown
(4)
Arm raking
Green
(4)
Boom raising
Gray
P
P-port
White
P
P-port
White
T
T-port
None
T
T-port
None
Q'ty
(5)
Pipe joint (S, G1/4-8.6)
5
(6)
Filter
1
Pipe joint (S, G1/4-8.4)
1
(7)
Valve, assembly (Pilot)
1
(8)
Yellow paint
1
Bucket raking
Color of hose tape
Swivel Left
Part Name
(1)
Position for use
(1)
No.
Red
No.
Remarks
Other than P-port
P-port only
II-86
Pink
WSM U15-3
f. Cylinders
1. Cylinder speed
(A) Reference on new vehicle
(B) Allowable limit
Boom cylinder
Arm cylinder
Bucket cylinder
Boom swing cylinder
Dozer cylinder
(Full stroke)
Unit
U15-3
Down (A)/(B)
sec
2.2 ± 0.3
MAX to GL
Up (A)/(B)
sec
2.5 ± 0.3
GL to MAX
Cushion
sec
*0.5 ~1.5
Empty bucket/crowded
Crowd (A)/(B)
sec
3.5 ± 0.3
Dump (A)/(B)
sec
2.4 ± 0.3
Crowd (A)/(B)
sec
2.8 ± 0.3
Dump (A)/(B)
sec
1.9 ± 0.3
LH (A)/(B)
sec
4.6 ± 0.3
RH (A)/(B)
sec
3.7 ± 0.3
Down (A)/(B)
sec
1.9 ± 0.3
Up (A)/(B)
sec
1.4 ± 0.3
Remarks
* Hydraulic oil temperature 50° C
2. Gravity fall
(A) Reference on new vehicle
(B) Allowable limit
Unit
(Bucket under load)
U15-3
Remarks
kg
72
Bucket pile-up x earth specific gravity 1.8
Boom cylinder
(A)/(B)
mm
Arm cylinder
(A)/(B)
mm
25 >
=/125 >
=
>
15 >
/75
=
=
Bucket cylinder
(A)/(B)
mm
10 >
=/50 >
=
Swing block
90° swivel,
100 times
mm
6.0 >
=
90° swivel, 100 times
Dozer cylinder
(A)/(B)
mm
25 >
=/125 >
=
Machine body raised
(Bucket under no load)
Actual reference on new vehicle
Boom cylinder
(A)
mm
5
Arm cylinder
(A)
mm
3
Bucket cylinder
(A)
mm
0
Swing block
(A)
mm
0
Dozer cylinder
(A)
mm
2
(Measuring procedure)
1. Equip the machine with standard bucket.
2. Air-vent all the cylinders.
3. Measure the gravity fall for 10 minutes.
90° swivel, 100 times
4. Arm dump and bucket bottom 1 m above ground
5. Load : Heaped in bucket
Soil gravity : 1.8
II-87
WSM U15-3
3. Specifications and part codes of boom, arm, bucket and swing cylinder
Boom
Unit
U15-3
Tube outside diameter - Inside
diameter - Rod outside diameter
mm
70-60-30
Stroke
mm
469
Fully retracted
mm
765
YW181-9521'
Sealing kit part code
Piston tightening torque
N•m
(kgf•m)
410 ~ 450
(42 ~ 46)
Piston thread size
Arm
M24 x 1.5
Piston wrench size
mm
41
Tube outside diameter - Inside
diameter - Rod outside diameter
mm
70-60-35
Stroke
mm
335.5
Fully retracted
mm
924.5
YW182-9531'
Sealing kit part code
Piston tightening torque
N•m
(kgf•m)
510 ~ 550
(52 ~ 56)
Piston thread size
Piston wrench size
Bucket
Swing
M24 x 1.5
mm
36
Unit
U15-3
Tube outside diameter - Inside
diameter - Rod outside diameter
mm
70-60-35
Stroke
mm
269
Fully retracted
mm
529
YW182-9531'
Sealing kit part code
N•m
(kgf•m)
510-550
(52~56)
Piston thread size
mm
M24 x 1.5 8T
Piston wrench size
mm
36
Tube outside diameter - Inside
diameter - Rod outside diameter
mm
65-55-30
Stroke
mm
326
Fully retracted
mm
610
Piston tightening torque
YW179-9511'
Sealing kit part code
N•m
(kgf•m)
343.0 ~ 392
(35 ~ 40)
Piston thread size
mm
M22 x 1.5
Piston wrench size
mm
32
Piston tightening torque
Remarks
II-88
Remarks
WSM U15-3
Blade cylinder
Blade
Unit
U15-3
Tube outside diameter - Inside
diameter - Rod outside diameter
mm
70-60-30
Stroke
mm
112
Fully retracted
mm
348
YW181-9521'
Sealing kit part code
N•m
(kgf•m)
343.0 ~ 392.0
(35 ~ 40)
Piston thread size
mm
M22 x 1.5
Piston wrench size
mm
32
Tube outside diameter - Inside
diameter - Rod outside diameter
mm
65-55-30
Stroke
mm
250
Fully retracted
mm
478
Piston tightening torque
Leg
stretcher
Remarks
YW178-9511'
Sealing kit part code
N•m
(kgf•m)
343 ~ 395
(35 ~ 40)
Piston thread size
mm
M22 x 1.5
Piston wrench size
mm
32
Piston tightening torque
4. List of cylinder dimensions
A
B
C
D
E
F
G
H
J
Port thread
dia.
Boom
40-30
40-30
45
45
30
60
70
35
35
G1/4
Arm
40-30
40-30
45
45
35
60
70
32
32.5
G1/4
Bucket
40-30
40-30
45
45
35
60
70
32
32
G1/4
Swing
40-30
40-30
35
35
30
55
65
32
32
G1/4
Blade
40-30
40-30
45
45
30
60
70
32
32
G1/4
Track
34-30
34-30
35
35
30
55
65
27.5
28
G1/4
Model
U15-3
Fully extracted (stroke)
II-89
Remarks
WSM U15-3
5. Cylinders’ section view
(Bucket, Arm)
T.T.
(21)
(20)
(17)
(18) (19)
T.T.
[mm]
Arm
(1) Cylinder tube
(6) Backup-ring
(11) DU-bushing
Bucket
(2) Cylinder rod
(7) Scraper
(12) Piston
(17) Stroke
(3) Bushing
(8) O-ring
(13) Piston seal
(18) Retracted L
529
(4) Cylinder head
(9) Backup-ring
(14) Wear-ring
(19) Extended L
924.5 ± 2.5
(5) Packing
(10) O-ring
(15) Lock nut, M24
(20)
802 -05
325
(16) grease nipple
(21)
79
76.5
269
+3
0
335.5
589 ± 1.5
387.5
(Boom)
T.T.
(3)
(1)
(2)
T.T.
(Blade)
(1)Retracted L = 765 ± 1.5 (2)Extended L = 1234 ± 2.5 (3)Stroke = 469
(1) (2)
(3)
T.T.
T.T.
(1)Retracted L = 348 ± 1.5 (2)Extended L = 460 ± 2.5 (3)Stroke = 112
II-90
WSM U15-3
(Swing)
(1)
(2)
(3)
(1)Retracted L = 610 +30 (2)Extended L = 940 -05 (3)Stroke = 330
(Truck)
(1)
(2)
T.T.
(3)
(1)Retracted L = 478 ± 1.5 (2)Extended L = 728 ± 2.5 (3)Stroke = 250
T.T. : Tightening torque
[Cylinder essential quality]
1. Seal durability:
Must conform to class “A” (0.05 ml / 100m) of “JIS B 8354”
under following conditions.
Oil pressure : 21.6 MPa (220 kgf / cm2),
Oil temperature : 100 deg, Speed : 16.6 m / min,
Sliding distance : 300km
2. Dust Seal properties :
Dust enter must be 11 mg or less under following conditions.
Speed : 16.6 m / min, Stroke : 150 mm,
Number of repetitions : cycles,
Vibration applied to facility : 7.4 Hz
3. Internal oil leakage :
Must be within 1 cm3 for 3 min under the condition of the
main relife pressure 21.6 MPa (220 kgf / cm2) applied to
the stroke end (Oil temperature 50 ± 5 deg).
4. Minimum operating pressure :
Must be within 4 % of the main relief pressure 0.86 MPa
(8.8 kgf / cm2) applied to the bottom port after 3 or more
cycles with full stroke sliding under none load (Oil temperature 50 ± 5 deg).
5. Withstanding pressure :
Permanent deformation and oil leakage must not occur
after pressure 2 times as high as the main relief pressure
43.1 MPa (440 kgf / cm2) is applied by 40000 time or more.
II-91
6. Withstanding external force :
Any damages, distortions, oil leakage, permanent deformations must not occur in any parts when external force 2
times as high as the main relief pressure 43.1 MPa (440
kgf / cm2) the cylinder thrust force (12240 kgf) is applied by
30000 times or more.
7. Rust prevention of plating :
Must be rating number 9 or higher after 4 cycles (64 hour)
of CASS testing. Thickness of platinf must be kept more
than Ep-ICr30 (0.03 mm)
8. Cushion performance : (Cushion type cylinder only)
Cushion facility must be set in bottom side for contraction
with following performance.
Oil temperature : 30 deg / cushion time : 2 seconds or less
Oil temperature : 50 deg / cushion time : 1 ± 0.3 seconds
Oil temperature : 80 deg / cushion time : 0.3 seconds or more
9. Piston rod surface treatment :
Piston rod rubbing part : Ni-Hcr or Hcr plating
Thickness 9.03 mm or more
Hardness HV (25g) 700 or more
Induction hardening : HRC 50 to 56, Depth 2 to 3 mm
WSM U15-3
g. Swivel Joint (Rotary joint)
1. Swivel Joint (1)
Shaft side
No.
Q'ty
Remarks
(1)
Swivel joint, assembly
1
(2)
Bolt
4
M12 x 1.25 7T
(3)
Adapter
1
B
(4)
Pipe joint (L, G1/4-G1/4)
1
C
(5)
Pipe joint (L, G1/4-G1/8)
1
C
(6)
Pipe joint (L, G1/4-10)
1
D
(7)
Pipe joint (L, G3/8-G3/8)
4
E, F, H, I
(8)
Pipe joint (L, G1/8-G1/4)
2
A, J
O-ring
4
For 1/4 B, C, D, G
O-ring
2
(9)
Body side
Part Name
Pipe joint (L, G3/8-G3/8)
4
e, f, h, i
(10) Pipe joint (L, G1/4-G1/4)
4
b, c, g
(11) Pipe joint (L, G1/4-G1/4)
2
a, j
(12) Pipe joint (L, G1/4-G1/4)
2
d
2
For 1/4 a, j
O-ring
Front
(25)
(30)
(31)
(26)
(27)
(32)
(28)
Pa
(29)
Pa
lel
ral
l el
r al
(33)
(34)
(17)
(13)
(22)
(19)
(14)
(23)
(15)
(16)
Right
(18)
(20)
Front
(21)
O-rings are adopted at
Joint is of O-ring type.
upper and lower sides for
prevention of water entry.
Left
(13) Travel (Right) upper port (e)
(24) Travel (Left) lower port (h)
(14) Travel drain (d)
(25) Travel 2-speed signal
(15) Travel (Right) lower port (e)
(26) Travel (Right) lower port
(16) Travel 2-speed signal (g)
(27) Travel (Left) lower port
(17) Blade cyl. (Rod) (b)
(28) Travel (Left) upper port
(18) Truck cyl. (Bottom) (i)
(29) Truck cyl. (Rod)
(19) Blade cyl. (Bottom) (c)
(30) Travel (Right) upper port
(20) Truck cyl. (Rod) (a)
(31) Travel drain
(21) Travel 2-speed signal (g)
(32) Truck cyl. (Bottom)
(22) Travel (Left) upper port (i)
(33) Blade cyl. (Bottom)
(23) Travel drain (d)
(34) Blade cyl. (Rod)
II-92
(24)
Rear
WSM U15-3
2. Swivel Joint (2)
O-rings are added.
No.
Part Name
Q'ty
(1)
Shaft (Swivel joint)
1
(2)
Ring (Backup)
18
(3)
Ring (D)
9
(4)
Ring (Backup)
2
(5)
O-ring
2
(6)
Collar
1
(7)
Body (Swivel joint)
1
(8)
Plug (R1/8)
2
(9)
Collar
1
(10) Shaft circlip
1
(11) Plug (R1/8)
2
(12) Base (Swivel joint)
7
(13) Bolt
1
(14) Shaft (Swivel joint)
4
Remarks
M10 x1.25 7T
II-93
WSM U15-3
3. Route of Hose (Travel, dozer)
Route of hose (Swivel joint ~ Travel motor)
Dozer
Machine left side
Left leg
Right leg
Retractable leg
Swivel joint side
Travel motor, cyl. Side
a. Retractable leg (Retraction)
Cyl. rod side
b. Dozer UP
Cyl. rod side
c.
Cyl. bottom side
Dozer DOWN
Machine right side
d. Drain
Right and left drain ports
e. Right backward
Right A (Lower)
f.
Right forward
Right B (Upper)
g. Dual pilot
Left/Right travel 2-speed
h. Left backward
Left A (Lower)
i.
Left forward
Left B (Upper)
j.
Retractable leg (Elongation)
Cyl. bottom side
No.
(1)
Q'ty
Dimension (mm)
Rotary joint (i) ~ Travel motor left A
Mounting Position
1
750
Rotary joint (b) ~ Travel motor left B
1
750
Rotary joint (f) ~ Travel motor right B
1
750
Rotary joint (e) ~ Travel motor right A
1
750
Rotary joint (g) ~ Travel motor left PP
1
780
white x 1
Rotary joint (g) ~ Travel motor right PP
1
780
white x 1
(3)
Rotary joint (d) ~ Travel motor left DR
1
740
Rotary joint (d) ~ Travel motor right DR
1
740
(4)
Rotary joint (b) ~ Relay
1
310
Rotary joint (c) ~ Relay
1
310
Rotary joint (b) ~ Relay
1
310
(2)
(5)
Rotary joint (c) ~ Relay
1
310
(6)
Relay ~ Dozer cyl. rod
1
930
(7)
Relay ~ Dozer cyl. rod
1
660
II-94
WSM U15-3
4. Route of Hose (Truck Cylinder Hose)
As viewed from below the truck frame
(1)
(2)
(3)
(5)
(4)
(1)
(2)
(3)
(4)
Truck cylinder
To cyl. rod side
To cyl. bottom side
Adjust the angle of the adaptor and secure the clearance between the plate of C and the hose to be
more than 1 mm and less than 10 mm.
(5) Clamp the hose at this position by vinyl tape.
(Secure more than 1 mm clearance between the retractable cylinder and the rod. (œ))
II-95
WSM U15-3
h. Unload valve
1. Structure
Maker : Nishina
Red
Black
(1) Shim
(11) Plug
(2) spring
(12) Hollow bolt
(3) Name plate
(13) Washer
(4) Plunger
(14) Screw
(5) Spring
(15)
(6) Spool
(16) O-ring
(7) Body
(17)
(8) Solenoid
(18) Cable clamp
(9) Cover
(19) Protection tube
2. Specifications
(1) Allowable voltage: DC 10.8 ~ 14.4V
(2) Current:
Red
(3)
Black
Power consump14.4W
tion:
(4) Coil resistance:
Approx. 10 : at 20 °C
(5) Insulation:
JIS C 4003 H
(6) Surge killer:
Diode
(7)
Relief valve set
pressure:
+0.2
2
3.9 +0.2
0 MPa (40 0 kgf/cm )
at 6l/min
(8)
Cracking
pressure:
(9)
Valve pressure
loss:
3.4 MPa (35kgf/cm2)
at 2l/min
p o A, B
0.5 MPa (5.1 kgf/cm2) or
less at 6l/min
A, B, G = G 1/4
P, T = G 3/8
(JIS B2351 O - type)
(10) Port size:
(19)
II-96
1.2 A at 20 °C
WSM U15-3
3. Adaptor installation
(17)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
No.
Part Name
Q'ty
Remarks
No.
(1)
Valve, assembly (Unloading)
1
(2)
Straight pipe joint (Drain)
1
T
(10) PV · Right side P
O-ring
1
For G3/8 P
(11) PV · Left side P
(3)
Pipe joint (L. G1/4-G1/4)
1
B
(12) Unloading
(4)
T-pipe joint (F2)
1
B
(13) 2-speed
(5)
Shouldered elbow
1
B
(14) CV · Pp
O-ring
1
For G1/4 A
(15) Pump · P4
(6)
Pipe joint (L. G1/4-G1/4)
1
A
(16) Swivel joint · 2-speed signal (G)
(7)
Straight pipe joint
1
P
(17) Hydraulic oil tank
O-ring
1
Bolt
2
(8)
(9)
Part Name
M10 x 1.5 7T
II-97
Tank cover
WSM U15-3
i. Selector valve
1. Structure
2. Function
This valve is to select the oil flow direction for blade cylinder or track cylinder.
3. Specifications
1) Operating pressure and flow : Main relief pressure (20.6 MPa) at 10.4 l/min.
2) Inside leakage : 8 cc/min at 20.6 Mpa, 50 °C
II-98
WSM U15-3
j. Accessaries of hydraulic compornents
1. Check valve assy
(6)
(7)
(8)
(1) Shim
(2) spring
(4) Plunger
(10) (11)
(9)
(3) Name plate
(5) Spring
Model
(8)
(9)
(10)
(6)
(7)
KX36-3
KX41-3
EU
KX41-3V
67
55
G 1/2 I26 30.02
27
U15-3
65
53
G 3/8 I18.6 25.4
22
2)
Cracking pressure : 196 ± 29 KPa (2 ± 0.3 kgf/cm
U15-3 : Check valve = RB238-63802
2. Hydraulic filter
Specifications items
Suction filter
Return filter
1.Filtration area
1650 cm2
3600 cm2
2.Filtration level
105 Pm (150 mesh)
10 Pm nominal
3.Oil flow
80 l/min
70 l/min
4.Hex.spanner
41 mm
36 mm
5.Filter dia.
I85
I90
6.Filter length
105
125
7.Relief opening pressure
8.Code number
0.1MPa (1.0 ± 0.15 kgf/cm2)
RB238-62151
(Return filter)
RA011-62191
(Suction filter)
II-99
[mm]
(11)
HEX
WSM U15-3
3. Oil Tank
(12)
(13)
(16)
(14)
(15)
(10)
(17)
(11)
(19)
(20)
(18)
No.
Part Name
Q'ty
No.
Part Name
(1)
Oil tank
1
(10) Hose (1/2)
(2)
Cover (Tank, return)
1
(11) Pump
(3)
Filter (Return)
1
(12) Unloading valve
O-ring
1
(13) Direct the pipe joint (F2) as shown in the figure.
Plug (Oil filler)
1
(14) Press it securely up to the hilt.
O-ring
1
(15) Hose (Suction)
(5)
Bolt
6
(16) Pump
(6)
Filter (Suction)
1
(17) Pipe (Return)
(7)
Gauge (Oil level)
1
(18) Swivel joint · Travel drain
O-ring
1
(19) Right PV · T
(8)
Plug
1
(20) Left PV · T
(9)
Washer with rubber
1
(4)
II-100
WSM U15-3
4. Oil cooler
Core
Core
Hole
Core
Oil cooler specifications
Div.
Item
Unit
Standard
kW (kcal/h)
4.81 (4140)
Oil-side pressure loss
kPa (Kgf/cm2)
95
Air-side pressure loss
Pa (mmAq)
118
Test pressure
kPa (Kgf/cm2)
981 (10)
Repeated pressure resistance
kPa (Kgf/cm2)
981 (10) x 105 times
Static pressure breakdown
kPa (Kgf/cm2)
2.45 (25)
Heat radiation
Ve=15L/min. 't=75 °C.to1=110°C
Va=8m/s. Vw=-L/mim
Performance specifications
Type of core
Drawn-cup type, louver-less, corrugated
Core dimensions
Structural specifications
Remarks
275 (W) x 145 (H) x 32 (D) f.p=4.0/2
Oil-side radiating area
m2
0.2228
Air-side radiating area
m2
1.1584
Oil capacity
L
0.22
Dry weight
kg
0.88
Black coating (powder)
II-101
WSM U15-3
5. Accumlator
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(1)
(2)
(3)
Gas plug
Shell
Holder
Bladder
Poppet
Oil port
O - ring type
Across
Specs
1.
2.
3.
4.
5.
6.
(4)
(5)
(6)
Gas : Nitrogen
Gas volume : 300cc
Max.operating pressure : 6.9 MPa (70 kgf/m2)
Initial gas pressure : 1.2 MPa (12kgf/m2) at 20 °C
Operating oil temp. : -30 100°C
Weight : 1.1 kgf
Machine models used : U15-3, U20-3, U25-3
(7)
(8)
warning
It contains nitrogen under high pressure.
Don’t allow fire or heat near it. Don’t try to disassemble it.Wear eye protection and carefully drill a holl at
the point marked
to release gas pressure before
disposal.
II-102
WSM U15-3
h. Hydraulic system flow
1. Hydraulic Pressure Hose Circuit (High-pressure)
(19)
(20)
(18)
(21)
(22)
Hoses at upper side
No.
Position for use
Q'ty
No.
Part Name
(1)
Pump (P1)~CV (P1) White
P1
1
(18) Control valve
(2)
Pump (P2)~CV (P2) White
P2
1
(19) Selector valve
(3)
Pump (P3)~CV (P3) White
P3
1
(20) Swing cyl.
(4)
CV (A7)~SJ (I) Yellow
Travel Left Backward
1
(21) Swivel motor
(5)
CV (B7)~SJ (H) Green
Travel Left Forward
1
(22) Pump
(6)
CV (A6)~SJ (F) Blue
Travel Right Backward
1
(7)
CV (B6)~SJ (E) Red
Travel Right Forward
6
(8)
CV (B3)~Swivel Motor (B) Gray
Swivel Left
1
(9)
CV (A3)~Swivel Motor (A) Light blue
Swivel Right
1
(10) CV (A1)~Swing cyl. (Bottom) ?
Swing Left
1
(11) CV (B1)~Swing cyl. (Rod) Orange
Swing Right
1
(12) CV (B2)~Selector V (P1) Pink
CV dozer raising
1
(13) CV (A2)~Selector V (P2) Brown
CV dozer lowering
1
(14) SJ (B)~Selector V (B2)
Dozer raising (Rod)
1
(15) SJ (C)~Selector V (B1)
Dozer raising (Bottom)
1
(16) SJ (J)~Selector V (A1)
Truck elongation (Bottom)
1
(17) SJ (A)~Selector V (A2)
Truck retraction (Rod)
1
II-103
WSM U15-3
2. Hydraulic Pressure Hose Circuit (Low-pressure)
(12)
(8)
(9)
(13)
(10)
(11)
Low-pressure hoses
No.
Position for use
Q'ty
No.
Part Name
(1) Pipe return~Oil cooler Front
Oil cooler OUT
1
(8)
Control valve
(2) CV (T3)~Oil cooler Rear
Oil cooler IN
1
(9)
Return pipe
(3) CV (T2)~Pipe return
Oil cooler bypass
1
(10)
Oil cooler
(4) Pipe return~Oil tank
Return
1
(11)
Swivel motor
(5) Swivel motor (T)~ CV (T1)
Swivel motor drain
1
(12)
Oil tank
(6) Unloading V (T)~Oil tank
Unloading V return
1
(13)
Unloading valve
(7) SJ (D)~Oil tank
Travel drain
1
II-104
WSM U15-3
3. Travel Unloading function
Pp
(1)
(2)
(3)
P1
(4)
(5)
(6)
P2
(7)
(8)
(9)
(10)
(11)
P䋳
(1) Bucket
(2) Boom
(3) Travel Left
(4) Supply
(5) Travel Right
(6) Arm
(7) Service
(8) Confluence
(9) Swivel
(10)Dozer
(11)Swing
With the unload lever being raised, oil of P1 and P2 flows from the supply section directly to the return circuit
and results in no functions of P1 and P2 pump, from bucket (1) to service port (7) except pump 3 circuit.
When the unload lever is lowered, the supply section opens to supply oil of P1 and P2.
II-105
WSM U15-3
4. Boom Confluence
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
P䌢
(1) Bucket
(2) Boom
(3) Travel Left
(4) Supply
(5) Travel Right
(6) Arm
(7) Service
(8) Confluence
(9) Swivel
(10)Dozer
(11)Swing
P1
P2
P3
When boom operation is performed, the boom is operated so that the joint valve is switched over to joint P1
and P3.
5. Service port Confluence
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Breaker
P1
P2
P3
When service port pedal is depressed, P2 and P3 pump’s oil will be supplied to service port section.
II-106
WSM U15-3
6. Straight Travel Circuit
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
P䌢
P1
P2
P䋳
(1) Bucket
(2) Boom
(3) Travel Left
(4) Supply
(5) Travel Right
(6) Arm
(7) Service
(8) Confluence
(9) Swivel
(10)Dozer
(11)Swing
Since only the Boom and Service are jointed with P3, straight travel is possible.
When left and right travel levers are shifted, F or R, P1 supplies oil to the travel motor and P2, to the right
motor.
P3 supplies oil to the boom section.
Therefore, only boom and service port operations are possible together with travel function.
II-107
WSM U15-3
l. Service port system
1. Component layout
This pedal is used to operate attachments
such as breakers.
NOTE:
• When the service port is not in use, fold
the service port pedal forward. The pedal
gets fixed and can be used as footrest.
(1) Service port pedal
(A) Sends oil to the port (A)
(B) Sends oil to the port (B)
(1) Service port pedal (A) “Fix”
(1) Port (A)
(2) Port (B)
• Push the right part of the pedal ( ) to
send oil to the port (A).
• Push the left part of the pedal ( ) to send
oil to the port (B).
Max. Flow Volume
Theoretical L min.
27.0
Max. Pressure MPa
(kgf/cm2)
18.6 (190)
IMPORTANT:
• When the service port is not used for a
long period, dirt particles can settle in the
lower part of the service port lines.
When the plugs on the service port lines
are removed to connect attachments,
drain approx. 100 cc of oil per side.
Concerning the choice of a breaker, contact your dealer.
II-108
WSM U15-3
2. 1-way or 2-way valve
The selection valve which select 1-way or 2way circuit of service port has been installed
on the control valve.
When the breaker will be used, position the
lever of selection valve to the "OPENED"
position (1-way circuit) to reduce the back
pressure.
IMPORTANT:
• When the equipment (auger, crusher,
telescopic arm, ...), which need 2-way circuit will be used, position the lever to the
"CLOSED" position.
II-109
WSM U15-3
II-110
WSM U15-3
m.Hydraulic components layout : U15-3
(16)
(18)
(21) (22)
(4)
(1)
(13)
(5) (3)
(2)
No.
(7)
(14)
(8)
(17)
Main pump
2
Pilot valve, L
3
Pilot valve, R
4
Accumulater
5
Unload valve
6
Control valve
7
Swivel motor
8
Rotary joint
9
Travel motor, L
10
Travel motor, R
11
Change valve for SP
(1 way, 2 way)
12
Change valve : Dozer-track
13
Hydraulic oil tank
14
Oil cooler
15
Boom cylinder
16
(6)
(15)
(12)
(19)
(20)
(25)
(24)
(11)
(9)
PART NAME
1
Arm cylinder
17
Bucket cylinder
18
Swing cylinder
19
Dozer cylinder
20
Track cylinder
21
Suction filter
22
Return filter
23
Track rollers
24
Grease tension cylinder
25
Idler
(23)
II-111
WSM U15-3
n. Hydraulic circuit diagram
II-112
WSM U15-3
E.Electrical system
a. New Functions of Electric System
1. Starter automatic release function
When the key is turned ON, the automatic release relay is excited to rotate the starter.
When the engine is started (the signal from the engine speed sensor exceeds the set value), the automatic release relay is demagnetized to shut down the power to the starter.
2. Auto-glow
Engine water temperature is detected and the glow plug is pre-heated for the time required for starting
the engine.
At the starting position, the glow plug is pre-heated irrespective of water temperature.
3. Theft-proof Specification
This is different from 3 ton, 4 ton class machines in the following points.
(1) It is not a standard part but specification to be adopted.
(2) Since it has no digital panel, preparation of a key setting panel is needed.
(3) Horn does not sound in emergency.
(1) Main key SW
(2) Travel hi - low SW
(3) Meter panel
(4) Auto glow controller
(5) Auto release controller
(6) Glow relay
(7) Change valve
(8) Fuel sensor
(9) Fuel pump
(10) Horn
(11) Work lamp
(12) Startor
(13) Battery
(14) SBF (Slow blow fuse)
(15) Fuse box
(2) (1) (3) (4) (5)
(9)
(8)
(6)
(7)
(15)
(14)
(10)
(11)
(13)
(12)
II-113
WSM U15-3
b. Battery circuit
1 (AC)
OFF
2 (Start)
3
Key SW
Cab relay
15A
M
Light SW
Stater motor
60A
50A
Battery
Alternator
1. Keep in mind that the battery voltage is applied through the above circuit all the time.
2. A 60A fuse is added close to the alternator, otherwise part of the harness may get short-circuited due to the
alternator's current generated while the engine is running. In this way, the devices and harness can be
protected against burn-out.
II-114
WSM U15-3
c. Key switch (Engine starter switch)
Rotor
Dust seal
I3 water drain
Return spring
Contact
Detent
O-ring
Key position
30
AC
Start
1st : AC position
z
z
z
z
z
z
Off
2nd : Start position
II-115
WSM U15-3
d. Safty lever lock switch
Part No.:RC411-53473
PVC tube, black
Crimp here(4 location)
apply silicone resin
stroke
(1)
(2) (3) (4)
(5)
(6) (7)
(8)
Crimp here
(All around)
(9) (10) (11) (12)
(1) Plunger
(2) Washer
(3) Boot
(4) Contact plate
(5) Body
(6) Base comp.
(7) Packing
(8) Cord
(9) O-ring
(10)Action spring
(11)Roller
(12)Spring
Specifications
1. Rated
:DC14V, 1.5A
2. Insulasion
:2M: or more
3. Operationg force of plunger:
at Free position =17 ± 3 N
at Max. stroke
=32 ± 4 N
4. Full stroke
:9 ± 5 mm
OFF
AC
(2)
start
(4)
(5)
(6)
(3)
(7)
(1)
II-116
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Battery
Fuse, 50A
Key SW
Fuse, 5A
Lever lock SW, R
Lever lock SW, L
Lever lock solenoid
WSM U15-3
(2) Safety lever lock circuit malfunction
1) Check battery voltage at (+) terminal of coupler.
Check the fuse if no voltage were tested.
Upper side solenoid valve is for the safety lock circuit.
Lower one is for the travel hi-low function.
(1)
(1) Safety lock valve
2) Pull the harness to see if the coupler is not out of the lever
lock solenoid valve. (Pull by a 3 kg or less force.)
3) Continuity test of corresponding harness are required.
4) Solenoid valve check
1. Coil resistance test
Specification: Approx. 10 : at 20 °C
• Shown here is a measurement with digital tester.
(Note that the positive (+) and negative (-) connections are reversed with the analog type.)
2. Coil insulation test
Specification: Over 1 M:
5) Check lever lock switch for continuity by operating the lever
and 12V test.
(Continuity test : Lever down)
(Battery 12V test : Key switch is on)
II-117
WSM U15-3
e. Solenoid valve
Maker : Nishina
1. Structure
(1) Shim
(11) Plug
(2) spring
(12) Hollow bolt
(3) Name plate
(13) Washer
(4) Plunger
(14) Screw
(5) Spring
(15)
(6) Spool
(16) O-ring
(7) Body
(17)
(8) Solenoid
(18) Cable clamp
(9) Cover
(19) Protection tube
Red
Black
2. Specifications
(1) Alow voltage:
DC 10.8 ~ 14.4V
(2) Current:
1.2 A at 20 °C
(3) Power consumption
14.4 W
(4) Coil resistance:
Approx. 10: at 20 °C
(5) Insulation:
JIS C 4003 H
(6) Surge killer:
Diode
+0.2
+0.2
2
(7) Relief valve set pressure: 3.9 0 MPa (40 0 kgf/cm )
at 6l/min
(8) Cracking pressure:
(9) Valve pressure loss:
(10) Port size:
3.4 MPa (35kgf/cm2)
at 2l/min
p o A, B
0.5 MPa (5.1 kgf/cm2) or
less at 6l/min
A, B, G = G 1/4
P, T = G 3/8
(JIS B2351 O - type)
E : Electromotive force generated in coil (N)
N : No. of turns of coil
dI:Rate of magnetic flex (I)
dt variation in short interval (dt second)
dI
E = N · dt
II-118
WSM U15-3
3. Solenoid test method
Solenoid continuity test procedure (In case of diode
incorporafed.)
Red lead
Black lead
Pointer circuit tester
Connect the black and red leads to the positive (+) and
negative (-) terminals, respectively, of a circuit tester
(pointer type). Make sure the coupler is positioned as
shown in the figure. In this state, the coil resistance can be
measured properly.
Be careful not to confuse the above connections. If
reverse-connected, the measuring current of the circuit
tester flows to the diode too and the coil resistance cannot
be measured correctly.
Digital circuit
tester (resistance
range)
Incorrect conection
[TIPS]
The circuit tester is battery-powered. The battery voltage
is applied across the
resistor, by which a current flows and
Adjusted
the resistance is measured.
The built-in battery’s polarities are different between the
pointer type and digital type as illustrated below. In measuring the resistance of a diode-fitted coil, make connection between the positive (+) output terminal of the built-in
battery and the cathode of the diode.
(Digital type)
(Pointer type)
Built-in battery
(Pointer type)
(Digital type)
1. Construction and principle of circuit tester
at 0 ohm
Battery
Fig. Ohmmeter principle
Fig. in the left shows the inside of an ohmmeter. The built-in
battery provides current through the circuit and makes the
pointer swing accordingly. Before measuring a resistance, it is
necessary to make 0-ohm adjustment. Bring the tester probes
in contact with each other for short-circuiting. By so doing, the
variable resistor R3 will be readjusted so that the pointer
should swing full-scale, and also the built-in battery's power
will be regulated. It should be noted that the measured resistance and the current flowing in the coil are not in proportion
to each other. The scale is irregularly spaced. Changing the
resistance of resistor R4 allows to adjust the ohmmeter's
measuring range.
II-119
WSM U15-3
f. Travel hi-speed control circuit
1. Hi - Low switch and circuit diagram
R/G
(1) Travel speed switch
(2)
mark
P2
P1
DR
Travel hi- speed
switch
ST
AC
10A
2
1
Hi - Low
self - hold
circuit
B
OFF
Travel speed will increase when pushing down this switch.
1. Press the travel speed switch. The travel speed changes
from first speed to second. The
mark lights up.
2. Press the travel speed switch again, and the travel speed
changes from second to first. The
mark lights out.
NOTE:
Each time the travel speed switch is
pressed, the travel speed is switched
between first and second.
2. Troubleshooting: Travel hi-speed malfunction
1) Turn the key switch to the ON position to see if 12 V is applied to terminal 2 of the travel hi-speed switch.
2) Press the travel hi-speed switch to see if the 12 V signal comes to terminal 1.
3) Turn on and off the travel hi-speed switch and check the continuity and discontinuity.
4) Check the continuity of the travel hi-speed solenoid coil and measure its resistance.
5) If there is no problem with the above steps, it means the electrical system functions. Now go to the
hydraulic system.
6) Possible troubles with the hydraulic system include stuck solenoid spool, poorly performing pilot pump,
malfunctioning primary relief valve, stuck Hi-Lo selector spool, etc.
II-120
WSM U15-3
3. Testing Hi - Low SW
1) Location of Hi-Low SW coupler and how to disconnect
the coupler.
Small size driver (match-repair driver) is required.
2) Check battery 12V.
3) Check continuity of the switch.
4) Testing Hi-Low solenoid coil resistance.
II-121
WSM U15-3
4. Hi - Low self hold circuit
1) Lever lock SW isn’t linked.
(7)
OFF
(3)
AC
ON-15-2
ON-15-1
(10)
Start
(4)
ON-306-4
ON-801-2
ON-306-2
ON-306-3
ON-13-1
ON-800-1
ON-306-1
(5)
ON-306-3
ON-306-4
ON-801-1
ON-306-4
ON-306-2
ON-801-2
ON-13-2
ON-306-3
ON-306-1
(1)
(2)
ON-801-2
(6)
ON-306-4
ON-800-1
ON-800-1
ON-306-2
ON-306-3
ON-306-1
ON-306-1
ON-306-2
ON-801-2
ON-306-1
(9)
ON-801-2 ON-800-1
ON-306-4
ON-306-2
ON-306-3
ON-800-1
ON-801-2
2) Lever lock SW is wired.
(7)
OFF
(8)
(3)
AC
ON-15-2
ON-15-1
(10)
Start
(4)
ON-306-4
ON-801-2
ON-801-2
(6)
ON-306-4
ON-800-1
ON-306-2
(1)
(2)
ON-801-1
ON-306-4
ON-306-2
ON-800-1
ON-801-2
ON-13-2
ON-13-1
ON-306-3
ON-306-1
(5)
ON-306-3
ON-306-4
ON-306-3
ON-306-1
ON-800-1
ON-306-2
ON-306-3
ON-306-1
ON-306-1
ON-306-2
ON-801-2
ON-306-1
(9)
ON-306-3
ON-801-2 ON-800-1
ON-306-2
ON-306-4
ON-800-1
ON-801-2
Note :
Lever lock SW (8) was not installed for the early production machines. It was connected with unload
valve solenoid only.
Therefore, in these machines, travel speed won’t be reset to low range with the lever lock SW OFF condition.
II-122
WSM U15-3
3) Key SW is ON and lever lock SW is ON.
(7)
OFF
(8)
(3)
AC
ON
(10)
Start
(4)
ON-800-1
(1)
(2)
ON-801-2
(6)
(5)
(9)
(1)
Travel hi-low drive relay
(6)
Second self-hold relay
(2)
Travel hi-low solenoid
(7)
Main Key SW
(3)
Travel hi-low SW
(8)
Lever lock SW
(4)
Negative function relay
(9)
Self-hold cancel relay
(5)
First self-hold relay
(10) High speed lamp
4) Push the travel hight-low SW ON. (Hold SW Button ON)
Then travel high-low drive relay turns on and travel high-low solenoid (2) becomes activated. And so
travel motor runs at high speed.
ON condition relays : (1) Travel hi-low drive relay
(4)Negative function relay
(7)
OFF
ON
(8)
AC
(3)
ON
(10)
Start
(4)
ON-800-1
ON
ON-801-2
(6)
(2)
(1)
ON
(5)
(9)
II-123
WSM U15-3
5) Hand off from the high-low SW button
As first self-hold relay (5) is B-type relay, buttery current flows through this normal close contact terminal
and activates travel high-low drive relay (1). In this was travel motor keeps running at high speed.
ON condition relay : (1) Travel hi-low drive relay
(6) Second self-hold relay
(9) Self-hold cancel relay
(7)
OFF
(8)
(3)
AC
ON
OFF
(10)
Start
ON
(4)
ON-800-1
(1)
(2)
ON-801-2
(6)
ON
(5)
ON
ON
(9)
6) Push the travel high-low SW ON again (Hold the SW button ON)
When the travel high-low SW is pushed ON, battery current flows through the coil of travel high-low drive
relay (1) and turn it ON.
Then the travel high-low solenoid is activated and runs the travel motor at high speed. On this stage, all
5 relay turn ON positions.
(7)
OFF
ON
(8)
AC
(3)
ON
(10)
Start
ON
(4)
ON-800-1
ON
ON-801-2
(6)
(2)
(1)
ON
(5)
ON
ON
ON
(9)
II-124
WSM U15-3
7) Hand off from the travel high-low SW button.
(7)
OFF
(8)
(3)
AC
ON
OFF
(10)
Start
(4)
ON-800-1
(1)
(2)
ON-801-2
(6)
(5)
(9)
8) Pull up the lever lock SW (OFF position)
No battery current flows in this system and so the travel motor runs at low speed even after leaving the
machine previously at high speed conditions.
(7)
OFF
(8)
(3)
AC
OFF
(10)
Start
(4)
ON-800-1
ON-801-2
(6)
(2)
(1)
(5)
(9)
Note :
Lever lock SW (8) was not installed as shown above for the early production machines. It was connected
with unload valve solenoid only.
Therefore, in these machines, travel speed won’t be reset to low range with the lever lock SW OFF condition.
II-125
WSM U15-3
9) Function chart : Lever lock SW isn’t wired
ON
*
Key SW
OFF
Hi-Low SW
ON
(Push & hold)
OFF
(Hand-off)
Hi-Low
solenoid
High
Low
10)Function chart : Lever lock SW is wired
ON
Main Key SW
OFF
ON
Lever lock SW
OFF
Hi-Low SW
ON
(Push & hold)
(1)
(2)
(1)
(2)
(1)
OFF
(Hand-off)
Hi-Low
solenoid
High
Low
*
Note :
Although it is technically possible to turn the main key SW ON and OFF or shift the lever lock SW Up
and Down while holding the travel high-low SW. But normally operator won’t do. This is just for your
information.
II-126
WSM U15-3
g. Meter panel
(4)
(5)
(2)
(6)
1. Installation view
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(3)
(7)
Meter panel
Main key SW
Horn SW
Hi - Low SW
Dozer lever
Accel lever
Work lamp SW
(1)
2. Mater inside view
(1) Horn meter
(2) Fuel gauge
(1)
II-127
(2)
WSM U15-3
3. Warning lamps indication
Warning Lamp "Engine Oil Pressure"
This lamp lights up when there is an abnormality in the engine
oil circulation.
It lights up when the starter switch is in position “RUN” and
goes out as soon as the engine starts running. Should the
lamp light up while the engine is running, check the engine oil
level.
Warning Lamp "Battery Charge"
This lamp lights up when there is a malfunction in the charge
system. The lamp lights up when the Starter Switch is in position “RUN” and goes out as soon as the engine starts.
Indicator Lamp "Glow"
This lamp lights up when the starter switch is in position “ON”
and goes out after the engine has been sufficiently preheated.
Warning Lamp "Fuel Level too Low"
This lamp lights up when the fuel level in the fuel tank is lower
than in the following table.
2L
(1) Fuel level indicator
The meter counts up about 1 for one operating hour. The electric meter keeps counting even when the engine is stopped but
the key is in position “ON”.
(1) Hourmeter
II-128
WSM U15-3
4. Meter structure
Fuel meter
(1) Indicator is of movable magnet type (MG-23)
and vibration-proof.
(2) Performance is as per JIS D5606.
(3) The scale graduations other than E, F and 1/2
are dummy.
Graduation specifications
Graduation
F
(1/2)
+7.5
0
Allowable error ( )
Resistance value (:)
-
10
E
0
-7.5
(38)
90
Test voltage:
DC14.5 ± 0.5 V
Test temperature:20 ± 5 °C
Test order :
Order of OFF o F o E
(Wait for longer than 3 minutes
before inspection.)
Point F
Points E and F on the scale
Point E
Details of counter
White number on black background
White number on black background
White number on black background
Indicator display
Flashing in green every 2 seconds
White number on black background
White number on black background
Black number on white background
Nippon Amp
Pin arrangement
Code No.
(1)
Illumi (+)
(11) Empty
(2)
Engine hydraulic
(12) Empty
(3)
Charge
(13) Meter power
(4)
Empty
(14) Fuel meter
(5)
Ground (lamp)
(15) Illumi, meter GND
(6)
Bi-speed travel
(16) Empty
(7)
Glow
(17) HM GND
(8)
Power (+)
(18) Empty
(9)
Fuel short alarm
(19) Empty
(10) Empty
II-129
(20) Empty
WSM U15-3
5. Meter panel circuit diagram
ON-1-8
E. Oil Pressure
Charge
ON-1-5
ON-1-2
E. Oil Press
ON-1-3
Charge
ON-1-4
ON-1-7
Travel Hi - Lo
ON-1-6
Glow
ON-1-11
Fuel
ON-1-10
ON-1-11
ON-1-12
ON-1-17
1234.5
ON-1-1
Back light
Fuel
ON-1-13
ON-1-15
Water temp
ON-1-14
ON-1-20
OFF
AC
ON-1-8
E. Oil Pressure
ON-1-2
E. Oil Press
ON-1-3
Charge
Charge
Start
ON-1-5
ON-335-4
ON-334-4
E. Oil switch
ON-28
Alternator
ON-1-4
ON-1-7
Travel Hi - Lo
ON-1-6
Glow
ON-1-11
Fuel
ON-1-10
Hi - Lo solenoid
Glow relay
ON-23-3
ON-1-11
ON-1-12
ON-1-17
1234.5
ON-1-1
ON-1-13
ON-1-15
Back light
Fuel
ON-1-14
Water temp
II-130
ON-1-20
ON-23-2
ON-23-1
Fuel sensor
WSM U15-3
Key SW at ON (AC) position
(Engine stop condition)
OFF
AC
ON-1-8
E. Oil Pressure
Charge
Start
ON-1-5
ON-1-2
E. Oil Press
ON-1-3
Charge
ON-335-4
ON-334-4
E. Oil switch
ON-28
Alternator
ON-1-4
ON-1-7
Travel Hi - Lo
ON-1-6
Glow
ON-1-11
Fuel
ON-1-10
Hi - Lo solenoid
Glow relay
ON-23-3
ON-1-11
ON-1-12
ON-1-17
1234.5
ON-1-1
ON-1-13
ON-1-15
Back light
Fuel
Water temp
II-131
ON-1-14
ON-1-20
ON-23-2
ON-23-1
Fuel sensor
WSM U15-3
6. Fuel gauge coil resistance test
Sample data : 86.8 :
between 3 : 65.8 :
terminal :
152.6 :
7. Hour meter function test LED and stepping
motor function check.
Connect the battery 12V to the white harness and the
ground to the black wire.
Check to see LED lights up every two seconds and the
internal gears are turning.
Then hour meter function is OK.
Notice :
Above two test procedures are only for your information.
II-132
WSM U15-3
h. Fuses
1. Replacing Fuses
3. Slow Blow Fuse
1) Remove the cover of the fuse box.
2) Replace the burnt out fuse with a fuse having
the same capacity.
Slow blow fuse is provided to protect the
electrical circuits. If the fusible link is blown,
check the electrical circuits for trouble and
then replace with a new compatible slow blow
fuse.
2. Fuse Capacities and Circuits
(1) Fuse box
(1) Slow blow fuse
Capacity of the slow blow fuse : 50 A
(2 pieces)
No.
Capacity
Circuit
(1)
5A
Auto glow
(2)
5A
Anti theft main
(3)
15A
Cigarette lighter
(4)
10A
Anti theft sub
(5)
5A
Auto release
(6)
10A
Beacon
(7)
15A
Work light
(8)
10A
Horn
(9)
5A
Lever lock, Travel Hi-Low
(10)
10A
Alternator, Fuel pump, Meter
(11) 5A, 10A, 15A Spare fuses
II-133
WSM U15-3
i. Auto glow circuit
OFF
Key st
ON
Key on
ON
Key SW
ON
OFF
ST
ST
OFF
ST
Glow relay
5A
Glow plug
50A
OR
Glow lamp
Water tempt sensor
t
‫ޓ‬
Auto glow controller
Battery
1. Function
1. The glow controller receives a water temperature sensor signal or a key switch start position signal and
makes the signal voltage (1) drop to the ground level. Now the current starts flowing to the relay coil.
(NOR signal circuit)
2. Turn the key switch from the OFF to ON position, and the glow relay is kept on for the time "t" as shown
in Fig. 2 (Function chart) to light up the glow lamp.
3. While the key switch is set at the ST position, the glow relay is turned on again to light up the glow lamp.
4. As indicated in Fig. 3 (Timer curve), the pre-glow time (glow lamp-on time) "t" is compensated depending
on the water temperature.
5. Once the current flows to the relay coil, the battery voltage starts flowing to the glow plug.
Reference: NOR logic circuit
Water temp sensor signal
Key SW ST signal
H
H
H
L
H
L
H
L
L
H
H
L
L
L
L
H
OR
The NOR logic circuit is a composite circuit of OR gate and NOT gate.
II-134
H: High level, 12V
Indicates that a signal voltage
is applied.
L: Low level, 0V
Indicates that no signal voltage
is applied or that the terminal
is grounded.
WSM U15-3
Fig 2. Function chart
Key Switch
Glow lamp
Pre-glow time t (SEC)
Glow relay
Sencor
Open
Water temp (°C)
Fig 3. Timer curve
Table 1. Timer function values
Water temp (°C)
Thermistor resistance (:)
Pre-glow time (sec)
140
58
2.55
100
155
2.73
80
277
2.95
60
530
3.37
40
1100
4.22
20
2525
5.85
10
3997
7.12
0
6544
8.77
-10
11123
10.81
-20
19716
12.00
-30
36630
12.00
-40
71770
12.00
II-135
WSM U15-3
2. Auto glow control circuit diagram
(3)
ON-14-3
off
on
Start
(4)
ON-14-1
ON-14-2
(5)
ON-320-2
ON-320-3
ON-34-2
ON-34-3
(6)
(9)
ON310-6
ON-320-4
ON-320-1
(7)
ON-310-2
ON-34-4
ON-34-1
ON-308-1
ON-310-1
(8)
ON-309-1
ON310-4
(11)
(10)
(12)
(2)
ON-300-3
ON-17-4
ON-17-3
ON-17-2
ON-17-1
(13)
ON-300-1
ON-300-6
(14)
ON-300-5
ON-32-2
ON-300-2
ON-301-11
ON-301-11
ON-32-1
ON-300-4
(1)
ON-115
(15)
(1)
Battery
(9)
Auto release relay
(2)
Fuse 50A
(10)
To starter motor
(3)
Key SW
(11)
From altemator
(4)
Fuse SA 5A
(12)
Glow relay
(5)
Auto release stabilizing relay
(13)
Auto glow controller
(6)
Auto release controller
(14)
Water temp sensor
(7)
Low-voltage detection
(15)
To glow lamp
(8)
Rotation detection
(16)
Glow plug
II-136
(16)
WSM U15-3
1) At key ON position :
According to the water temp. sensor signal, auto glow controller detects and calculates the required time to
glow plugs and supply the current to the glow relay to turn on.
Then the battery current flows to the glow plugs and the glow lamp.
(3)
ON-14-3
off
on
Start
(4)
ON-14-1
ON-14-2
(5)
ON-320-2
ON-320-3
ON-34-2
ON-34-3
(6)
(9)
ON310-6
ON-320-4
ON-320-1
(7)
ON-310-2
ON-34-4
ON-34-1
ON-308-1
(8)
ON-310-1
ON-309-1
ON310-4
(11)
(10)
(12)
(2)
ON-300-3
ON-17-4
ON-17-3
ON-17-2
ON-17-1
(13)
ON-300-1
ON-300-6
(14)
ON-300-5
ON-32-2
ON-300-2
ON-301-11
ON-301-11
ON-32-1
ON-300-4
(1)
ON-115
(1)
Battery
(9)
Auto release relay
(2)
Fuse 50A
(10)
To starter motor
(3)
Key SW
(11)
From altemator
(4)
Fuse SA 5A
(12)
Glow relay
(5)
Auto release stabilizing relay
(13)
Auto glow controller
(6)
Auto release controller
(14)
Water temp sensor
(7)
Low-voltage detection
(15)
To glow lamp
(8)
Rotation detection
(16)
Glow plug
II-137
(15)
(16)
WSM U15-3
2) Key SW at “start“ position :
(Engine stop condition)
(3)
ON-14-3
off
on
Start
(4)
ON-14-1
ON-14-2
(5)
ON-320-2
ON-320-3
ON-34-2
ON-34-3
(6)
(9)
ON310-6
ON-320-4
ON-320-1
(7)
ON-310-2
ON-34-4
ON-34-1
ON-308-1
(8)
ON-310-1
ON-309-1
ON310-4
(11)
(10)
(12)
(2)
ON-300-3
ON-17-4
ON-17-3
ON-17-2
ON-17-1
(13)
ON-300-1
ON-300-6
(14)
ON-300-5
ON-32-2
ON-300-2
ON-301-11
ON-301-11
ON-32-1
ON-300-4
(1)
ON-115
(15)
(1)
Battery
(9)
Auto release relay
(2)
Fuse 50A
(10)
To starter motor
(3)
Key SW
(11)
From altemator
(4)
Fuse SA 5A
(12)
Glow relay
(5)
Auto release stabilizing relay
(13)
Auto glow controller
(6)
Auto release controller
(14)
Water temp sensor
(7)
Low-voltage detection
(15)
To glow lamp
(8)
Rotation detection
(16)
Glow plug
II-138
(16)
WSM U15-3
3) After engine start running :
(3)
ON-14-3
off
on
Start
(4)
ON-14-1
ON-14-2
(5)
ON-320-2
ON-320-3
ON-34-2
ON-34-3
(6)
(9)
ON310-6
ON-320-4
ON-320-1
(7)
ON-310-2
ON-34-4
ON-34-1
ON-308-1
(8)
ON-310-1
ON-309-1
ON310-4
(11)
(10)
(12)
(2)
ON-300-3
ON-17-4
ON-17-3
ON-17-2
ON-17-1
(13)
ON-300-1
ON-300-6
(14)
ON-300-5
ON-32-2
ON-300-2
ON-301-11
ON-301-11
ON-32-1
ON-300-4
(1)
ON-115
(1)
Battery
(9)
Auto release relay
(2)
Fuse 50A
(10)
To starter motor
(3)
Key SW
(11)
From altemator
(4)
Fuse SA 5A
(12)
Glow relay
(5)
Auto release stabilizing relay
(13)
Auto glow controller
(6)
Auto release controller
(14)
Water temp sensor
(7)
Low-voltage detection
(15)
To glow lamp
(8)
Rotation detection
(16)
Glow plug
II-139
(15)
(16)
WSM U15-3
3. Auto glow controller
(C/N RC417-53791)
1) If the automatic glow controller seems to malfunction, take it out of the machine, as shown at left,
and check the performance of the controller itself
referring to the circuit diagram below.
2) The circuit diagram below shows the actual connections. In practice, apply the battery voltage
between the coupler pin 3, and ground the coupler
pin 4.
3) When the coupler pins 5 and 6 are connected as
shown in the diagram, the glow lamp stays on for a
certain period of time, and the relay gets activated,
it means that the automatic glow controller functions well.
4) If the water temperature sensor signal is not fed to
the coupler pin 2, the controller will be in action for
about 12 seconds the same way as for the -20 °C
condition.
Auto glow controller
Key SW
Glow relay
Glow lamp
Battery
Water temp. sensor
Circuit diagram to test
2
1
3
Note : If a test-purpose glow lamp is not available, set the
circuit tester to the V range and watch the tester's
pointer movement.
4
6
6
6
5
3
4
2
4
3
12 seconds: Without temp. sensor
With temp. sensor
II-140
WSM U15-3
5) Practical inspection
Checking the auto glow controller on actual machines
1. Set the key switch to AC position.
2. Make sure the glow lamp lights up.
Turn on the key switch and set it to AC
position.
Does the glow lamp light up?
No
Does the glow relay turn on?
Yes
Yes
No
The lamp does not light up if
the water temperature is over
81°C.
Check the glow relay performance.
Glow lamp broken on meter
panel.
Meter panel power failure.
Does the glow lamp go out
within the specified time?
Yes
No
Auto glow controller defective.
Auto release controller defective.
Glow lamp wrongly kept on.
(Starter possibly burnt-out)
The auto glow controller functions.
II-141
WSM U15-3
4. Auto glow circuit
1) Water temperature sensor circuit check
When the water temperature sensor and its wiring function, the engine’s water temperature is
detected and the glow plug is preheated for a time required to get the engine started.
2) First make sure the water temperature sensor functions. Disconnect the water temperature sensor coupler and put your fingers in
slight contact with the glow relay. Now turn
the key switch to the ON position and feel the
glow relay clicking.
• When it clicks, check the glow plug coupler
as well as the glow relay.
• If it does not click, measure the voltage,
check for continuity, and check the glow
relay.
3) Voltage check
• Keep the glow relay coupler in position.
• Turn the key switch to the ON position.
1. Measure the voltage between the auto
glow relay coupler terminals [3] and [4] as
well as between [1] and [2] to see if it is
12 V.
• 12 V reading for both: Check the glow
relay.
• Other reading: Measure the voltage in
Step (2) below. Also check for continuity.
2. Measure the voltage between the glow
relay coupler terminal [4] and the body
ground to see if it is 12 V.
Battery
(5A main power)
17
Glow relay
-115
II-142
WSM U15-3
4) Continuity check
• Turn the key switch to the OFF position.
• Disconnect the meter coupler .
• Disconnect the glow relay coupler .
1. Check for continuity between the auto
glow relay coupler terminal [CN300-5]
and the glow relay coupler CN terminal
[CN17-1].
2. Check for continuity between the auto
glow relay coupler terminal [CN300-3]
and the glow relay coupler terminal
[CN17-2].
3. Check for continuity between the glow
relay coupler terminal [CN17-3] and the
glow plug coupler.
4. Check for continuity between the glow
relay coupler terminal [CN17-4] and the
battery’s positive (+) terminal.
5) Glow relay check
1. Glow relay
Code No. : T1060-33711
2. Disconnect the glow relay coupler. Measure the resistance between points (1)
and (2) on the glow relay alone.
(Relay coil resistance)
Specification
52 - 80 ǡ
Actual measurement(Sample)
About 58 ǡ
3. Apply 12 V between points (1) and (2) of
the glow relay to check for continuity
between points (3) and (4).
II-143
3
6
2
1
5 4
Battery
WSM U15-3
j. Auto release control system
1. Outline
1) When the engine has started and the alternator has reached the specified rpm (N1 = 800 rpm in the figure below), the auto release controller is activated to turn off the auto release relay.
2) With the auto release relay off, the starter motor current is shut off to prevent the battery current from
flowing to the starter motor.
3) In this way, the starter motor can be protected against key seizure even if the key switch fails to get back.
(3)
ON-14-3
off
on
Start
ON-14-1
(4)
ON-14-2
(5)
ON-320-2
ON-320-3
ON-34-2
ON-34-3
(6)
(9)
ON310-6
ON-320-4
ON-320-1
(7)
ON-310-2
ON-34-4
ON-34-1
ON-308-1
(8)
ON-310-1
ON-309-1
ON310-4
(13)
ON-37
(10)
ON-113
60A
(12)
ON-114
ON-25-2
Charge
ON-25-3
(2)
ON-331-4
ON-25-1
ON-331-4
(1)
(11)
(1)
Battery
(2)
Fuse 50A
(3)
Key SW
(4)
Fuse SA 5A
(5)
Auto release stabilizing relay
(6)
Auto release controller
(7)
Low-voltage detection
(8)
Rotation detection
(9)
Auto release relay
(10)
Alternator
(11)
Meter panel
(12)
Starter
(13)
To auto glow controller
1
4
2
X
X
6
II-144
WSM U15-3
2. Auto relase control, structure and function
(1) Battery 12V
(7)
(2) Main switch
(3) Alternator
(2)
(4) P - terminal
(5)
2
(5) Low voltage detection
6V
(6) Rotation detection
6
(3)
(1)
(4)
(8)
(6)
1
650r/min 800r/min
(7) Starter relay
(Auto relase lever)
(8) Starter
4
ON
N1 :
N2 :
OFF
N1
ON
(N = 120f)
P
N2
DV)
OFF
Function :
1. After engine starts and when alternator speed reaches to set value (P-terminal = N1), then transistor of
the auto release controller turns OFF, terminal stays H-level and auto release relay gose OFF - condition.
2. While engine is running (P-terminal = N2 or more), auto release controller terminal stays H-level and
auto release relay stays OFF - condition.
Even if the main key is turned to the start - position.
3. Under the condition of low battery voltage (approx 6 V or lower) and main switch being at start position
even at any engine speed, then the transistor of the auto release controller turns ON - condition, terminal
become L-level and auto release relay gose ON - condition. Then battary current flows to the starter.
II-145
WSM U15-3
3. Key SW to engine start position
(3)
ON-14-3
off
on
Start
(4)
ON-14-1
ON-14-2
(5)
ON-320-2
ON-320-3
ON-34-2
ON-34-3
(6)
ON-320-1
(9)
ON310-6
ON-320-4
(7)
ON-310-2
ON-34-4
ON-34-1
ON-308-1
(8)
ON-310-1
ON-309-1
H
ON310-4
60A
(13)
ON-37
(10)
ON-113
(12)
ON-114
ON-25-2
(2)
Charge
ON-25-3
ON-331-4
ON-25-1
ON-331-4
(1)
(11)
(1)
Battery
(9)
Auto release relay
(2)
Fuse 50A
(10)
Alternator
(3)
Key SW
(11)
Meter panel
(4)
Fuse SA 5A
(12)
Starter
(5)
Auto release stabilizing relay
(13)
To auto glow controller
(6)
Auto release controller
(7)
Low-voltage detection
(8)
Rotation detection
1) Turn the key switch to the engine start position, and the battery voltage starts flowing as shown above
and the auto release stabilize relay (5) turns on.
2) When the relay has turned on, current starts flowing in the auto release controller (6). This allows the
base current into the transistor, which gets turned on.
3) Once the transistor has come on, the auto release relay (9) turns on too.
4) With the relay (9) now on, the battery current flows to turn on the starter solenoid switch. The start up
current from the battery then switches on the starter, which gets the engine started.
II-146
WSM U15-3
4. Key SW to AC position
(3)
ON-14-3
off
on
Start
(4)
ON-14-1
ON-14-2
(5)
ON-320-2
ON-320-3
ON-34-2
ON-34-3
(6)
(9)
ON310-6
ON-320-4
ON-320-1
(7)
ON-310-2
ON-34-4
ON-34-1
ON-308-1
(8)
ON-310-1
ON-309-1
ON310-4
60A
(13)
ON-37
(10)
ON-113
(12)
ON-114
ON-25-2
Charge
ON-25-3
(2)
ON-331-4
ON-25-1
ON-331-4
(1)
(11)
(1)
Battery
(9)
Auto release relay
(2)
Fuse 50A
(10)
Alternator
(3)
Key SW
(11)
Meter panel
(4)
Fuse SA 5A
(12)
Starter
(5)
Auto release stabilizing relay
(13)
To auto glow controller
(6)
Auto release controller
(7)
Low-voltage detection
(8)
Rotation detection
1) When the engine has got started, the operator is supposed to release the key at the engine start position. Now the key switch comes to the AC position.
2) The battery current stops flowing to the relay, which turns off the power to the starter.
II-147
WSM U15-3
5. When the Key SW is stucked at the start position
(3)
ON-14-3
off
on
Start
(4)
ON-14-1
ON-14-2
(5)
ON-320-2
ON-320-3
ON-34-2
ON-34-3
(6)
(9)
ON310-6
ON-320-4
ON-320-1
(7)
ON-310-2
ON-34-4
ON-34-1
ON-308-1
(8)
ON-310-1
ON-309-1
L
ON310-4
60A
(13)
ON-37
(10)
ON-113
(12)
ON-114
ON-25-2
Charge
ON-25-3
(2)
ON-331-4
ON-25-1
ON-331-4
(1)
(11)
(1)
Battery
(9)
Auto release relay
(2)
Fuse 50A
(10)
Alternator
(3)
Key SW
(11)
Meter panel
(4)
Fuse SA 5A
(12)
Starter
(5)
Auto release stabilizing relay
(13)
To auto glow controller
(6)
Auto release controller
(7)
Low-voltage detection
(8)
Rotation detection
1) The key switch may get stuck for some reason. Even if the engine has got started and the operator has
released the key, the key switch does not come back to the AC position.
2) With the key switch at the start position, the battery current starts flowing to turn on the auto release stabilize relay (5).
3) But the alternator (10) is sending the turning signal to the auto release controller (6). In so doing, the
turning detection function gets activated and the auto release relay (9) turns off.
4) In this way, the battery current stops flowing to the starter (2). It helps protect the starter against burnout.
II-148
WSM U15-3
6. Key to the start position while engine is running
(3)
ON-14-3
off
on
Start
(4)
ON-14-1
ON-14-2
(5)
ON-320-2
ON-320-3
ON-34-2
ON-34-3
(6)
(9)
ON310-6
ON-320-4
ON-320-1
(7)
ON-310-2
ON-34-4
ON-34-1
ON-308-1
(8)
ON-310-1
ON-309-1
L
ON310-4
60A
(13)
ON-37
(10)
ON-113
(12)
ON-114
ON-25-2
Charge
ON-25-3
(2)
ON-331-4
ON-25-1
ON-331-4
(1)
(11)
(1)
Battery
(9)
Auto release relay
(2)
Fuse 50A
(10)
Alternator
(3)
Key SW
(11)
Meter panel
(4)
Fuse SA 5A
(12)
Starter
(5)
Auto release stabilizing relay
(13)
To auto glow controller
(6)
Auto release controller
(7)
Low-voltage detection
(8)
Rotation detection
1) Let's suppose that the operator turns the key to the start position while the engine is running.
2) In this case too, the turning signal comes from the alternator (10) as discussed before. In other words,
the auto release relay (9) remains off.
7. Function of low-voltage detection
When battery voltage decreases down below 5 to 6 V at the cold start, this low-voltage detection functions to turn on the transistor and so turn on the auto release relay unconditionally.
II-149
WSM U15-3
8. Auto release and auto glow circuit combined
Glow plug
Glow lamp
II-150
WSM U15-3
k. Water temp. sensor & gauge
Thermister
(1)
(1)
(1) sensor
1. Water temp. sensor circuit malfunction
Water temp. sensor signal is sent to the auto glow controller.
1) Check couplers
Pull the harness to see if the water temperature sensor coupler is not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or
less force.)
• If out of position, attach the coupler tightly and check
the lamp and gauge again.
II-151
WSM U15-3
2) Check battery voltage at (+) terminal of harness coupler.
If no battery voltage, check the fuse and continuity of
wireharness.
Sample data is 0.979V.
3) Water temperature sensor check
• Disconnect the coupler from the water temperature sensor and measure the resistance referring
to the figure at right.
The temperature vs. resistance curve must meet
the criteria listed below.
Resistance (k:)
-20
18.80 ± 12.6%
40
1.136 ± 8.4%
100
0.1553 ± 4.5%
Resistance (:)
Temp (°C)
Water temp. vs Sensor resistance
Water temp. (°C)
II-152
WSM U15-3
l. Fuel control circuit
(1) Function)
OFF
Fuel pump
AC
B
ON-24-1
10A
ON-24-2
Start
ON-1-8
E. Oil Pressure
Charge
ON-1-5
ON-335-4
ON-1-2
E. Oil Press
ON-1-3
Charge
ON-334-4
E. Oil switch
ON-28
Alternator
ON-1-4
ON-1-7
Travel Hi - Lo
ON-1-6
Glow
ON-1-11
Fuel
ON-1-10
ON-36-2
ON-36-1
Engine stop SOL
Hi - Lo solenoid
Glow relay
ON-23-3
ON-1-11
ON-36-1
ON-23-2
ON-1-12
ON-1-1
Back light
Fuel
ON-1-13
ON-1-15
ON-23-1
ON-1-17
1234.5
15A
Fuel sensor
Water temp
ON-1-14
ON-1-20
Engine stop solenoid
Solenoid guide
Stop lever
Injection pump
Engine stop solenoid
Idling limitter
Control rack
1. The fuel control circuit is mainly composed of the following devices.
1)Fuel feed pump
2)Engine stop solenoid
3)Fuel gauge
4)Fuel sensor
5)Fuel residual sensor
2. The fuel sensor detects the position of the float and the remaining fuel amount is displayed in the fuel
gauge.
3. The fuel residual sensor has a thermistor. When the sensor is well below the fuel level, the resistance
value is high enough to allow no current to the warning lamp. If the fuel level has dropped below specified, however, the thermistor gets exposed to the air and becomes smaller in resistance. This allows the
current to flow to the warning lamp that will light up.
II-153
WSM U15-3
m.Engine stop solenoid
1. Structure
Suicide switch
filter
plunger
spring
holding coil
:DC12V
:32A / DC12V
:77A / DC12V
at 20°C
3. Resistance (Sample data)
Pull-in coil
: 0.3 ~ 0.8 :
Hold coil
: 15.0 ~ 16.0 :
Pull-in coil
Pull-in coil
oil seal
Holding coil
plunger
Holding coil
Pull-in coil
Specifications
1. Rated voltage
2. Rated ampare
Pull-in coil
Hold coil
The engine stop solenoid circuit is as shown at left.
Turn the key switch to the ON position, and the battery current flows both to the pull-in coil and the
holding coil. These coils are excited to attract and
lift the plunger.
Now the fuel injection pump is ready to get the
engine started.
Being attracted upward, the plunger pushes and
opens the contact, which discontinues the current
flow to the pull-in coil.
With the current still flowing to the holding coil, the
plunger stays in this position.
Turn the key switch to the OFF position, and the
current flow to the holding coil is also interrupted.
By the force of the return spring, the plunger comes
back to the original position. By so doing, the fuel
injection pump will be back to the engine-off status.
Solenoid voltage
2. Circuit and its function
Temp.
II-154
WSM U15-3
3. Engine stop solenoid
(C/N 1A021-6001-3)
Operation of engine stop solenoid can be test as in the pictures.
1) Connect 12 V battery voltage to two terminal of engine stop
solenoid.
2) Get body earth as shown in picture.
3) Then plunger pin comes out.
This means pull-in coil is normal.
4) Take off pull-in coil terminal connection.
5) Plunger pin still keeps pushing out.
This means hold-coil is normal.
6) Take off second terminal connection.
7) This time plunger pin should be returned back by spring.
This means engine stop solenoid functions normal.
Pull-in coil
Hold coil
Connector
Pull-in coil
Battery
II-155
Hold coil
WSM U15-3
n. coil commander
1. Location
The coil commander is connected with the
engine stop solenoid as shown in the picture.
(1)
(1) Coil commander
Resistance (Sample data)
Red l Black : 21.2 :
White o Black : 77.1 :
2. Circuit diagram
Hold
(Red)
Pull
(white)
Pull
coil
Hold
coil
Timer
circuit
FE Transistor
Gnd
(Black)
Coil commander
Engine stop solenoid (pull in type)
3. Function
Under some condition, such as low temp, large current flows to pull coil and may cause to cut the coil.
Coil commander is to regulate the current flow to pull coil by controlling the current time according to the
temperature
Temperature vs Current Time
II-156
WSM U15-3
4. Inspeetion & troubleshooting
1) Check the continuity of hold coil.
2) Check pull in coil function after wiring 12V to red and while terminal and ground to black color terminal.
Then engine solenoid functions and pull in the plunger head.
Photo : pull in condition
Photo : hold condition
II-157
WSM U15-3
o. Fuel sensor
1. Fuel sensor
(8)
(7)
* Insulation resistance: Over 3 M :
(measured with DC500V megger)
(9)
(11)
(10)
(12)
(13)
(15)
(14)
(16)
(17)
(23)
(22)
(18)
(24)
(19)
(21)
(20)
(1)
Lock collar assembly
(13)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Cord assembly
Float
Float arm
Mount spacer
Thermistor assembly
(Tank mounting pan-head screw dia.)
Terminal to be retightened GND (black)
F. unit (blue)
Thermistor (red)
(Tank hole)
Sealing compound to be applied
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Connector housing: Sumitomo HM090, water-proof, SPM
Sumitomo Denso Part Code (6187-3801)
Heat fusion
GND AV0.5f (black)
Unit AV0.5f (blue)
Thermistor AV0.5f (black)
When mounted
Manufacturing date code stamped (Black indelible ink)
Soldered
Remaining-fuel sensor action level
(Fuel shortage warning level: Production Control Dimension)
Fuel shortage warning
Terminal not atop lock collar
II-158
WSM U15-3
Fuel tank
Light oil or light oil gas
Water or mud deposits possible on flange surface
DC 12V
DC 10 ~ 16V
Float position
Full
1/2
Empty
Resistance (:)
3
32.5
110
Allowable error (:)
±2
±5
±5
DC14V
Thermister
Circuit diagram
To be measured with constant current of 40 mA.
2. Fuel sensor testing
Sample data at certain amount of fuel.
Red
(1466 )
(1358 )
( 108 )
Blue
Black
1) Pull the harness to see if the fuel sensor couplers and
the relay couplers are not out of position. Be sure that
the coupler harness is tightly connected.
• If out of position, attach the coupler tightly and check
the meter reading again.
Gauge
Fuel
Unit
12V 3.4W
Thermister
II-159
WSM U15-3
2) Check battery voltage at (+) terminal of wireharnesscoupler.
If no battery voltage, check the fuse and continuity of
wireharness.
3) Fuel sensor check
• Apply the positive (+) test lead to the coupler-fitted
terminal.
• Apply the negative (-) test lead to the plated part to
measure the resistance.
• Ref. value
Float position
Resistance (:)
F
1/2
E
3 ± 1.5
32.5 ± 1.5
110 ± 3.5
4) Directly connect the (+) terminal of wireharness coupler to the earth.
Then meter gauge indication raises gradually up to full
range.
Because resistance is 0:
In this case, meter gauge function is normal.
II-160
WSM U15-3
p. Engine oil pressure sensor circuit
OFF
AC
Change
Start
High - Low
Fuel residual
1. Engine oil pressure sensor is N.C.(Normal close) type.
2. Check relay is N.O.(Normal open) type.
3. Meter panel (Big): (1)Engine oil pressure line.
(1) In normal
(2)Battery IG(+)
(3)Charge line
(4)Check relay line
(1)
Oil switch
(2)
1.
2.
3.
4.
5.
Code No, :15531-39011
DC12V
Warning lamp :SW
Operating pressure :0.5 ± 0.1 kgf/cm2
Insulation resistance :3M: or more
(3)
(4)
(1) In normal condition
When the engine lube oil pressure goes up, the
contact of oil switch 6 opens to turn off the lamp.
(2) In trouble
When the above pressure comes down, the
contact of oil switch 6 closes to turn on the lamp.
Operating pressure of oil switch
······Ref. value : 0.5 kgf/cm2 , 7.1 psi, 0.05 MPa
(1) Turminal
(5) Contact revet
(2) Insulator
(6) Contact
(3) Spring
(7) Body
(4) Rubber
II-161
(5)
(6)
(7)
(2) In trouble
WSM U15-3
q. Engine electrical system
1. Engine oil pressure failure
1) Check engine oil pressure lamp.
Engine Condition
Lamp condition
Normal
Trouble case (1)
Trouble case (2)
Before engine starts
ON
ON
OFF
After engine starts
OFF
ON
OFF
Trouble case (1) :Engine oil pressure is low or oil switch fails.
Trouble case (2) :Wire harness is cut or oil switch fails.
2) Check oil amount and replenish if nessesary.
3) Pull the harness to see if the oil switch coupler is not
out of position. Be sure that the coupler harness is
tightly connected. (Pull by a 3 kg or less force.)
• If out of position, attach the coupler tightly and check
the meter reading again.
4) Check battery valtage at (+).
Terminal of wireharness coupler. If no battery voltage,
check the fuse and continuity of wireharness.
5) Check continuity of oil switch between switch terminal
and body earth.
Engine condition
Continuity of oil switch
Engine stop
Yes
Engine starts
No
Engine oil switch is NC (Normal close) type.
(1)
(1) Engine oil pressure sensor (NC)
II-162
WSM U15-3
6) Check engine oil pressure
Idling rpm
0.4 MPa(4 kgf/cm2)
MAX. rpm
0.6 MPa(6 kgf/cm2)
• Oil switch operating pressure
Ref. value:0.05 ± 0.01MPa (0.5 ± 0.1kgf/cm2)
Oil switch Condition
Engine
stops
Engine
starts
II-163
Engine
oil
pressure
WSM U15-3
r. Horn circuit
1. Structure
(1)
(2)
(1)
(2)
(3)
(4)
Diaphram
Point
Horn coil
Nut
(5) Stop screw
(6) Stay
(7) Air gap
(7)
(6)
(3)
(4)
(5)
The horn consists of acoustic diaphragm, point, horn coil and other parts. It comes in spiral, flat and
other types in construction.
Currently, the flat type is most widely used. A typical flat horn is shown at right.
(1) Battery
(2) Horn switch
(3) Horn relay
(4) Diaphram
(5) Core
(6) Coil
(7) Moving bolt
(8) Adjust nut
(9) Moving plate
(8)
(3)
(9)
(6)
(1)
(2)
(5)
(4)
(7)
2. Function
Shown above is the horn drive circuit. When the horn switch is pressed, current flows to the horn relay to
get its contact P1 closed. The current from the battery now flows directly through the horn coil and the
contact P2, which magnetizes the core and attracts the moving plate. Then the contact P2 opens itself
and the current is interrupted. The magnetic force then disappears and the spring-loaded diaphragm
comes back to the original position. The contact P2 closes itself, and the current flows again through the
coil to attract the moving plate. The above series of actions are repeated to keep the diaphragm vibrating, producing sound.
II-164
WSM U15-3
3. Current flow
(3)
(8)
(9)
(6)
(1)
(5)
(2)
(7)
(4)
(1) Battery
(2) Horn switch
(3) Horn relay
(4) Diaphram
(5) Core
(6) Coil
(7) Moving bolt
(8) Adjust nut
(9) Moving plate
Horn
Relay
Diode
Switch
For your information
1. Function of diode: Prevention of horn switch by absorbing the surge current.
Inductive type of load, such as solenoid valve generates arc spark at switch point.
This diode installed parallel to solenoid valve let the surge current energy flow back to coil to consume
as a joule heat.
In this way, surge current won't flow to horn switch.
II-165
WSM U15-3
4. Horn circuit
• When horn switch is off, current
doesnít flow through relay.
So relay remains off condition and
horn doesnít sound.
(Horn SW is off position)
Horn SW
Horn
GND
Diode
• When horn switch is on position, current flows through relay, magnetizes
it and activates horn.
(Horn SW is on position)
Horn SW
Horn
GND
Diode
II-166
WSM U15-3
s. Charging system (Alternator)
1) Alternator structure (Code No. 16678-64012)
Nameplate (brown)
Terminal B: M6
(Terminal B nut tightening torque
ng
n
io
ct
re
di
i
rn
Tu
To
p
dir
ec
tio
np
(Shaft center reference)
res
ett
ab
le
ran
ge
(Theoretical value)
Nameplate
Flat area
Frame ID projection
presettable range
Anti-corrosion treatment
Rear cover ID projection
presettable range
Allowed if no ND marking
Connector pin layout
II-167
(1) Pulley
(2) Nut
(3) Collar, space
(4) Frame assembly, drive end
(5) Bearing, ball
(6) Plate, retainer
(7) Screw
(8) Bolt, stud
(9) Rotor assembly
(10) Bearing, ball
(11) Cover, bearing
(12) Frame, end, rear
(13) Holder subassembly, rectifier
(14) Holder subassembly, brush
(15) Regulator assembly
(16) Screw, with washer
(17) Screw with washer
(18) Bolt, with washer
(19) Screw with washer
(20) Bolt, with washer
(21) Cover, end, rear
(22) Insulation bushing, terminal
(23) Nut
(24) Nut
(25) Washer
WSM U15-3
2) Circuit diagram
IC regulator
Alternator assembly
3) Specifications
(3.5V constant, ambient temperature 25 °C)
When cold
Output current (A)
When hot
Alternator turning speed (x103 rpm)
Rated voltage
12 V
Rated output (13.5 V when hot)
40 A (500rpm)
Startup rpm (13.5 V when hot)
1350 rpm
Allowable maximum rpm
15000 rpm
Allowable ambient temperature
-30 °C ~ 90 °C
Turning direction
Right (when viewed from pulley)
Polarity
Negative-side grounding
Weight
About 2.75 kg
Initial excitation function
Total excitation
Allowable input load at terminal L
Lamp 12V: 3.4W x 6 pcs.
Potential at terminal L
Generation off: Below 1.5V (With alarm
on) (12V applied at terminal IG)
Output current at terminal P
Average current: Below 0.5A
Vibration proof
(overall value of alternator itself)
Up/down, right/left: 290 m/s2
To-and-fro (axial): 250 m/s2
Belt tension (Type HM)
270 ~ 444 N
Regulator set voltage
14.2 ~ 14.8 V / 500rpm, 10A, 25 °C
Set voltage vs. temperature
Set voltage (V)
Standard characteristics
Regulator case surface temperature ( °C)
Alarm function: Broken rotor coil
II-168
Charge lamp light-up
WSM U15-3
4. Charging system malfunction
1) Check charge lamp condition.
Engine Condition
Lamp condition
Normal
Trouble case (1)
Trouble case (2)
Engine stops
ON
ON
OFF
Engine starts
OFF
ON
OFF
Trouble case (1):Fan belt breakage, B-terminal failure charging system malfunction.
Trouble case (2):Wireharness problem, L-terminal failure
2) Pull the harness to see if the alternator coupler is not
out of position. Be sure that the coupler harness is
tightly connected. (Pull by a 3 kg or less force.)
• If out of position, attach the coupler tightly and check
the lamp.
3) Check for continuity to make sure the 60A slow-blow
fuse (60A) is not blown out.
4) Check for continuity to make sure the 15A fuse is not
blown out. (For the travel hi-speed and fuel pump)
• If this fuse is blown out, both the fuel pump and
travel hi-speed control do not work.
II-169
WSM U15-3
5) Check battery voltage at B-terminal of wireharness coupler.
If no battery voltage, check the fuse and continuity of wireharness.
6) Alternator B-terminal check
1)Measure the voltage between the alternator’s terminal B and the body ground. Make sure the measurement is 12 V or so. If the measured voltage is lower
than this, it means that the battery capacity may be
low or that the wire connections before the alternator
may be loose.
2)Next start the engine and measure the voltage being
generated while the alternator is running. For this,
measure the voltage between the alternator’s terminal B and the body ground. Make sure the measurement goes up to 14 V or so (alternator-generated
voltage). If the measurement is still the battery voltage (12 V or so), it means that the alternator or the
regulator may be in trouble.
7) P-terminal check
P-terminal signal indicates the alternator speed.
This pulse signal is sent to the auto release controller terminal (CN-310-1) to detect the engine rotating
condition.
Alternator assembly
II-170
IC regulator
WSM U15-3
t. Relay
1. Relays location
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(N) (G) (H) (I)
Starter lock relay
Auto release relay
Auto release stabilizer relay
ESS relay
Lever lock relay
Cab relay
First self hold relay
Reverse relay
(J) (K) (L)
(I) Second self hold relay
(J) Self hold release relay
(K) Travel high relay
(L) Horn relay
(M) Auto release controller
(N) Auto glow controller
(D)·(E) Anti theft version only
2. Purpose of relays
Electrical devices on the load side - heater, glow plug,
(M)
(A) (B) (C) (D) (E) (F)
cab instruments, for example - tend to require large
current. This means that the wire harnesses running
the power source up to the switches and loads must involve thick, large-capacity cables. This is disadvantageous in costs, weight and safety. What's worse, turning on and off a large-current circuit with a
manual switch may cause a spark and get the switch in trouble.
Here come the relays in the switching circuits. The relays can be on/off-controlled using fine, small-current cables, and the switches can last longer. These switches may also be conveniently located.
A large-capacity harness may be connected from the power source via the relay to the load. In this
design, the harness is made shorter, less expensive, and safer.
1) Switch OFF
2) Switch ON
Relay
Relay
sw
Load
sw
Load
Type of relay
Normal open relay (a-type)
Power-on state
Normal state
Contacts marked with white dots
Normal close relay (b-type)
Combined relay
Contacts marked with black dots
No current flowing
Current flowing
Current flowing
No current flowing
Current flowing
No current flowing
No current flowing
Current flow
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WSM U15-3
3. Structure of relay
Fig. in the left shows the sample of relay
Starter lock relay (N.C)
Code No. : RB419-5371-1
(1)
Body
(2)
Case
(3)
Coil bin
(4)
Terminal
(5)
Iron
(6)
Core
(7)
Coil
(8)
Spring
(9)
Contact
(10) Terminal
(11) Terminal
(12) Common
(13) Terminal
(14) Adhesive
(15) Rubber bracket
Battery
side
B
G
g
e
Load
side
4. Specifications
(Sample relay : starter lock relay)
1) Product name: CA relay
2) Code: CA1b-12V- -5
3) Type: 1b, Brushseal, 12V
4) Performance
(1) Coil ratings
1. Rated operating voltage
: DC 12 V
2. Operating voltage (initial, at 20 °C) : Below DC 8 V
3. Open-circuit voltage (initial, at 20 °C) : DC 0.6 ~ 6.0 V
4. Coil resistance (at 20 °C)
: 80 : ± 10 %
5. Rated excitation current (at 20 °C) : 150 mA ± 10 %
6. Rated power consumption
: 1.8 W
(2) Contact ratings
1. Contact type
2. Contact material
3. Contact resistance (initial)
4. Contact voltage drop
(after electrical service life)
5. Rated control capacity
6. Maximum duty current
(at 20 °C, for 1 minute)
: 1b
: Special silver alloy
: Below 50 m: (DC6V, 1A, fall-of-potential method)
: Below 0.3 V (DC12V, 20A, fall-of-potential method)
: 20A, 12 VDC, resistance load
: 12A (coil-applied voltage DC 14V)
II-172
WSM U15-3
5. Checking relays
1) When current flows through the coil of a relay, its core is
magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is
turned off, the iron piece is made to return to its original
position by a spring, opening the contact (OFF).
2) By using a relay, a heavy current can by turned on and off
by a switch of small capacity. For example, in the circuit
shown here, when the switch is turned on (closed), current
flows to the coil of the relay. Then, its contact is turned on
(closed) and the light comes on. The current flowing at this
time to the switch is the relay coil current only and is very
small.
3) The relays may be classified into the normal open type
and the normal close type by their contact construction.
NOTE
The deenergized state means that no current is flowing
through the coil and the energized state means that current is flowing through the coil.
When a normal close type relay as illustrated here is
checked, there should be continuity between terminals (1)
and (2) and between terminals 3 and 4 when the relay is
deenergized, and the continuity should be lost between
terminals 3 and 4 when the battery voltage is applied to
the terminals I and 2. A relay can be checked in this manner and it cannot be determined if a relay is okay or faulty
by checking its state only when it is deenergized (or energized).
II-173
WSM U15-3
u. Route of Electric Wiring
1. Unloading, horn
(2)
(3)
(4)
(1)
(5)
(1)
(2)
(3)
(4)
(6)
(5)
(6)
(7)
(8)
(9)
(7)
(8)
Fix it at 2 positions from inside.
Unloading switch
Connector
Clamp the cable once when it comes out of
the hole.
Clamp and pass it through the hole 5.5.
Branch of wire harness
Pass it behind the round bar.
Clamp it at 2 positions.
Insert a clip into the swivel frame.
(9)
Wiring of the horn switch at the right of the operation stand
(1) One-finger clearance should be secured
after clamping the cables and turning the
lever in every direction.
(2) Length to the clamp: 200 mm
(3) Caulk it by caulking tool.
(4) Clamp (134L)
(5) The connector at main wire harness side
and the clamp at wiring side should be fixed
firmly to the bracket.
(6) Clamp (112L, 2-3. 2T)
(5)
(6)
(1)
(2)
(3)
(4)
II-174
WSM U15-3
2 Route of Electric Wiring (Engine Rear)
(1)
(4)
(5)
(3)
(2)
(6)
(9)
(12)
(7)
(11)
(8)
(10)
(1)
(2)
(3)
(4)
(5)
Theft-proof key setting terminal
Key setting connector
Slow-blow fuse
Direct the fuse box so that the slot comes to the right.
Pass the battery cord, dozer cable and wire harness to the theft-proof unit through the hole of the vertical
rib.
(6) Insert RA221-5322' battery cord (Plus) into the threaded hole from the front side of the mount.
(7) Facing directly above
(8) Clamp the wire harness and the rubber cap after assembling the terminal.
(9) Pass the power cord through the upper hole.
(10)Pass the minus cord through the lower hole.
(11)The minus terminal should be directed abeam at the machine front.
(12)Pass the plus power cord behind the arch.
II-175
WSM U15-3
3. Route of Electric Wiring (Engine Upper Side)
(8)
(9)
(1)
(2)
(7)
(3) (4)
(5)
(6)
(11)
(12)
(13)
(14)
(10)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Glow, engine stop solenoid
Unloading valve, meters, relays, etc.
Key setting
(Downwards) Power supply, theft-proof unit
Fuse
Alternator, starter motor
Facing directly above
Unloading: Left hole
Green-colored wire harness
Upper solenoid
(9) 2-speed:
Right hole
Yellow-colored wire harness
Lower solenoid
(10)Ground wire
(11)Connect the engine stop solenoid.
(12)Glow terminal:Tighten it to face the right side of the machine.
(13)Tighten the clamp (RP821-6738') to the water flange together with the stay (wire harness 1, boom 3).
(14)Insert a clip.
II-176
WSM U15-3
4. Route of Electric Wiring (Starter Motor, Body Grounding)
(1)
(2)
(3)
(4)
(5)
(7)
(6)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(8)
Cord (Body grounding)
Battery cord (Plus)
Facing directly below
Facing directly above
Mount it into the lower hole.
Projection (Rear side)
Cover (Right)
Groove
Starter switch
II-177
(9)
WSM U15-3
5. Route of Electric Wiring (Right Side of the Operation Stand)
Connect the black relay (T1060-3372' Relay (Starter)) to the black connector and the blue relay (RB4195371' Relay (Starter, NC)) to the blue connector.
(1)
(2)
(1)
(2)
(3)
(4)
(5)
(4)
Controller (Auto-glow)
Bolt x 1
Controller (Safety)
Relay (Glow)
Machine Front
(3)
Note : Mount the starter switch after passing
the antenna cable.
(6)
(7)
(8)
(6) Antenna (Theft-proof)
(7) Starter switch
(8) Bolt
The parts shown in the frame are provided for
theft-proof specification only.
(5)
Application of Relays
Color
Wire color
A
Starter lock relay
Blue
Green/White wire, Yellow, Black/White wire, Red/Black wire
B
Automatic release relay
Black
Yellow, Black/White wire, Black/White wire, Black/White wire
C
Automatic release stabilizing relay
Black
Black/White wire, Red/Black wire, Black/White wire, Black/White wire
D
ESS relay
Black
Red/White wire, Red/White wire, Red/Black wire, Red/White wire
E
Lever lock relay
Black
Red/White wire, Green/White wire, Red/Black wire, Blue/White wire
F
Cab relay
Black
G
First self hold relay
Blue
H
Reverse relay
Blue
I
Second self hold relay
Black
J
Self hold release relay
Black
K
Travel high speed relay
Black
L
Horn relay
Black
The relays shown in the frame are provided for theft-proof specification only.
II-178
WSM U15-3
6. Route of Electric Wiring (Front)
(1)
(2)
(3)
(5)
(4)
(1) Connect the red wires and yellow wires in their respective groups and fix them to the working light frame
by cord clamps.
(2) Clamp the position marked with white tape outside the hole.
Use care so that the wire harness should not be drawn into the hole.
(3) Tighten the black wire together with the bolt.
(4) Pass it under the boom pin.
(5) Fix the clip to the metal.
II-179
WSM U15-3
II-180
WSM U15-3
v. Electrical component layout
Key switch panel
Controller (Auto Glow)
Unload valve
Back of engine
Stop solenoid
Fuse, slow-blow fuse
Thermal unit
Lock lever limit switch
Glow
Ground
Battery
Oil switch
High-speed switch
Alternator
Fuel sensor
Horn
Horn
Lamp
Relay
Fuel pump
II-181
Starter motor
WSM U15-3
w. Electric Circuit
Lever lock
Key switch
Lever lock switch
Dual-speed
Lever lock
Automatic release stabilizing relay
Automatic release controller
Automatic release relay
Low-voltage
detection
Rotation
detection
Starter
Glow relay
Auto glow
Glow plug
Auto glow controller
Fuel pump
Meter, alternator, fuel pump
Water temperature sensor
Alternator
Engine stop
Battery
2004.11.16
II-182
WSM U15-3
1. Battery direct line and ground (Earth) line
Lever lock
Key switch
Lever lock switch
Dual-speed
Lever lock
Automatic release stabilizing relay
Automatic release controller
Automatic release relay
Low-voltage
detection
Rotation
detection
Starter
Glow relay
Auto glow
Glow plug
Auto glow controller
Fuel pump
Meter, alternator, fuel pump
Water temperature sensor
Alternator
Engine stop
Battery
2004.11.16
II-183
WSM U15-3
2. Key switch ON (AC - position)
Lever lock
Key switch
Lever lock switch
Dual-speed
Lever lock
Automatic release stabilizing relay
Automatic release controller
Automatic release relay
Low-voltage
detection
Rotation
detection
Starter
Glow relay
Auto glow
Glow plug
Auto glow controller
Fuel pump
Meter, alternator, fuel pump
Water temperature sensor
Alternator
Engine stop
Battery
2004.11.16
II-184
WSM U15-3
3. Key switch to the start position
Lever lock
Key switch
Lever lock switch
Dual-speed
Lever lock
Automatic release stabilizing relay
Automatic release controller
Automatic release relay
Low-voltage
detection
Rotation
detection
Starter
Glow relay
Auto glow
Glow plug
Auto glow controller
Fuel pump
Meter, alternator, fuel pump
Water temperature sensor
Alternator
Engine stop
Battery
2004.11.16
II-185
WSM U15-3
4. Engine running at travel high renge
ON
Lever lock switch
Lever lock
Key switch
Dual-speed
Lever lock
Automatic release stabilizing relay
Automatic release controller
Automatic release relay
Low-voltage
detection
Rotation
detection
ON
Starter
Glow relay
ON
Auto glow
Auto glow controller
OFF
Glow plug
Fuel pump
Meter, alternator, fuel pump
Water temperature sensor
OFF
Alternator
ON
OFF
ON
Engine stop
Battery
ON
OFF
ON
2004.11.16
II-186
WSM U15-3
x. Electrical Wiring diagram
Japan/EU
Japan/EU
Japan/EU
Soldered to terminals 1 & 3
Japan/EU
Japan
Japan
USA/ (KX91, U35)
Japan/EU
Japan
Japan/EU
Japan/EU
Japan
LA terminal
Soldered
Soldered
KTA
Soldered
Soldered
LA terminal
Battery positive terminal
2004.11.16
II-187
WSM U15-3
Japan/EU
Japan/EU
Japan/EU
Soldered to terminals 1 & 3
Japan/EU
Japan
Japan
USA/ (KX91, U35)
Japan/EU
Japan
Japan/EU
Japan/EU
Japan
LA terminal
Soldered
Soldered
KTA
Soldered
Soldered
LA terminal
II-188
Battery positive terminal
ss
Conversion Tables
KUBOTA Corporation
CONSTRUCTION MACHINERY DIVISION
1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN
EDITOR:
CONSTRUCTION MACHINERY MANUFACTURING DEPT.
SERVICE ENGINEERING SECTION
HIRAKATA PLANT
1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN
PHONE :+81-72-890-2888
FAX
:+81-72-890-2886
KUBOTA Corporation
Printed in Japan 0503.CMC.e.12
Code No.97899-61270