PDF Service Manual TCM E803 E804 E805 E806 Wheel Loader - 3 MB
This is the official service manual for the TCM E803, E804, E805, and E806 series wheel loaders.
It provides comprehensive technical information for maintenance, troubleshooting, and repair.
This guide is essential for service technicians, offering detailed procedures and specifications for all major systems.
Ensure your TCM wheel loader is maintained to factory standards with this manual.
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0．SPECLFICAT10NS
〕oLlOUTERV［EWS
Unit：mm（in）
同 （つ r
卜、寸Ln⊂〉 凹同寸⊂） ▼−￣
ヽ．ノ
︑︑−ノ
ヽjノ
Fig．0．10uterView（E803）
−1一
--- Page 4 ---
2．OuterViewsofEngine
（l）DllO5・KADieselEngine
1．WERTEMPERArURE
GAUGESENSORFITTING
PORT
2．ALrERNATOR
3．CABHEATERⅥ仏TER
INLET
4．COOLINGWERINLET
5．OmPRESSURESWITCH
FITTING PORT
0
1
6．0ILFILTER
7．WERDRAINCOCK
8．WERTEMPERATURE
1
1
SENSOR（FORGLOW）
＼lノ／
9．EXHAUSTMANIFOLD
5
lO．SIARTERMOTOR
2
−
ll．FI＿YWHEELHOUSING
6
12．CRANKCASE
13．0ILPAN
7
＼ノ
14．NOZZLEHOLDER
15．CYLINDERHEADCOVER
16．INLETMANIFOLD
17．CYLINDERHEAD
18．ENGINESTOPSOLENOID
19．COOLINGWEROUTLET
20．CABHEATERⅥ仏TER
OUTLET
21．FUELSUCTIONPIPE
（FROMFUELPUMP）
22．INJECTIONPUMP
23．COOLINGFAN
24．Ⅴ月EIJ
＼1．．ノ
Fig．1．2 DllO5−KADieselEngine
−11一
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（Unit：mm（in））
Float Resistance
POSition （n）
FULL 10：
3／4 （19）
1／2 32±3
＼−ノ
1／4 （49．5）
EMPTY 80：圭2
﹁ノ
Fig．1．11FuelLevelSenderUnit
︑︶・
−21−
--- Page 6 ---
2．1HSTUN［T
2．1．1HYDRAULICDRIVE
l．GeneralDescription
Hydraulicdrivesconvertenginepowernrsttofluidpowerandthentomechanicalpower（1inearorrota
tionalmotion）whichdrivesthewheelsorothercomponents・Thefluidtobeusedismineralhydraulicoil
thissense，yOuCanCallallhydraulicdrivesatypeofhydrostatictransmission（HST），However，thehydro−
Statictransmission（HST）general1ymeansthekindofhydraulicdrivethattransmitsonlyrotationalpower．
Hydraulicdrivesareclassinedintotwotypes：thehydrostatictypewhichusespressureenergyandthe
hydrodynamictypewhichuseskineticenergy・
（1）HydrodynamicUnit
Thehydrodynamicunituseskineticenergyproduced
byfluidflowlngatahighspeed．Thehigh−SPeed，low−
PreSSurefluidisdischargedftomthecentrifugalpump，hits
theturbinewheelbladestoturntheturbinewheelandthus
thetutbineshaft，OutOfwhichtherotationalpoweristaken．
ThetorqueconverterisatypICalhydrodynamicunitandis
usedforwhee1loadersandothervehicles．
Fig．2．3
（2）HydrostaticUnit
Thehydrostaticunituseshigh−PreSSure，low−SPeedfluid
（Oilpressure）．Thepressureoildischargedfromthepump
issenttothehydraulicmotorwhichisinturnrotatedto
tranSmitthepowertothedrivewheels・Thiskindofhydro−
Staticunitiscalledahydrostatictransmission（HST）．The
HSTpumpandHSTmotorformaclosedloop；theyare
COnneCtedthroughthehydrauliclinessothatthefluidflows
betweenthepumpandmotor．Sincethefluidisnon−COm−
PreSSive，itactsas arigidlinkthatconnectsthepumpto
themotor．Thiskindofunitisusedforskidsteerwheel
loadersandsmall−Sizedwheelloaders．
Fig．2．4
ー31−
--- Page 7 ---
、）
R X4．X2
Sol a excited
Fi MA
I I 「
（Explanationofports） （Partname）
Al，Bl：DischargePOrt 1．MAINPUMP
Tl，T3：Drainandnllerport 2．HSTCHARGINGPUMP
T2，T4：Drainport 3．HIGH−PRESSURERELIEFV互LVE（B）
MA：Gaugeport（Aside） 4・HIGH−PRESSURERELIEFⅥ1LVE（A）
MB：Gaugeport（Bside） 5．DAVALVE
R ：Airbleedingport 6．LOW−PRESSURERELIEFVALVE
Xl，X2：ControIpressureport 7．SOLENOIDa
X3，X4：ControIpressureport 8．SOLENOIDb
G ：Gaugeport（chargingline） 9．DIRECTIONALCONTROLVALVE
Fi：Chargepressureinletport lO．INCHINGLEVER
Sl：Suctionport
Fo：Chargepressureoutletport
S2：Suctionport
B2：Dischargeport
Fig・2・16 HSTPump
−41−
--- Page 8 ---
（5）AntomaticSpeedControl
①ThecontroIpressureproportionaltoenginespeedisconnectedflowsfromtheDAvalvetothetilt−rO1
CylinderselectedbythedirectionalcontroIvalve．
②withtheengineatidle，thecontroIpressureis
．
③Asenginespeedincreases，thecontroIpressurealsoincreasヲSSOthatthetilt−rOllingpistonmovestolet
thepumptiltroll・SincethepumpdischargevarieswithenglneSPeed，itispossibletocontrolthetravel−
1ngSPeedoftheloadersmoothlywiththeacceleratorpedal．
Control pressure Displacementvo）ume
（。3？（㌣
（P3）
qmaX
†／一㌻ナ‡ （N）
Control pressure Enginespeed
Fig. 2.28 Engine Speed vs. Traveling Speed
（6）TbrqueControIFunction
①withthepressureincreasing，thetilt−rOllingrestorationforceincreasestoreducethetiltrollingofthe
PumPSOthatthepumpproducesanapproximatelyconstanttorquecontrol．（Fig．A）
②ThesettingtorqueisdeterminedbythebalancebetweenthecontroIpressure，tilt−rOllingcylinderspring
PreSSure，andtilt−rOllingrestorationforce・Withthemaincircuitoilpressureconstant，itvarieswi
enginespeed．（Fig．B）
③Ifaloadexceedingenginetorquewereapplied，enginespeedwoulddropf王omNltON2．Ifenginespeed
drops，thepump sabsorptlOntOrquealsodecreasessothatthetiltrollingactionofthepumpisbal
Withenginetorque・（Fig・C）Thatis，Whentheloadincreases，theengineslightlyslowsdownan
PumPautOmatica11ycontroIsitstiltrollingaction，thusmakinggooduseofenglnetOrqueWithouts
Plngtheenglne．
Fig．A Fig．B Fig．C
Fig．2．29 TbrqueControIFunction
−51−
--- Page 10 ---
②whentheoilpressuraCtingontheservospoolislowerthanthespringpressre，PCisdirectedtotheoil
tank（insidethehouslng）sothatthecontroIpistonmovestowardthedirectlOnOfqmax．Bycontras
WhentheoilpressurehigherthanthesprlngPreSSure，PCisconnectedtoPHsothatthecontroIpiston
movestowardthedirectionofqmin．
Neutral（q：heldconstant） PxxA−PHXB＝FAJ＋FFB
Tilt−rOlling（Changestoqmax） PxxA−PHXB＜FAJ＋FFB
Tilt−rOlling（Changestoqmin） PxxA−PHXB＞FAJ＋FFB
・Tilt−RollingStartPressure（Pi）
Thetilt−rOllingstartpressureisa句ustablewiththe
aqjustlngSPrlngPreSSureFAJ・
FAJ：1arge→Pi：Small
PivarieswiththechangeinPx
Px：large一◆Pi：large
・Override（△P）
TheoverrideisfactorysetdependingupontheareaB
andthesprlngCOefBcientoftheftedbacksprlng・Donot
trytoaqjusttheoverride・
Fig．2．3，
・LoaderperformanceandDAcharacteristics
Thesettingvarieswithenginespeed（HSTpumpinputspeed）・Whentheloadislightandtheenginerun
atidle，tilt−rO11inglSmaXimized．AsenglneSPeedincreases，tilt−rOllingautomatical1yshiftstothesm
Side，allowlngtheenglnetOrunathigherspeeds・Astheloadincreases，tilt−rOllingalsobecomeslarge，th
makingavailablelargertractionforce・Thatis，judgingtheintentionoftheoperatorfromtheenglneSPeed，
theDAregulatorautomatica11ycontroIstheamountoftorqueaccordingtothemagnitudeoftheload．
−61−
--- Page 11 ---
）
Note：B＞6：：：：：：コ2．9kg−m（21ft−1bs），14＝ゝThreadedarea‥LOCTITE＃262
駐＞6：：：：：コ5．6kg−m（40ft−1bs），疋＝ゝThreadedarea＝LOCTITE＃262
匪＞ぢ＝＝コ25kg−m（180侶bs）
駐＞紹＝ゝOuterdiameter：Liquidseal，l⊂＝恥Betweenlips：Grease
B＞Backlashbetweenringgearandpiniongear：0．09−0．13mm（0．0035−0．0051in）
匪＞Shimaqjustingprocedure
①Tbrqueretainerplateboltto5kg−m（36f［−1bs）andpushinaxleshaf［bearingcone，tuming
axlesha氏．
②Measurespacingbetweenretainerplateandaxleshaft．Measuredvalue＝Y
−0．15（0．0059in）
③chooseshimssothatthespacingisY−0．20（0．0079in）．
④Insta11shimsandinstallretainerplateandbolt．
ぢ：：：：：コ14．4kg−m（104ft−1bs），超＝ゝ∋Threadedarea‥LOCTITE＃262
（Thebearing srotationalresistancetorqueis3to5kg（7−111bs）onthetube丘ttingbolt
Pitchcircle．）
1．PLANETCARRIER 9．CASEA 16．SIDEGEAR
2．BALL lO．DIFFERENTIALBODY 17．PINIONGEAR
3．SHAFT ll．RINGGEAR 18．SHIM（0．1−1．Omm
4．PLANETGEAR 12，CASEB （0・004−0．039in），5types）
5．NEEDLEBEARING 13．SHIM（0．1−1．Omm 19．SPACER
6．RETAINERPLATE （0．004−0．0039in），5types） 20．PINIONGEAR（DRIVEPINION）
7．SHIM（0．1−1．Omm 14．BEARINGRETAINER 21．SEAL
（0．004−0．039in），5types） 15．PINIONPIN（E803） 22．BEARINGCAGE
8，GEAR＆SHAFT SPIDER（E804，E805，E806） 23．FLANGE
Fig．2．47 FinalReductionGearAssemblyandDifftrential
−71−
--- Page 12 ---
2．ServiceBrakeReleased
①whenthebrakepedal（1）isreleased，thepushrodofthemastercylinder（3）ispdlledouttoitsori
POSition，retumingthebrakeoil丘omtheservicebrakecylinderchamber（15）tothemastercylinder．
③Theservicebrakepiston（9）becomesfree
．
mode．
Fig．3．4 ServiceBrakeReleased
−81−
--- Page 13 ---
4．3 STEE−RINGWHEELUN］T
Thesteeringwheelunitisinstalledinthecockpit・Belowitisthesteervalve（orbitrol）．Whenthesteeri
Wheelisturned，therotationistranSmittedthroughthesteerlngShaftwhichinturnaCtuateStheofbitrol．
SteeringWheelUnitMounting
Note：B＞6：＝＝コ4．0±0．5kg−m（29±4ft−1bs）
恒＞〆＝＝恥Splines：Molybdenumgrease（about3g（0．0071bs））
匪＞〆＝＝恥Grease 陸＞疋⊃ゝWater−PrOOfseal
B＞血syntheticrubberadhesive
匝＞〆＝＝恥Hornelectrodecontactsurface‥Molybdenumgrease
1．STEERINGWHEEL 4．STEERVAINE 7．BEARING
2．STEERINGWHEELUNIT 5．BUSHING 8．STEERINGSHAFT
3．MAT 6．GROMMET 9．STEERINGCOLUMN
Fig．4．4 SteerlngWheelUnit
−91−
--- Page 14 ---
5．FRAMEANDCOCKPJT
5．1FRAME
The丘ameisasteel−Plateweldedtypeanddividedintotwoparts‥frontandrearffames・Thecockpit
OPeratOr sseataremountedontherearffame．
ADonottrytomod桝heROPS（Roll・OVerprOteCtionstructure），ifmounted，Withoutpriorper
missionfromthemanufactureIこIftheROPSshouldgetdamagedordebrmedduetoturnlngOVe
COllision，itisadvisabletoreplaceitwithanewone，becauseadamagedordeformedROPShasalo
StruCturalstrength・Be払retryingtomountanewROPS，besuretowIPeaWaypaintandlubr
fromthemountingsurfacesofthestructureandtheframe．
Note：B＞ぢ：：：：コCockpitmountingbolt‥9．Okg−m（65ft−1bs）
除碇＝＝コBalanceweightmountingbolt‥16kg−m（120氏−1bs）
〕
Fig．5．1Frame
−101−
--- Page 15 ---
6．2．1MA］N PUMP
ThemainpumpdoublesasthesteerlngPumP・Themainpumppicksuphydraulicoil丘omtheoiltank
Sendsittothesteervalve（VPvalve）whereitisdividedintotwoportions：theoneforthesteeringhyd
Circuitandtheoneforthemainhydrauliccircuit．
6．2．2 HSTCHARGJNG PUMP
Theoildischarged丘・OmtheHSTcharglngPumPISuSedforthefollowlngthreepurposes‥Charglngthe
HSTclosedloop，Pilotoilfortilt−rOllingcontrol（E804，E805，E806）andreleasingtheparkingbrake．
Note：FortheHSThydrauliccircuit，reftrto 2．1HSTUNIT（2．1．2）．
Fig・6・6 DoublePumps
ー111−
--- Page 16 ---
6．3．3 REuEFVALNE
ThecontroIvalvehasamainreliefvalveandaportreliefvalve．
Themainreliefvalveislocatedbetweentheneutraloilpassageandthelow−PreSSureOilpassage（returnOil
PaSSage）intheinletsection・Theportreliefvalveislocatedbetweentherodcylinderportandthelow
PreSSureOilpassage（returnoilpassage）inthebucketspooIsection．
Operation
（1）InInoperativeState
①Thepressureoilinthehigh−PreSSureOilpassae
（HP）flowsthroughthethrottlehole（2）inthemaln
POPPet（1）to丘11theintemalcavity（3）．
②owingtothedifferenceinaeaonwhichthehy−
draulicpressureactsthemalnPOPPet（1）closely
SeatStOthesleeve（4）．
LP 1 3
Fig．6．17InInoperativeState
（2）Operation（A）
①whenthepressureinthehigh−PreSSureOilpasage
（HP）risesandexceedsthereliefpressuresettlng，
thepilotpoppet（5）opens．
②Thepressureoilflowsfromthepilotpoppetinto
thelowpressureoilpassage（LP），PaSSingbetween
thesleeve（4）andthehousing（6）．
LP 5
Fig・6・18 0peration（A）
（3）Operation（B）
Asthepilotpoppet（5）opens，thepressureinthe
internalcavity（3）lowerstomovethemainpoppet（1）
SOthatthepressureoilintheoilpassage（HP）flows
directlyintothelowerpressureoilpassage（LP）．
LP 3 5
Fig．6．19 0peration（B）
−121−
--- Page 17 ---
）
1
＼︑︶ノ
Note：B＞ぢ：＝＝＝コ（E803）：28kg−m（200ft−1bs），（E804）：35kg−m（250ft−1bs），（E805，E806）：
39kg−m（280氏−1bs）
紹＝ゝThreadedarea：ThreeB。nd＃1901
桓＞ぢ＝：＝コ（E803）：29kg−m（210ft−1bs），（E804）：52kg−m（380f［−1bs），（E805，E806）：
68kg−m（490ft−1bs）
B＞ぢ＝コ0．70kg−m（5．1ft−1bs）（Aftertightening，Calk2parts．）
1．PINBUSHING 7．0−RING 13．PISTON
2．WIPERRING 8．BUSHING 14．SEALRING／0−RING
3．LOCKWASHER 9．U−RING 15．SLIDERING
4．0−RING lO．PISTONROD 16．SETSCREW
5．PISTON ll．CYLINDERTUBE 17，STEELBALL
6．BACK−UPRING 12．SHIM
Note：TheabovesketchshowstheboomcylinderoftheE804・Thesizeandappearancearesom
difftrentfromthoseoftheothermodels．
Fig．7．6 BoomCylinder
−131−