HL770 7

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CONTENTS

SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
Group 3 Operational Checkout Record Sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-22

SECTION 2 ENGINE
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Fan drive circuit for cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5

SECTION 3 POWER TRAIN SYSTEM


Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-59
Group 3 Test and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-71
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-74

SECTION 4 BRAKE SYSTEM


Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-29
Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-37
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-39

SECTION 5 STEERING SYSTEM


Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-18
Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-28
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-36

SECTION 6 WORK EQUIPMENT


Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-35
Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-46
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-62
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location 7-1
Group 2 Electrical Circuit 7-3
Group 3 Monitoring System 7-23
Group 4 Electrical Component Specification 7-35
Group 5 Connectors 7-44
Group 6 Troubleshooting 7-61
FOREWORD

1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.

Structure and function


This group explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
Operational checks and troubleshooting
This group explains the system operational checks and troubleshooting charts correlating problem to
remedy.
Tests and adjustments
This group explains checks to be amide before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Disassembly and assembly
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.

The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your Hyundai distributor for the latest information.

0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(①②③…)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to Hyundai distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the service manual can be of ample
Example 1 practical use, important places for safety and
3-3 quality are marked with the following symbols.
Section number (3. Power train
system) Symbol Item Remarks
Consecutive page number for
Special safety precautions are
each section necessary when performing the
3. Additional pages : Additional pages are work.
Safety
indicated by a hyphen(-) and number after the
Extra special safety precautions
page number. File as in the example. are necessary when performing
10 - 4 the work because it is under
internal pressure.
10 - 4 - 1
Added pages Special technical precautions or
10 - 4 - 2
10 - 5 ※ Caution
other precautions for preserving
standards are necessary when
performing the work.

0-2
3. CONVERSION TABLE
Method of using the Conversion Table.
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.

Example
1. Method of using the Conversion Table to convert from millimeters to inches.
Convert 55mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ⓐ, then draw a horizontal
line from ⓐ.
(2) Locate the number 5 in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.

2. Convert 550mm into inches.


(1) The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55mm.
(2) Carry out the same procedure as above to convert 55mm to 2.165 inches.
(3) The original value(550mm) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550mm = 21.65 inches.

Millimeters to inches ⓑ
1mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354


10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

0-3
Millimeters to Inches 1mm = 0.03937in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354


10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1kg = 2.2046lb

0 1 2 3 4 5 6 7 8 9

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84


10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

0-4
Liter to U.S. Gallon
1ℓ = 0.2642 U.S.Gal

0 1 2 3 4 5 6 7 8 9

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378


10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153

Liter to U.K. Gallon 1ℓ = 0.21997 U.K.Gal

0 1 2 3 4 5 6 7 8 9

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980


10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

0-5
kg・m to lb・ft 1kg・m = 7.233lb・ft

0 1 2 3 4 5 6 7 8 9

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1


10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

0-6
kg/cm2 to lb/in2 1kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0


10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°
C °
F °
C °
F °
C °
F °
C °
F

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8


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

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


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

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


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

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


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

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0

0-8
SECTION 1 GENERAL

Group 1 Safety Hints 1-1


Group 2 Specifications 1-10
Group 3 Operational Checkout Record Sheet 1-22
SECTION 1 GENERAL
GROUP 1 SAFETY HINTS

FOLLOW SAFE PROCEDURE


Unsafe work practices are dangerous. Understand
service procedure before doing work; Do not
attempt shortcuts.

WEAR PROTECTIVE CLOTHING


Wear close fitting clothing and safety equipment
appropriate to the job.

73031GE01

WARN OTHERS OF SERVICE WORK


Unexpected machine movement can cause
serious injury.
Before performing any work on the wheel loader,
WARN
attach a「 Do Not Operate」」tag on the right side
DO
controller lever. NOT
OPERATE

7707GE01

USE HANDHOLDS AND STEPS


Falling is one of the major causes of personal injury.
When you get on and off the machine, always
maintain a three point contact with the steps and
handrails and face the machine. Do not use any
controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, 73032E01
steps, and handrails when leaving the machine.

1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire department
near your telephone.

73031GE03

WORK IN CLEAN AREA


Before starting a job :
・ Clean work area and machine.
・ Make sure you have all necessary tools to do
your job.
・ Have the right parts on hand.
・ Read all instructions thoroughly; Do not attempt
shortcuts.
73031GE26

PROTECT AGAINST FLYING DEBRIS


Guard against injury from flying pieces of metal or
debris; Wear goggles or safety glasses.

73031GE04

PROTECT AGAINST NOISE


Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.

73031GE05

1-2
PARK MACHINE SAFELY
Before working on the machine:
・ Park machine on a level surface.
・ Lower bucket to the ground.
・ Turn key switch to OFF to stop engine. Remove
key from switch.
・ Move pilot control shutoff lever to locked position.
・ Allow engine to cool.
73031GE23

SUPPORT MACHINE PROPERLY


Always lower the attachment or implement to the
ground before you work on the machine. If you
must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under continuous
load.
Do not work under a machine that is supported
solely by a jack. Follow recommended procedures
in this manual. 73031GE06

SERVICE COOLING SYSTEM SAFELY


Explosive release of fluids from pressurized
cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool
enough to touch with bare hands.

73031GE07

HANDLE FLUIDS SAFELY-AVOID FIRES


Handle fuel with care; It is highly flammable. Do
not refuel the machine while smoking or when near
open flame or sparks. Always stop engine before
refueling machine.
Fill fuel tank outdoors.

73031GE08

1-3
Store flammable fluids away from fire hazards. Do
not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease,
and debris.
Do not store oily rags ; They can ignite and burn
spontaneously.

73031GE09

BEWARE OF EXHAUST FUMES


Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
If you must operate in a building, be positive there
is adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air into
the area.

REMOVE PAINT BEFORE WELDING OR


HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
・ If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator.
・ If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating. 73031GE10

1-4
ILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or
oil.

73031GE11

SERVICE MACHINE SAFELY


Tie long hair behind your head. Do not wear a
necktie, scarf, loose clothing or necklace when you
work near machine tools or moving parts. If these
items were to get caught, severe injury could
result.
Remove rings and other jewelry to prevent
electrical shorts and entanglement in moving parts.
73031GE12

STAY CLEAR OF MOVING PARTS


Entanglements in moving parts can cause serious
injury.
To prevent accidents, use care when working
around rotating parts.

73031GE13

1-5
AVOID HIGH PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure fluids.
73031GE14
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result.

73031GE15

AVOID HEATING NEAR PRESSURIZED FLUID


LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat by
welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install fire resisting guards to protect hoses or other
materials. 73031GE16

PREVENT BATTERY EXPLOSIONS


Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
Warm battery to 16°
C(60°F).
73031GE17

1-6
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
73031GE18

USE TOOLS PROPERLY


Use tools appropriate to the work. Makeshift
tools, parts, and procedures can create safety
hazards.
Use power tools only to loosen threaded tools and
fasteners.
For loosening and tightening hardware, use the
correct size tools. Avoid bodily injury caused by
73031GE19
slipping wrenches.
Use only recommended replacement parts.(See
Parts catalogue.)

1-7
SERVICE TIRES SAFELY
Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not
inflate the tires above the recommended pressure.
Never weld or heat a wheel and tire assembly.
The heat can cause an increase in air pressure
resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to stand
to one side and not in front of or over the tire
assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts. 73031GE24

USE PROPER LIFTING EQUIPMENT


Lifting heavy components incorrectly can cause
severe injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.

73031GE25

DISPOSE OF FLUIDS PROPERLY


Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of waste
from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
73031GE20
DO NOT pour oil into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, brake fluid, filters,
batteries, and other harmful waste.

1-8
REPLACE SAFETY SIGNS
Replace missing or damaged safety signs. See
the machine operator's manual for correct safety
sign placement.

73031GE21

LIVE WITH SAFETY


Before returning machine to customer, make sure
machine is functioning properly, especially the
safety systems. Install all guards and shields.

KEEP ROPS INSTALLED PROPERLY


Make certain all parts are reinstalled correctly if the
roll-over protective structure(ROPS) is loosened or
removed for any reason. Tighten mounting bolts
to proper torque.
The protection offered by ROPS will be impaired if
ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way
altered by welding, bending, drilling, or cutting. A
damaged ROPS should be replaced, not reused. 73031GE22

1-9
GROUP 2 SPECIFICATION

1. MAJOR COMPONENT

Bucket Tire Head light Hydraulic tank Air cleaner Radiator

Boom Boom cylinder Main control valve Battery Counterweight

Bell crank Bucket cylinder Cab Main pump Precleaner Muffler Engine

Bucket link Front axle Steering cylinder Transmission Rear axle Fuel tank

77072SE01

1-10
2. SPECIFICATIONS
1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET
B

F
I
J

5870
4310
H

3466
C
K
40

G
60
700 00

D
5
E 2247
A
77072SE02

Description Unit Specification


Operating weight kg(lb) 22800(50270)
Struck 3.4(4.5)
Bucket capacity m3(yd3)
Heaped 3.9(5.1)
Overall length A 8530(28' 0")
Overall width B 3100(10' 2")
Overall height C 3550(11' 8")
Ground clearance D 505( 1' 8")
Wheelbase E mm(ft-in) 3440(11' 3")
Tread F 2300( 7' 7")
Dump clearance at 45 G 3194(10' 6")
Dump reach(Full lift) H 1226( 4' 0")
Width over tires I 2975( 9' 9")
Dump angle J 48
Degree ( )
Roll back angle(Carry position) K 49
Lift(With load) 5.7
Cycle time Dump(With load) sec 1.4
Lower(Empty) 2.8
Maximum travel speed km/hr(mph) 38(23.7)
Braking distance 12(39' 4")
m(ft-in)
Minimum turning radius(Center of outside tire) 6(19' 8")
Gradability Degree ( ) 30
First gear 7.4(4.6)
Second gear 12.3(7.7)
Forward
Third gear 26.3(16.4)
Travel speed Fourth gear km/hr(mph) 38.0(23.7)
First gear 7.4(4.6)
Reverse Second gear 12.3(7.7)
Third gear 26.3(16.4)

1-11
2) WITH BOLT-ON CUTTING EDGE TYPE BUCKET
B

F
I
J

5870
4310
H

3466
C
K
40

G
60
703

D
5 00
E 2247
A
77072SE03

Description Unit Specification


Operating weight kg(lb) 22800(50270)
Struck 3.45(4.51)
Bucket capacity m3(yd3)
Heaped 4.0(5.2)
Overall length A 8635(28' 4")
Overall width B 3100(10' 2")
Overall height C 3550(11' 8")
Ground clearance D 505( 1' 8")
Wheelbase E mm(ft-in) 3440(11' 3")
Tread F 2300( 7' 7")
Dump clearance at 45 G 3117(10' 3")
Dump reach(Full lift) H 1254( 4' 1")
Width over tires I 2975( 9' 9")
Dump angle J 48
Degree ( )
Roll back angle(Carry position) K 49
Lift(With load) 5.7
Cycle time Dump(With load) sec 1.4
Lower(Empty) 2.8
Maximum travel speed km/hr(mph) 38(23.7)
Braking distance 12(39' 4")
m(ft-in)
Minimum turning radius(Center of outside tire) 6(19' 8")
Gradability Degree ( ) 30
First gear 7.4(4.6)
Second gear 12.3(7.7)
Forward
Third gear 26.3(16.4)
Travel speed Fourth gear km/hr(mph) 38(23.7)
First gear 7.4(4.6)
Reverse Second gear 12.3(7.7)
Third gear 26.3(16.4)

1-12
3) WITH TOOTH TYPE BUCKET
B

F
I
J

5870
4310
H

3466
C
K
40

G
60
711

D
00
0
E 2247
A
77072SE04

Description Unit Specification


Operating weight kg(lb) 22800(50270)
Struck 3.4(4.5)
Bucket capacity m3(yd3)
Heaped 3.9(5.1)
Overall length A 8750(28' 9")
Overall width B 3150(10' 4")
Overall height C 3550(11' 8")
Ground clearance D 505( 1' 8")
Wheelbase E mm(ft-in) 3440(11' 3")
Tread F 2300( 7' 7")
Dump clearance at 45 G 3000( 9' 10")
Dump reach(Full lift) H 1340( 4' 5")
Width over tires I 2975( 9' 9")
Dump angle J 48
Degree ( )
Roll back angle(Carry position) K 49
Lift(With load) 5.7
Cycle time Dump(With load) sec 1.4
Lower(Empty) 2.8
Maximum travel speed km/hr(mph) 38(23.7)
Braking distance 12(39' 4")
m(ft-in)
Minimum turning radius(Center of outside tire) 6(19' 8")
Gradability Degree ( ) 30
First gear 7.4(4.6)
Second gear 12.3(7.7)
Forward
Third gear 26.3(16.4)
Fourth gear km/hr(mph) 38(23.7)
Travel speed
First gear 7.4(4.6)
Reverse Second gear 12.3(7.7)
Third gear 26.3(16.4)

1-13
3. WEIGHT

Item kg lb

Front frame assembly 2105 4640


Rear frame assembly 2327 5130
Front fender(LH & RH) 37 82
Counterweight 1400 3087
Cab assembly 1000 2205
Engine assembly 723 1594
Transmission assembly 753 1660
Drive shaft(Front) 44 97
Drive shaft(Center) 46 101
Drive shaft(Rear) 27 60
Front axle(Include differential) 1350 2976
Rear axle(Include differential) 957 2110
Tire(26.5-25 20PR, L3) 394 869
Hydraulic tank assembly 260 573
Fuel tank assembly 431 950
Main pump assembly 39 86
Fan & brake pump assembly 24 53
Main control valve 94 207
Flow amplifier 29 64
Boom assembly 1620 3571
Bell crank assembly 497 1096
Bucket link 70 154
4.0m bucket, with bolt on cutting edge
3
2070 4564
3.9m3 bucket, with tooth 2000 4409
3.9m bucket, without tooth and cutting edge
3
1790 3946
Boom cylinder assembly 225 496
Bucket cylinder assembly 235 518
Steering cylinder assembly 44 97
Seat 40 88
Battery 55 121

1-14
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE

Item Specification

Model Cummins QSC8.3-C


Type 4-cycle turbocharged, charge air cooled diesel engine
Control type Electronic control
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore stroke 114 135mm(4.49" 5.31")
Piston displacement 8270
Compression ratio 17.1
Rated gross horse power 280ps at 2200rpm
Maximum gross torque at 1400rpm 138kgf m(1000lbf ft)
Engine oil quantity 20 (5.3 U.S. gal)
Wet weight 723kg(1594lb)
High idling speed 2340 50rpm
Low idling speed 900 50rpm
Rated fuel consumption 156g/ps hr
Starting motor Nippondenso(24V-7.5kW)
Alternator Delco Remy 22SI(24V-70Amp)
Battery 2 12V 200Ah

1-15
2) MAIN PUMP
Item Specification
Type Fixed displacement double vane pump
Capacity 120.6+79.3cc/rev
Maximum operating pressure 210kgf/cm2(2990psi)
Rated oil quantity 431ℓ/min(114U.S.gpm)
Rated speed 2200rpm

3) FAN + BRAKE PUMP


Specification
Item
FAN BRAKE
Type Fixed displacement double helical gear pump
Capacity 22.9cc/rev 11.9cc/rev
Maximum operating pressure 120kgf/cm (1710psi)
2
150kgf/cm2(2130psi)
Rated oil quantity 55ℓ/min(14.5U.S.gpm) 29ℓ/min(7.7U.S.gpm)
Rated speed 2200rpm

4) MAIN CONTROL VALVE

Item Specification

Type 2 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 210kgf/cm2(2990psi)
Overload relief valve pressure(Boom) 240kgf/cm2(3420psi)

5) REMOTE CONTROL VALVE

Item Specification

Type Pressure reducing type


Minimum 5.8kgf/cm2(82.5psi)
Operating
Maximum 19kgf/cm2(270psi)
Single operation stroke Lever 70mm(2.8in)

1-16
6) CYLINDER
Item Specification

Boom cylinder Bore dia Rod dia Stroke 180 100 765mm
Bucket cylinder Bore dia Rod dia Stroke 200 100 570mm
Steering cylinder Bore dia Rod dia Stroke 100 50 480mm

7) DYNAMIC POWER TRANSMISSION DEVICES


Item Specification

Model ZF 4WG260-IV
Converter Single-stage, single-phase
Type
Transmission Transmission Full-automatic power shift
Gear shift Forward fourth gear, reverse third gear
Adjustment Electrical single lever type, kick-down system
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation 13 of center pin-loaded
Wheels Tires 26.5-25, 20PR(L3)
Travel Four-wheel, wet-disc type, full hydraulic
Brakes Spring applied, hydraulic released brake on front
Parking axle
Type Full hydraulic, articulated
Steering
Steering angle 40 to both right and left angle, respectively

1-17
5. TIGHTENING TORQUE OF MAJOR COMPONENT
No Items Size kgf m lbf ft

1 Engine mounting bolt(6EA) M24 2.0 100 15 723 109


2 Engine mounting bolt(Bracket, rear 8EA) M12 1.75 10.7 2.1 77.4 15.2
3 Engine mounting bolt(Bracket, front 8EA) M16 2.0 19.4 3.0 140 32.5
Engine
4 Radiator mounting bolt M16 2.0 29.7 4.5 215 32.5
5 Fuel tank mounting bolt M16 2.0 29.7 4.5 215 32.5
6 Air cleaner mounting bolt M12 1.75 12.3 2.5 89.0 18.1
7 Main pump housing mounting bolt M16 2.0 29.7 4.5 215 32.5
8 Main control valve mounting bolt M12 1.75 12.8 3.0 92.6 21.7
9 Steering unit mounting bolt M10 1.5 6.9 1.4 49.9 10.1
10 Flow amplifier mounting bolt M10 1.5 6.9 1.4 49.9 10.1
11 Brake valve mounting bolt M 8 1.25 2.5 0.5 18.1 3.6
Hydraulic
12 Fan and brake pump mounting bolt M10 1.5 6.9 1.4 49.9 10.1
system
13 Cut-off valve mounting bolt M12 1.75 12.8 3.0 92.6 21.7
14 Remote control lever mounting bolt M 6 1.0 1.1 0.2 8.0 1.4
15 Pilot supply unit mounting bolt M 8 1.25 2.5 0.5 18.1 3.6
16 Safety valve M 8 1.25 2.5 0.5 18.1 3.6
17 Hydraulic oil tank mounting bolt M20 2.5 69 9.0 499 65.1
18 Transmission mounting bolt M20 2.5 46.3 7.0 335 50.6
19 Torque converter housing mounting bolt M10 1.5 4.6 0.7 33.3 5.1
20 Power train Front axle mounting bolt, nut M30 2.0 199 29.9 1439 216
21 system Rear axle support mounting bolt, nut M36 3.0 308 46.2 2228 334
22 Tire mounting nut M22 1.5 79 2.5 571 18
23 Drive shaft joint mounting bolt 1/2-20UNF 15.5 0.5 112 3.6
24 Counterweight mounting bolt M30 2.0 199 29.9 1439 216
25 Others Operator’s seat mounting bolt M 8 1.25 3.4 0.8 24.6 5
26 ROPS Cab mounting bolt(4EA) M27 2.0 124 900

1-18
6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread

8T 10T
Bolt size
kgf m lbf ft kgf m lbf ft
M 6 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242

(2) Fine thread


8T 10T
Bolt size
kgf m lbf ft kgf m lbf ft
M 8 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561

1-19
2) PIPE AND HOSE(FLARE TYPE)

Thread size Width across flat mm kgf m lbf ft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 12 86.8
1" 41 14 101

3) PIPE AND HOSE(ORFS TYPE)

Thread size Width across flat mm kgf m lbf ft

13/16-16" 24 4.4 32.5


1-3/16-12" 36 9.3 67.3
1-7/16-12" 41 13.2 95.5
1-11/16-12" 50 18.3 132
2-12" 55 22.6 164

4) FITTING

Thread size Width across flat mm kgf m lbf ft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109

1-20
7. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.

Ambient temperature C( F)
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
(U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)

SAE 30

SAE 10W
Engine oil pan Engine oil 20(5.3)
SAE 10W-30

SAE 15W-40

SAE 10W-30
Transmission Oil 55(14.5)
SAE 15W-40

Front : 78(20.6)
Axle Gear oil SAE 80W-90LSD/API GL-5
Rear : 53(14.0)

Tank: ISO VG 32
200(52.8)
Hydraulic tank Hydraulic oil ISO VG 46
System:
320(85) ISO VG 68

ASTM D975 NO. 1


Fuel tank Diesel fuel 430(114)
ASTM D975 NO. 2

NLGI NO. 1
Fitting
Grease As required
(Grease nipple)
NLGI NO. 2

Mixture of
antifreeze Ethylene glycol base permanent type
Radiator and water 56(14.8)
50 : 50

1-21
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET

・Owner :
・Date :
・Hours :
・Serial No. :
・Technician :

※ Use this sheet to record operational


checkout results.
Perform the operational check before
installing any test equipment. 7707GE02

OK NOT
Item Comments
OK

1. Monitor indicator and gauge checks(Engine OFF)

・ Hourmeter and gauge check


・ Battery check
・ Monitor indicator circuit check
・ Monitor turn signals and warning indicator check

2. Transmission, axle and engine linkages, neutral start


switch and reverse warning alarm switch checks

・ Transmission control lever and neutral


・ Neutral start and reverse warning
・ Alarm circuit checks
・ Engine speed control linkage check

3. Monitor indicator and gauge checks(Engine running)

・ Monitor display and alternator output checks


・ Monitor bypass circuit and seat belt indicator check
・ Monitor primary and secondary level check
・ Transmission oil warm up procedure
・ Transmission temperature gauge check

1-22
4. Brake system and clutch cut off checks

・ Park brake capacity check


・ Park brake transmission lockout check
・ Service brake pump flow check
・ Service brake capacity check
・ Brake accumulator precharge check
・ Brake system leakage check
・ Service brake pedal check
・ Service and park brake system drag check
・ Clutch cut off check

5. Driving checks

・Transmission oil warm up procedure


・Transmission noise check
・Speedometer check
・Transmission kick down system check
・1st, 2nd, 3rd and 4th speed clutch pack drag check
・Transmission pressure, pump flow and leakage check
・Transmission shift modulation check
・Torque converter check
・Engine power check

6. Hydraulic system checks

・Hydraulic system warm up procedure


・Hydraulic pump performance check
・Pilot control valve boom float check
・Boom down solenoid valve check
・Control valve lift check
・Bucket rollback circuit relief valve check
・Bucket dump circuit relief
Low pressure check
High pressure check
・Boom and bucket cylinder drift check
・Boom down solenoid valve leakage check
・Pilot controller check
・Return to dig check
・Boom height kickout check-if equipped

1-23
7. Steering system checks

・Steering valve check


・Steering system leakage check
・Priority valve
Low check pressure
High check pressure

8. Accessory checks

・Operating lights check


・Work light check
・Brake light check
・Cab light check
・Horn circuit check
・Windshield washer and wiper check
・Defroster blower check
・Heater/Air conditioner blower check
・Heater functional check
・Air conditioner functional check
・Start aid system check

9. Cab components and vandal protection checks

・Cab door latch check


・Cab door hold open latch check
・Cab door release button check
・Cab door lock check
・Cab door window check
・Cab window latch check
・Steering column adjustment check
・Seat and seat belt check
・Air intake filter door check
・Engine side panels check
・Radiator cap access door check
・Frame locking bar check
・Boom lock check
・Service decal check

1-24
SECTION 2 ENGINE

Group 1 Structure and Function 2-1


Group 2 Fan drive circuit for cooling system 2-5
SECTION 2 ENGINE
GROUP 1 STRUCTURE AND FUNCTION

1. STRUCTURE

Engine air inlet

Intake manifold
temperature sensor
Intake manifold
pressure sensor
Injection pump

ECM
Fuel filter
/water separator
Oil pressure port
Fuel lift pump

Dipstick

Turbocharger Engine oil fill


wastegate actuator

Lifting bracket
Coolant outlet
Injector drain fuel
outlet connection
Turbocharger
air outlet

Coolant filter Alternator

Flywheel
Coolant inlet

Lubricating
oil filter

7707EG01

・ Direct 4-stroke, 6-cylinders, water-cooling and charge air cooled diesel engine in installed, cylinder
block and cylinder head are made of case iron and turbocharger is attached.

2-1
2. SYSTEM DIAGRAMS
The following drawings show the flow through the engine systems.
1) Fuel system
1 Fuel from supply tank
2 Electronic lift pump
3 Fuel filter and water separator
4 Fuel drain line
5 Injection pump
6 Distributor outlet fitting
7 High-pressure supply lines
8 Fuel connector
9 Injectors
10 Fuel return to supply tank 7707EG02

2) Lubricating oil system


1 Gerotor lubricating oil pump
2 Pressure-regulating valve closed
3 Pressure-regulating valve open
4 From lubricating oil pump
5 To lubricating oil cooler
6 To lubricating oil pan
7 Lubricating oil cooler
8 Filter bypass valve
9 Filter bypass valve closed
10 Filter bypass valve open
11 To lubricating oil filter
12 Full-flow lubricating oil filter
13 From lubricating oil filter
7707EG03
14 Main lubricating oil rifle

(1) Lubrication for the turbocharger


1 Lubricating oil filter
2 Turbocharger lubricating oil supply
3 Turbocharger lubricating oil drain
4 To main lubricating oil rifle.

7707EG04

2-2
(2) Lubrication for the power components
1 From lubricating oil cooler
2 Main lubricating oil rifle
3 To camshaft
4 From main lubricating oil rifle
5 To piston cooling nozzle
6 To connecting rod bearing

7707EG05

(3) Lubrication for the overhead


1 From cam bushings
2 Transfer slot
3 Rocker lever support
4 Rocker lever shaft
5 Rocker lever bore
6 Rocker lever

7707EG06

3) Cooling system
1 Coolant inlet from radiator
2 Water pump suction
3 Coolant flow through lubricating oil cooler
4 Block lower water manifold(to cylinders)
5 Coolant filter inlet
6 Coolant filter outlet
7 Coolant supply to cylinder head
8 Coolant return from cylinder head
9 Block upper water manifold
10 Thermostat bypass
7707EG07
11 Coolant return to radiator

4) Air intake system


1 Intake air inlet to turbocharger
2 Turbocharger air to charge air cooler
3 Charge air cooler
4 Intake manifold
(Integral part of cylinder head)
5 Intake valve

7707EG08

2-3
5) Exhaust system
1 Exhaust valve
2 Exhaust manifold(pulse type)
3 Dual-Entry turbocharger
4 Turbocharger exhaust outlet

7707EG09

6) Compressed air system


1 Air in
2 Air out
3 Coolant out
4 Coolant in
5 Lubricating oil in
6 Lubricating oil out is internal to the gear
housing

7707EG10

2-4
GROUP 2 FAN DRIVE CIRCUIT FOR COOLING SYSTEM

1. REQUIRED TOOL
Item Spec
Pressure gauge 250~300kgf/cm2(3550~4270psi)
rpm gauge 200~2000rpm
Wrench 13mm
Tool
Hex. wrench 3mm

2. PRESSURE CHECK AND ADJUSTMENT


1) Specification
Cooling fan speed(rpm) Pressure[kgf/cm2(psi)]
1200±20 115~125(1640~1780)

2) Check point Harness connector


(CN-154) Relief valve

Relief valve Harness connector


(CN-154)
Uni-dictional Bi-dictional
WTHCS01P

3) Pressure check
(1) Install the pressure gauge to fan drive motor. ( )
(2) Disconnect CN-154.
(3) Check the fan drive motor pressure at high engine rpm.
(4) Check the cooling fan speed using rpm gauge at high engine rpm.

4) Adjustment
(1) Turn the adjusting screw clockwise to
increase the cooling fan rpm and relief
pressure.
(2) Turn the adjusting screw counter
clockwise to decrease the cooling fan rpm
and relief pressure.
Adjusting screw

WTHCS02

2-5
SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and Function 3-1


Group 2 Operational Checks and Troubleshooting 3-59
Group 3 Tests and Adjustments 3-70
Group 4 Disassembly and Assembly 3-73
SECTION 3 POWER TRAIN SYSTEM
GROUP 1 STRUCTURE AND FUNCTION

1. POWER TRAIN COMPONENT OVERVIEW

Transmission Engine

Front axle

Front drive shaft Center drive shaft Rear drive shaft Rear axle

7707PT01

The power train consists of the following components:


Transmission
Front, center and rear drive shafts
Front and rear axles
Engine power is transmitted to the transmission through the torque converter.
The transmission is a hydraulically engaged four speed forward, three speed reverse countershaft type
power shift transmission. A calliper-disc type parking brake is located on the front axle.
The transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft
is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame.
The front axle is equipped with limited slip differential.
The rear axle is mounted on an oscillating pivot. The rear axle is equipped with limited slip differential.
The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of
differential. It then passes from the differential to the sun gear shaft(Axle shaft) of final drive.
The power of the sun gear is reduced by a planetary mechanism and is transmitted through the
planetary hub to the wheel.

3-1
HYDRAULIC CIRCUIT

KR K4 K1 K3 KV K2

F 55 E 60 D 56 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D

Y1 Y2 NFS Y3 NFS Y4 NFS Y5 Y6 NFS


NFS NFS

Pressure
Temp reducing
sensor valve
9 bar
System
pressure
valve
Valve block control circuit 16+2 bar

Converter

Relief Filter
valve
8.5 bar
Oil cooler Pressure
holding Pump
valve 16+2 bar
Bypass 5 bar
valve
3 bar Coarse filter

Oil sump
Lubrication
Main oil circuit

7704PT01

NFS Follow-on slide P3 Proportional valve clutch K1


D Oscillation damper P4 Proportional valve clutch K3
B Orifice P5 Proportional valve clutch KV
P1 Proportional valve clutch KR P6 Proportional valve clutch K2
P2 Proportional valve clutch K4 Y1~Y6 Pressure regulator valve with filter

Current
Forward Reverse Engaged Positions No. of the
Speed Neutral clutch on the measuring
valve block points
1 2 3 4 1 2 3
Y1 X X X KR F 55
Y2 X K4 E 60
Y3 X X K1 D 56
Y4 X X X K3 C 58
Y5 X X X KV B 53
Y6 X X K2 A 57
Engaged
K1,KV KV,K2 KV,K3 K4,K3 KR,K1 KR,K2 KR, K3 - - -
clutch
X : Pressure regulator under voltage

3-2
2. TORQUE CONVERTER

5 1 2 3 4

7704PT03

1 Pump 3 Turbine 5 Input shaft


2 Stator 4 Transmission pump

The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the
characteristics, and with it the favorable efficiency of a fluid clutch.
The converter will be defined according to the engine power so that the most favorable operating
conditions for each installation case are given.
The Torque converter is composed of 3 main components :
Pump wheel - turbine wheel - stator(Reaction member)
These 3 impeller wheels are arranged in such a ring-shape system that the fluid is streaming through
the circuit components in the indicated order.
Pressure oil is constantly streaming out of the transmission pump through the converter. In this way, the
converter can fulfill its task to multiply the torque of the engine, and at the same time, the heat created in
the converter is dissipated through the escaping oil.
The oil, escaping out of the pump wheel, enters the turbine wheel and is there inversed in the direction
of flow.
According to the rate of inversion, the turbine wheel and with it also the output shaft, receive a more or
less high reaction moment. The stator(Reaction member), following the turbine, has the task to inverse
again the oil which is escaping out of the turbine and to delivery it under the suitable discharge direction
to the pump wheel.
Due to the inversion, the stator receives a reaction moment.
The relation turbine moment/pump moment is called torque conversion. This is the higher the greater
the speed difference of pump wheel and turbine wheel will be.
Therefore, the maximum conversion is created at standing turbine wheel.
With increasing output speed, the torque conversion is decreasing. The adaption of the output speed to
a certain required output moment is infinitely variable and automatically achieved by the torque
converter.

3-3
If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the
turbine moment becomes equal to that of the pump moment.
From this point on, the converter is working similar to a fluid clutch.
A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the
conversion range the moment upon the housing, and is released in the coupling range.
In this way, the stator can rotate freely.

Function of a hydrodynamic torque converter(Schematic view)

TP = Torque of the pump wheel


TT = Torque of the turbine wheel
TR = Torque of the reaction member(Stator)
Pump wheel TR

Turbine wheel
From the engine
TT

TP

To the gearbox

Starting
condition 1 1.5 Reaction member 2.5
nT = 0
(Stator) Machine stopped

Intermediate
condition 1 <1.5 <2.5 nT < n engine

Condition shortly
before the converter 1 1 nT = 0.8n engine
clutch is closed. 0

Turbine wheel is running with


about the same speed as
pump wheel.

3-4 (770-3)

3-4
3. TRANSMISSION
1) LAYOUT

2 3 4 5

6
1

KV K1 7

16
9
15
KR K2

14

10

K4 K3
13

11

12

7704PT02

1 Engine connection 7 Converter change and 12 Output shaft


2 Torque converter control pressure pump 13 Lay shaft
3 Breather 8 1st clutch(K1) 14 4th clutch(K4)
4 Drive 9 2nd clutch(K2) 15 Reverse clutch(KR)
5 Electro-hydraulic shift control 10 3rd clutch(K3) 16 Forward clutch(KV)
6 1st power take off 11 Output shaft

3-5
2) INSTALLATION VIEW

2 4 11 1 3 13 16 17

K2 KR KV K4 K3

14 19

10 18
15

7 12
8

6 9

7707PT13

1 Lifting lugs 11 Converter


2 Breather 12 Emergency steering pump connection(Option)
3 Electro-hydraulic shift control 13 Engine driver
4 Engine connection 14 Pressure line clutch K2
5 Coarse filter 15 Pressure line clutch KR
6 Oil drain plug M22 1.5 16 Pressure line clutch KV
7 Output-rear axle 17 Pressure line clutch K4
8 Output-front axle 18 Pressure line clutch K3
9 Transmission suspension holes M20 19 Pressure line clutch K1
10 Mounting holes

3-6
3) OPERATION OF TRANSMISSION
(1) Forward
Forward 1st
In 1st forward, forward clutch and 1st clutch are engaged.
Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

KV K1

KR K2

K4 K3

OUTPUT OUTPUT

7704PT07

3-7
Forward 2nd
In 2nd forward, forward clutch and 2nd clutch are engaged.
Forward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

KV K1

KR K2

K4 K3

OUTPUT OUTPUT

7704PT08

3-8
Forward 3rd
In 3rd forward, forward clutch and 3rd clutch are engage.
Forward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

KV K1

KR K2

K4 K3

OUTPUT OUTPUT

7704PT09

3-9
Forward 4th
In 4th forward, 4th clutch and 3rd clutch are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

KV K1

KR K2

K4 K3

OUTPUT OUTPUT

7704PT10

3-10
(2) Reverse
Reverse 1st
In 1st reverse, reverse clutch and 1st clutch are engaged.
Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

KV K1

KR K2

K4 K3

OUTPUT OUTPUT

7704PT11

3-11
Reverse 2nd
In 2nd reverse, reverse clutch and 2nd clutch are engaged.
Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

KV K1

KR K2

K4 K3

OUTPUT OUTPUT

7704PT12

3-12
Reverse 3rd
In 3rd reverse, reverse clutch and 3rd clutch are engaged.
Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

KV K1

KR K2

K4 K3

OUTPUT OUTPUT

7704PT13

3-13
4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE

2 1 3

A A
Y6 Y1

Y5 Y2

B
Y4 Y3

3 6

2 6 1 4 11 9 10

Y5

SECTION A-A SECTION B-B


8 7
73033CV01

1 Pressure reducing valve(9bar) 7 Intermediate sheet


2 System pressure valve(16+2bar) 8 Duct plate
3 Housing 9 Oscillation damper
4 Cable harness 10 Follow-on slide
5 Cover 11 Pressure regulator
6 Valve block

Transmission control see schedule of measuring points, hydraulic schematic and electro-hydraulic
control unit at page 3-2, 3-14 and 3-71.
The six clutches of the transmission are selected through the 6 proportional valves P1 to P6. The
proportional valve(Pressure regulator-unit) consists of pressure regulator(e.g. Y1), booster valve
oscillation damper.
The pilot pressure of 9 bar for the control of the follow-on slides is created by the reducing valve.
The pressure oil (16+2bar) is directed through the follow-on slide to the corresponding clutch.

3 - 14
By the direct proportional selection with separate pressure modulation for each clutch, the
pressures to the clutches, taking part in the gear change, are controlled. In this way, a hydraulic
overlab of the clutches to be engaged and disengaged is achieved.
This is leading to fast shiftings without traction force interruption.
At the shifting, the following criteria are considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode(Up-, down-, reverse shifting and gear engaging from neutral).
- Load level(Full- and partial load, traction, coasting inclusive consideration of load cycles during the
shifting).
The system pressure valve is limiting the maximum control pressure to 16+2 bar and releases the
main stream to the converter and lubricating circuit.
A converter relief valve is installed in the converter inlet, which protects the converter against high
internal pressures(Opening pressure 9bar).
Within the converter, the oil transfers the power transmission according to the well-known
hydrodynamic principle(See torque converter, page 3-3).
In order to avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter back pressure valve, following the converter, with an opening
pressure of about 3.5bar.
The oil, escaping from the converter, is directed to a oil cooler.
The oil is directed from the oil cooler to the transmission and from there to the lubricating-oil circuit
so that all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit there are 6 pressure regulators installed.

5) GEAR SELECTOR(DW-3)
The gear selector is designed for the
mounting on the left side of the steering
column. The positions(Speeds) 1 to 4 are
F
selected by a rotary motion, the driving 1
2
3
N
4

direction Forward(F)-Neutral(N)-Reverse(R) R

by tilting the gear selector lever.


The gear selector is also available with
integrated kickdown control knob.
A neutral lock is installed as protection
against inadvertent drive off.
N D
Position N - Gear selector lever blocked in
this position.
Position D - Driving. 73033TM17

3 - 15
6) LCD
Cluster 1( ) LCD
1
2( ) MENU
M 2 - Display main menu
MENU

- Return to the normal display


BACK
3
3( ) BACK
4
NEXT
Return to the previous menu
5
SELECT
4( ) NEXT
Move to the next selection
5( ) SELECT
77073CD72
Activate the currently chosen item

(1) Normal display

TYPE 1 TYPE 2

1
c
a e 3
2 d
b

6 4

5
77073CD73

No Symbol Meaning Remark

Forward, reverse, neutral LCD type 1, Display during AEB mode


F, R, N Forward, reverse, neutral LCD type 2, Display during AEB mode
1
1, 2, 3, 4 Actual gear -
P Parking brake mode active -
a Wiper motor intermittently operating -
2 When operating intermittently, it
b -
shows an operating time interval.
c, d Up and down shifting c : Forward, d : Reverse
3 Automatic mode
e Pre-selected gear -
HOUR

4 Hour meter Display the total operation hours of the machine


COOLANT
5 C Engine coolant temperature Display in accordance with selected items
AUT Ride control mode active Ride control switch AUTO position, see page 7-36
6 ON Ride control mode active Ride control switch ON position, see page 7-36
(Option)
OFF Ride control mode turn off Ride control switch MIDDLE position, see page 7-36
Both type1 and type2 are LCD modes and they can be changed each other by operator’s selection.

3 - 16
(2) Machine fault codes
When selecting the fault code menu, it shows all of the fault codes which mean abnormal
conditions of present time.

Press To go out from fault explanation window,


press button.
030 Er : 030 (Press , to go out to first menu.)
050 No error will be indicated in case that
025 there’s no fault.
046
Fuel level sensor open
or short to power

77073CD60

Description Code Meaning Remark

010 Power input voltage low Below 18V


011 Power input voltage high Above 38V
Electrical 012 Alternator voltage low Below 5V
system 013 Alternator voltage high Above 36V
014 Buzzer circuit open or short to ground
015 Buzzer circuit short to power
Hydraulic 020 Hydraulic oil temperature sensor open or short to power
system 021 Hydraulic oil temperature sensor short to ground
030 Fuel level sensor open or short to power
Engine 031 Fuel level sensor short to ground
system 034 Cooling fan driving valve open or short to ground
035 Cooling fan driving valve short to power
050 Auto select switch supply power open or short to power
051 Auto select switch supply power short to ground
T/M system
052 Clutch cutoff supply power open or short to power
053 Clutch cutoff supply power short to ground
Steering 060 Emergency steering relay open or short to ground Option
system 061 Emergency steering relay short to power Option
070 MCU communication error
Communication 071 TCU communication error
072 ECM communication error
MCU : Machine control unit TCU : Transmission control unit ECM : Engine control module

3 - 17
(3) Display during AEB mode

Symbol Meaning Remarks

K1~K4, KV, KR Calibrating clutch K1~K4, KV


or KR respectively
- And Kx Wait for start, initialization of
clutch Kx, x : 1, 2, 3, 4, V, R
And Kx Fast fill time determination of
clutch Kx
= And Kx Compensating pressure
determination of clutch Kx
OK Calibration for all clutches Transmission stays in neutral, you have to restart the
finished TCU(Ignition off/on) after removing AEB-Starter
STOP AEB cancled(Activation Transmission stays in neutral, you have to restart the
stopped) TCU(Ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't Transmission stays in neutral, you have to restart the
be calibrated TCU(Ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmission stays in neutral, you have to restart the
finished TCU(Ignition off/on)
E Engine speed too low,
- Raise engine speed
E Engine speed too high,
- Lower engine speed
T Transmission oil temperature
too low,
- Heat up transmission
T Transmission oil temperature
too high,
- Cool down transmission
FT Transmission temperature not Transmission stays in neutral, you have to restart the
in defined range during TCU(Ignition off/on)
calibration
FB Operating mode not NORMAL Transmission stays in neutral, you have to restart the
or transmission temperature TCU(Ignition off/on)
sensor defective or storing of
calibrated values to EEPROM
has failed
FO Output speed not zero Transmission stays in neutral, you have to restart the
TCU(Ignition off/on)
FN Shift lever not in neutral Transmission stays in neutral, you have to restart the
position TCU(Ignition off/on)
FP Park brake not applied Transmission stays in neutral, you have to restart the
TCU(Ignition off/on)
STOP AEB-Starter was used incorrect Transmission stays in neutral, you have to restart the
or is defective. Wrong device TCU(Ignition off/on)
or wrong cable used
AEB mode : It controls the disk internal of the transmission, automatically.
Refer to page 7-29, 30.

3 - 18
(4) Engine fault codes

Fault code No. Reason Effect(only when fault code is active)


ECM internal hardware error. Possible no effect or engine may run rough or not
111 start.
No engine speed or position signal detected at Engine power derate.
115
pin 17 of the engine harness. Possible white smoke.
No engine speed or position signal detected at No engine speed and position backup for main
121
pin 9 of the engine harness speed/position sensor.
High voltage detected at the boost pressure Engine will derate to no-boost fueling.
122
sensor signal pin 45 of the engine harness.
Low voltage detected at boost pressure sensor Engine will derate to no-boost fueling.
123
signal pin 45 of the engine harness.
High voltage detected at throttle position signal Engine idles when idle validation switch indicates
131 pin 30 of the machine harness. idle and ramps up to a default set speed when
the idle validation switch indicates off-idle.
Low voltage detected at throttle position signal Engine idles when idle validation switch indicates
132 pin 30 of the machine harness. idle and ramps up to a default set speed when
the idle validation switch indicates off-idle.
High voltage detected at remote throttle position Engine will not respond to remote throttle input.
133
signal pin 9 of the machine harness.
Low voltage detected at remote throttle position Engine will not respond to remote throttle input.
134
signal pin 9 of the machine harness.
High voltage detected at oil pressure signal pin Default value used for oil pressure.
135
33 of the engine harness. No engine protection for oil pressure.
Low voltage detected at oil pressure signal pin 33 Default value used for oil pressure.
141
of the engine harness. No engine protection for oil pressure.
Oil pressure signal indicates oil pressure below Power and/or speed derate and possible engine
143 the low engine protection limit. shutdown if engine protection shutdown feature
is enabled.
High voltage detected at coolant temperature Default value used for coolant temperature.
144
signal pin 23 of the engine harness. No engine protection for coolant temperature.
Low voltage detected at coolant temperature Default value used for coolant temperature.
145
signal pin 23 of the engine harness. No engine protection for coolant temperature.
Coolant temperature signal indicates coolant Power derate and possible engine shutdown
146 temperature has exceeded the minimum engine feature is enabled.
protection limit.
A frequency below a calibrated value has been Engine will not espond to changes in frequency
147 detectected at the frequency throttle signal pin 4 throttle. Engine will go to low idle.
of the engine harness.
A frequency below a calibrated value has been Engine will not respond to changes in frequency
148 detectected at the frequency throttle signal pin 4 throttle. Engine will go to low idle.
of the engine harness.
Coolant temperature signal indicates coolant Speed derate and possible engine shutdown if
151 temperature has exceeded the maximum engine engine protection shutdown feature is enabled.
protection limit.
High voltage detected at intake manifold Default value used for intake manifold temperature.
153
temperature signal pin 34 of the engine harness. No engine protection for intake manifold temperature.
Low voltage detected at intake manifold temper- Default value used for intake manifold temperature.
154
ature signal pin 34 of the engine harness. No engine protection for intake manifold temperature.
Intake manifold air temperature signal indicates Speed derate and possible engine shutdown if
155 intake manifold air temperature is above the engine protection shutdown feature is enabled.
maximum engine protection limit.
Error detected in the control synchronization of Multiple unit synchronization will be disable.
184
multiple engines. Engine will only idle.
Air conditioner clutch driver signal indicates a Air conditioner clutch will not operate.
191
short to ground when commanded on.

3 - 18-1
Fault code No. Reason Effect(only when fault code is active)
211 Machine specific fault code has occurred. No effect on engine performance.
High voltage detected at ambient air pressure Engine power derate.
221 signal pin 32 of the engine harness.
Low voltage detected at ambient air pressure Engine power derate.
222
signal pin 32 of the engine harness.
Engine speed signal indicates engine speed has Fuel to injectors disabled until engine speed falls
234
exceeded the overspeed limit. below the overspeed limit.
Coolant level signal at pin 37 of the engine Power and/or speed derate and possible engine
235 harness indicates coolant level is low. shutdown if engine protection shutdown feature
is enabled.
Vehicle speed signal on pins 8 and 18 of the EEngine speed limited to "Max. Engine Speed
machine harness has been lost. without VSS". Cruise control, gear-down
241 protection and the road speed governor will not
work. Trip information data that is based on
mileage will be incorrect.
Possible tampering has been detected on the Engine speed limited to " Max. Engine Speed
vehicle speed circuit pins 8 and 18 of the mach- without VSS". Cruise control, gear-down
242 ine harness protection and the road speed governor will not
work. Trip information data that is based on
mileage will be incorrect.
Error detected in the exhaust brake relay enable Exhaust brake will not work.
243 circuit at pin 42 of the engine harness.
Error detected in fan clutch relay enable circuit at Electronic control; module(ECM) can not control
245 pin 41 of the engine harness. the engine cooling fan. Fan will remain on or off.
High voltage detected at the fuel temperature Default value used for fuel temperature.
263
sensor signal pin 35 of the engine harness. Possible low power.
Low voltage detected at the fuel temperature Default value used for fuel temperature.
265
sensor signal pin 35 of the engine harness. Possible low power.
Fuel pressure in the accumulator is not changing Power derate.
268
with engine operating conditions. Engine may run rough.
Low or no current detected on front pumping Low power or poor performance.
271 control valve return pin 21.(Set only during
control valve click test)
High current detected on front pumping control Low power or poor performance.
272
valve retum pin 21. Possible damage to the ECM.
Low or no current detected on rear pumping Low power or poor performance.
273 control valve return pin 15.(Set only during
control valve click test)
High current detected on rear pumping control Low power or poor performance.
274
valve return pin 15. Possible damage to the ECM.
Engine ECM has detected a failure in the front Low power or poor performance.
275
pumping element.
High current detected on injection control valve Injection Control Valve is shutdown and engine
276
return pin 7. will not run. Possible ECM damage.
Engine ECM has detected a failure in the Low power. Engine may not run.
277
injection control valve.
Error detected in lift pump circuit at pin 11 of the Possible low power, engine may die, run rough
278
engine harness. or be difficult to start.
Low or no current detected on injection control Low power. Engine may not run.
279 valve return pin 7.(Set only during control valve
click test)
Engine ECM has detected a failure in the front Possible no effect or engine power derate.
281 pumping element.
Engine ECM has detected a failure in the rear Possible no effect or engine power derate.
282 pumping element.

3 -18-2
Fault code No. Reason Effect(only when fault code is active)
High voltage detected at main engine speed/ ECM will use the engine position signal as a
283 position sensor voltage supply pin 8 of the engine backup. Possible white smoke and power loss.
harness.
Low voltage detected at main engine speed/ po- ECM will use the engine position signal as a
284 sition sensor voltage supply pin 8 of the engine backup.
harness. Possible white smoke and power loss.
The ECM expected information from a At least one multiplexed device will not operate
285 multiplexed device but did not receive it soon properly.
enough or did not receive it at all.
The ECM expected info from a multiplexed At least on multiplexed device will not operate
286 device but only received a portion of the properly.
necessary information
The machine vehicle electronic control unit The engine will only idle.
287
(VECU) detected a fault with its throttle pedal.
The machine vehicle electronic control unit The engine will not respond to the remote
288
(VECU) detected a fault with its remote throttle. throttle.
OEM pressure signal at pin 48 of the OEM Speed derate and possible engine shutdown if
296 harness indicates pressure outside the engine engine protection shutdown feature is enabled.
protection limit.
High voltage detected at machine pressure Default value used for machine pressure. Lose
297
signal pin 48 of the machine harness. ability to control machine pressure.
Low voltage detected at machine pressure signal Default value used for machine pressure. Lose
298
pin 48 of the machine harness. ability to control machine pressure.
Engine shutdown by device other than key switch No action taken by the ECM.
before proper engine cool down resulting in
299
filtered load factor above maximum shutdown
threshold.
Power to the real time clock has been interrupted Time stamp in ECM powerdown data will be
319
and its setting is no longer valid incorrect.
Engine ECM has detected a failure in the rear Low power. Engine may not run.
328
pumping element.
Engine ECM has detected an overpumping Engine power derate, engine may die.
329
failure in the CAPS pump.
Auxiliary speed signal frequency indicates the Engine will go to idle and lose ability to control
349
frequency is above a calibrated threshold value.speed of the auxiliary device.
Low voltage detected at engine position sensor Default value used for sensors connected to this
+5 VDC supply, pin 10 of the engine harness. +5 VDC supply. Engine will derate to no-boost
352 fueling and loss of engine protection for oil
pressure, intake manifold pressure, and ambient
air pressure.
Error detected in cold start aid relay 1 enable Intake air heater can not be fully energized by the
381 circuit at pin 41 of the machine harness. ECM.
Possible white smoke and/or hard starting.
Error detected in cold start aid relay 2 enable Intake air heater can not be fully energized by the
382 circuit at pin 31 of the machine harness. ECM.
Possible white smoke and/or hard starting.
385 High voltage detected at machine harness sens- Sensors connected to this +5 VDC supply(i.e.
or +5 VDC supply pin 10 of the machine harness. remote throttle position sensor) will not function.
High voltage detected at the engine harness Default value used for sensors connected to this
sensor +5 VDC supply pin 10 of the engine +5 volts supply. Engine will derate to no-boost
386 harness. fueling and loss of engine protection for oil
pressure, intake manifold temperature, and
coolant temperature.
High voltage detected at the throttle position Engine idles when idle validation switch indicates
387 sensor +5 VDC supply pin 29 of the machine idle and ramps up to a default set speed when
harness. idle validation switch indicates off-idle.

3 -18-3
Fault code No. Reason Effect(only when fault code is active)
Oil pressure signal indicates oil pressure elow the Speed derate and possible engine shutdown if
415 very low engine protection limit. engine protection shutdown feature is enagled.
Water-in-fuel signal indicates the water in the fuel Excessive water in the fuel can lead to severe
418 filter needs to be drained. fuel sysm damage.
Voltage detected simultaneously on both the No engine protection for coolant level.
coolant level high and low signal pins 27 and 37
422 of the engine harness or no voltage detected on
either pin.(Fault is active for switch type coolant
level sensors only)
Low voltage detected at water-in-fuel signal pin No water-in-fuel protection.
429 40 of the machine harness.
Idle validation signals on pins 25 and 26 of the No effect on performance, but loss of idle
machine harness indicate voltage detected validation.
431 simultaneously on both pins or no voltage
detected on either pin.
Idle validation signal at pin 26 of the machine Engine will only idle.
harness indicates the throttle is at the idle
position when the throttle position signal at pin 30
of the machine harness indicates the throttle is
432 not at the idle position...OR...idle validation signal
at pin 26 of the machine harness indicates the
throttle is not at the idle position when the throttle
position signal at pin 30 of the machine harness
indicates the throttle is at the idle position.
Boost pressure signal indicates boost pressure is Possible overfueling during acceleration.
high when other engine parameters(i.e. speed Increase in black smoke.
433 and load) indicate boost pressure should be
low...OR...boost pressure is low when other
engine parameters indicate it should be high.
All data gathered by the ECM since the last key None on performance. Fault code table, trip
on(i.e.faults, trip information data. etc.)was notinformation data, maintenance monitor data,
434 stored to permanent memory at the last key off. trending data and user activated datalogger data
may be inaccurate.
Voltage detected at ECM power supply pins 38, Engine will die or run rough.
441 39, 40 and 50 of the engine harness indicates the
ECM supply voltage fell below 6 VDC.
Voltage detected at ECM power supply pins 38, None on performance.
39, 40 and 50 of the engine harness indicates the
442
ECM supply voltage is above the maximum
system voltage level.
Low voltage detected at throttle position sensor Engine idles when idle validation switch indicates
443 +5 VDC supply pin 29 of the machine harness. idle and ramps up to a default set speed when
idle validation switch indicates off-idle.
Low voltage detected at machine harness sensor Sensors connected to this +5 VDC supply (i.e.
444
+5 VDC supply pin 10 of the machine harness. remote throttle position sensor) will not function.
Fuel pressure signal indicates that fuel pressure Fuel pumping is stopped until pressure returns to
449 has exceeded the maximum limit for the given normal. Possible fuel pump damage may result.
engine rating.
High voltage detected at fuel pressure sensor Low power, reduced performance.
451
signal pin 46 of the engine harness.
Low voltage detected at fuel pressure sensor Low power, reduced performance.
452
signal pin 46 of the engine harness.
Fuel pressure in the accumulator is not changing Power and/or speed derate;
456
with engine operating conditions. engine will possibly run rough.

3 -18-4
Fault code No. Reason Effect(only when fault code is active)
Intake manifold temperature signal indicates Power derate and possible engine shutdown if
488 intake manifold temperature is above the minm- engine protection shutdown feature is enabled.
um engine protection limit.
Auxiliary device speed signal on pins 8 and 18 of Lose ability to control the speed of the auxiliary
489 the OEM harness is out of range of the ECM device.
threshold.
ECM has detected a circuit failure on the injection Slight loww of performance.
493 control valve certifier circuit.
Error detected in the multiple unit synchronizat- Multiple unit synchronization feature will be
497 ion control switch input, pins 24 and 38 of the disabled.
OEM harness.
High voltage detected at the auxiliary +5 VDC Auxiliary device will not function.
515 sensor supply voltage pin 49 of the engine
harness.
Low voltage detected at the auxiliary +5 VDC Auxiliary device will not function.
516 sensor supply voltage pin 49 of the engine
harness.
Error detected on the high speed governor droop Operator can not select alternate high speed
524 selection switch in put pin 24 of the engine governor droop. Normal droop is used.
harness.
Error detected in the dual output driver "A" circuit The device being controlled by the dual output
527 pin 5 of the machine harness. driver "A"signal will not function properly.
Error detected on the torque curve selection Operator can not select alternate torque curves.
528 switch input pin 39 of the machine harness. Normal torque curve is used.
Error detected in the dual output driver "B" circuit The device being controlled by the dual output
529 pin 1 of the engine harness. driver "B" signal will not function properly.
Open circuit failure of the injection control valve Low power, possible ECM damage.
539 transorb pin 6 of the engine harness.
Idle validation signals on pins 25 and 26 of the Engine will only idle.
551 machine harness indicate voltage detected
simultaneously on both pins.
Software has initiated an engine shutdown based Engine will shutdown.
599
on machine sensor inputs
Error detected in the output device driver(VGT or Can not control the VGT or transmission, depend-
768 transmission shift modulation signal) signal pin ing on application.
21 of the machine harness.
OEM switch signal at pin 16 of the engine harness Power derate and possible engine shutdown if
779
indicates engine protection condition. engine protection shutdown feature is enabled.
Some fault codes are not applied to this machine.

3 - 18-5
(5) DEFINITION OF OPERATING MODES
Normal
There's no failure detected in the transmission system or the failure has no or slight effects on
transmission control. TCU will work without or in special cases with little limitations.(See
following table)
Substitute clutch control
TCU can't change the gears or the direction under the control of the normal clutch modulation.
TCU uses the substitute strategy for clutch control. All modulations are only time controlled.
(Comparable with EST 25)
Limp-home
The detected failure in the system has strong limitations to transmission control. TCU can
engage only one gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator
must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear
selector into forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-
home gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home
gear of the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The
operator has to slow down the vehicle and must shift the gear selector into neutral position.
Transmission-shutdown
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply(VPS1).
Transmission shifts to neutral. The park brake will operate normally, also the other functions
which use ADM1 to ADM8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
TCU-shutdown
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies(VPS1, VPS2). The
park brake will engage, also functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off

3 -19
(6) Transmission fault codes
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

11 48 Logical error at gear range signal TCU shifts transmission to Check the cables from TCU to Failure cannot be detected in
TCU detected a wrong signal combination neutral shift lever systems with DW2/DW3 shift
for the gear range OP-mode : Transmission Check signal combinations of lever
Cable from shift lever to TCU is broken shutdown shift lever positions for gear Fault is taken back if TCU
Cable is defective and is contacted to range detects a valid signal for the
battery voltage or vehicle ground position
Shift lever is defective

12 46 Logical error at direction select signal TCU shifts transmission to Check the cables from TCU to Fault is taken back if TCU
TCU detected a wrong signal combination neutral shift lever detects a valid signal for the
for the direction direction at the shift lever
Cable from shift lever to TCU is broken OP-Mode : Transmission Check signal combinations of
Cable is defective and is contacted to shutdown shift lever positions F-N-R
battery voltage or vehicle ground
Shift lever is defective

13 95 Logical error at engine derating device After selecting neutral, TCU Check engine derating device This fault is reset after power
TCU detected no reaction of engine while change to OP mode limp home up of TCU
derating device active

15 176 Logical error at direction select signal 2 shift TCU shifts transmission to Check the cables from TCU to Fault is taken back if TCU
lever neutral if selector active shift lever 2 detects a valid neutral signal
TCU detected a wrong signal combination OP mode : Transmission Check signal combinations of for the direction at the shift
for the direction shutdown if selector shift lever positions F-N-R lever
Cable from shift lever 2 to TCU is broken active
Cable is defective and is contacted to
battery voltage or vehicle ground
Shift lever is defective

16 178 Logical error at axle connection OP mode : Normal Check the cables from TCU to
Feedback axle connection measured by TCU feedback axle connection switch
and output signal axle connection don't fit Check signals of the feedback
Axle can't be connected or disconnected axle connection switch
due to mechanical problem
One of the cables from feedback axle
connection switch to TCU is broken

3-20
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

21 32 S.C. to battery voltage at clutch cut off input Clutch cut off function is disabled Check the cable from TCU to
The measured voltage is too high: OP mode : Normal the sensor
Cable is defective and is contacted to Check the connectors
battery voltage Check the clutch cut off sensor
Clutch cut off sensor has an internal defect
Connector pin is contacted to battery voltage

22 29 S.C. to ground or O.C. at clutch cut off input Clutch cut off function is disabled Check the cable from TCU to
The measured voltage is too low: OP mode : Normal the sensor
Cable is defective and is contacted to Check the connectors
vehicle ground Check the clutch cut off sensor
Cable has no connection to TCU
Clutch cut off sensor has an internal
defect
Connector pin is contacted to vehicle
ground or is broken

23 S.C. to battery voltage at load sensor input Retarder function is affected Check the cable from TCU to Availability of retarder
The measured voltage is too high: TCU uses default load the sensor depends on default load
Cable is defective and is contacted to OP mode : Normal Check the connectors
battery voltage Check the load sensor
Load sensor has an internal defect Check the assembly tolerances
Connector pin is contacted to battery voltage of load sensor

24 S.C. to ground or O.C. at load sensor input Retarder function is affected Check the cable from TCU to Availability of retarder
The measured voltage is too low: TCU use default load the sensor depends on default load
Cable is defective and is contacted to OP mode : Normal Check the connectors
vehicle ground Check the load sensor
Cable has no connection to TCU Check the assembly tolerances
Load sensor has as internal defect of load sensor
Connector pin is contacted to vehicle
ground or is broken

3-21
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

25 33 S.C. to battery voltage or O.C. at transmission No reaction, TCU use default Check the cable from TCU to
sump temperature sensor input temperature the sensor
The measured voltage is too high: OP mode : Normal Check the connectors
Cable is defective and is contacted to Check the temperature sensor
battery voltage
Cable has no connection to TCU
Temperature sensor has an internal defect
Connector pin is contacted to battery
voltage or is broken

26 30 S.C. to battery voltage or O.C. at transmission No reaction, TCU uses default Check the cable from TCU to
sump temperature sensor input temperature the sensor
The measured voltage is too low: OP mode : Normal Check the connectors
Cable is defective and is contacted to Check the temperature sensor
vehicle ground
Temperature sensor has an internal defect
Connector pin is contacted to vehicle
ground

27 76 S.C. to battery voltage or O.C. at retarder No reaction, TCU uses default Check the cable from TCU to
temperature sensor input temperature the sensor
The measured voltage is too high: OP mode : Normal Check the connectors
Cable is defective and is contacted to Check the temperature sensor
battery voltage
Cable has no connection to TCU
Temperature sensor has an internal defect
Connector pin is contacted to battery
voltage or is broken

28 74 S.C. to ground at retarder temperature No reaction, TCU uses default Check the cable from TCU to
sensor input temperature the sensor
The measured voltage is too low: OP mode : Normal Check the connectors
Cable is defective and is contacted to Check the temperature sensor
vehicle ground
Temperature sensor has an internal defect
Connector pin is contacted to vehicle ground

3-22
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

27 76 S.C. to battery voltage or O.C. at converter No reaction, TCU uses default Check the cable from TCU to
output temperature sensor input temperature the sensor
The measured voltage is too high: OP mode : Normal Check the connectors
Cable is defective and is contacted to Check the temperature sensor
battery voltage
Cable has no connection to TCU
Temperature sensor has an internal defect
Connector pin is contacted to battery
voltage or is broken

28 74 S.C. to ground at converter output No reaction, TCU uses default Check the cable from TCU to
temperature sensor input temperature the sensor
The measured voltage is too low: OP mode : Normal Check the connectors
Cable is defective and is contacted to Check the temperature sensor
vehicle ground
Temperature sensor has an internal defect
Connector pin is contacted to vehicle ground

31 38 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch control Check the cable from TCU to
speed input the sensor
TCU measures a voltage higher than 7.00V Check the connectors
at speed input pin Check the speed sensor
Cable is defective and is contacted to
battery voltage
Cable has no connection to TCU
Speed sensor has an internal defect
Connector pin is contacted to battery
voltage or has no contact

32 34 S.C. to ground at engine speed input OP mode : Substitute clutch control Check the cable from TCU to
TCU measures a voltage less than 0.45V at the sensor
speed input pin Check the connectors
Cable/connector is defective and is Check the speed sensor
contacted to vehicle ground
Speed sensor has an internal defect

3-23
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

33 42 Logical error at engine speed input OP mode : Substitute clutch control Check the cable from TCU to This fault is reset after power
TCU measures a engine speed over a the sensor up of TCU
threshold and the next moment the Check the connectors
measured speed is zero Check the speed sensor
Cable/connector is defective and has bad Check the sensor gap
contact
Speed sensor has an internal defect
Sensor gap has the wrong size

34 39 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch control Check the cable from TCU to
speed input If a failure is existing at output the sensor
TCU measures a voltage higher than 7.00V speed, Check the connectors
at speed input pin TCU shifts to neutral Check the speed sensor
Cable is defective and is contacted to OP mode : Limp home
vehicle battery voltage
Cable has no connection to TCU
Speed sensor has an internal defect
Connector pin is contacted to battery
voltage or has no contact

35 35 S.C. to ground at turbine speed input OP mode : Substitute clutch control Check the cable from TCU to This fault is reset after power
TCU measures a voltage less than 0.45V at If a failure is existing at output the sensor up of TCU
speed input pin speed, Check the connectors
Cable/connector is defective and is TCU shifts to neutral Check the speed sensor
contacted to vehicle ground OP mode : Limp home
Speed sensor has an internal defect

36 43 Logical error at turbine speed input OP mode : Substitute clutch control Check the cable from TCU to
TCU measures a turbine speed over a If a failure is existing at output the sensor
threshold and at the next moment the speed, Check the connectors
measured speed is zero TCU shifts to neutral Check the speed sensor
Cable/connector is defective and has bad OP mode : Limp home Check the sensor gap
contact
Speed sensor has an internal defect
Sensor gap has the wrong size

3-24
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

37 40 S.C. to battery voltage or O.C. at internal OP mode : Substitute clutch control Check the cable from TCU to
speed input the sensor
TCU measures a voltage higher than 7.00V Check the connectors
at speed input pin Check the speed sensor
Cable is defective and is contacted to
vehicle battery voltage
Cable has no connection to TCU
Speed sensor has an internal defect
Connector pin is contacted to battery
voltage or has no contact

38 36 S.C. to ground at turbine speed input OP mode : Substitute clutch control Check the cable from TCU to
TCU measures a voltage less than 0.45V at the sensor
speed input pin Check the connectors
Cable/connector is defective and is Check the speed sensor
contacted to vehicle ground
Speed sensor has an internal defect

39 44 Logical error at internal speed input OP mode : Substitute clutch control Check the cable from TCU to This fault is reset after power
TCU measures a internal speed over a the sensor up of TCU
threshold and at the next moment the Check the connectors
measured speed is zero Check the speed sensor
Cable/connector is defective and has bad Check the sensor gap
contact
Speed sensor has an internal defect
Sensor gap has the wrong size

3A 41 S.C. to battery voltage or O.C. at output Special mode for gear selection Check the cable from TCU to
speed input OP mode : Substitute clutch control the sensor
TCU measures a voltage higher than 12.5V If a failure is existing at turbine Check the connectors
at speed input pin speed, Check the speed sensor
Cable is defective and is contacted to TCU shifts to neutral
battery voltage OP mode : lamp home
Cable has no connection to TCU
Speed sensor has an internal defect
Connector pin is contacted to battery
voltage or has no contact

3-25
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

3B 37 S.C. to ground at output speed input Special mode for gear selection Check the cable from TCU to
TCU measures a voltage less than 1.00V at OP mode : Substitute clutch control the sensor
speed input pin If a failure is existing at turbine Check the connectors
Cable/connector is defective and is speed, Check the speed sensor
contacted to vehicle ground TCU shifts to neutral
Speed sensor has an internal defect OP mode : lamp home

3C 45 Logical error at output speed input Special mode for gear selection Check the cable from TCU to This fault is reset after power
TCU measures a turbine speed over a OP mode : Substitute clutch control the sensor up of TCU
threshold and at the next moment the If a failure is existing at turbine Check the connectors
measured speed is zero speed, Check the speed sensor
Cable/connector is defective and has bad TCU shifts to neutral Check the sensor gap
contact OP mode : lamp home
Speed sensor has an internal defect
Sensor gap has the wrong size

3D 71 Turbine speed zero doesn't fit to other speed - - Not used


signals

3E 72 Output speed zero doesn't fit to other speed Special mode for gear selection Check the sensor signal of This fault is reset after power
signals OP mode : Substitute clutch control output speed sensor up of TCU
If transmission is not neutral and the shifting If a failure is existing at turbine Check the sensor gap of
has finished, speed, output speed sensor
TCU measures output speed zero and TCU shifts to neutral Check the cable from TCU to
turbine speed or internal speed not equal to OP mode : lamp home the sensor
zero.
Speed sensor has an internal defect
Sensor gap has the wrong size

3-26
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

71 22 S.C. to battery voltage at clutch K1 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve is OP mode : Limp home the gearbox
out of limit, the voltage at K1 valve is too high If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending TCU to the gearbox
contact to battery voltage TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Cable/connector is defective and has OP mode : TCU shutdown Check internal wire harness of
contact to another regulator output of the the gearbox
TCU
Regulator has an internal defect

72 10 S.C. to ground at clutch K1 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve is OP mode : Limp home the gearbox
out of limit, the voltage at K1 valve is too low If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to vehicle ground TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

73 16 O.C. at clutch K1 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit If failure at another clutch is Check the connectors from
Cable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

74 23 S.C. to battery voltage at clutch K2 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit, the voltage at K2 valve is too If failure at another clutch is Check the connectors from
high pending gearbox to TCU
Cable/connector is defective and has TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
contact to battery voltage OP mode : TCU shutdown Check internal wire harness of
Cable/connector is defective and has the gearbox
contact to another regulator output of the
TCU
Regulator has an internal defect

3-27
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

75 11 S.C. to ground at clutch K2 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve is OP mode : Limp home the gearbox
out of limit, the voltage at K2 valve is too low If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to vehicle ground TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

76 17 O.C. at clutch K2 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit If failure at another clutch is Check the connectors from
Cable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

77 24 S.C. to battery voltage at clutch K3 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit, the voltage at K3 valve is too If failure at another clutch is Check the connectors from
high pending gearbox to TCU
Cable/connector is defective and has TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
contact to battery voltage OP mode : TCU shutdown Check internal wire harness of
Cable/connector is defective and has the gearbox
contact to another regulator output of the
TCU
Regulator has an internal defect

78 12 S.C. to ground at clutch K3 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve is OP mode : Limp home the gearbox
out of limit, the voltage at K3 valve is too low If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to vehicle ground TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

3-28
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

79 18 O.C. at clutch K2 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit If failure at another clutch is Check the connectors from
Cable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

7A 78 S.C. to battery voltage at converter clutch - -

7B 79 S.C. to ground at converter clutch - -

7C 80 O.C. at converter clutch - - Not used

7D 166 S.C. ground at engine derating device Engine derating will be on until Check the cable from TCU to Not used
Cable is defective and is contacted to TCU power down even if fault the engine derating device
vehicle ground vanishes(Loose connection) Check the connectors from Not used
Engine derating device has an internal defect OP mode : Normal engine derating device to TCU
Connector pin is contacted to vehicle ground Check the resistance* of engine * See Chapter (7)
derating device

7E 168 S.C. battery voltage at engine derating No reaction Check the cable from TCU to
device OP mode : Normal the engine derating device
Cable/connector is defective and is Check the connectors from
contacted to battery voltage backup alarm device to TCU
Engine derating device has an internal Check the resistance* of * See Chapter (7)
defect backup alarm device

7F 167 O.C. at engine derating device No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the engine derating device
pin, that looks like a O.C. for this output pin Check the connectors from
Cable is defective and has no connection engine derating device to TCU
to TCU Check the resistance* of * See Chapter (7)
Engine derating device has an internal engine derating device
defect
Connector has no connection to TCU

3-29
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

81 25 S.C. to battery voltage at clutch K4 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit, the voltage at K4 valve is too If failure at another clutch is Check the connectors from
high pending gearbox to TCU
Cable/connector is defective and has TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
contact to battery voltage OP mode : TCU shutdown Check internal wire harness of
Cable/connector is defective and has the gearbox
contact to another regulator output of the
TCU
Regulator has an internal defect

82 13 S.C. to ground at clutch K4 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve is OP mode : Limp home the engine derating device
out of limit, the voltage at K4 valve is too low If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to vehicle ground TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

83 19 O.C. at clutch K4 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to TCU TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

84 26 S.C. to battery voltage at clutch K4 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit, the voltage at K4 valve is too If failure at another clutch is Check the connectors from
high pending gearbox to TCU
Cable/connector is defective and has TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
contact to battery voltage OP mode : TCU shutdown Check internal wire harness of
Cable/connector is defective and has the gearbox
contact to another regulator output of the
TCU
Regulator has an internal defect

3-30
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

85 14 S.C. to ground at clutch KV TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve is OP mode : Limp home the gearbox
out of limit, the voltage at K4 valve is too low If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to vehicle ground TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

86 20 O.C. at clutch KV TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to TCU TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

87 27 S.C. to battery voltage at clutch KR TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit, the voltage at KR valve is too high If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to battery voltage TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Cable/connector is defective and has contact OP mode : TCU shutdown Check internal wire harness of
to another regulator output of the TCU the gearbox
Regulator has an internal defect

88 15 S.C. to ground at clutch KR TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve is OP mode : Limp home the gearbox
out of limit, the voltage at KR valve is too low If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to vehicle ground TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

89 21 O.C. at clutch KR TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit If failure at another clutch is Check the connectors from
Cable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral Check the regulator resistance* * See Chapter (7)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox

3-31
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

91 1 S.C. to ground at relay reverse warning Backup alarm will be on until Check the cable from TCU to
alarm TCU power down even if fault the backup alarm device
TCU detected a wrong voltage at the output vanishes(Loose connection) Check the connectors from
pin, that looks like a S.C. to vehicle ground OP mode : Normal backup alarm device to TCU
Cable is defective and is contact to vehicle Check the resistance* of * See Chapter (7)
ground backup alarm device
Backup alarm device has an internal defect
Connector pin is contacted to vehicle ground

92 3 S.C. to battery voltage at relay reverse No reaction Check the cable from TCU to
warning alarm OP mode : Normal the backup alarm device
TCU detected a wrong voltage at the output Check the connectors from
pin, that looks like a S.C. to battery voltage backup alarm device to TCU
Cable is defective and is contacted to Check the resistance* of * See Chapter (7)
battery voltage backup alarm device
Backup alarm device has an internal
defect
Connector pin is contacted to battery
voltage

93 2 O.C. at relay reverse warning alarm No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the backup alarm device
pin, that looks like a O.C. for this output pin Check the connectors from
Cable is defective and has no connection backup alarm device to TCU
to TCU Check the resistance* of * See Chapter (7)
Backup alarm device has an internal defect backup alarm device
Connector has no connection to TCU

94 4 S.C. to ground at relay starter interlock No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the stater interlock relay
pin, that looks like a S.C. to vehicle ground Check the connectors from
Cable is defective and is connection to starter interlock relay to TCU
vehicle ground Check the resistance* of * See Chapter (7)
Starter interlock relay has an internal defect starter interlock relay
Connector pin is contacted to vehicle
ground

3-32
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

95 6 S.C. to battery voltage at relay starter No reaction Check the cable from TCU to
interlock OP mode : Normal the starter interlock relay
TCU detected a wrong voltage at the output Check the connectors from
pin, that looks like a S.C. to battery voltage starter interlock relay to TCU
Cable is defective and has no connection Check the resistance* of * See Chapter (7)
to battery voltage starter interlock relay
Starter interlock relay has an internal defect
Connector pin is contacted to battery voltage

96 5 O.C. at relay starter interlock No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the starter interlock relay
pin, that looks like a O.C. for this output pin Check the connectors from
Cable is defective and has no connection starter interlock relay to TCU
to TCU Check the resistance* of * See Chapter (7)
Starter interlock relay has an internal defect starter interlock relay
Connector has no connection to TCU

97 7 S.C. to ground at park brake solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the park brake solenoid
pin, that looks like a S.C. to vehicle ground Check the connectors from
Cable is defective and is connection to park brake solenoid to TCU
vehicle ground Check the resistance* of park * See Chapter (7)
Park brake solenoid has an internal defect brake solenoid
Connector pin is contacted to vehicle
ground

98 9 S.C. to battery voltage at park brake No reaction Check the cable from TCU to
solenoid Optional : (Some customers) the park brake solenoid
TCU detected a wrong voltage at the output TCU shifts to neutral caused by Check the connectors from
pin, that looks like a S.C. to battery voltage park brake feed back park brake solenoid to TCU
Cable is defective and is connection to OP mode : Normal Check the resistance* of park * See Chapter (7)
battery voltage brake solenoid
Park brake solenoid has an internal defect
Connector pin is contacted to battery
voltage

3-33
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

99 8 O.C. at park brake solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output Optional : Some customers the park brake solenoid
pin, that looks like a O.C. for this output pin TCU shifts to neutral caused by Check the connectors from
Cable is defective and has no connection park brake feed back park brake solenoid to TCU
to TCU OP mode : Normal Check the resistance* of park * See Chapter (7)
Park brake solenoid has an internal defect brake solenoid
Connector has no connection to TCU

9A 66 S.C. to ground at converter lock up clutch No reaction Check the cable from TCU to
solenoid OP mode : Normal the converter clutch solenoid
TCU detected a wrong voltage at the output Check the connectors from
pin, that looks like a S.C. to vehicle ground converter clutch solenoid to
Cable is defective and is contacted to TCU
vehicle ground Check the resistance* of park * See Chapter (7)
Converter clutch solenoid has an internal brake solenoid
defect
Connector pin is contacted to vehicle ground

9B 67 O.C. at converter lock up clutch solenoid Converter clutch always open, Check the cable from TCU to
TCU detected a wrong voltage at the output retarder not available the converter clutch solenoid
pin, that looks like a O.C. for this output pin OP mode : Normal Check the connectors from
Cable is defective and has no connection converter clutch solenoid to
to TCU TCU
Converter clutch solenoid has an internal Check the resistance* of park * See Chapter (7)
defect brake solenoid
Connector has no connection to TCU

9C 68 S.C. to battery voltage at converter lock up No reaction Check the cable from TCU to
clutch solenoid OP mode : Normal the converter clutch solenoid
TCU detected a wrong voltage at the output Check the connectors from
pin, that looks like a S.C. to battery voltage converter clutch solenoid to
Cable is defective and has no contacted TCU
to battery voltage Check the resistance* of * See Chapter (7)
Converter clutch solenoid has an internal converter clutch solenoid
defect
Connector pin is contacted to battery voltage

3-34
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

9D 81 S.C. to ground at retarder solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the retarder solenoid
pin, that looks like a S.C. to vehicle ground Check the connectors from
Cable is defective and is contacted to retarder solenoid to TCU
vehicle ground Check the resistance* of * See Chapter (7)
Retarder solenoid has an internal defect retarder solenoid
Connector pin is contacted to vehicle
ground

9E 82 O.C. at retarder solenoid No reaction Check the cable from TCU to


TCU detected a wrong voltage at the output OP mode : Normal the retarder solenoid
pin, that looks like a O.C. for this output pin Check the connectors from
Cable is defective and has no connection retarder solenoid to TCU
to TCU Check the resistance* of * See Chapter (7)
Retarder solenoid has an internal defect retarder solenoid
Connector has no connection to TCU

9F 83 S.C. to battery voltage at retarder solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the retarder solenoid
pin, that looks like a S.C. to battery voltage Check the connectors from
Cable is defective and has no connection retarder solenoid to TCU
to battery voltage Check the resistance* of * See Chapter (7)
Retarder solenoid has an internal defect retarder solenoid
Connector pin is contacted to battery voltage

3-35
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

A1 84 S.C. to ground at difflock or axle connection No reaction Check the cable from TCU to
solenoid OP mode : Normal the difflock solenoid
TCU detected a wrong voltage at the output Check the connectors from
pin, that looks like a S.C. to vehicle ground difflock solenoid to TCU
Cable is defective and is contacted to Check the resistance* of * See Chapter (7)
vehicle ground difflock solenoid
Difflock solenoid has an internal defect
Connector pin is contacted to vehicle ground

A2 85 S.C. to battery voltage at difflock or axle No reaction Check the cable from TCU to
connection solenoid OP mode : Normal the difflock solenoid
TCU detected a wrong voltage at the output Check the connectors from
pin, that looks like a S.C. to battery voltage difflock solenoid to TCU
Cable is defective and has no connection Check the resistance* of * See Chapter (7)
to battery voltage difflock solenoid
Difflock solenoid has an internal defect
Connector pin is contacted to battery voltage

A3 86 O.C. at difflock or axle connection solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the difflock solenoid
pin, that looks like a O.C. for this output pin Check the connectors from
Cable is defective and has no connection difflock solenoid to TCU
to TCU Check the resistance* of * See Chapter (7)
Difflock solenoid has an internal defect difflock solenoid
Connector has no connection to TCU

A4 96 S.C. to ground at warning signal output No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the warning device
pin, that looks like a S.C. to vehicle ground Check the connectors from
Cable is defective and is contacted to warning device to TCU
vehicle ground Check the resistance* of * See Chapter (7)
Warning device has an internal defect warning device
Connector pin is contacted to vehicle ground

3-36
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

A5 97 O.C. voltage at warning signal output No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the warning device
pin, that looks like a O.C. for this output pin Check the connectors from
Cable is defective and has no connection warning device to TCU
to TCU Check the resistance* of * See Chapter (7)
Warning device has an internal defect warning device
Connector has no connection to TCU

A6 98 S.C. to battery voltage at warning signal No reaction Check the cable from TCU to
output OP mode : Normal the warning device
TCU detected a wrong voltage at the output Check the connectors from
pin, that looks like a S.C. to battery voltage warning device to TCU
Cable is defective and has is contacted to Check the resistance* of * See Chapter (7)
battery voltage warning device
Warning device has an internal defect
Connector pin is contacted to battery
voltage

3-37
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

B1 60 Slippage at clutch K1 TCU shifts to neutral Check pressure at clutch K1


TCU calculates a differential speed at closed OP mode : Limp home Check main pressure in the
clutch K1. If this calculated value is out of If failure at another clutch is system
range, TCU interprets this as slipping clutch pending Check sensor gap at internal
Low pressure at clutch K1 TCU shifts to neutral speed sensor
Low main pressure OP mode : TCU shutdown Check sensor gap at output
Wrong signal at internal speed sensor speed sensor
Wrong signal at output speed sensor Check signal at internal speed
Wrong size of the sensor gap sensor
Clutch is defective Check signal at output speed
sensor
Replace clutch

B2 61 Slippage at clutch K2 TCU shifts to neutral Check pressure at clutch K2


TCU calculates a differential speed at closed OP mode : Limp home Check main pressure in the
clutch K2. If this calculated value is out of If failure at another clutch is system
range, TCU interprets this as slipping clutch pending Check sensor gap at internal
Low pressure at clutch K2 TCU shifts to neutral speed sensor
Low main pressure OP mode : TCU shutdown Check sensor gap at output
Wrong signal at internal speed sensor speed sensor
Wrong signal at output speed sensor Check signal at internal speed
Wrong size of the sensor gap sensor
Clutch is defective Check signal at output speed
sensor
Replace clutch

B3 62 Slippage at clutch K3 TCU shifts to neutral Check pressure at clutch K3


TCU calculates a differential speed at closed OP mode : Limp home Check main pressure in the
clutch K3. If this calculated value is out of If failure at another clutch is system
range, TCU interprets this as slipping clutch pending Check sensor gap at internal
Low pressure at clutch K3 TCU shifts to neutral speed sensor
Low main pressure OP mode : TCU shutdown Check sensor gap at output
Wrong signal at internal speed sensor speed sensor
Wrong signal at output speed sensor Check signal at internal speed
Wrong size of the sensor gap sensor
Clutch is defective Check signal at output speed
sensor
Replace clutch

3-38
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

B4 63 Slippage at clutch K4 TCU shifts to neutral Check pressure at clutch K4


TCU calculates a differential speed at closed OP mode : Limp home Check main pressure in the
clutch K4. If this calculated value is out of If failure at another clutch is system
range, TCU interprets this as slipping clutch pending Check sensor gap at internal
Low pressure at clutch K4 TCU shifts to neutral speed sensor
Low main pressure OP mode : TCU shutdown Check sensor gap at turbine
Wrong signal at internal speed sensor speed sensor
Wrong signal at turbine speed sensor Check signal at internal speed
Wrong size of the sensor gap sensor
Clutch is defective Check signal at turbine speed
sensor
Replace clutch

B5 64 Slippage at clutch KV TCU shifts to neutral Check pressure at clutch KV


TCU calculates a differential speed at closed OP mode : Limp home Check main pressure in the
clutch KV. If this calculated value is out of If failure at another clutch is system
range, TCU interprets this as slipping clutch pending Check sensor gap at internal
Low pressure at clutch KV TCU shifts to neutral speed sensor
Low main pressure OP mode : TCU shutdown Check sensor gap at turbine
Wrong signal at internal speed sensor speed sensor
Wrong signal at turbine speed sensor Check signal at internal speed
Wrong size of the sensor gap sensor
Clutch is defective Check signal at turbine speed
sensor
Replace clutch

B6 65 Slippage at clutch KR TCU shifts to neutral Check pressure at clutch KR


TCU calculates a differential speed at closed OP mode : Limp home Check main pressure in the
clutch KR. If this calculated value is out of If failure at another clutch is system
range, TCU interprets this as slipping clutch pending Check sensor gap at internal
Low pressure at clutch KR TCU shifts to neutral speed sensor
Low main pressure OP mode : TCU shutdown Check sensor gap at turbine
Wrong signal at internal speed sensor speed sensor
Wrong signal at turbine speed sensor Check signal at internal speed
Wrong size of the sensor gap sensor
Clutch is defective Check signal at turbine speed
sensor
Replace clutch

3-39
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

B7 87 Overtemp sump No reaction Cool down machine


TCU measured a temperature in the oil OP mode : Normal Check oil level
sump that is over the allowed threshold. Check temperature sensor

B8 88 Overtemp retarder TCU disables retarder Cool down machine


TCU measured a temperature in the retarder OP mode : Normal Check oil level
oil that is over the allowed threshold Check temperature sensor

B9 89 Overspend engine Retarder applies -


OP mode : Normal

BA 90 Differential pressure oil filter No reaction Check oil filter


TCU measured a voltage at differential OP mode : Normal Check wiring from TCU to
pressure switch out of the allowed range differential pressure switch
Oil filter is polluted Check differential pressure
Cable/connector is broken or cable/ switch(Measure resistance)
connector is contacted to battery voltage
or vehicle ground
Differential pressure switch is defective

BB 172 Slippage at converter lockup clutch Check pressure at converter


TCU calculates a differential speed at closed lockup clutch
converter lockup clutch. If this calculated Check main pressure in the
value is out of range, TCU interprets this as system
slipping clutch Check sensor gap at engine
Low pressure at converter lockup clutch speed sensor
Low main pressure Check sensor gap at turbine
Wrong signal at engine speed sensor speed sensor
Wrong signal at turbine speed sensor Check signal at engine speed
Wrong size of the sensor gap sensor
Clutch is defective Check signal at turbine speed
sensor
Replace clutch

3-40
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

BD 169 S.C. to ground at engine brake solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal engine brake solenoid
pin, that looks like a S.C. to vehicle ground Check the connectors from
Cable is defective and is contacted to engine brake solenoid to TCU
vehicle ground Check the resistance* of engine * See Chapter (7)
Engine brake solenoid has an internal brake solenoid
defect
Connector pin is contacted to vehicle ground

BE 171 S.C. to battery voltage at engine brake No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the engine brake solenoid
pin, that looks like a S.C. to battery voltage Check the connectors from
Cable is defective and is contacted to engine brake solenoid to TCU
battery voltage Check the resistance* of engine * See Chapter (7)
Engine brake solenoid has an internal defect brake solenoid
Connector pin is contacted to battery voltage

BF 170 O.C. at engine brake No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the engine brake solenoid
pin, that looks like a O.C. for this output pin Check the connectors from
Cable is defective and has no connection engine brake solenoid to TCU
to TCU Check the resistance* of engine * See Chapter (7)
Engine brake solenoid has an internal brake solenoid
defect
Connector has no connection to TCU

3-41
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

C3 91 Overtemp converter output No reaction Cool down machine


TCU measured a oil temperature at the OP mode : Normal Check oil level
converter output that is the allowed threshold Check temperature sensor

C4 129 S.C. to ground at joystick status indicator No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal joystick status indicator
pin, that looks like a S.C. to vehicle ground Check the connectors from
Cable is defective and is contacted to joystick status indicator to TCU
vehicle ground Check the resistance* of *See chapter (7)
Joystick status indicator has an internal joystick status indicator
defect
Connector pin is contacted to vehicle ground

C5 131 S.C. to battery voltage at joystick status No reaction Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
TCU detected a wrong voltage at the output Check the connectors from
pin, that looks like a S.C. to battery voltage joystick status indicator to TCU
Cable is defective and is contacted to Check the resistance* of *See chapter (7)
battery voltage joystick status indicator
Joystick status indicator has an internal
defect
Connector pin is contacted to battery voltage

C6 130 O.C. at joystick status indicator No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal joystick status indicator
pin, that looks like a O.C. for this output pin Check the connectors from
Cable is defective and has no connection joystick status indicator to TCU
to TCU Check the resistance* of *See chapter (7)
Joystick status indicator has an internal joystick status indicator
defect
Connector pin has no connection to TCU

3-42
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

D1 54 S.C. to battery voltage at power supply for See fault codes No.21 to 2C Check cables and connectors Fault codes No.21 to No.2C
sensors to sensors, which are supplied may be reaction of this fault
TCU measures more than 6V at the pin AU1 from AU1
(5V sensor supply) Check the power supply at the
pin AU1(Should be appx. 5V)

D2 55 S.C. to ground at power supply for sensors See fault codes No.21 to 2C Check cables and connectors Fault codes No.21 to No.2C
TCU measures less than 4V at the pin AU1 to sensors, which are supplied may be reaction of this fault
(5V sensor supply) from AU1
Check the power supply at the
pin AU1(Should be appx. 5V)
Low voltage at battery
D3 53 Measured voltage at power supply is lower Shift to neutral Check power supply battery
than 18V(24V device) OP mode : TCU shutdown Check cables from batteries to
TCU
Check connectors from
batteries to TCU
High voltage at battery
D4 52 Measured voltage at power supply is higher Shift to neutral Check power supply battery
than 32.5V(24V device) OP mode : TCU shutdown Check cables from batteries to
TCU
Check connectors from
batteries to TCU
Error at valve power supply VPS1
D5 57 TCU switched on VPS1 and measured Shift to neutral Check fuse
VPS1 is off or TCU switched off VPS1 and OP mode : TCU shutdown Check cables from gearbox to
measured VPS1 is still on TCU
Cable or connectors are defect and are Check connectors from
contacted to battery voltage gearbox to TCU
Cable or connectors are defect and are Replace TCU
contacted to vehicle ground
Permanent power supply KL30 missing
TCU has an internal defect

3-43
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

D6 58 Error at valve power supply VPS2 Shift to neutral Check fuse


TCU switched on VPS2 and measured OP mode : TCU shutdown Check cables from gearbox to
VPS2 is off or TCU switched off VPS2 and TCU
measured VPS2 is still on Check connectors from
Cable or connectors are defect and are gearbox to TCU
contacted to battery voltage Replace TCU
Cable or connectors are defect and are
contacted to vehicle ground
Permanent power supply KL30 missing
TCU has an internal defect

3-44
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

E1 91 S.C. battery voltage at speedometer output - - Not used

S.C. to ground or O.C at speedometer


E2 92 output - - Not used

S.C. to battery voltage at display output


E3 TCU sends data to the display and No reaction Check the cable from TCU to
measures always a high voltage level on the OP mode : Normal the display
connector Check the connectors at the
Cable or connectors are defective and are display
contacted to battery voltage Change display
Display has an internal defect

S.C. to ground at display output


E4 TCU sends data to the display and No reaction Check the cable from TCU to
measures always a high voltage level on the OP mode : Normal the display
connector Check the connectors at the
Cable or connectors are defective and are display
contacted to battery voltage Change display
Display has an internal defect

Communication failure on DeviceNet


E5 93, 104 Shift to neutral Check Omron master
OP mode : TCU shutdown Check wire of DeviceNet-Bus
Check cable to Omron master
DISPID1 timeout
E5 104 Timeout of CAN-massage DISPID1 from TCU select parameter set with Check display controller
display controller ID0 Check wire of CAN-Bus
Interference on CAN-Bus OP mode : Limp home Check cable display controller
CAN wire/connector is defective
Can wire/connector is defective and has
contact to vehicle ground or battery voltage

3-45
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks

F1 51 General EEPROM fault No reaction Replace TCU Often shown together with
TCU can't read non volatile memory OP mode : Normal fault code F2
TCU is defective

F2 56 Configuration lost Transmission stay neutral Reprogram the correct


TCU has lost the correct configuration and OP mode : TCU shutdown configuration for the vehicle
can't control the transmission (e.g. with cluster controller,...)
Interference during saving data on non
volatile memory
TCU is brand new or from another vehicle

F3 59 Application error Transmission stay neutral Replace TCU This fault occurs only if an test
Something of this application is wrong OP mode : TCU shutdown engineer did something wrong
in the application of the vehicle

F5 173 Clutch failure Transmission stay neutral Check clutch TCU shows also the affected
AEB was not able to adjust clutch filling OP mode : TCU shutdown clutch on the display
parameters
One of the AEB-Values is out of limit

F6 174 Clutch adjustment data lost No reaction, Execute AEB


TCU was not able to read correct clutch Default values : 0 for AEB
adjustment parameters Offsets used
Interference during saving data on non OP mode : Normal
volatile memory
TCU is brand new

3-46
(7) Measuring of resistance at actuator/sensor and cable
Actuator

2 G 76043PT19

Open circuit R12 = R1G = R2G =


Short cut to ground R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to ground, G is connected to vehicle ground)
Short cut to battery R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to battery, G is connected to battery voltage)

Cable

UBat

P(Power supply)
TCU
1 Actuator/
2 Sensor

C(Chassis)

Ground 76043PT20

Open circuit R12 = R1P = R1C = R2P = R2C=


Short cut to ground R12 = 0; R1C = R2C = 0, R1P = R2P =
Short cut to battery R12 = 0; R1C = R2C = 0, R1P = R2P = 0

3 - 47
7) ELECTRIC CONTROL UNIT
(1) Complete system

2
1

4 10
3 9

A
7

11

2
6
13

12
14

8
7707PT03

1 Control unit(EST-37A)
2 Kickdown switch
3 Clutch cut off switch
4 Full automatic switch
5 LCD
6 Gear selector(DW-3) with integrated kickdown switch
7 Supply-system connection
8 Transmission
9 Cable to inductive transmitter - speed central gear train
10 Cable to inductive transmitter - speed turbine
11 Cable to inductive transmitter - speed engine
12 Cable to speed sensor output and speedometer
13 Cable to plug connection on the electro - hydraulic control unit
14 Brake pressure sensor/load sensor
(2) Description of the basic functions
The powershift-reversing transmissions will be equipped with the electronic transmission control
unit(EST-37A), developed for them.
The system is processing the wishes of the driver according to the following criteria.
Speed definition as a function of gear selector position, driving speed and load level.

3 - 48
Protection against operating errors, as far as possible and practical.
Protection against overspeeds(On the basis of engine and turbine speed).
Reversing-automatic system(Driving speed-dependent).
Pressure cut off(Disconnecting of the drive train for maximum power on the power take-off).
Switch for manual or automatic operation.
Reversing function button, respectively kickdown function.

(3) Gearshifts
The control unit(EST-37A) is shifts the required speeds fully-automatically under consideration of
the following criteria.
Gear selector position
Driving speed
Load level
At the same time, the following speeds are picked up by the control unit(EST-37A).
n Engine
n Turbine
n Central gear train
n Output

- Neutral position
Neutral position is selected through the gear selector.
After the ignition is turned on, the electronics remains in the waiting state; By the position neutral
of the gear selector, respectively by pressing on the key neutral, the control unit(EST-37A)
becomes ready for operation.
Now, a speed can be engaged.
- Speed engagement
In principle, the speed, adapted to the driving speed(At standing, or rolling machine), will be
engaged. The engagement is realized in dependence on load and rotational speed.
- Upshifting under load
Upshifting under load will be then realized if the machine can still accelerate by it.
- Downshifting under load
Downshifting under load will be realized if more traction force is needed.
- Upshifting in coasting condition
In the coasting condition, the upshifting will be suppressed if the speed of the machine on a slope
shall not be further increased.
- Downshifting in coasting condition
Downshiftings in the coasting condition will be realized if the machine shall be retarded.
- Reversing
At speeds below the reversing limit, direct reversing can be carried out at any time in the speeds
1F 1R and 2F 2R(As a rule, this is the maximum driving speed of the 2nd speed).

3 - 49
Reversings in the speeds 3 and 4 are realized dependent on the driving speed.
- Above the programmed reversing limit, the machine is braked down by downshifts of the
electronic control unit(EST-37A) to the permitted driving speed, and only then, the reversing into
the correspondingly preselected speed will be carried out.
- Below the permitted driving speed, the reversing is carried out immediately.
(4) Specific kickdown function
By means of the kickdown-button, integrated in the gear selector, it is at any time possible to select
in the speeds 2F and 2R(i.e. position 2 of the gear selector, at automatic mode also in the 2nd
speed of the automatic range) the 1st speed by a short touch. This kickdown state can be
cancelled by :
1. Pressing the kickdown-button again
2. Realization of a reversal operation
3. Change of the gear selector position by the following modification
Gear selector(DW-3) - (Rotation) of the driving position 1...4.
The kickdown function will be always terminated by shifting to neutral.
(5) Clutch cut off
Especially at wheel loaders, the clutch cut off can be activated through a switch signal. It is
interrupting the power flow in the transmission as long as this signal is active. Besides, this
function can be used for the transmission-neutral shifting at applied hand brake or as emergency-
stop(In this case, a restarting is only possible through the gear selector-neutral position).

3 - 50
5. AXLE
1) OPERATION
The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the
axle shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and
is sent to the wheels.
(1) Front axle

2
3

5
1
4

7707PT04

1 Final drive 3 Housing 5 Wheel nut


2 Differential 4 Parking brake

(2) Rear axle

2
3

4
1

7707PT05

1 Final drive 2 Differential 3 Housing 4 Wheel nut

3 - 51
2) FRONT AXLE DIFFERENTIAL SECTION

10 9 6 7

4
3

2
7707PT14

1 Roller bearing 6 Side gear


2 Input flange 7 Clutch
3 Bevel gear set 8 Planetary gear
4 Differential housing 9 Spider
5 Adjusting screw 10 Bevel thrust washer of side gear

3 - 52
3) REAR AXLE DIFFERENTIAL SECTION

9 8 5 6

3 4

7707PT15

1 Roller bearing 6 Clutch


2 Input flange 7 Planetary gear
3 Bevel gear set 8 Spider
4 Difterential housing 9 Bevel thrust washer of side gear
5 Side gear

3 - 53
4) DIFFERENTIAL

(1) Description
3
When the machine makes a turn, the
2 4
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion(1) and is transmitted
to the bevel gear(2). The bevel gear
changes the direction of the motive force
by 90 degree, and at the same time
reduces the speed. 1
It then transmits the motive force through
the differential(3) to the axle gear shaft(4). 770-3 [3-26(1)]

(2) When driving straight forward


Pinion gear
When the machine is being driven straight
forward and the right and left wheels are Side gear Side gear
rotating at the same speed, so the pinion Axle gear shaft
gear inside the differential assembly do not
rotate. The motive force of the carrier is
send through the pinion gear and the side
gear, therefore the power is equally Carrier
transmitted to the left and right axle gear Pinion gear
shaft.

770-3 [3-26(2)]

(3) When turning


Swing
When turning, the rotating speed of the
Pinion gear
left and right wheels is different, so the
Side gear Side gear
pinion gear and side gear inside the
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
The power of the carrier is then
transmitted to the axle gear shafts. Carrier

Pinion gear Ring gear

770-3 [3-26(3)]

3 - 54
5) TORQUE PROPORTIONING DIFFERENTIAL
(1) Function
Because of the nature of their work, 4-
wheel-drive loaders have to work in
places where the road surface is bad.
In such places, if the tires slip, the ability
to work as a loader is reduced, and also
the life of the tire is reduced.
The torque proportioning differential is
installed to overcome this problem.
In structure it resembles the differential of
an automobile, but the differential pinion
gear has an odd number of teeth.
Because of the difference in the
resistance from the road surface, the
position of meshing of the pinion gear
and side gear changes, and this changes
the traction of the left and right tires.

(2) Operation Spider rotating


When traveling straight direction
(Equal resistance from road surface to
left and right tires)
Under this condition, the distances
involving the engaging points between FL
FR
right and left side gears and pinion-a and Engaging a b Engaging
point point
b-are equal and the pinion is balanced as
FL a=FR b. Thus, FL=FR, and the
right and left side gears are driven with Left side gear Right side gear
the same force. Pinion
770-3 (3-27)

3 - 55
When traveling on soft ground
(Resistance from road surface to left and
right tires is different)
If the road resistance to the left wheel is
Spider rotating
smaller, the left side gear tends to rotate direction
forward, and this rotation changes the
engaging points between the side gears
and pinion. As a result, the distances
involving the engaging points becomes FL
Small road FR Large road
a>b. The pinion now is balanced as FL resistance a b resistance
a=FR b, where FL>FR. The right Engaging Engaging
side gear is driven with a greater force point point
than the left side gear. The torque can
Left side gear Right side gear
be increased by up to about 30% for Pinion
either side gear.
The pinion therefore does not run idle
and driving power is transmitted to both
side gears until the difference between
road resistance to the right and left
770-3 (3-27)
wheels reaches about 30%.

3 - 56
6) FINAL DRIVE SECTION(Front & rear)

6 7 8 9
10 11
5

19

18

12
13

17 16 15 14

7707PT16

1 Sun gear 8 Pressure plate 14 Lug disc


2 Side gear(Planetary gear) 9 Bevel gear support 15 Brake disc(Friction plate)
3 Side gear carrier pin 10 Pin(Push rod) 16 Piston return spring
4 Final drive cover 11 Spindle 17 Retaining spring ring
5 Side gear carrier support(Hub drum) 12 Half shaft 18 Ring nut
6 Wheel hub 13 Brake drive piston 19 Disc carrier hub
7 Bevel gear(Ring gear)

(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(12) to sun gear(1) is transmitted to
planetary gear(2). The planetary gear rotates around the inside of a fixed ring gear(7) and in this
way transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.

3 - 57
6. TIRE AND WHEEL

770-3 (3-30)

1 Wheel rim 3 O-ring 5 Side ring


2 Tire 4 Lock ring 6 Valve assembly

1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.

3 - 58
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. POWER TRAIN OPERATIONAL CHECKS


This procedure is designed so that the mechanic can make a quick check of the system using a
minimum amount of diagnostic equipment. If you need additional information, read Structure and
function, Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information :

Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments

3-59
※ Transmission oil must be at operating temperature for these checks.

Item Description Service action

Transmission oil warm- Start engine. Apply service OK


up procedure brakes and release parking brake. Check completed.
Select full automatic switch to
manual mode①.
Move gear selector lever to 3rd
speed.
Move gear selector lever to
forward "F" position.
1
2 Increase engine speed to high idle
for 30 seconds.
A

Move gear selector lever to


neutral "N" position and run for 15
seconds.
1

4
2
3
F
N
R
Repeat procedure until
transmission temperature gauge
arrow points to bar above dial.

Gear selector lever and Move gear selector lever to each OK


neutral lock latch 1

4
2
3
position. Check completed.
checks
NOTE : Gear selector lever
Engine OFF. NOT OK
position changes slightly as
Repair lock or replace
steering column is tilted.
switch.
FEEL : Lever must move freely
through all positions.
Engage neutral lock.
Apply slight effort to move lever
into forward(F) and reverse(R).
LOOK : Neutral lock must stay
engaged.

Automatic shifting Start engine. OK


check Check completed.
Move gear selector lever to 4th
speed.
1

4
2
3
F
N
R NOT OK
Turn full automatic switch ON.
Go to transmission error
code group at page 3-20~
LOOK : Automatic sign on
Automatic sign 3-46.
display.
Repair or replace the
Move gear selector lever to display or harness.
forward or reverse position.
Increase engine rpm.
LOOK : Speed(2nd~4th) on
display must vary with machine
speed.

3-60
Item Description Service action

Transmission noise Run engine at approximately OK


check 1

4
2
3
1600rpm. Check completed.
Engine running.
Drive unit with transmission in NOT OK
each forward and reverse speed. Go to transmission makes
excessive noise group 3.
LISTEN : Transmission must not
make excessive noise in any
range.
Engine rpm must not "lug down"
as unit is shifted between gears.

Transmission "quick Release parking brake and select OK


shift" check full automatic switch to manual Check completed.
Engine running. mode .
NOT OK
Shift to 2nd forward. Check connector at base
of control valve.
Drive machine at approximately
5km/h and press gear selector IF OK
lever kick down switch or RCV Go to transmission
lever switch once. controller circuit in group
1.
LOOK/FEEL : Transmission must
shift to and remain in 1st gear.
Press gear selector lever kick
down switch once.
1
2
3
4

LOOK/FEEL : Transmission must


shift back to 2nd gear.
Shift to (3rd or 4th) gear and press
gear selector lever kick down
switch once.
LOOK/FEEL : Transmission must
not shift down.
Select full automatic switch to
automatic mode②.
Drive machine at approximately
90% speed of max speed in each
gear(2nd or 3rd or 4th).
Shift to(2nd or 3rd or 4th) gear in
each forward and reverse speed
and press gear selector kick down
lever switch or RCV lever switch
once.
LOOK/FEEL : Transmission must
shift to lower(1st or 2nd or 3rd)
gear respectively.
Press gear selector lever kick
down switch or RCV lever switch
once again.

3-61
Item Description Service action

LOOK/FEEL : Transmission
must shift to former(2nd or 3rd or
4th) gear.
NOTE : If gear selector lever kick
down switch or RCV lever switch
is pressed twice, transmission
will shift down the immediately
back to former gear.
Forward, reverse and Park unit on level surface. OK
4th speed clutch pack 1
2
3
Check completed.
Apply service brakes.
4

drag check
NOT OK
※ Transmission must Move gear selector lever to
If unit moves, repair
be warmed up for neutral.
transmission.
this check.
Move gear selector lever to 1st.
Engine running.
Release parking brake and
service brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.

Transmission shift Run engine at approximately OK


modulation check 1
2
3
1300rpm. Check completed.
Engine running.
4

Put transmission in 1st forward, NOT OK


shift several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.

Torque converter check Start engine. Apply service OK


1

4
2
3
brakes and release parking brake. Check completed.
Move gear selector lever to 3rd NOT OK
speed. If stall rpm are too low or
too high, problem may be
Move gear selector control lever
engine power or torque
to forward "F" position.
converter.
Increase engine speed to high
IF OK
idle.
Replace transmission
LOOK : Torque converter stall torque converter.
rpm must be within the following
range.
Stall rpm : 1st gear : 2050±70rpm
2nd/3rd/4th gear
: 2085±70rpm
Move gear selector control lever
to neutral "N" position and run for
15 seconds.

3-62
2. TROUBLESHOOTING
1) TRANSMISSION
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1.)
Step 2. Operational checks(In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments(See group 3.)

Problem Cause Remedy

Transmission slippage Low oil level. Add oil.


Wrong oil grade. Change oil.
Restricted transmission pump Remove and clean screen.
suction screen.
Leak in transmission control valve Remove valve and inspect gaskets.
or gasket.
Low transmission pump flow due Do transmission pump flow test.
to worn pump.
Weak or broken pressure regulat- Do transmission system pressure test.
ing valve spring.

Error code on display Something wrong in transmission. Go to transmission error code group at page
3-20~3-46.

3-63
Problem Cause Remedy

Machine will not move Low oil level. Add oil.


Applied park brake. Check parking brake fuse.
Check continuity to parking brake switch.
No power to transmission contro- Check transmission controller fuse.
ller.
Malfunctioning parking brake Remove and inspect parking brake solenoid
solenoid valve. valve.
Check for power to solenoid valve.
Restricted orifice of PPC valve. Remove orifice and check for contamination
and/or plugging.
(Do not remove valve housing for this purpose.)
Excessive leakage in Do transmission element leakage test using
transmission element. system pressure.
Worn clutch disks. Repair transmission.
Low or no transmission See transmission pressure is low in this group.
pressure.
Service brake will not release. Do brake pedal operational check.
Do service and park system drag checks.
Failed torque converter. Do torque converter stall test.
If engine pulldown in normal, torque converter is
good.
Broken shafts or gears. Drain transmission to determine if large pieces
of metal contamination are present.
Broken drive shafts. Inspect drive shafts and universal joints for
external damage. Repair.

Broken ring or pinion gear. If drive shaft rotate with transmission in gear but
machine does not move, a differential failure is
indicated. Repair.

Machine does not Malfunctioning transmission Check solenoid valve.


engage in low gear control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve. spools.
Stuck PPC valve. Remove end cover to inspect PPC valve.
Replace if necessary.
Malfunctioning transmission Check speed sensor.
speed sensor.

3-64
Problem Cause Remedy

Transmission pressure Low oil level. Check transmission oil level and refill if
is low(All gears) necessary.
Failed transmission pressure Verify transmission system pressure. Do
switch. transmission system pressure test.
Plugged suction strainer. Transmission pump may be noisy if transmission
suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken spring. Inspect for damage(See transmission control
valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining
control valve to transmission.

Transmission system Failed transmission pump. Do pump flow test.


pressure is low (One or
Failed transmission control valve Inspect transmission control valve for external
two gears)
gasket. leakage. Remove control valve.
Inspect or replace gasket.
Leakage in clutch piston or seal Disassemble and repair.
ring.

Transmission shifts too Low oil level(Aeration of oil). Add oil.


low
Low transmission pressure. Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen.
Low transmission pump flow. Do transmission pump flow test.
Excessive transmission Do transmission element leakage test using
element leakage. system pressure.
Stuck PPC valve. Remove end cover to inspect modulation spool.
Replace if necessary.
Restricted PPC valve orifice. Remove orifice and inspect for contamination
and /or plugging.
Restricted oil passages between Remove control valve and inspect oil passage.
control valve and transmission
elements.
Incorrect transmission oil. Change oil(SAE 10W-30/15W-40)

3-65
Problem Cause Remedy

Transmission shifts too Wrong transmission controller. Check if transmission controller has been
fast changed
System pressure too high. Do transmission system pressure test.
Stuck PPC valve. Remove and inspect PPC valve.
Replace if necessary. Also remove end cover to
inspect PPC valve and control valve housing.
Replace if necessary.
Stuck or missing check valves. Inspect transmission control valve.
Missing O-ring from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring. Disassemble and inspect clutch.
Incorrect transmission oil. Change oil(SAE 10W-30/15W-40)

Machine "creeps" Warped disks and plates in Check transmission.


in neutral transmission.

Transmission hydraulic High oil level. Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level. Add oil.
Wrong oil grade. Change oil.
Park brake dragging. Check for heat in park brake area.
Pinched, restricted or leaking lube Check cooler lines.
lines.
Machine operated in too high gear Operate machine in correct gear range.
range.
Malfunction in temperature gauge Install temperature sensor the verify temperature.
or sensor. Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass valve(In Disassemble and inspect.
thermal bypass valve).
Failed thermal bypass valve. Remove thermal bypass valve and check to see
if machine still overheats. Do transmission oil
cooler thermal bypass valve test.
Internally restricted oil cooler. Do oil cooler restriction test.
Leakage in transmission hydraulic Do transmission system pressure, element
system. leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.

3-66
Problem Cause Remedy

Excessive transmission Too low engine low idle. Check engine low idle speed.
noise(Under load or no
Worn parts or damaged in Remove transmission suction screen. Inspect
load)
transmission. for metal particles.
Repair as necessary.
Warped drive line between engine Inspect drive line.
and torque converter.
Low or no lube. Do converter-out and lube pressure test. Do
transmission pump flow test.

Foaming oil Incorrect type of oil. Change oil.


High oil level. Transmission overfilled or hydraulic pump seal
leaking.
Low oil level. Add oil.
Air leak on suction side of pump. Check oil pickup tube on side of transmission.

Oil ejected from dipstick Plugged breather. Inspect breather on top of transmission.
Replace.

Machine vibrates Aerated oil. Add oil.


Low engine speed. Check engine speed.
Failed universal joints on Check universal joints.
transmission drive shaft or
differential drive shafts.

Machine lacks power Engine high idle speed set too Check high idle adjustment.
and acceleration low.
Incorrect transmission oil. Change oil.
Aerated oil. Add oil.
Low transmission pressure. Do transmission system pressure test.
Warped transmission clutch. Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.
gasket.
Brake drag. Do brake drag check.
Failed torque converter. Do torque converter stall speed test.
Low engine power. Do engine power test.

Torque converter stall Aerated oil. Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Stuck open converter relief valve. Do converter-out pressure test.
Leakage in torque converter seal.
Do converter-out pressure test.
Torque converter not
transferring power(Bent fins,
broken starter). Replace torque converter.

3-67
Problem Cause Remedy

Torque converter stall Low engine power. Do engine power test.


RPM too low
Mechanical malfunction. Remove and inspect torque converter.

Transmission pressure Low oil level. Add oil.


light comes ON when
Cold oil. Warm oil to specification.
shifting from forward to
reverse(All other gears Leak in reverse pack. Do transmission pressure, pump flow, and
OK) leakage check.

Transmission pressure Cold oil. Warm oil to specification.


light comes ON for each
No time delay in monitor. Do monitor check.
shift
Restriction in modulation orifice. Remove orifice and inspect for restriction and/or
plugging.
Stuck PPC valve. Remove and inspect.
Low transmission pressure circuit. Do transmission system pressure test.

Leak in transmission pressure Do converter out pressure test.


circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.

3-68
2) DIFFERENTIAL / AXLE

Problem Cause Remedy

Differential low on oil External leakage. Inspect axle and differential for leaks.

Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for
and/or axle noise metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil. Change oil
Dragging brakes. Do brake check.
Failed pinion bearing. Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring
between ring and pinion gear. and pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and/or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
Mechanical failure in axle Remove differential. Inspect, repair.
planetary.

Oil seeping from outer Excessive end play in axle. Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing,
cup, spacer, and seal. Replace, if necessary.
Overfilled differential. Check differential oil return system for excessive
internal restriction.

Axle overheats Low differential oil. Add oil.


Overfilled differential. See differential overfills with oil in this group.
Brake drag. See brakes drag in this group.

3) DRIVE LINE

Problem Cause Remedy

Excessive drive line Yokes not in line on drive shafts. Inspect. Align drive shaft yokes.
vibration or noise
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining nuts(Drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.

3-69
GROUP 3 TESTS AND ADJUSTMENTS

1. CLUTCH CUT-OFF PRESSURE SWITCH TEST


The setting pressure of the clutch cut-off
pressure switch should be suited with the
specification. The rated pressure is 25kgf/cm2.
For the detailed method for pressure
adjusting, refer to page 4-22.

BL1

Clutch cut off


pressure switch

Brake valve

7707PT12

3-70
2. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurements have to be carried out at hot transmission(About 80~95°C).

9 51 65 30 29
X

K2 KR KV K4 K3

K1

KV

K2

16
KR
K3

K4
13

14 5

56 58
D C

60 53
E B

F A
55 57
J G
K 69
H
49

68 51 65
VIEW X
7707PT17

1) OIL PRESSURE AND TEMPERATURE

Port Description Size

51 Converter inlet-opening pressure(8.5bar) H M10×1.0


52 Converter outlet-opening pressure(5bar) M10×1.0
53 Forward clutch(16+2bar) KV B M10×1.0
55 Reverse clutch(16+2bar) KR F M10×1.0
56 1st clutch(16+2bar) K1 D M10×1.0
57 2nd clutch(16+2bar) K2 A M10×1.0
58 3rd clutch(16+2bar) K3 C M10×1.0
60 4th clutch(16+2barr) K4 E M10×1.0
63 Converter outlet temperature 100°
C, short-time 120°
C M14×1.5
65 System pressure(16+2bar) K M10×1.0

3 - 71
2) CONNECTIONS

Port Description Size

15 Connection to the oil cooler M42×2.0


16 Connection from the oil cooler M42×2.0
29 Connection from filter M42×2.0
30 Connection to filter 1-11/16 UN 2A ANSI
49 Plug connection on the hydraulic control unit -
68 Pilot pressure(Option) J M16×1.5
69 System pressure(Option) G M16×1.5

3) INDUCTIVE TRANSMITTER AND SPEED SENSOR

Port Description Size

5 Inductive transmitter n Central gear chain M18×1.5


9 Inductive transmitter n Engine M18×1.5
13 Speed sensor n Output and speedometer -
14 Inductive transmitter n Turbine M18×1.5

3-72
GROUP 4 DISASSEMBLY AND ASSEMBLY

1. CONTROL VALVE
1) DISASSEMBLY
(1) Illustration on the right shows the
complete control unit.

73073CV001

(2) Mark the installation position of the


different covers, the housing and cable
harness with the valve housing.

73073CV002

(3) Loosen socket head screws.


Separate duct plate, 1st gasket,
intermediate plate and 2nd gasket from
the valve housing.
Special tool
Box spanner 5873 042 002

73073CV003

(4) Remove retaining clip.

73073CV004

3-73
(5) Loosen socket head screws.
Separate cover from housing and cable
harness.
Special tool
Box spanner 5873 042 002

73073CV005

(6) Disassemble opposite cover.


Disconnect pressure regulator and
remove cable harness.

73073CV006

(7) Loosen socket head screws, remove fixing


plate and pressure regulators(3EA).
Special tool
Box spanner 5873 042 002

73073CV007

(8) Loosen two socket head screws and


locate housing provisionally, using
adjusting screws(Housing is under spring
preload).
Now, loosen remaining socket head
screws.
Special tool
Box spanner 5873 042 002
Adjusting screws 5870 204 036
73073CV008

3-74
(9) Separate housing from valve housing by
loosening the adjusting screws uniformly.
Special tool
Adjusting screws 5870 204 036

73073CV009

(10) Remove components.

73073CV010

(11) Remove opposite pressure regulators,


housing as well as components
accordingly.

73073CV011

3-75
2) ASSEMBLY
Check all components for damage and
renew if necessary.
Prior to the installation, check free travel of
all moving parts in the housing.
Spools can be exchanged individually.
Oil the components prior to the assembly.
Insert diaphragms with the concave side
showing upward until contact is obtained.
Installation position, see arrows.
73073CV015

(1) Illustration on the right shows the following


components.
1 Vibration damper
2 Follow-on slide
3 Pressure reducing valve

73073CV016

(2) Install components according to figure (1).


Preload compression spring of the follow-
on slides and locate spool provisionally by
means of cylindrical pins 5.0mm
(Assembly aid), see arrows.

73073CV017

(3) Install two adjusting screws.


Assemble gasket(Arrow 1) and housing
cover. Now, position the housing cover
uniformly, using adjusting screws, until
contact is obtained and remove cylindrical
pins(Assembly aid) again(See the next
figure).
Pay attention to the different housing covers.
Install recess 15mm (Arrow 2), facing the
spring of the pressure reducing valve.
Special tool 73073CV018

Adjusting screws 5870 204 036

3-76
73073CV019

(4) Fasten housing cover by means of socket


head screws.
Torque limit : 0.56kgf m(4.06lbf ft)
Special tool
Box spanner 5873 042 002

73073CV020

(5) Introduce pressure regulators and fix by


means of fixing plates and socket head
screws.
Install fixing plate, with the claw showing
downward.
Pay attention to the radial installation
position of the pressure regulators, see
figure.
Torque limit : 0.56kgf m(4.06lbf ft)
Special tool 73073CV021
Box spanner 5873 042 002

Pre assemble opposite side


(6) Illustration on the right shows the following
components.
1 Main pressure valve
2 Follow on slide
3 Vibration damper

73073CV022

3-77
(7) Install components according to figure (6).
Preload compression springs of the follow-
on slides and locate spool provisionally by
means of cylindrical pins 5.0mm
(Assembly aid), see arrows.
Install two adjusting screws.
Assemble gasket(Arrow 1) and housing
cover, and position them uniformly against
shoulder, using adjusting screws.
Pay attention to the different housing 73073CV023
covers-install the recess 19mm(Arrow 2),
facing the main pressure valve.
Now, fasten housing cover by means of
socket head screws.
Torque limit : 0.56kgf m(4.06lbf ft)
Remove cylindrical pins(Assembly aid)
again.
Special tool
Adjusting screws 5870 204 036
Box spanner 5873 042 002

(8) Introduce pressure regulators and fix by


means of fixing plates and socket head
screws.
Install fixing plates, with the claw showing
downward.
Pay attention to the radial installation
position of the pressure regulators, see
figure.
Torque limit : 0.56kgf m(4.06lbf ft)
Specail tool 73073CV024
Box spanner 5873 042 002

(9) Introduce cable harness and connect


pressure regulators(6EA).
Pay attention to the installation position of
the cable harness, ass also markings
(See figure(2), page 3-73).

73073CV025

3-78
(10) Introduce female connector against
shoulder, with the groove facing the guide
nose of the cover.
Install gasket(Arrow) and fasten cover by
means of socket head screws.
Torque limit : 0.56kgf m(4.06lbf ft)
Special tool
Box spanner 5873 042 002

73073CV026

(11) Fix female connector by means of


retaining clamp, see figure.
Install opposite cover.

73073CV027

(12) Install two adjusting screws and mount


gasket .
Pay attention to the different gaskets, see
on the right figure and (15).
Special tool
Adjusting screws 5870 204 063

73073CV028

Intermediate plate-Version with screens


(13) Insert screens(6EA) flush mounted into the
bore of the intermediate plate, see arrow.
Pay attention to the installation position-
screens are showing upward(Facing the
duct plate).

73073CV029

3-79
(14) Mount intermediate plate, with the screens
showing upward.

73073CV030

(15) Mount gasket .

73073CV031

(16) Mount duct plate and fasten it uniformly by


means of socket head screws.
Torque limit : 0.97kgf m(7.0lbf ft)
Special tool
Box spanner 5873 042 002

73073CV032

(17) Equip screw plugs(8EA) with new O-rings


and install them.
Torque limit : 0.56kgf m(4.06lbf ft)
The installation of the hydraulic control unit
is described, starting from page 3-153.

73073CV033

3-80
2. GEARBOX
1) DISASSEMBLY
Fasten transmission on assembly car.
Special tool
Assembly car 5870 350 000
Clamping bracket 5870 350 071

770-3ATM (100)

Disassemble complete shift control, remove


pressure lines and duct plate.

770-3ATM (101)

(1) Converter-input
Separate torque converter from
transmission, using lifting device.
Special tool
Set of eye bolts 5870 240 002

770-3ATM (102)

Loosen screw connection.


Separate bearing cover from converter
bell, using forcing screws(3EA).
Special tool
Forcing screws(M10) 5870 204 005

770-3ATM (103)

3-81
Pull oil feed flange out of the converter
bell, using special device.
Special tool
Puller device 5870 000 089

770-3ATM (104)

Remove converter safety valve


(Composed of ball, spring and disk).

770-3ATM (105)

Separate converter bell from gearbox


housing, using lifting device and pry bar.
Special tool
Set of eye bolts 5870 204 002
Pry bar 5870 345 036

770-3ATM (106)

Remove shim.

770-3ATM (107)

3-82
Remove rectangular ring(Arrow).

770-3ATM (108)

Press drive shaft out of the spur gear


bearing.
Remove released bearing inner race and
spur gear.
If necessary, drive bearing outer race out
of the housing bores.

770-3ATM (109)

Press bearing inner race from drive shaft.

770-3ATM (110)

Remove converter pressure valve.

770-3ATM (111)

3-83
(2) Drive shaft, pump, power take-off
Pull complete drive shaft out of the
gearbox housing(Pump).

770-3ATM (112)

Remove rectangular ring(Arrow).

770-3ATM (113)

Separate spur gear from shaft and


squeeze circlip(Arrow) out.

770-3ATM (114)

Pull bearing inner race from spur gear.


Special tool
Grab sleeve(Super) 5873 001 020
Basic set 5873 001 000

770-3ATM (115)

3-84
Loosen socket head screw and remove it
along with clamping plate.

770-3ATM (116)

Pull bearing inner race and driver from


the shaft.
Support puller on the end face/drive
shaft. Pay attention to released shim.
Special tool
Three-leg puller 5870 971 002

770-3ATM (117)

Separate bearing inner race from driver.


Pay attention to released shim.
Squeeze circlips(3EA) out.

770-3ATM (118)

(3) Transmission pump


Tilt gearbox housing 180 .
Loosen hexagon head screws and
remove both pump flanges(Arrows).

770-3ATM (119)

3-85
Loosen socket head screws(M8) and
position puller device.
Pull transmission pump out of the
housing bore.
Tapping on the housing face is a help
during the extraction operation.
Special tool
Puller device 5870 000 089

770-3ATM (120)

(4) Output-laysaft assembly


Loosen screw connection and remove
brake caliper.

770-3ATM (125)

Unlock and loosen hexagon head


screws, tap brake disk loose and
separate it from output shaft.

770-3ATM (126)

Pry shaft seal out of the housing bore.


Special tool
Crow bar 5870 345 071

770-3ATM (127)

3-86
Tilt gearbox housing.
Remove sealing covers(Arrows).
Special tool
Crow bar 5870 345 071

770-3ATM (128)

Loosen hexagon head screws.

770-3ATM (129)

Pull idler shaft by means of puller out of


the housing bore.
Special tool
Counter support 5870 300 020
Set screw 5870 204 048

770-3ATM (130)

Tilt gearbox housing 180 .


Loosen hexagon head screws and pull
bearing cover K1/KV out of the housing
bore.
Special tool
Counter support 5870 300 020
Threaded insert 5870 204 042

770-3ATM (131)

3-87
Loosen hexagon head screws and
remove bearing cover KR/K2 and K3/K4.

770-3ATM (132)

Squeeze rectangular rings(3 pieces/axle)


out, see arrows.

770-3ATM (133)

Squeeze circlip out and remove released


washers.
Special tool
Set of external pliers 5870 900 015

770-3ATM (134)

Support output flange against gearbox


housing, see arrows.

770-3ATM (135)

3-88
Loosen hexagon head screws and
separate housing cover from gearbox
housing, using forcing screws and lifting
device.
Special tool
Forcing screws(M10) 5870 204 005
Set of eye bolts 5870 204 002

770-3ATM (136)

Unlock and loosen hexagon head screws.


Remove output flange and pry shaft seal
out of the housing bore.

770-3ATM (137)

Loosen hexagon head screws and


remove oil baffle.

770-3ATM (138)

Remove output gear along with shaft.

770-3ATM (139)

3-89
Separate output shaft from spur gear.

770-3ATM (140)

Pull bearing inner race from output gear.


Special tool
Three-leg puller 5870 971 003

770-3ATM (141)

Remove plate.

770-3ATM (142)

Drive roller bearing out of the housing


bore and remove it.

770-3ATM (143)

3-90
(5) Disassemble clutches and layshaft gear
Remove clutches K3/K4, KR/K2 and KV/
K1 by means of lifting device.
At the removal of the clutch K3/K4,
displace clutch KR/K2 in direction of
arrow, see figure on the right.
Special tool
Set of eye bolts 5870 204 002

770-3ATM (144)

Illustration on the right shows the


clutches in removed condition.

770-3ATM (145)

Remove layshaft gear.

770-3ATM (146)

(6) Disassemble power take-off


Squeeze circlip out and remove shim.

770-3ATM (147)

3-91
Pull Pto-shaft by means of internal puller
out of the housing bore until the bearing
outer race is released.
Special tool
Internal puller 5870 300 006
Counter support 5870 300 003

770-3ATM (148)

Take shaft out of the housing.

770-3ATM (149)

Pull bearing inner race from shaft(Figure


on the right).
Press opposite bearing inner race from
the shaft.
The separation of shaft and gear is not
possible(Shrink fit).
Special Tool
Grab sleeve(Super) 5873 001 020
Grab sleeve(Super) 5873 001 027
770-3ATM (150)
Basic set 5873 001 000

(7) Disassemble clutches


Clutch-K3/K4
Locate clutch by means of special device.
Remove rectangular rings(3EA, see arrow)
Special tool
Clamping ring 5870 654 022

770-3ATM (151)

3-92
Loosen slotted nut.
Slotted nut is secured with loctite.
To prevent the damage of the thread,
heat slotted nut prior to loosen it(About
120 C).
Special tool
Hook spanner 5870 401 110
Hot-air blower 220V 5870 221 500
Hot-air blower 110V 5870 221 501
770-3ATM (152)

Pull off tapered roller bearing.


Special tool
Grab sleeve 5870 003 030
Reducer 5870 003 011
Basic set 5870 002 001

770-3ATM (153)

Remove flanged disk.

770-3ATM (154)

Remove upper roller bearing.

770-3ATM (155)

3-93
Remove angle ring, squeeze snap ring
out and remove thrust ring.

770-3ATM (156)

Press spur gear K3 from plate carrier and


remove released roller bearing.

770-3ATM (157)

Remove split ring.

770-3ATM (158)

Squeeze snap ring out and remove


complete plate pack K3.

770-3ATM (159)

3-94
Tilt clutch 180 .
Loosen slotted nut.
Slotted nut is secured with loctite.
To prevent the damage of the thread,
heat slotted nut prior to loosen it(About
120 C).
Special tool
Hook spanner 5870 401 115
Hook spanner 5870 401 118
770-3ATM (160)

Pull off tapered roller bearing.


Special tool
Grab sleeve 5873 001 037
Basic set 5873 001 000

770-3ATM (161)

Pull spur gear K4 from plate carrier.


Special tool
Three-leg puller 5870 971 003

770-3ATM (162)

Remove oil feed ring and pull ball bearing


from plate carrier.
Special tool
Three-leg puller 5870 971 002

770-3ATM (163)

3-95
Squeeze snap ring out and remove
complete plate pack K4.

770-3ATM (164)

Preload compression spring by means of


special device.
Squeeze snap ring(Arrow) out and
remove released components.
Now, separate piston from plate carrier,
using compressed air.
Disassemble opposite piston accordingly.
Special tool
Pressure piece 5870 345 072
770-3ATM (165)

Clutch KR/K2
Locate clutch by means of special device
and loosen slotted nut.
Loosen opposite slotted nut(Arrow)
accordingly.
The slotted nuts are secured with loctite-
heat prior to loosen them.
Special tool
Clamping ring 5870 654 022
770-3ATM (166)
Hook spanner 5870 401 099
Hook spanner 5870 401 118
Hook spanner 5870 401 115

Pull off tapered roller bearing.


Special tool
Grab sleeve(Super) 5873 002 039
Basic set 5873 002 001

770-3ATM (167)

3-96
Press spur gear K2 from the shaft.
Remove released shim and bush.

770-3ATM (168)

Pull off tapered roller bearing.


Special tool
Grab sleeve(Super) 5873 002 038
Basic set 5873 002 001

770-3ATM (169)

On the opposite side, pull off tapered


roller bearing.
Special tool
Grab sleeve(Super) 5873 002 038
Basic set 5873 002 001

770-3ATM (170)

Pull spur gear KR from the shaft.


Remove released bearing inner race,
disassemble both bearing outer races
and circlip.
Special tool
Three-leg puller 5870 971 003

770-3ATM (171)

3-97
Remove adjusting ring.

770-3ATM (172)

Pull off tapered roller bearing(Spur gear


bearing).
Special tool
Grab sleeve(Super) 5873 002 035
Basic set 5873 002 001

770-3ATM (173)

Disassemble plate packs KR and K2 as


well as compression springs and piston
(Accordingly as at clutch K3/K4).

770-3ATM (174)

Clutch KV/K1
Locate clutch by means of special device
and loosen slotted nut.
Loosen opposite slotted nut(Arrow)
accordingly.
The slotted nuts are secured with loctite-
heat prior to loosen them.
Special tool
Clamping ring 5870 654 022
770-3ATM (175)
Hook spanner 5870 401 118
Hook spanner 5870 401 115

3-98
Pull off tapered roller bearing.
Special tool
Grab sleeve(Super) 5873 001 023
Basic set 5873 001 000

770-3ATM (176)

Remove shim.

770-3ATM (177)

Pull off spur gear K1.


Now, squeeze circlip out and drive ball
bearing out of the spur gear bore.
Special tool
Three-leg puller 5870 971 003

770-3ATM (178)

Remove both rings.

770-3ATM (179)

3-99
Pull off second ball bearing(Spur gear
bearing).
Special tool
Two-leg puller 5870 970 006

770-3ATM (180)

On the opposite side, pull off tapered


roller bearing.
Special tool
Grab sleeve(Super) 5873 001 037
Basic set 5873 001 000

770-3ATM (181)

Pull spur gear KV from the shaft.


Remove released bearing inner race,
disassemble both bearing outer races
and circlip.
Special tool
Three-leg puller 5870 971 003

770-3ATM (182)

Remove adjusting ring.

770-3ATM (183)

3-100
Pull off tapered roller bearing(Spur gear
bearing).
Special tool
Grab sleeve(Super) 5873 002 035
Basic set 5873 002 001
Now, remove plate pack KV and K1 as
well as compression springs and piston
(Accordingly as at clutch K3/K4).
Special tool
770-3ATM (184)
Pressure piece 5870 345 072

3-101
2) REASSEMBLY
(1) Power take-off
Undercool shaft(About 80 C), heat gear
(About 120 C) and assemble, respectively
press it against shoulder.

770-3ATM (190)

Press bearing inner race against


shoulder.
Press opposite bearing inner race
against shoulder until contact is obtained.

770-3ATM (191)

Insert bearing outer race(Arrow) into the


housing bore until contact is obtained.

770-3ATM (192)

Position preassembled Pto-shaft in the


housing.

770-3ATM (193)

3-102
Insert bearing outer race until contact is
obtained-bearing must be playfree.

770-3ATM (194)

Adjust Pto-bearing playfree, using disk


and circlip.
Special tool
Set of pliers 5870 900 013

770-3ATM (195)

Tilt gearbox housing 180 .


Insert sealing disk(Arrow) into the
housing bore until contact is obtained.
Cover contact surfaces with loctite(Type
No.262).
Do not damage the centric orifice hole
0.8mm at the installation of the sealing
disk.

770-3ATM (196)

(2) Multi disk clutch K3/K4


Fix plate carrier by means of clamping
ring.
Close both bores(Arrows) by means of
set screws.
Insert set screws with loctite(Type
No.262).
Special tool
Clamping ring 5870 654 022
770-3ATM (200)

3-103
Clutch K3
Insert purge valve(Arrow) until contact is
obtained.

770-3ATM (201)

Insert both O-ring scrollfree into the ring


grooves of the piston, see arrows.

770-3ATM (202)

Oil O-rings and piston race, and insert


piston until contact is obtained.
Pay attention to the installation position of
the piston, see figure.

770-3ATM (203)

Install disk(Arrow) and compression


spring.

770-3ATM (204)

3-104
Lay guide ring upon the compression
spring and assemble snap ring(Figure on
the right).
Pay attention to the installation position of
the guide ring install chamfer(Arrow)
showing upward.
Now, preload compression spring by
means of special device and fix it by
engaging the snap ring(Arrow), see figure.
770-3ATM (205)
Special tool
Pressure piece 5870 345 072

770-3ATM (206)

General instructions for the plate


installation
In principle, the stacking of the outer and K4 K3
inner plates has to be carried out X

alternately.
The piston side has to be started with a
one sided coated outer plate.
At clutch KR and KV, a one sided coated
outer plate has to be additionally installed
7704PT21
on the end shim side. The uncoated
side must be always installed facing the
piston, respectively the end shim. Plate arrangement K3(Long plate carrier side):
At plates with different thickness(Inner Active number of the friction surface = 14
plates), the thinner plates must be
installed on the end shim side. 1 Outer plate(One sided coated)
The respective clutch side can be 7 Outer plates s = 2.5mm
identified on the length of the plate 3 Inner plates s = 3.5mm
carrier, see draft/ dimension X. 3 Inner plate s = 3.0mm
Install plate pack K3, see draft as well as 1 Inner plate(Optional) s = 2.0~4.0mm
figure( ), Example A:

3-105
Install plate pack, mount end shim and fix
it by means of snap ring.

770-3ATM (207)

Check plate clearance K3 = 2.2~2.4mm


(See figure, Example A):
Determine dimension from the end face
of the plate carrier to the end shim.
Dimension e.g. 2.40mm

770-3ATM (208)

Position end shim against snap ring


(Toward upward) until contact is obtained
and determine dimension .
Dimension e.g. 0.20mm

770-3ATM (209)

Example A
Dimension e.g. 2.40mm
Dimension e.g. - 0.20mm
Difference = Plate clearance 2.20mm
In case of a deviation from the required
plate clearance, correction can be carried
out with corresponding inner plate
(Optional s=2.0~4.0mm) or with different
snap rings(Figure ).
Pay attention to the note, page 3-105.

3-106
Tilt clutch into horizontal position and
introduce spur gear K3 until all inner
plates are accommodated.
This step will facilitate the later spur gear
installation.
Now, tilt clutch again into vertical position
and pull spur gear carefully out of the
plate pack.

770-3ATM (210)

Insert split ring(Arrow) with grease into


the recess.
Pay attention to the exact contact of the
split ring in the bottom of the recess.

770-3ATM (211)

Carry out the following steps of figure


and immediately in chronological order
to prevent a cooling down of the heated
components.
Heat bearing bore of spur gear(Figure )
as well as bearing inner race of the roller
bearing(Figure ) to about 120 C.

Introduce heated spur gear until all inner


plates are accommodated.

770-3ATM (212)

3-107
Insert heated bearing inner race until
contact is obtained.

770-3ATM (213)

Introduce disk, lift spur gear slightly and


squeeze snap ring into the annular
groove of the spur gear.

770-3ATM (214)

Install angle ring, with the stepped face


facing the snap ring.

770-3ATM (215)

Introduce bearing inner race and mount


flange disk.
Install flanged disk, with the chamfer on
the inner diameter showing upward.

770-3ATM (216)

3-108
Heat bearing inner race and place it
against shoulder.

770-3ATM (217)

Clutch K4
Install purge valve, piston and
compression spring accordingly as at
clutch K3(Figure ~ /page 3-104, 105).
Install plate pack K4 and check plate
clearance.
Plate arrangement K4(Short plate carrier
side)
Active number of the friction surfaces = 12
1 Outer plate(One sided coated)
6 Outer plates s = 2.5mm
4 Inner plates s = 3.5mm
1 Inner plate s = 3.0mm
1 Inner plate(Optional) s = 2.0~4.0mm
Pay attention to the general instructions
for the plate installation and draft/ page
3-105.
Check plate clearance K4 = 2.2~2.4mm
accordingly as at clutch K3, see page
3-106.

Tilt clutch into horizontal position and


introduce spur gear K4 until all inner
plates are accommodated.
This step will facilitate the later
reassembly of the spur gear.
Now, tilt clutch again into vertical position
and pull spur gear carefully out of the
plate pack.

770-3ATM (218)

3-109
Spur gear K4
The following steps(Figure ~ ) are
describing the reassembly of the spur
gear bearing K4, version with ball bearing.
At the version with tapered roller bearing,
the reassembly has to be carried out
accordingly as at spur gear KR.
In this connection, pay attention to steps
of figure((1)~(10)/page 3-114~116).
770-3ATM (219)
Heat ball bearing and assemble it until
contact is obtained, see figure .
Prior to install the spur gear(Figure ),
cool ball bearing down to room temperature.

Mount oil feed ring(Figure on the right).

770-3ATM (220)

Carry out steps of figure and in


immediate sequence, to prevent a
cooling down of the components.
Heat bearing bore of the spur gear
(Figure ) and ball bearing(Figure ) to
about 120 C.
Introduce heated spur gear until all inner
plates are accommodated.

770-3ATM (221)

Insert heated ball bearing until contact is


obtained.

770-3ATM (222)

3-110
Heat tapered roller bearing and assemble
it until contact is obtained.

770-3ATM (223)

Preload complete clutch pack through


both bearing inner races(Arrows) with
100000N(10ton).
In this way, the exact contact of the
components, respectively the setting of
the complete bearing is ensured.
Special tool
Pressure pieces 5870 506 096

770-3ATM (224)

Mount disk.
Wet thread of the slotted nut with loctite
(Type No.262) and install slotted nut with
the chamfer showing downward(Figure
on the right).

770-3ATM (225)

Tighten slotted nut.


Torque limit : 56kgf m(550Nm)
Special tool
Hook spanner 5870 401 115
Hook spanner 5870 401 118

770-3ATM (226)

3-111
Tilt clutch 180 (K3 side).
Wet thread of the slotted nut with loctite
(Type No.262) and install slotted nut with
the chamfer showing downward.
Torque limit : 82kgf m(800Nm)
Special tool
Hook spanner 5870 401 110

770-3ATM (227)

Check function of the clutches by means of


compressed air
For this purpose, squeeze rectangular
rings in, engage them and assemble
bearing cover.
At correctly installed components, the
closing, respectively opening of the
clutches is clearly audible.
Now, remove bearing cover again.
770-3ATM (228)

3-112
3) PREASSEMBLE MULTI DISK CLUTCH KR/K2
Install purge valves, piston and compression KR K2
spring(Each clutch side 1 set of the
components) accordingly as at multi-disk
clutch K3(Figure ~ /page 3-104, 105).
Install plate pack KR and K2 check plate
clearance, see also right draft.
Plate arrangement KR(Long plate carrier
side): 7704PT22

Active number of the friction surfaces = 24


2 Outer plate(One sided coated)
11 Outer plates s = 2.5mm
11 Inner plates s = 2.5mm
1 Inner plate(Optional) s = 2.0~4.0mm
Pay attention to the general instructions for
the plate installation, page 3-105.
Check plate clearance KR = 2.8~3.0mm
accordingly as at clutch K3, see page 3-106.
Plate arrangement K2(Short plate carrier
side):
Active number of the friction surfaces = 24
1 Outer plate(One sided coated)
7 Outer plates s = 2.5mm
3 Inner plates s = 3.5mm
3 Inner plates s = 3.0mm
1 Inner plate(Optional) s = 2.0~4.0mm
Pay attention to the general instructions for
the plate installation, page 3-105.
Check plate clearance K2 = 2.2~2.4mm
accordingly as at clutch K3, see page 3-106.

3-113
(1) Spur gear KR
Components:
1 Bearing inner race
2 Bearing outer race
3 Spur gear
4 Circlip
5 Adjusting ring(Optional)

770-3ATM (229)

(2) Determine axial play of the spur gear


bearing 0.03~0.08mm(Example B):
Squeeze circlip(4) in and place bearing
outer race(2) against shoulder.
Special tool
Driver 5870 058 021
Handle 5870 260 002

770-3ATM (230)

(3) Place spur gear upon the bearing inner race.


Support bearing inner race.

770-3ATM (231)

(4) Measure dimension from the end face of


the bearing inner race.
Dimension e.g. 24.95mm
Special tool
Digital depth gauge 5870 200 072

770-3ATM (232)

3-114
(5) Measure dimension from the end face of
the circlip.
Dimension e.g. 20.85mm
Special tool
Digital depth gauge 5870 200 072

770-3ATM (233)

(6) Determine differential dimension from


bearing outer race to bearing inner race
+
on the upper tapered rolled bearing.
The draft on the right shows two tapered
roller bearings with different measuring
results. -
Dimension (Differential dimension) in
the actual case e.g. + 0.15mm

7704PT23

Example B
Dimension 24.95mm
Dimension - 20.85mm
Intermediate result 4.10mm
Dimension + 0.15mm
Result = Differential dimension - Zero
4.25mm
Required axial play(0.03-0.08) + 0.05mm
Result = Adjusting ring s = 4.30mm 770-3ATM (235)

Select adjusting ring with corresponding


thickness.

(7) Check axial play


Install upper bearing outer race.
Insert adjusting ring e.g. s = 4.30mm and
bearing inner race.
Preload spur gear bearing with about
50000N(5ton).
Determine axial play.
At deviations from the required axial play
0.03~0.08mm, correct with corresponding
770-3ATM (236)
adjusting ring.

3-115
(8) Heat lower tapered roller bearing and
assemble it until contact is obtained.

770-3ATM (237)

(9) Introduce spur gear KR into the


preassembled plate carrier until all inner
plates are accommodated.

770-3ATM (238)

(10) Assemble adjusting ring e.g. s=4.30mm


(See Example B):
Pay attention to the installation position oil
feed grooves are showing upward.
Now, heat upper bearing inner race(Spur
gear bearing) and assemble it until contact
is obtained.

770-3ATM (239)

(11) Heat bearing inner race(Clutch bearing)


and assemble it until contact is obtained.

770-3ATM (240)

3-116
(12) Spur gear K2
Components:
1 Tapered roller bearing
2 Bush
3 Shim
4 Spur gear

770-3ATM (241)

(13) Adjust axial play of the spur gear bearing


0.05~0.15mm(Figure (13)~(16)):
Place spur gear upon the bearing inner
race.
Support bearing inner race.

770-3ATM (242)

(14) Introduce bush as well as shim(s=3.80mm/


empirical value) and align it centrically.

770-3ATM (243)

(15) Install upper tapered roller bearing.

770-3ATM (244)

3-117
(16) Preload spur gear bearing with about
50000N(5ton) and determine axial play.
At a deviation from the required axial play
0.05~0.15mm, correct with corresponding
shim(Figure (12)/page 3-117).
Special tool
Magnetic stand 5870 200 055
Dial indicator 5870 200 057

770-3ATM (245)

(17) Heat bearing inner race and assemble it


until contact is obtained.

770-3ATM (246)

(18) Introduce spur gear K2 until all inner


plates are accommodated.

770-3ATM (247)

(19) Install bush and corresponding shim.

770-3ATM (248)

3-118
(20) Heat second tapered roller bearing of the
spur gear bearing and assemble it until
contact is obtained.

770-3ATM (249)

(21) Heat bearing inner race(Clutch bearing)


and place it against shoulder.

770-3ATM (250)

(22) Proload complete clutch pack through


both bearing inner race(Arrows) with
100000N(10ton).
In this way, an exact contact of the
components, respectively the settling of
the complete bearing is ensured.
Special tool
Pressure pieces 5870 506 096

770-3ATM (251)

(23) Install and tighten both slotted nuts.


Torque limit : 82kgf m(800Nm)
Pay attention to the installation position of
the slotted nuts, chamfer is always facing
the bearing inner race.
Secure slotted nuts with loctite(Type
No.262).
Special tool
Clamping ring 5870 654 022
770-3ATM (252)
Hook spanner 5870 401 099
Hook spanner 5870 401 118
Hook spanner 5870 401 115

3-119
4) PREASSEMBLE MULTI DISK CLUTCH KV/K1
Install purge valves, piston and compression
spring(Each clutch side 1 set of the KV K1

components) accordingly as at multi-disk


clutch K3(Figure ②~⑥/page 3-104, 105).
Install plate pack KV and K1 and check
plate clearance, see also right draft.
Plate arrangement KV(Long plate carrier
side): 7704PT24

Active number of the friction surfaces = 24


2 Outer plate(One sided coated)
11 Outer plates s = 2.5mm
11 Inner plates s = 2.5mm
1 Inner plate(Optional) s = 2.0~4.0mm
※ Pay attention to the general instructions for
the plate installation, page 3-105.
Check plate clearance KV = 2.8~3.0mm
accordingly as at clutch K3, see page 3-106.
Plate arrangement K1(Short plate carrier
side):
Active number of the friction surfaces = 14
1 Outer plate(One sided coated)
7 Outer plates s = 2.5mm
3 Inner plates s = 3.5mm
3 Inner plates s = 3.0mm
1 Inner plate(Optional) s = 2.0~4.0mm
※ Pay attention to the general instructions for
the plate installation, page 3-105.
Check plate clearance K1 = 2.2~2.4mm
accordingly as at clutch K3, see page 3-106.

(1) Close both bores(Arrows) by means of set


screws.
※ Insert set screws with loctite(Type No.262).

770-3ATM (253)

3-120
(1) Spur gear-KV
Components:
1 Bearing inner race
2 Bearing outer race
3 Spur gear
4 Circlip
5 Ring(Optional)

770-3ATM (254)

(2) Determine axial play of the spur gear


bearing 0.03~0.08mm(Example C):
Squeeze circlip(4) in and place bearing
outer race(2) against shoulder.
※ Special tool
Driver 5870 058 021
Handle 5870 260 002

770-3ATM (255)

(3) Place spur gear upon the bearing inner race.


※ Support bearing inner race.

770-3ATM (256)

(4) Measure dimensionⅠfrom the end face of


the bearing inner race.
・DimensionⅠ e.g. 24.95mm
※ Special tool
Digital depth gauge 5870 200 072

770-3ATM (257)

3-121
(5) Determine dimensionⅡfrom the end face
of the circlip.
・DimensionⅡ e.g. 20.85mm
※ Special tool
Digital depth gauge 5870 200 072

770-3ATM (258)

(6) Determine differential dimension from


bearing outer race to bearing inner race
on the upper tapered roller bearing.
※ The draft on the right shows two tapered
roller bearings with different measuring
results.
・DimensionⅢ(Differential dimension) in
the actual case e.g. + 0.15mm

Example C
DimensionⅠ 24.95mm
DimensionⅡ - 20.85mm
Result A 4.10mm
DimensionⅢ + 0.15mm
※ Result = Differential dimension - Zero
4.25mm
Required axial play(0.03-0.08) + 0.05mm
Result = Adjusting ring s = 4.30mm 770-3ATM (260)

Select adjusting ring with corresponding


thickness.

(7) Check axial play


Install upper bearing outer race.
Insert adjusting ring e.g. s = 4.30mm and
bearing inner race.
Preload spur gear bearing with about
50000N(5ton).
Determine axial play.
※ At deviations from the required axial play
0.03~0.08mm, correct with corresponding
770-3ATM (261)
adjusting ring.

3-122
(8) Heat lower bearing inner race and
assemble it until contact is obtained.

770-3ATM (262)

(9) Introduce spur gear KR into the


preassembled plate carrier until all inner
plates are accommodated.

770-3ATM (263)

(10) Assemble adjusting ring e.g. s=4.30mm


(See Example C).
※ Pay attention to the installation position oil
feed grooves are showing upward.
Now, heat upper bearing inner race(Spur
gear bearing) and assemble it until contact
is obtained.

770-3ATM (264)

(11) Heat bearing inner race(Clutch bearing)


and assemble it until contact is obtained.

770-3ATM (265)

3-123
(12) Spur gear K1
1 Ball bearing
2 Ring(Optional)
3 Splash ring
4 Circlip
5 Spur gear
6 Ball bearing

770-3ATM (266)

(13) Adjust axial play of the spur gear


bearing 0.01~0.04mm
・Determine thickness of splash ring(3) e.g.
s=17.15mm

770-3ATM (267)

※ Total dimension of circlip 4 and ring 2


(Optional) must be selected 0.01~0.04mm
thinner.
・Total dimension of circlip and ring
therefore 17.14~17.11mm

770-3ATM (268)

(14) Heat ball bearing and assemble it until


contact is obtained.
Now, cool ball bearing down to room
temperature, to allow the later installation
of the spur gear(Figure (17)/page 3-125).

770-3ATM (269)

3-124
(15) Assemble ring(Optional) and splash ring.

770-3ATM (270)

(16) Squeeze circlip into the annular groove of


the spur gear.

770-3ATM (271)

※ Carry out steps of figure (17) and (18) in


immediate sequence to prevent the
cooling down of the components.
(17) Heat bearing bores of the spur gear
(Figure on the right) and ball bearing
(Figure (18)).
Introduce spur gear until all inner plates
are accommodated.

770-3ATM (272)

(18) Introduce heated ball bearing until contact


is obtained.

770-3ATM (273)

3-125
(19) Assemble spacer(s=1.50mm).
Heat tapered roller bearing and place it
against shoulder.

770-3ATM (274)

(20) Preload complete clutch pack through


both bearing inner races(Arrows) with
100000N(10ton).
In this way, an exact contact of the
components, respectively the settling of
the complete bearing is ensured.
※ Special tool
Pressure pieces 5870 506 096

770-3ATM (275)

(21) Fix clutch pack by means of disks(Arrows)


and slotted nuts.
※ Pay attention to the installation position of
the slotted nuts, chamfer is always facing
the bearing inner race.
Wet thread of the slotted nuts with loctite
(Type No.262).

770-3ATM (276)

(22) Tighten both slotted nuts.


・Torque limit : 56kgf・m(550Nm)
※ Special tool
Clamping ring 5870 654 022
Hook spanner 5870 401 118
Hook spanner 5870 401 115

770-3ATM (277)

3-126
(23) Squeeze in and engage rectangular ring
(3EA, See arrows).

770-3ATM (278)

(24) Assemble bearing cover and check


function of the clutches by means of
compressed air.
※ At correctly installed components, the
closing, respectively opening of the
clutches is clearly audible.
Now, remove bearing cover again.

770-3ATM (279)

5) INSTALL MULTI DISK CLUTCHES, LAYSHAFT


GEAR AND OUTPUT GEAR
(1) Squeeze circlips in, see arrows.
※ Special tool
Set of external snap ring pliers
5870 900 015

770-3ATM (280)

(2) Introduce spacer ring.

770-3ATM (281)

3-127
(3) Insert bearing outer race until contact is
obtained.
※ Install spacer rings, respectively bearing
outer races of clutch KR/K2 and KV/K1
accordingly, see arrows.
※ Special tool
Driver 5870 058 078
Driver 5870 058 050
Handle 5870 260 002
770-3ATM (282)

(4) Install roll pin.

770-3ATM (283)

(5) Adjust axial play of the layshaft gear


bearing = 0.0~0.05mm(Example D):
Determine dimension Ⅰ, see figure.
・DimensionⅠ e.g. 57.10mm

770-3ATM (284)

(6) Install both bearing inner races and


determine dimension Ⅱ(Total height of the
layshaft bearing).
・DimensionⅡ e.g. 53.95mm

770-3ATM (285)

3-128
(7) Determine dimension Ⅲ from the contact
face of the bearing inner race to the
contact face of the axle.
・DimensionⅢ e.g. 0.60mm

770-3ATM (286)

Example D
DimensionⅡ 53.95mm
DimensionⅢ + 0.60mm
Intermediate result A 54.55mm
DimensionⅠ 57.10mm
Intermediate result A - 54.55mm
Result = Differential dimension - Zero
2.55mm
※ At a required axial play of 0.0~0.05mm,
the shim has therefore to be selected
thinner for max 0.05mm.
Shim thickness therefore 2.55~2.50mm

(8) Position shim and layshaft gear.


※ The fixing of the layshaft gear can be
carried out only after the installation of the
clutch.

770-3ATM (287)

(9) Position clutch KV/K1 by means of lifting


device.
※ Special tool
Set of eye bolts 5870 204 002

770-3ATM (288)

3-129
(10) Install clutch KR/K2.
※ Special tool
Set of eye bolts 5870 204 002

770-3ATM (289)

(11) Displace clutch KR/K2 in direction of


arrow and position clutch K3/K4.

770-3ATM (290)

(12) Undercool bearing outer race and insert it


into the housing bore until contact is
obtained.

770-3ATM (291)

(13) Heat bearing inner race and assemble it


until contact is obtained.

770-3ATM (292)

3-130
(14) Position oil baffle.

770-3ATM (293)

(15) Install output gear.

770-3ATM (294)

(16) Insert second oil baffle and fasten both


plates by means of hexagon head screws
(Mount plain washers).
・Torque limit(M8/8.8) : 2.3kgf m(23Nm)
※ Secure hexagon head screws with loctite
(Type No.262).

770-3ATM (295)

(17) Undercool output shaft and introduce it


until contact is obtained.
※ Pay attention to the installation position,
see figure.

770-3ATM (296)

3-131
(18) Wet mounting face with sealing compound
(Loctite, type No.574).
Install two adjusting screws and position
housing cover by means of lifting device
on the gearbox housing until contact is
obtained.
※ Special tool
Set of eye bolts 5870 204 002
Adjusting screws(M10) 5870 204 007
770-3ATM (297)

(19) Install both cylindrical pins(Arrow 1 and 2)


and roll pin(Arrow 3).

770-3ATM (298)

(20) Fasten housing cover by means of socket


head screws(2 pieces) and hexagon head
screws.
・Torque limit(M10/8.8) : 4.7kgf m(46Nm)
※ Pay attention to the position of the two
socket head screws, see arrows.

770-3ATM (299)

(21) Adjust axial play of the output bearing =


0.3~0.5mm(Figure (21)~(23))
Determine dimension Ⅰ from the plane
face/housing to the end face/output shaft.
・DimensionⅠ e.g. 53.20mm
※ Special tool
Digital depth gauge 5870 200 072

770-3ATM (300)

3-132
(22) Measure dimension Ⅱ from the plane
face/housing to the contact face of the ball
bearing.
・DimensionⅡ e.g. 50.40mm

770-3ATM (301)

Example E
DimensionⅠ 53.20mm
DimensionⅡ - 50.40mm
Difference = 2.80mm
Required axial play(0.3~0.5)
e.g. - 0.40mm
Gives shim s = 2.40mm

(23) Assemble shim(e.g. s = 2.40mm).

770-3ATM (302)

(24) Insert ball bearing until contact is obtained.

770-3ATM (303)

3-133
(25) Fix ball bearing by means of disk(s=4.00mm),
shim(Optional) and circlip playfree.
※ Special tool
Set of external snap ring pliers
5870 900 021

770-3ATM (304)

(26) Install shaft seal, with the sealing lip


showing downward.
※ At the use of the prescribed driver, the
exact installation depth is obtained.
Cover outer diameter with sealing
compound(Loctite, type No.574).
Grease sealing lip.
※ Special tool
Driver 5870 048 150
770-3ATM (305)

(27) Assemble output flange.

770-3ATM (306)

(28) Wet contact face of the disk with sealing


compound.
Mount disk and fasten output flange by
means of hexagon head screws.
・Torque limit(M10/8.8) : 4.7kgf m(46Nm)

770-3ATM (307)

3-134
(29) Fix hexagon head screws by means of
lock plate.
※ Special tool
Driver 5870 057 009
Handle 5870 260 002

770-3ATM (308)

(30) If necessary, install studs, insert O-ring


into the annular groove(Arrow) and fasten
cover by means of hexagon nuts.
・Torque limit(M8/8.8) : 2.3kgf m(23Nm)
※ Insert studs with loctite(Type No.262).

770-3ATM (309)

(31) Install screws plug(Arrow 1).


Mount gasket and fasten cover(Arrow 2)
by means of hexagon head screws.
・Torque limit(M8/8.8) : 2.3kgf m(23Nm)

770-3ATM (310)

(32) Fasten brake assembly(According to the


version) on the housing, using hexagon
head screws.
・Torque limit(M14/10.9) : 18.9kgf m
(185Nm)

770-3ATM (311)

3-135
(33) Undercool bearing outer race(Clutchs
K3/K4 and KR/K2) and insert them into
the housing bores until contact is
obtained.

770-3ATM (312)

(34) Adjust bearing preload-Clutch K3/K4 =


0.15~0.20mm(Figure (34)~(36))
Align clutched centrically by rotating the
output flange and place bearing outer race
carefully against shoulder.
※ Bearing must not be preloaded - Bearing
cage, respectively bearing rollers are still
easy to be moved.

770-3ATM (313)

(35) Determine dimension Ⅰ from the bearing


outer race to the mounting face.
・DimensionⅠ e.g. 5.70mm
※ Apply several measuring points and
determine the average.

770-3ATM (314)

(36) Measure dimension Ⅱ from the mounting


face/cover to the contact face/bearing
outer race.
・DimensionⅡ e.g. 7.13mm

770-3ATM (315)

3-136
Example F
DimensionⅡ 7.13mm
DimensionⅠ - 5.70mm
Difference = 1.43mm
Required bearing preload(0.15~0.20)
e.g.+ 0.17mm
Result = Shim s = 1.60mm

(37) Insert shim(e.g. s=1.60mm) with grease


into the bearing cover.
Insert O-ring into the annular groove
(Arrow) and grease it.

770-3ATM (316)

(38) Squeeze rectangular rings(3 pieces, see


arrows) in and engage them.
Now, grease rectangular rings and align
them centrically.

770-3ATM (317)

(39) Pull cover by means of hexagon head


screws uniformly against shoulder.
・Torque limit(M10/8.8) : 4.7kgf m(46Nm)
※ Special tool
Adjusting screws(M10) 5870 204 007

770-3ATM (318)

Mounting bearing cover-KR/K2 accordingly.


Bearing preload KR/K2 = 0.20~0.25mm

3-137
(40) Close both bores of the bearing cover -
KV/K1 by means of slotted plug.
※ Insert slotted plug with loctite(Type No.262).

770-3ATM (319)

(41) Adjust bearing preload- Clutch KV/K1 =


0.15~0.20mm(Example G)
Install bearing outer race.

770-3ATM (320)

(42) Press the bearing outer race uniformly on


and determine the dimension Ⅰ from the
mounting face to the bearing outer race.
・DimensionⅠ e.g. 64.95mm
※ Special tool
Digital depth gauge 5870 200 072
※ Apply several measuring points and
determine the average.

770-3ATM (321)

(43) Measure dimension Ⅱ from the mounting


face of the cover(Arrow) to the contact
face/bearing outer race.
・DimensionⅡ e.g. 63.90mm

770-3ATM (322)

3-138
Example G
DimensionⅠ 64.95mm
DimensionⅡ - 63.90mm
Difference = 1.05mm
Required bearing preload(0.15~0.20)
e.g. + 0.15mm
Result = Shim s = 1.20mm

(44) Install shim(e.g. s=1.20mm).


Undercool bearing outer race and insert it
until contact is obtained.
Insert O-ring into the annular groove
(Arrow) and grease it.
※ Special tool
Driver 5870 058 051
Handle 5870 260 002

770-3ATM (323)

(45) Squeeze rectangular rings(3 pieces) into


the annular grooves of the clutch shaft
(Arrow) and engage them.
Now, grease rectangular rings and align
them centrically.

770-3ATM (324)

(46) Install two adjusting screws, introduce


bearing cover and pull it uniformly against
shoulder, using hexagon head screws.
・Torque limit(M10/8.8) : 4.7kgf m(46Nm)
※ Special tool
Adjusting screws(M10) 5870 204 007

770-3ATM (325)

3-139
(47) Tilt housing 180°.
Align layshaft gear and shim centrically,
undercool preassembled bolt and insert it
until contact is obtained.
※ Pay attention to the overlapping of the roll
pin with the bore in the housing.

770-3ATM (326)

(48) Fix bolt axially by means of hexagon head


screws.
・Torque limit(M10/8.8) : 4.7kgf m(46Nm)
※ Wet thread of hexagon head screw with
Loctite(Type No.243).

770-3ATM (327)

(49) Drive in the sealing covers(1,2,3 and 4)


flush mounted, with the end face showing
downward.
Install sealing cover(5), with the recess
showing upward.
※ Wet sealing surface with loctite(Type No.
262).

770-3ATM (328)

(50) Install shaft seal(Arrow), with the sealing


lip showing downward.
※ At the use of the prescribed driver, the
exact installation position is obtained.
Cover outer diameter with sealing
compound(Loctite, type No.574).
Grease sealing lip.
※ Special tool
Driver 5870 048 150
770-3ATM (329)

3-140
(51) Assemble output flange.
Wet contact face of the disk with sealing
compound(Loctite, type No.574) and fix
output flange by means of hexagon head
screws.
・Torque limit(M10/8.8) : 4.7kgf m(46Nm)

770-3ATM (330)

(52) Fix hexagon head screws by means of


lock plate.
※ Special tool
Driver 5870 057 009
Handle 5870 260 002

770-3ATM (331)

6) INSTALL FILTER
(1) Mount filter(Complete)
※ Grease sealing ring(Arrow).

770-3ATM (332)

(2) Fasten cover by means of hexagon head


screws(Mount plain washers).
※ Install new O-ring(Arrow).
・Torque limit(M8/8.8) : 2.3kgf m(23Nm)

770-3ATM (333)

3-141
(3) Equip screw plug(Arrow 1) with new O-ring
and install it.
※ Mount gasket and fasten cover plate by
means of hexagon head screws, see
arrow 2.
・Torque limit(Screw plug / M22×1.5)
: 6.1kgf m(60Nm)
・Torque limit(M8/8.8) : 2.3kgf m(23Nm)

770-3ATM (334)

7) HYDRAULIC PUMP
(1) Press needle sleeve in, with the reinforced
shell facing the press-in tool until contact
is obtained.

770-3ATM (335)

(2) Insert bearing outer race until contact is


obtained.
※ Special tool
Driver 5870 058 084
Handle 5870 260 002

770-3ATM (336)

(3) Undercool pump-about -80° C.


Clean area of suction and pressure port
(Arrow 1) again and wet it with loctite
(Type No.262).
Assemble and oil O-ring(Arrow 2).

770-3ATM (337)

3-142
(4) Install two adjusting screws and introduce
pump until contact is obtained.
※ Pay attention to the radial installation
position.
※ Special tool
Adjusting screw 5870 204 021

770-3ATM (338)

(5) Install O-ring(Arrow) and fasten pump


flange, respectively pump by means of
hexagon head screws.
・Torque limit(M12/8.8) : 8.1kgf m(79Nm)

770-3ATM (339)

(6) Insert O-ring(Arrow) into the annular


groove of the pump flange(Power take-off)
and oil it.
Mount two adjusting screws and fasten
flange by means of hexagon head screws.
・Torque limit(M14/8.8) : 12.7kgf m
(125Nm)
※ Special tool
Adjusting screw 5870 204 022
770-3ATM (340)

8) DRIVE SHAFT(Power take-off pump)


(1) Squeeze V-rings(3EA) into the recess of
the driver(Internal gearing). Mount fitting
key(Arrow).

770-3ATM (341)

3-143
(2) Adjust gap = 0.5mm(Driver - Drive shaft)
(Figure (2)~(6)).

0.5mm
7704PT25

(3) Assemble disk s=1.90mm and place


bearing inner race against shoulder.

770-3ATM (343)

(4) Determine dimension Ⅰ from the bearing


inner race to the end face/driver.
・DimensionⅠ e.g. 9.60mm

770-3ATM (344)

(5) Determine dimension Ⅱ(A-B).


・DimensionⅡ e.g. 10.60mm
Example H
DimensionⅡ 10.60mm
DimensionⅠ - 9.60mm
Difference 1.00mm
Required gap + 0.50mm
Gives shim(s) s = 1.50mm
770-3ATM (345)

3-144
(6) Assemble shim e.g.=1.50mm and position
driver, respectively bearing inner race
against shoulder.

770-3ATM (346)

(7) Fix driver by means of clamping disk and


socket head screw.
※ Insert socket head screw with loctite(Type
No.242).
・Torque limit(M10/8.8 DIN 6912)
: 3.3kgf m(32Nm)

770-3ATM (347)

(8) Press bearing inner race upon the collar of


the drive gear power take-off.

770-3ATM (348)

(9) Squeeze circlip in(Arrow) and assemble


drive gear.

770-3ATM (349)

3-145
(10) Squeeze in and engage rectangular ring
(Arrow).

770-3ATM (350)

(11) Introduce preassembled drive shaft until


contact is obtained.
※ Pay attention to the overlapping of fitting
key / fitting key groove.

770-3ATM (351)

(12) Adjust axial play of the drive shaft


bearing = 0.0~0.05mm(Figure (12)~(14)).
Mount gasket.
Mount bearing outer race, press it uniformly
on and determine dimension Ⅰ from the
mounting face(Gasket) to the bearing outer
race.
・DimensionⅠ e.g. 129.55mm
※ Apply several measuring points and
770-3ATM (352)
determine the average.
※ Special tool
Straightedge 5870 200 022
Digital depth gauge 5870 200 072

(13) Measure dimension Ⅱ from the mounting


face/converter bell to the contact face/
bearing outer race.
・DimensionⅡ e.g. 127.43mm
※ Special tool
Gauge blocks 5870 200 080

770-3ATM (353)

3-146
Example J
DimensionⅠ 129.55mm
DimensionⅡ - 127.43mm
Difference 2.12mm
Axial play(0.0~0.05) e.g. - 0.02mm
Gives shim s = 2.10mm

※ Shims are available in 0.05mm gradation.


(14) Insert shim e.g. s=2.10mm and position
bearing outer race against shoulder.

770-3ATM (354)

9) INPUT-CONVERTER BELL
(1) Insert bearing outer race into the housing
bore until contact is obtained and install
bearing inner race, see arrow.

770-3ATM (355)

(2) Introduce spur gear(Arrow), starting from


the side, with the long collar showing
upward, and position it.

770-3ATM (356)

3-147
(3) Insert both roll pins(Ø2.5 and Ø1.5mm)
flush mounted into the bore(Arrow) of the
drive shaft.

770-3ATM (357)

(4) Undercool drive shaft and introduce it until


contact is obtained.

770-3ATM (358)

(5) Heat bearing inner race and assemble it


until contact is obtained.

770-3ATM (359)

(6) Place bearing outer race against shoulder.


※ Spur gear bearing must be playfree.

770-3ATM (360)

3-148
Adjust bearing preload of drive gear
bearing 0.0~0.07mm(Example K)
(7) Measure dimensionⅠ from the mounting
face to the bearing outer race.
・DimensionⅠ e.g. 62.10mm
※ Special tool
Straightedge 5870 200 022
Digital depth gauge 5870 200 072

770-3ATM (361)

(8) Mount gasket(Arrow) and determine


dimension Ⅱ from the mounting face to
the contact face of the bearing outer race.
・DimensionⅡ e.g. 60.85mm
※ Special tool
Gauge blocks 5870 200 067
Straightedge 5870 200 022

770-3ATM (362)

Example K
DimensionⅠ 62.10mm
DimensionⅡ - 60.85mm
Difference 1.25mm
Bearing preload(0.0~0.07) e.g.+ 0.05mm
Gives shim s = 1.30mm
※ Reassembly of the shim, see figure(12).

(9) Insert needle bearing until contact is


obtained.
Install shaft seal flush mounted, with the
sealing lip showing downward.
※ Wet outer diameter of shaft seal with
sealing compound(Loctite, type No.574).
Grease sealing lip.
※ Special tool
Driver 5870 055 031
770-3ATM (363)
Handle 5870 260 002

3-149
(10) Install two adjusting screws and mount
gasket.
Install converter safety valve, composed of
disk, compression spring and ball(Arrow 1).
Squeeze rectangular ring into the annular
groove of the drive shaft and engage it
(Arrow 2).
Now, grease rectangular ring and align it
centrically.
770-3ATM (364)
※ Special tool
Adjusting screws(M12) 5870 204 021

※ Carry out the following steps(Figure (11)~


(14)) immediately within short chronological
order.
(11) Undercool oil feed flange about -80°C.
Clean area of suction and pressure port
(Arrow) again and wet it with loctite(Type
No.241).

770-3ATM (365)

(12) Make shim e.g. s=1.30mm(See example K)


adhere with grease in the bearing bore.

770-3ATM (366)

(13) Introduce oil feed flange until contact is


obtained.
※ Pay attention to the radial installation
position.
※ Special tool
Adjusting screws 5870 204 007

770-3ATM (367)

3-150
(14) Mount gasket(Arrow) and install bearing
cover.
・Torque limit(M10/8.8) : 4.7kgf m(46Nm)
※ Pay attention to the radial installation
position.

770-3ATM (368)

(15) Insert roll pin until contact is obtained.

770-3ATM (369)

(16) Install converter pressure valve.


Install temperature sensor(Arrow 1) and
screw plug(Arrow 2).
※ Install new O-rings each time.

770-3ATM (370)

(17) Heat housing bore(About 120°C).


※ Special tool
Preheating sleeve 5870 801 003
Hot air blower(220V) 5870 221 500
Hot air blower(110V) 5870 221 501

770-3ATM (371)

3-151
(18) Install two adjusting screws and mount
gasket(Arrow 1).
Introduce converter bell by means of lifting
device until contact is obtained and fasten
it by means of hexagon head screws.
※ Pay attention to the radial installation
position.
Slight rotary motions of the drive shaft will
facilitate the insertion.
・Torque limit(M8/10.9) : 3.5kgf m(34Nm) 770-3ATM (372)
・Torque limit(M12/10.9) : 11.7kgf m
(115Nm)
※ Special tool
Adjusting screws(M12) 5870 204 021

10) CONVERTER
(1) Fasten diaphragms(3EA) on the converter,
using hexagon head screws(Mount plain
washers).
※ Insert hexagon head screws with loctite
(Type No.243).
・Torque limit(M10/8.8) : 4.7kgf m(46Nm)

770-3ATM (373)

(2) Squeeze in and engage rectangular ring


(Arrow).
Now, grease rectangular ring and align it
centrically.

770-3ATM (374)

(3) Introduce converter by means of lifting


device until contact is obtained.

770-3ATM (375)

3-152
(4) Tilt transmission 90°.
Install breather(Arrow).
Insert pot flush mounted to the housing
surface.
※ Wet sealing surface with loctite(Type No.
262).

770-3ATM (376)

(5) Equip screw plugs(1 and 2) with new O-ring


and install them.
Install both fixing plates(Arrow 3).
・Torque limit(Screw plug M42×2)
: 14.8kgf m(145Nm)
・Torque limit(M16/8.8)
: 19.9kgf m(195Nm)

770-3ATM (377)

11) MOUNT HYDRAULIC CONTROL UNIT


(1) Preassemble and mount plate(Figure
(1)~(5)).
Equip fitting(1~6) with new O-rings and
install them.
※ Install screw plugs(7 and 8).
Install new O-rings each time.

770-3ATM (380)

(2) Install two adjusting screws(M6) and


mount housing gasket.
※ At the following steps(Figure(2)~(6), pay
attention to the installation positions of the
different gaskets.
※ Special tool
Adjusting screws 5870 204 063

770-3ATM (381)

3-153
(3) Mount intermediate plate.

770-3ATM (382)

(4) Mount 2nd gasket.

770-3ATM (383)

(5) Mount plate and fasten it uniformly by


means of socket head screws.
・Torque limit : 2.3kgf m(23Nm)

770-3ATM (384)

(6) Mount gasket.

770-3ATM (385)

3-154
(7) Assemble complete control unit and fasten
it uniformly by means of socket head screw
(2×M6×105 and 21×M6×80mm).
※ Pay attention to the position of the two
socket head screws M6×105, see arrows.
・Torque limit : 0.97kgf m(9.5Nm)

770-3ATM (386)

(8) Install pressure lines according to the


K2 KR KV K4 K3
following draft.
Ref. draft
KV = Hydraulic line Clutch KV
KR = Hydraulic line Clutch KR
K1
K1 = Hydraulic line Clutch K1 S2
K2 = Hydraulic line Clutch K2 KV
K2
S1
K3 = Hydraulic line Clutch K3 S2
K4 = Hydraulic line Clutch K4 KR K3
S1
S1 = Lubricating oil line Clutch KR/K2
K4
S2 = Lubricating oil line Clutch K4/K3

7704PT20

12) INDUCTIVE TRANSMITTER AND SPEED


SENSOR
(1) The following drafts show the installation
position of the single inductive transmitters
9
and the speed sensor. 5
5= Inductive transmitters 14
n Central gear train
9 = Inductive transmitters
n Engine
14 = Inductive transmitters
n Turbine
13 = Speed sensor
n Output and speedometer

13

7704PT21

3-155
(2) Setting-Inductive transmitter
The following figures are describing the
reassembly, respectively the setting of the
inductive transmitter n Engine(9).
The reassembly of the inductive
transmitters n Turbine(14) and n Central
gear train(5) has to be carried out
accordingly.
※ Pay attention to the different setting
7704PT28
dimensions.
Setting dimension corresponds to the
distance between contact face-Inductive
transmitter and tooth tip, see figure.
Setting dimension - Inductive transmitter
n Engine(9) and n Turbine(14) = 0.5+0.3mm
Setting dimension - Inductive transmitter n
Central gear train(5) = 0.3±0.1mm

(3) Turn counting disk radially until one tooth


tip is situated centrally to the inductive
transmitter hole.
Insert measuring pin until the end face has
got contact on the tooth tip, respectively
the circlip on the screw in face of the
housing.
※ Special tool
Measuring pin 5870 200 040
770-3ATM (391)

(4) Remove measuring pin and measure


dimension Ⅰ from the end face/measuring
pin to the circlip.
・DimensionⅠ e.g. 30.10mm
Measure dimension Ⅱ from the contact
face - inductive transmitter to the contact
face.
・DimensionⅡ e.g. 30.00mm
770-3ATM (392)

3-156
Example L1
DimensionⅠ 30.10mm
Required gap(0.5 mm)e.g. - 0.60mm
+0.3

Gives installation dimension 29.50mm

Example L2
DimensionⅡ 30.00mm
Installation dimension - 29.50mm
Difference = Shim s = 0.50mm

(5) Assemble corresponding shim and wet


thread(Arrow) with loctite(Type No.574).

770-3ATM (393)

(6) Install inductive transmitter n Engine(9),


n Turbine(14) and n Central gear train(5).
・Torque limit : 3.1kgf m(30Nm)
Now, install screw plugs(Arrows).
※ Equip screw plugs with new O-rings.
・Torque limit(M26×1.5) : 8.2kgf m
(80Nm)
・Torque limit(M18×1.5) : 5.1kgf m
(50Nm)
770-3ATM (394)

(7) Speed sensor(Hall sensor) n Output


and speedometer
Illustration on the right shows the speed
sensor 13.
1 Speed sensor
2 Plate
3 O-ring

770-3ATM (395)

3-157
(7) Grease O-ring and fasten speed sensor
(Arrow) by means of socket head screw.
・Torque limit(M8/8.8) : 2.3kgf m(23Nm)
※ Prior to the commissioning of the
transmission, carry out the oil filling
according to the operating instructions.

770-3ATM (396)

3-158
3. AXLE
1) GENERAL INSTRUCTIONS
(1) SHIMS
All adjustments shall be carried out after all adjustment shims have been selected measuring
them one by one with a micrometer gauge and, then, summing up all values measured; don’t trust
incorrect measurement of pack as a unit or sum of nominal value printed on each shim.
(2) SEALS FOR REVOLVING SHAFTS
Proceed as follows for proper fitting of captioned seals:
① Prior assembly, seals should be kept, for at least half an hour, in a bath with the same oil to be
sealed;
② Clean thoroughly shaft and make that working surface be not damaged;
③ Position sealing lip against the fluid to be sealed; in case of hydrodynamic lip lines should be
oriented so as that, considering direction of revolving shaft, they lead fluid inside of sealing
means;
④ Smear sealing lip with a film of lubricant(oil is better than grease) and fill up with grease the space
between sealing lip and dust shield lip, if using double sealing lip type seals;
⑤ Press seal in relevant seat or use a proper fitter with flat contact surface; never use hammer or
mallet to mount seal;
⑥ When press fitting seal make sure that it be correctly driven in relevant seat, i.e., perpendicular
with respect to its seat, as fitting is completed make sure, if required, that seal itself be in contact
with relevant shoulder;
⑦ To prevent damage of seal lip when inserting shaft, duly protect component during assembly.
(3) O-RING SEALS
Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.
Clean matching surface as follows prior, smearing compound:
① Remove old deposits using a metal brush;
② Degrease surfaces by one the following cleaners: trichloroethylene, kerosene or a warm water
and soda solution.
(4) BEARINGS
When assembling them it is advisable to proceed as follows:
① Heat them with 80 to 90°C before fitting on relevant shafts;
② Cool them before inserting in relevant external seats.
(5) SPRING PINS
When using split pins be sure that lengthwise cleft be positioned toward stress on pin.
Coil pins don’t require specific position.

3-159
2) REDUCTION ASSEMBLY
(1) DISASSEMBLY
① Turn the plug toward top position and
remove the plug for the air vent.
Assemble the plug temporary.

AX001

② Drain oil from final drive unit.

AX002

③ Loosen screws securing side gear carrier to


wheel hub.

AX003

④ Pull out complete side gear carrier.

AX004

3-160
⑤ Pull out wheel shaft with sun gear, discs
carrier hub and thrust plate.

AX005

⑥ Remove brake disc pack.

AX006

⑦ Remove lock ring nut locks.

AX007

⑧ Remove locks.

AX008

3-161
⑨ Install the proper tool on pressure plate and
apply the eye bolt(3EA) temporary.
Tighten the eye bolt tool perfectly.

AX009

⑩ Remove the nut-adjusting by the use of the


special tool.

AX0010

⑪ Remove the pressure plate, spring, cover.

AX0011

⑫ Remove the ring gear assembly.


※ Attention to the weight.

AX0012

3-162
⑬ Pry off lock ring from ring from ring gear by a
screw driver, and remove ring gear support.

AX0013

⑭ Remove piston, it’s easier by blowing


compressed air in brake oil delivery ducting.

AX0014

⑮ Remove wheel hub assembly.

AX0015

⑯ Pry off wheel hub seal and remove inner


race with roller cage of wheel inside bearing.
By using a punch remove from wheel hub
outer races of inner and outer bearings.

AX0016

3-163
AX0017

⑰ Remove final drive cover.

AX0018

⑱ It is provided with three threaded holes


(M10×1.5) to be used for puller screws.

AX0019

⑲ Remove the pin-planetary(3EA) from Drum-


Hub(Side gear carrier support) assembly.

AX0020

3-164
⑳ Remove the planetary gear and thrust
washer step by step.

AX0021

(2) ASSEMBLY
① Insert the inner bearing cone.

AX085

② Press fitting lip seal.


※ Smear loctite 573 or equivalent sealant on
outer diameter surface.

AX086

③ Support suitably wheel hub while assembling


parts to prevent damage of seal; then go on
by fitting wheel bearing on hub spindle.

AX087

3-165
④ Replace O-ring seals on piston.
※ Cover the oil on O-ring seal enough.

AX088

⑤ Insert piston full travel down on hub spindle.

AX089

⑥ Insert ring gear support in ring gear, then fit


spring ring retaining axle.

AX090

⑦ Mount on hub spindle the complete ring gear


unit.

AX091

3-166
⑧ Insert into relevant holes the six pins that, for
proper operation of whole system, have to
be of the same length and however in
accordance with relevant drawing.

AX092

⑨ Position spring return cover on pressure


plate, press compression tool.
(Front axle only)

AX093

⑩ Assemble support assembly with spring


compression tool on spindle and tighten nut-
adjusting.

AX094

⑪ With proper wrench lock ring so to reach the


specified wheel bearing pre-load
corresponding to a rotation torque and a
rope pull strength on studs included into
15~18kg.
To prevent wrong torque recording, it is
advisable to set bearings, by various wheel
revolutions, prior performing the check.

AX095

3-167
⑫ Remove spring compression tool.

AX096

⑬ Fit plate and assemble ring-retain.

AX097

⑭ Insert wheel shaft on which sequentially


mount ; the thrust washer, discs carrier hub,
sun gear and lock ring ; then push all
components fully down against hub spindle.

AX098

AX099

3-168
⑮ Install brake measuring tool on hub-wheel.
J
※ Distance of brake measuring tool J

AX100

⑯ Measure K between end of measuring tool


and pressure plate.

AX101

⑰ Install brake measuring tool on drum hub


and measure L.
L

AX102

3-169
⑱ To determine thickness of disc pack from
previsously computed value M. M

※ Assembly procedure of brake disc pack :


To drum hub from pressure plate C, B, C,
B......C, B.(C=disc-count, B=disc-brake)
※ Quantity of brake disc.
・Front axle : disc-count 6EA
disc-brake 6EA
・Rear axle : disc-count 5EA
AX103
disc-brake 5EA

⑲ Calculate stroke, and if it is not satisfied with


the specification, readjust stroke by means
of change the thickness of each disc.
Stroke : S=(K+L-2J)-M
・Stroke
Front axle : 4.2~4.8mm
Rear axle : 3.5~4.0mm

⑳ Assemble disc pack according to the


procedure.

AX104

Arrange side gear carrier on blocks made of


wood and remove pins.
Save needle rollers of filling bearing casings.
It is important to keep needle rollers joined
with relevant pin for allowance question of
pins themselves.

AX105

3-170
Arrange all the three side gears into relevant
seats of side gear carrier, position inner
thrust washers and align holes.

AX106

Mount on pins the two needle roller casings.


Insert outer thrust washers, grease lower half
of pin(head side) and position the first needle
roller casing, insert spacer and position the
second casing.
※ In case of needle roller replacement, use
needle roller of the same selection class for
the two casings of each side gear.

AX107

Insert the complete pins, taking care to avoid


any bump, cause of needle rollers fall.

AX108

Rotate pins so to align them and allow fitting


of cover that also prevent pin rotation.

AX109

3-171
Fit O-ring seal on outer side.
Mount side cover on final drive.
・Tightening torque
Front and rear axle : 2.9~3.6kgf m
(21.0~26.0lbf ft)

AX110

Assemble drum-hub on hub-wheel.

AX111

Tight the fixed bolt of drum-hub and


assemble plug.
・Tightening torque
Front and rear axle : 6.3~6.9kgf m
(45.6~50.0lbf ft)

AX112

3) PARKING BRAKE(FRONT AXLE ONLY)


(1) DISASSEMBLY
① Insert through oil adding hole of gripper the
pressure of 100~120bar, in order to obtain
calipers release.
Remove the cover bolts of caliper.

AX022

3-172
② Release nut and screw.

AX023

③ Remove the split pin and nut of caliper


brake. Remove the bolts.

AX024

④ Remove the caliper brake.

AX025

⑤ Remove the disc.

AX026

3-173
⑥ Remove the fixed bolts of bracket-caliper.

AX027

(2) ASSEMBLY
① Install bracket-caliper.
・Tightening trque
11.4~12.6kgf m(82.5~91.1lbf ft)

AX113

② Fit disc on flange, and tighten bolts.


・Tightening trque
6~7kgf m(43.4~50.6lbf ft)

AX114

③ Remove cover and O-ring of caliper, and


release nut and pin screw.

AX115

3-174
④ Release nuts on fixed bolts in order to obtain
the maximum opening of gripper.

AX116

⑤ Insert fixed bolts on caliper.

AX117

⑥ Tighten nuts and split pins.


・Tightening trque
1~3kgf m(7.2~21.7lbf ft)

AX118

⑦ Assemble the fixed parts on caliper-brake.


・Procedure1 : Insert O-ring in adapter blee-
1
der and assemble it, assem-
ble bleeder on adapter.
※ Adapeter tightening torque : 1.2~1.6Kgf m
(8.7~11.6lbf ft) 2
Bleeder tightening torque : 1.4~1.5Kgf m
(10.1~10.8lbf ft)
・Procedure2 : Fix copper washer and conn-
ector on caliper, and assem- AX119
ble it.
※ Connector tightening torque : 2.0~2.2Kgf m
(14.5~15.9lbf ft)

3-175
⑧ Press 110~120bar in brake port and close
adhesion pad on disc by means of tightening
pin-screw.

AX120

⑨ Check the gap between discs after unscrew-


ing pin screw 1/8~1/4turn.
※ Disc gap : Each 0.125~0.25mm

AX121

⑩ Tighten nut.
・Tightening torque : 14~16Kgf m
(101~116lbf ft)

AX122

⑪ Tighten bolts after assembling O-ring on cover.


・Tightening torque : 1.3~1.5Kgf m
(9.4~10.8lbf ft)

AX123

3-176
4) DIFFERENTIAL ASSEMBLY
(1) REMOVAL
① Remove screws and take away air
recirculation duct from differential support
and axle case.

AX0228

② Unlock and loosen screws retaining different-


ial group, then remove it from axle case.

AX029

AX030

(2) DISASSEMBLY
① Place differential unit upside down; mark
caps position.

AX031

3-177
② Unlock and remove caps fixing screws.

AX032

③ Remove lock pin of ring nut, remove caps.

AX033

④ Lift up differential from support, by a lifting


tool with proper capacity.

AX034

⑤ Place on proper support and lock the


differential. Straighten notches on pinion
nut, then position reaction tool on P.T.O.
flange and unlock nut; release pinion nut.
Remove drive flange from pinion shank.

AX035

3-178
AX036

⑥ Pry off seal from P.T.O. flange.

AX037

⑦ Drive out bevel pinion from differential


support hammering by a proper remover on
shank, don’t damage thread.

AX038

⑧ Remove the bearing cone.

AX039

3-179
⑨ Remove the shims from P.T.O flange.

AX040

※ The conditions of assembled only bearing


cone in pinion gear.
⑩ Remove the shim and spacer in removed
pinion.

AX041

⑪ Remove outer races of pinion shank and


under head bearings; save shims for axial
position of pinion and ail recirculation
impeller.
※ Press on impeller to drive out outer race of
under head bearing.

AX042

(3) ASSEMBLY
① Measure the dimensions for assembly
position of pinion bevel.
B
A

Decide the dimension X(shim thickness) by


the calculation.
C

AX043

3-180
② Both the pinion-bevel and the gear-bevel are
marked with a number. Confirmed the some
numbers both the pinion-bevel and gear-
bevel.
※ Number location of bevel set
Bevel pinion : Head surface
Bevel ring : Outer cutting side

AX044

③ Measure the carrier height A by the special


tool.
※ Standard value of A
・Front axle : 287.5mm
・Rear axle : 263.0mm

AX045

④ Decide a value B by the carved value of


pinion-bevel head.
・Front axle : B = 231.7±carved value
・Rear axle : B = 208.0±carved value
※ In case, the carved value is -10, B of
Front axle =231.7 - 0.1 = 231.6mm

AX046

⑤ Measure the width of bearing C.


※ Standard value of C
・Front axle : 54.77mm
・Rear axle : 54.0mm

AX047

3-181
⑥ Determine shim X thickness for correct axial
position of pinion-bevel.
X = A - (B + C)
※ Round up or down to the nearest tenth of
millimeter the computed thickness.
2.12 rounded down to = 2.1mm
2.18 rounded up to =2.2mm

AX047

⑦ Fit in pinion shank inner race of under head


bearing, heat or press-in part by installer.

AX049

⑧ Place correctly pump in relevant seat on


differential support.

AX050

⑨ Insert adjustment shim for axial position of


pinion.
Its value was computed previously ; also, fit
outer races of pinion under head and shank
bearings.

AX051

3-182
⑩ Turn the carrier upside down and assemble
the bevel pinion assembly.
※ In order to contact between the bearing cone
in pinion bevel and the bearing-cup of carrier
perfectly, support the pinion-bevel by
preferable tool.

AX052

⑪ Assemble the shims(3EA)

AX053

⑫ Assemble the spacer and shims(2EA).

AX054

⑬ Fit in bearing-cone by heating or pressing.

AX055

3-183
⑭ Assemble flange and holder in pinion-bevel,
and tighten nut-pinion.
※ Pinion nut tightening torque
·Front axle : 72~78kgf·m
·Rear axle : 58~64kgf·m
※ Don’t assemble seal.

AX056

⑮ Measure prelood and confirm the follow


value.
※ Bearing preload
·Front axle : 0.2~0.4kg·m
·Rear axle : 0.2~0.4kg·m
※ Before measuring preload, rotate two or three times.
Disassemble and change adjustment shims to
eliminate all end play up to reach a pre-load.

AX057

As bearing pre-load has been determined,


remove drive flange and nut-pinion holder.

AX058

Assemble seal.
※ Cover the seal with retaining compound.
Cover the seal lip and the flange with oil.

AX059

3-184
⑱ Assemble the flange and the holder on the
pinion-bevel, and tighten the nut-pinion and
the split pin.

AX060

⑲ Fit in the differential assembly on the carrier,


and assemble nut-adjusting temporary.

AX061

⑳ Install caps, care not to reverse position and


lock screws fixing to differential support with
belows.
※ Cap tightening torque
・Front axle : 63~69Kgf・m(456~499lbf・ft)
・Rear axle : 63~69Kgf・m(456~499lbf・ft)

AX062

Position a dial gauge perpendicular than ring


gear tooth and check, with pinion steady,
backlash that has to be of 0.25~0.33mm
(rear) and 0.39~0.54mm(front).
Otherwise rotate both ring nuts by displacing
them of the same number of notches and
nearing ring gear to pinion if backlash is
excessive, by moving away on the contrary.
※ Bevel set back lash
・Front axle : 0.39~0.54mm AX063

・Rear axle : 0.25~0.33mm

3-185
Brush red lead on some ring tooth, rotate to
mesh pinion and ring gear repeatedly, so to
make evident tooth contact. Proper and
correct tooth contact marks are visible on a
new bevel gear set as a result of an
optimum contact approached on the tester,
consequently, a proper axial position of
pinion against ring gear will emphasise
remarking of previous tester contact
markings.
AX064

Fit spring pins locking threaded rings of


differential unit.

AX065

(4) HOUSING AND DIFFERENTIAL MOUNTING


① Perform two securing notches on pinion nut.
Clean with care contact surfaces, apply hard
locking compound and then install the
differential unit on axle case ; lock the
connecting screws with a torque of
31.3~34.5Kgf m(226~250lbf ft).

AX082

② Assemble O-ring on tube assembly port(3EA).


(Front axle only)

AX083

3-186
③ Position the tube assembly, fit screws and lock
with a torque of 3.0~3.5Kgf m(21.7~25.3lbf ft).
(Front axle only)

AX084

5) SUPER MAX TRAC


(1) DISASSEMBLY
① Mark the two half cases(LH/RH).

AX066

② Unscrew and remove the screws and open


them.

AX067

③ Remove the planetary gear with relevant


intermediate and shim discs and clutch
discs.

AX068

3-187
④ Remove spider with the four side gears and
relevant bevel thrust washers.

AX069

⑤ Remove the planetary gear with relevant


intermediate and shim discs and clutch
discs, in half case on bevel gear side.

AX070

⑥ Loosen bevel gear fixing screws.

AX071

(2) ASSEMBLY
① Install gear-bevel on case-LH by bolts.
※ Tightening torque
・Front axle : 87~95kgf・m(629~687lbf・ft)
・Rear axle : 46~50kgf・m(333~362lbf・ft)

AX072

3-188
② Before assembling, each smooth face have
to be lubricated with oil.
・Insert a lug disc(a) (with outer lugs) into Planetary gear
half case. c
・Insert an intermediate disc(b) (with a
inner lugs), then another disc(a), a disc b
(b), still lug disc(a). a
b
※ Discs(b) are thin with lining on both faces, a
disc(c) is thick and lined on one face only.
・Insert a disc(c) with unlined face turned
upward.
・Smear oil on planetary gear and insert
taking care to mesh shaft splines with
inner lugs of clutch discs. 7707PT19

③ Assemble side gears with relevant bevel


thrust washers on spider and position them
on the half case.

AX074

④ Insert gear side assembly in case-LH.

AX078

3-189
⑤ Assemble spider and gear-side according to
procedure.

AX079

⑥ Mount the cover aligned against the lugs of


lug disks, taking care to align the reference
marked done before disassembling ; close
the two half casings.
Screw in fixing screws and lock a torgue of ;
・Front axle : 21~23kgf・m(152~166lbf・ft)
・Rear axle : 11.5~12.5kgf・m
(83.2~90.4lbf・ft)

AX080

⑦ As assembling is done, play of each clutch


pack have to be included between 0.05 and
0.1mm.
Check has to perform with 180°at the same
time on both clutch packs to prevent that
play between side gears and spider would
mislead reading.
Make sure of proper gear rotation.
If play value of clutches results different than
specified one, differential has to be
AX081
disassembled again, rearrange clutch pack
again, select proper disc shims.
Reassemble and check all over again.

3-190
6) TOOLS
① Spring compression tool.

AX124

② Nut adjusting tool of reduction assembly.

AX125

3-191
SECTION 4 BRAKE SYSTEM

Group 1 Structure and Function 4-1


Group 2 Operational Checks and Troubleshooting 4-24
Group 3 Tests and Adjustments 4-32
Group 4 Disassembly and Assembly 4-34
SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION

1. OUTLINE
※ The brakes are operated by a pressure compensated, closed center hydraulic system.
Flow is supplied by a fixed displacement, gear type brake pump.

BRAKE SYSTEM
The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit and
park brake circuits. It flows to three accumulator. The accumulator has a gas precharge and an
inlet check valve to maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve in cut-off valve.
The brake system contains the following components:
・Brake pump
・Parking brake solenoid valve in cut-off valve
・Cut-off valve
・Brake valve
・Accumulators
・Pressure switches

4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
service brakes with actuation that is faster 900
than air brake systems. Figure represents 800
a time comparison between a typical Brake pressure
700 (Full power)

Brake torque(lb・in)
air/hydraulic and full power hydraulic brake
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic device.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.

4-2
2. HYDRAULIC CIRCUIT

FRONT
28 REAR

Parking brake

17
20
BL1 BR1 BL2 BR2

8
T1 P1 T2 P2

16 15

16 7 B1 A1 B2 A2

A3
18 PS T1

B
Steering system
PS1

19
T
Parking brake
P
MCV RCV lever
solenoid Return line
21
Fan drive
motor
2 1

24
Return line

25
26 27 Return line
23

7707BS01

1 Main pump 17 Pressure switch 24 Air breather


2 Brake pump(+fan pump) 18 Pressure switch 25 Hydraulic tank
7 Cut off valve 19 Pressure switch 26 Return filter
8 Brake valve 20 Pressure switch 27 Bypass valve
15 Accumulator 21 Line filter 28 Axle
16 Accumulator 23 Oil cooler

4-3
1) SERVICE BRAKE RELEASED

28
FRONT REAR

17
20
BL1 BR1 BL2 BR2

8
T1 P1 T2 P2

16 15

16 7 B1 A1 B2 A2

A3
18 PS T1

B
Steering system
PS1

19
T
P
MCV RCV lever
Return line
21
Fan drive
motor
2 1

24
Return line

25
26 27 Return line
23

7707BS02

When the pedal of brake valve(8) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles
return to the tank(25).
Therefore, the service brake is kept released.

4-4
2) SERVICE BRAKE OPERATED

FRONT
28 REAR

17
20
BL1 BR1 BL2 BR2

8
T1 P1 T2 P2

16 15

16 7 B1 A1 B2 A2

A3
18 PS T1

B
Steering system
PS1

19
T
P
MCV RCV lever
Return line
21
Fan drive
motor
2 1

24
Return line

25
26 27 Return line
23

7707BS03

When the pedal of brake valve(8) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the cut-off valve(7) enters the
piston in the front and rear axles. Therefore, the service brake is applied.

4-5
3) PARKING BRAKE RELEASED

FRONT
28 REAR

Parking brake

17
20
BL1 BR1 BL2 BR2

8
T1 P1 T2 P2

16 15

16 7 B1 A1 B2 A2

A3
18 PS T1

B
Steering system
PS1

19
T
Parking brake
P
MCV RCV lever
solenoid Return line
21
Fan drive
motor
2 1

24
Return line

25
26 27 Return line
23

7707BS04

When the parking brake switch is pushed, the solenoid valve is energized and the hydraulic oil
controlled the pressure level by the cut-off valve(7) enters the parking brake on the front axle. It
overcomes the force of the spring and pushes the piston rod. This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston through the solenoid
valve and the parking brake is kept released.

4-6
4) PARKING BRAKE OPERATED

FRONT REAR

Parking brake

17
20
BL1 BR1 BL2 BR2

8
T1 P1 T2 P2

16 15

16 7 B1 A1 B2 A2

A3
18 PS T1

B
Steering system
PS1

19
T
Parking brake
P
MCV RCV lever
solenoid Return line
21
Fan drive
motor
2 1

24
Return line

25
26 27 Return line
23

7707BS05

When the parking brake switch is pushed once more, the solenoid valve is deenergized and the
valve open the exhaust port.
At the same time, the hydraulic oil in the parking brake return to the tank through the solonoid valve.
When the piston rod is returned by the force of the spring, the parking brake is applied.

4-7
3. BRAKE PUMP(+FAN PUMP)
1) STRUCTURE

17 Brake pump
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18

20

6
1 5
8
Fan pump 4

7707BS19

1 Body 9 Driven gear 17 Backing ring


2 Body 10 Driver gear 18 Body O-ring
3 Dowel pin 11 Driven gear 19 Intermediate plate
4 Front cover 12 Bushing 20 Coupling
5 Shaft seal 13 Bushing 21 Rear cover
6 Bushing 14 Bushing seal 22 Spring washer
7 Bushing 15 Backing ring 23 Screw
8 Driver gear 16 Bushing seal

This gear pump have a maximum delivery pressure of 150kgf/cm2.


The pressure loaded type gear pump is designed so that the clearance between the gear and the
bushing can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage
from the bushing is less than that in the case of the fixed bushing type under a high discharge pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.

4-8
2) PRINCIPLE OF OPERATION
(1) Mechanism for delivering oil
The drawing at right shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port is Suction Discharge
trapped in the space between two gear
teeth, and is delivered to the discharge
port as the gear rotates.
Except for the oil at the bottom of the gear
teeth, the oil trapped between the gear
teeth, is prevented from returning to the
suction side with the gears in mesh.
Since the gears are constantly delivering
oil, the oil delivered to the discharge port
is forced out of the port.
The amount of discharge increases with
the speed of rotation of the gear.
If there is no resistance in the oil passage
into which the discharged oil flows, the oil
merely flows through the passage,
producing no increase in pressure.
If however, the oil passage is blocked with
something like a hydraulic cylinder, there
will be no other place for the oil to flow, so
the oil pressure will rise. But the pressure
which rises in this way will never go
higher, once the hydraulic cylinder piston
starts moving because of the oil pressure.
As described earlier, the pump produces
the oil flow, but not the oil pressure. We
can therefore conclude that pressure is a
consequence of load.
In other words, the pressure depends on
a counterpart.

(770-3ATM) 4-9

4-9
(2) Internal oil leakage
Oil leaks from a place under higher
pressure to a place under lower pressure,
provided that a gap or a clearance exists
in between.
In the gear pump, small clearances are
provided between the gear and the case
and between the gear and the side plate
to allow the oil to leak out and to serve as
a lubricant so that the pump will be
rge
protected from seizure and binding.
scha
Di
The drawing at right shows how the
leaked oil flows in the pump. As such,
there is always oil leakage in the pump
from the discharge side(under higher
pressure) to the suction side. The
n
delivery of the pump is reduced by an ctio
Su
amount equal to the pump discharge.
In addition, the delivery of the pump will
also decrease as the amount of oil
leakage increases because of expanded
radial clearance resulting from the wear of
pump parts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
(770-3ATM) 4-10
viscosity oil.

4-10
(3) Forces acting on the gear
The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side. Drive gear
This phenomenon is shown in the
drawing at right.
In addition, the gears in mesh will receive
Suction Discharge
interacting forces. side side
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed
Driven gear
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero,
thus allowing the gear teeth and the case Pressure distribution
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
(770-3ATM) 4-11
interference of the gear with the case.

4-11
4. BRAKE VALVE
1) STRUCTURE

18
17-2 17-3,17-4
17-1
19
23 22
24
21
2

20 8,32,33
9
25
30
25
16 14
15 7
5 13
31
12 6
1,27,28,29 10
26
4
11
3

7707BS21

1 Lower body 13 Spring guide 22 Stop ring


2 Upper body 14 Stop ring 23 Hexagon bolt
3 Spool 15 Bushing 24 Hexagon nut
4 Plug 16 Pedal plate 25 Bolt
5 Holder 17-1 Pedal 26 Spring washer
6 Lower spring 17-2 Lock plate 27 Plastic plug
7 Upper spring 17-3 Hexagon bolt 28 Name plate
8 Main spring 1 17-4 Plain washer 29 Screw
9 Spring retainer 1 18 Rubber 30 Plain washer
10 O-ring 19 Cover 31 Stop ring
11 O-ring 20 Lock pin 1 32 Spring retainer 2
12 Oil seal 21 Torsion spring 1 33 Main spring 2

4-12
2) OPERATION

BL1 BR1 BL2 BR2

T1 P1 T2 P2
Hydraulic circuit

Porte Port name Port size

T1 P1, P2 Port PF3/8


BL1
T1, T2 Drain port PF3/8
P1
BR1, BR2 Brake cylinder port PF3/8
BR1
BL1 Pressure switch port PF1/4
T2 BL2 Pressure switch port M12×1.5
BL2
P2
BR2

7707BS22

4-13
(1) Purpose
The purpose of the brake valve is to sensitively increase and decrease the braking pressure when
the brake pedal is actuated.
(2) Ready position
When the braking system is ready for operation, its accumulator pressure acts directly on ports
(P1, P2) of the brake valve. A connection is established between ports(BR1, BR2) and ports(T1,
T2) so that the wheel brakes ports(BR1, BR2) are pressureless via the returns ports(T1, T2).
(3) Partial braking
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly(8) beneath base plate(16) is designed in such a way that the braking
pressure changes depending on the angle. In the lower braking pressure range, the machine
can be slowed sensitively.
When the braking process is commenced, the upper spool is mechanically actuated via spring
assembly(8), and the lower spool is actuated hydraulically by spool. As spools(3) move
downward, they will first close returns(T1, T2) via the control edges, thus establishing a
connection between accumulator ports(P1, P2) and ports(BR1, BA2) for the wheel brake
cylinders. The foot force applied now determines the output braking pressure. The control
spools(3) are held in the control position by the force applied(Spring assembly above the spools
and the hydraulic pressure below the spool(Balance of forces).
After output of the braking pressure, spools(3) are in a partial braking position, causing ports(P1,
P2) and ports(T1, T2) to close and holding the pressure in ports(BR1, BR2).
(4) Full braking position
When pedal is fully actuated, end position of the brakes is reached and a connection established
between accumulator ports(P1, P2) and brake cylinder ports(BR1, BR2). Returns(T1, T2) are
closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports(BR1, BR2) and return ports(T1, T2), closing accumulator ports(P1, P2).
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
(5) Limiting the braking pressure
Pedal restriction bolt(23) on base plate below pedal is used to limit the braking pressure.
(6) Failure of a circuit
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(8) will mechanically actuate spool(28). In the event of the upper circuit failing, the lower circuit
will remain operational since the lower spool(31) is mechanically actuated by spring assembly(21)
and spool(28).
(7) Installation requirements
Return lines(T1, T2) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.

4-14
(8) Maintenance of the brake valve
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the machine, please make sure that the water jet is not
aimed directly at the brake valve(To prevent damaging the bellows).
For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
(9) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
※ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(10) Replacing the pedal cover
Pedal cover(18) is simply pulled of by hand. The new pedal cover is pushed over pedal(17) and
tightened manually. Fasten the bellows with the strap retainers.
(11) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by
taking out the four bolts. Make sure that spring assembly(8) does not fall out. When installing the
new actuating mechanism, make sure that spring assembly(8) is fitted in the right order. Tighten
the four bolts(25).
(12) Replacing the bellows
To change bellows(19) it is advisable to remove pedal(17). For this purpose, loosen retaining ring
(22) and knock out pin(20) using a mandrill. When knocking out the bolt, make sure that the
mandrill is applied to the side of the bolt without a knurl. Remove pedal(17) and bellows(19).
Now fit the new bellows and proceed in reverse order as described above. The upper portion of
bellows is fastened to piston(5), its lower portion to base plate(1) secure the bellows using
clamps.

4-15
5. CUT-OFF VALVE
1) STRUCTURE

3 4

5 C B

D D

P PS1
A A
C B
SECTION A - A SECTION B - B
1 2

HYDRAULIC SYMBOL

B1 A1 A2 B2

A1 A2
A3
PS
PS T1 T1

B1 B2 B
PS1
A3
B

P T
SECTION C - C SECTION D - D

7707BS06

1 Cut-off valve 4 Coil


2 Relief valve 5 Solenoid valve
3 Check valve

2) OPERATION
When the pump works, the oil under the pressure flows into P port.
The oil in P port is stored in the accumulator on A3 port.
As the pressure on P line rises to 150bar, the cut off valve(1) starts cut-offing and the oil in the P
port is unloaded. The pressure on P line goes down 120bar by the minute leakage from valve and
other factors.
At this pressure, the cut-off valve starts cut-ining.
This process is repeated in the regular period of 30~40 seconds.

4-16
6. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0004 81L1-0003
Item
(Item15) (Item16)
Diameter 121mm 136mm
Mounting height 146mm 160mm
Norminal volume 0.75m 3
1.0m3
Priming pressure 50kgf/cm2 50kgf/cm2
Operating medium Oil Oil
B
Operating pressure Max 210kgf/cm 2
Max 200kgf/cm2
Thread M18×1.5 M18×1.5
A
C Priming gas Nitrogen Nitrogen

A Fluid portion C Diaphragm


D B Gas portion D Valve disk

(770-3ATM) 4-22

2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion (A) and a gas portion (B) with a diaphragm (C) as a
gas-tight dividing element. The fluid portion (A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk (D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
(3) Installation requirements
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.

4-17
(4) Maintenance of the accumulator
No special maintenance beyond the legal requirements is necessary.
The accumulator should be checked annually. It should be replaced if the initial gas pressure has
fallen by more than 30%(Please refer to Performance testing and checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this purpose,
drill a hole through gas chamber(B) using a drill approx. 3mm in diameter. The gas chamber is
located on the side opposite the threaded port above the welding seam around the center of the
accumulator.
※ Wear safety goggles when doing this job.
(6) Performance testing and checking of the accumulator
The accumulator is gradually pressurized via the test pump; until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from gauge
M. If the initial gas pressure is more than 30% below the prescribed value, the accumulator
needs to be replaced. If the measuring process needs to be repeated, wait for intervals of 3
minutes between the individual tests. Any accumulator whose initial gas pressure is insufficient
must be scrapped following the instructions under Disposal of the accumulator.
The amount of initial gas pressure can also be checked from the vehicle. Start the vehicle's
engine. The pump will now supply oil to the accumulators. Until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from the
gauge in the cab. If the initial gas pressure is more than 30% below the prescribed value, that
initial pressure lies outside the permissible range for at least one of the accumulators fitted in the
vehicle. This accumulator can be traced only by using the method described above, i.e. all
accumulators have to be individually tested. The accumulator whose initial gas pressure is
insufficient must be replaced and scrapped following the instruction under Disposal of the
accumulator.

Accumulator M

Safety valve
A

(770-3ATM) 4-23

4-18
(7) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine in switched off there will be some residual
pressure in the system.
※ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
For safety reasons the accumulators need to be replaced as a whole if damaged.

4-19
7. PRESSURE SWITCHES
1) STRUCTURE

・Normally closed

H1

H2 ・Normally open

(770-3ATM) 4-25

・ Technical data

H1 H2 Adjusting range Adjusting pressure Voltage


Item Type Medium G
mm mm kgf/cm2 kgf/cm2 V

Parking NC Oil M12×1.5 55 9 20 ~ 50 21 ± 2 Max 42


Charging NC Oil M12×1.5 55 9 50 ~ 150 100 ± 10 Max 42
Brake stop NO Oil M12×1.5 55 9 1 ~ 10 5±1 Max 42
Clutch cut-off NO Oil PF 1/4" 55 9 20 ~ 50 24 ± 2 Max 42
NC : Normally closed NO : Normally open

4-20
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a
warning facility.
(4) Installation requirements
No special measures need to be taken.
(5) Maintenance of the pressure switch
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
※ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
※ For safety reasons the pressure switch needs to be replaced as a whole if damaged.

4-21
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.

(-)

(+) Screw

(770-3ATM) 4-25

4-22
8. PARKING BRAKE

26
25
1
23
22
31 33
32 34

24

3 7,8
10
2
30
29
11 27
12
9
13
17
9 12 18
11 15
28
14
16
20
Flange
19
21

6
5

7707BS20

1 Caliper bracket 13 Piston 24 Bolt


2 Bolt 14 Ring 25 Nut
3 Spring washer 15 Plate ring 26 Split pin
4 Disc 16 Lock plate 27 Ring
5 Bolt 17 Pin 28 Seal
6 Spring washer 18 Nut 29 Ring
7 Brake caliper 19 Cover 30 O-ring
8 Body 20 O-ring 31 Breather adapter
9 Pad 21 Bolt 32 O-ring
10 Shuttle 22 Breather 33 Connector
11 Ring 23 Cap 34 Washer
12 Magnet

4-23
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:

Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments

4-24
※Hydraulic oil must be at operating temperature for these checks(Refer to page 6-51).

Item Description Service action

Parking brake capacity Start engine. OK


check 2 3 Check completed.
Fasten seat belt.
Seat belt must be worn 1 4
10 20
NOT OK
while doing this check to Release parking brake and put
0 0
mph
30
5 Inspect parking brake. Go
prevent possible injury Km/h
transmission in 2nd gear forward.
to group 3.
when machine stops
Drive machine at 8 km/hr and
suddenly.
switch parking brake ON.
LOOK/FEEL : Machine must
come to a stop within 2 meters(6
feet) when parking brake is
engaged at 8 km/hr.
Transmission must shift to neutral.

Parking brake Turn parking brake to ON. OK


transmission lockout Check completed.
Place transmission in 1st forward.
check
NOT OK
Engine running. Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.

4-25
Item Description Service action

Service brake pump Stop engine. OK


flow check Check completed.
Operate brake pedal approximately 20
※ Hydraulic oil must be at NOT OK
times.
operating temperature Check for brake circuit
Start engine and run at low idle.
for the check. leakage.
Engine OFF. Record number of seconds
required for low brake pressure Go to next page.
indicator lamp to go out. IF OK
LOOK : Indicator lamp must go Install a cap on line
out in less than 4 seconds from connected to inlet of brake
time engine starts. valve and repeat pump
flow check.
NOTE : Indicator will not come on
approximately 1 second after If time does not decrease,
starting engine. check for worn brake
pump. Go to brake pump
flow test, in section 3.

Turn clutch cut-off switch OFF. OK


Service brake capacity Check completed.
Apply service brakes, release
check
park brake and put transmission NOT OK
Engine running. Check brake pressure in
in 2nd forward.
group 3.
Increase engine speed to high
idle. IF OK
Inspect brake disk, see
LOOK : Machine may not move group 3.
or move at a very slow speed.
Repeat check three times to
ensure accurate results.

4-26
Item Description Service action
Brake accumulator Start and run engine for 30 OK
precharge check seconds. Check completed.
※ The axles and
Stop engine and turn start switch NOT OK
hydraulic oil must be at
to ON and wait 5 seconds. Make sure brake pedal is
operating temperature
not binding and keeping
for this check. NOTE : Engine oil pressure lamp
brakes partially engaged.
will be on due to no engine oil
pressure. Bleed brakes in group 3.
Count the number of times the Check brake system
brake pedal can be fully depressed pressure in group 3.
before the low brake pressure
NOT OK
warning lamp comes ON.
If light comes on with
LOOK : Warning lamp must come engine running,
on in 1-5 applications. accumulator has lost it's
charge. Inspect and
Start engine and operate at low
recharge accumulator,
idle.
group 3.
Observe cluster while applying
brake pedal with maximum force.
LOOK/LISTEN : Brake pressure
indicator must not come ON.

Brake system leakage ON Start engine and wait 30 seconds. OK


check Check completed.
Stop engine.
NOT OK
Wait 2 minutes.
If brake leakage is
Turn start switch to ON and wait 5 indicated with brakes
seconds. released, check leakage at
accumulator inlet check
LOOK : Brake oil pressure
valve and brake valve. If
warning lamp must not come on
brake leakage is indicated
within 2 minutes after stopping
with brakes applied, check
engine.
for leakage at brake valve
and brake pistons.
Check individual
component leakage.

4-27
Item Description Service action

Service brake pedal Slowly depress brake pedal. OK


check Check completed.
Listen for a hissing noise that
indicates oil is flowing to brake NOT OK
pistons. Inspect for debris under
brake pedal. Inspect
LISTEN/FEEL : A hissing noise
clutch cut-off linkage.
must be heard when pedal is
depressed.

Service and parking Position machine on gradual OK


brake system drag slope. Check completed.
checks
Lower bucket approximately
Engine running NOT OK
50mm(2 in) from ground.
Adjust park brake, go to
Release parking and service group 3.
brakes.
NOT OK
LOOK : Machine must move or
Check floor mat
coast.
interference to pedal or
NOTE : If machine does not debris build-up.
move, check brake pedals to be
sure they fully release when feet IF OK
are removed from pedals. Check for brake pressure
when brake is released.
Drive machine at high speed for
about 5 minutes.
Go to brake pressure test
Brake drag is indicated if brake on group 3.
areas in differential case are hot.
NOTE : Observe parking brake.
If disk is hot, parking brake drag is
indicated.

Clutch cut-off check Place clutch cut-off switch in ON OK


position. Check completed.
Release parking brake. NOT OK
Adjust clutch cut-off switch,
Run engine at half speed in 1st
see group 3.
forward.
Firmly depress brake pedal.
FEEL : Transmission must
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut-off pressure
switch can be adjusted to operator
preference to match your loading
needs.

4-28
2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See section 1)
Step 2. Operational checks(In this group)
Step 3. Troubleshooting
Step 4. Tests and adjustments(See group 3)

Problem Cause Remedy

Poor or no brakes Brake accumulator charge low Do brake accumulator check.


Brake pump standby pressure Do brake pump standby pressure test.
low
Brake pressure low Do brake valve pressure test.
Air in system Bleed brakes.
Worn brake surface material Inspect brake surface material.
Leakage in brake valve Do brake valve leakage test.
Leakage in brake piston seal Check for an over filled differential.
Apply brakes and check for leakage from check
plug.
※It is normal for the oil level to be slightly
above the check plug.

Aggressive brakes Internal restriction in circuit Remove lines and components.


Clutch cut-off switch out of Adjust switch.
adjustment
Brake valve malfunction Disassemble and inspect.
Low oil level Check oil level.

Brakes drag Brake pedal not returning Inspect floor mat and pedal.
properly
Debris holding valve partially Do brake valve pressure test.
open in brake valve
Warped brake disk Inspect brake disk.
Stuck brake piston Repair.

Brakes lock up Brake valve malfunction Clean or replace brake valve.

4-29
Problem Cause Remedy

Brakes chatter Air in brake system Do brake bleed procedure.


Worn brake surface material Inspect brake surface material.
Wrong oil in differential Drain. Refill.

Hissing noise when Leakage in brake valve, or brake Do brake system leakage test.
brake pedal is held with piston
engine stopped

Brake pressure warning Malfunction in brake low Replace switch.


light will not go out or pressure warning switch
stays on excessively
Brake accumulator pressure too Recharge accumulator.
long after start-up
low
Low brake pump standby Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage test.
manifold block
Do brake system components leakage tests.
Leakage in brake system
Do brake pump flow test.
Worn brake pump
Do parking brake pressure test.
Leakage in parking brake
solenoid

4-30
2) PARKING BRAKE MALFUNCTIONS

Problem Cause Remedy

Brake will not hold Pads not adjusted correctly Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid
Worn brake disk and / or brake Disassemble, inspect, repair.
pads
Brake piston hangs up in bore Remove and inspect. Repair.

Brake disk overheats Pads out of adjustment Adjust parking brake.


Brake not released Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.

Parking brake indicator Faulty wiring or switch Inspect for loose or broken lines between brake
in monitor does not pressure switch and indicator on dash.
come on when brake Inspect for a faulty indicator on dash. Replace if
applied necessary.

Brake will not apply Pads out of adjustment Adjust parking brake.
Malfunctioning wiring, switch, or Check electric circuit.
solenoid
Restriction between brake valve Remove hose and inspect. Replace.
and brake

4-31
GROUP 3 TESTS AND ADJUSTMENTS

1. PARKING BRAKE PERFORMANCE


1) MEASUREMENT CONDITION
(1) Tire inflation pressure:Specified pressure
(2) Road surface : Flat, dry, paved surface
with 1/5(11°
20') gradient.

(3) Machine : In operating condition 20%


gradient 11 20'
Item Standard valve
Parking brake Keep machine on 20%
performance (11°
20') gradient 7707BS16

2) MEASURING PROCEDURE
(1) Start the engine and drive the machine
straight up a 1/5 gradient with the bucket
unloaded.
(2) Depress the service brake, place the gear
selector lever in neutral, then stop the
engine.
(3) Turn the parking brake switch ON, then
20%
slowly release the service brake pedal 11 20' gradient
and the machine must be kept stopped.
※ The measurement must be made with
the machine facing either up or down
the slope. 7707BS17

2. EXTERNAL BRAKE INSPECTION


Inspect for wear of brake pad.
Adjust the gap(each 0.125~0.25mm) by adjust
nut(1). 1

Brake disc
7707BS26

4-32
3. HYDRAULIC BRAKE BLEEDING PROCEDURE
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before
applying pressure.
Search for leaks with a piece of
Breather vent B
cardboard. Protect hands and body from
high pressure fluids. Air breather

※ If an accident occurs, see a doctor Breather vent


immediately. Any fluid injected into the
skin must be surgically removed within a
few hours or gangrene may result.
Doctors unfamiliar with this type of injury
should reference a knowledgeable A
medical source.
Two people are required to bleed brake
system oil, one to operate brake valve and
other to open and close bleed screws.
1) Install frame locking bar. Engage parking
brake.
2) Put a clear plastic tube on bleed screw(B)
to route low to hydraulic reservoir filler tube
or container(A).
3) Start engine and run at low idle.
4) Push and hold brake pedal down until
brake bleeding procedure is complete.
※ If bubbles continue for more than 2 Safety lock bar
minutes, stop bleeding procedure.
Check for and correct problem, then
continue.
5) Open on bleed screw on differential and
axle assembly until hydraulic oil starts to
flow. Close bleed screw when oil is free of
air. Release brake pedal.
6) Repeat steps 1-5 for each bleed screw.
7) Push either brake pedal and hold down.
8) Check hydraulic oil level. 7707BS18

4-33
GROUP 4 DISASSEMBLY AND ASSEMBLY

1. BRAKE PUMP
1) STRUCTURE

17 Brake pump
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18

20

6
1 5
8
Fan pump 4

7707BS19

1 Body 9 Driven gear 17 Backing ring


2 Body 10 Driver gear 18 Body O-ring
3 Dowel pin 11 Driven gear 19 Intermediate plate
4 Front cover 12 Bushing 20 Coupling
5 Shaft seal 13 Bushing 21 Rear cover
6 Bushing 14 Bushing seal 22 Spring washer
7 Bushing 15 Backing ring 23 Screw
8 Driver gear 16 Bushing seal

4-34
2) DISASSEMBLY

17
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18

20

6
1 5
8
4

7707BS25

※ Before disassembling ensure that the unit itself, bench and tools are thoroughly clean.
(1) Lightly mark the rear cover(21), body(2) and plate(19) to ensure reassembly in the correct
position.
(2) Remove the bolts(23) and separate the brake pump unit from the fan pump using a soft faced
hammer.
(3) Remove splined coupling(20).
(4) Remove the plate(19) from the body(2), free from plate using a soft faced hammer.
(5) Remove the backing ring(15), the seal element(14) and the body O-ring(18).
(6) Remove the rear cover(21) from the body(2).
(7) Remove the backing ring(17), the seal element(16) and the body O-ring(18).
※ Before removing the internal components each bushing(7, 13) must be marked to denote its
location within the body. On the plain area of the bush away from the seal location, lightly mark.
(8) With the unit laying on its side grasp hold of the drive shaft(10) and pull it squarely out of the
body(2) bringing the bushing(13) with it.
(9) Remove the driven gear(11) and the remaining bushing(7).

4-35
3) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
① Inspect the body bore cut-in where both gears wipe into the body.
② The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
③ The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
④ The body should be inspected to ensure that there is no superficial damage which may adversely
effect performance or sealing. Pay particular attention to the port threads and body O-ring seal
recesses.
(3) Plate and cover
① The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
② Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Bushes
① The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The bush should be
replaced if there is any general scoring or fine scoring with a matt appearance or tearing of the
surface material. Often there is a witness where the tips of the opposing gears have wiped an
overlap reassembling a half moon shape. There must be no noticeable wear step as it is critical
that the bush side face is completely flat to the gear side face.
② The bearing liners are acceptable providing that they are not scored or show other damage. The
general outside area of the bush should not show any prominent signs of wear.
(5) Gears
① The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
② The gear teeth should then be carefully examined to ensure that there are no signs of bruising or pitting.
③ The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
④ Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
⑤ Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
⑥ As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.

4-36
4) ASSEMBLY

17
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18

20

6
1 5
8
4

7707BS25

※ Ensure that all parts are perfectly clean and lightly lubricate the bushes and gears with hydraulic
oil(Ensure body O-ring recess and end faces remain free from oil). This will assist with their
assembly when they are later fitted into the body.
(1) Refit the bushing(7) into the undowelled end of the body(2) from where they were removed.
(2) Place the rear cover(21) against the body(2) and then stand the assembly on the cover so that
the hollow dowels are uppermost, i.e. the bushing should be at the bottom with the bushings
against the cover.
(3) Fit the drive shaft(10) and driven gear(11) back into their original positions in the body(2).
(4) Refit the plate bushing(13) into their original bores.
(5) Fit the new body O-ring(18).
(6) Fit the new seal element(14) and backing ring(15) to the bushing.
(7) Carefully refit the plate(19) to the body(2). If the plate(19) is not fitted squarely the backup
seal(14) may become misplaced and trapped, resulting in internal damage if the unit is run in this
condition.

4-37
ASSEMBLY

17
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18

20

6
1 5
8
4

7707BS25

(8) Fit coupling(20) to the plate(19).


(9) Holding the whole unit together carefully turn it over, making sure it is supported on the spacer
plate(19) not the shaft.
(10) Slide off the rear over and fit seals as in(5) and (6) above.
(11) Fit the rear cover(21), taking care not to dislodge the backup seal(16) and bolt(23) the unit
together.
・Tightening torque : 4.8kgf・m(35lbf・ft)
※ Pour a small amount of oil into a port and check that the shaft can be rotated without undue force
using a smooth jawed hand wrench hooked around the shaft or a suitable half coupling locked
against the key.

4-38
5) RUNNING-IN

Pressure gauge

Test unit Variable


Microbic restrictor
filter

Flow
meter
Relief valve

Strainer

Tank

(730TM-3C) 4-48

(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully
run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80° C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.

4-39
SECTION 5 STEERING SYSTEM

Group 1 Structure and Function 5-1


Group 2 Operational Checks and Troubleshooting 5-17
Group 3 Tests and Adjustments 5-26
Group 4 Disassembly and Assembly 5-34
SECTION 5 STEERING SYSTEM
GROUP 1 STRUCTURE AND FUNCTION

1. OUTLINE
The steering system of this machine is a dynamic load sensing steering system.
This system offers faster response from the priority valve of flow amplifier and the pump. Also if
offers advantages in connection with cold start up and improvements in system stability.
The components of the steering system are :
・Steering pump
・Flow amplifier
・Steering unit
・Steering cylinders
The flow amplifier contain a directional valve, an amplification stage, a priority valve, a pilot pressure
relief valve and shock and suction valve.
The steering pump, the first pump of hydraulic pump, draws hydraulic oil from the reservoir.
Outlet flow from the pump flows to the priority valve of flow amplifier. The priority valve of flow
amplifier preferentially supplies flow, on demand, to the steering unit. When the machine is steered,
the steering unit routes flow to the steering cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the main pump for the operation of the
attachment.

5-1
2. HYDRAULIC CIRCUIT

LH RH

6 CL CR

L R

EF

T
PP
21MPa

HP LS HT

L 5 R

MCV RCV lever

P T LS

Brake system Fan drive


motor
2 1
Return line
24
Return line

25
26 27 Return line
23

7707SE01

1 Main pump 23 Oil cooler


2 Brake & fan pump 24 Air breather
5 Steering unit 25 Hydraulic tank
6 Flow amplifier 26 Return filter
9 Steering cylinder 27 Bypass valve

5-2
1) NEUTRAL

LH RH

6 CL CR

L R

EF

T
PP
D 21MPa

HP LS HT

L 5 R

MCV RCV lever

P T LS

Brake system Fan drive


motor
2 1 A

Return line
24
Return line

25
26 27 Return line
23

7707SE02

・ The steering wheel is not being operated so control spool(G) does not move.
・ The oil from the steering pump(A) enters port HP of the priority valve of flow amplifier and the inlet
pressure oil moves the spool(D) to the right.
・ Almost all of pump flow goes to the loader system(Main control valve) through the EF port and
partly flows into the hydraulic tank(25) through the control spool(D).
・ This small flow is useful to prevent the thermal shock problem of the steering unit(5).

5-3
2) LEFT TURN

LH RH

6 CL CR

L R
J

EF

T
PP
D K 21MPa

HP LS HT

L 5 R

MCV RCV lever

P T LS

Brake system Fan drive


motor
2 1 A

Return line
24
Return line

25
26 27 Return line
23

7707SE03

・ When the steering wheel is turned to the left, the spool(G) within steering unit(5) connected with
steering column shaft is pushed to the right direction.
・ The oil discharged from the pump(A) flows into HP port of flow amplifier(6).
・ The delivered oil passes through the main orifice of steering unit(5), through the priority valve spool
(D) of flow amplifier(6). The position of priority spool(D) is determined when the pressure difference
between front and rear of main orifice is balanced with control spring(K) force.
・ The oil supplied through the directional spool(J) from the steering unit(5) is combined with the direct
oil from the priority valve spool(D) in the amplifier spool(M). The amplified oil flows into the small
chamber of the left steering cylinder and large chamber of the right steering cylinder respectively.
・ Oil returned from left and right cylinder returns to hydraulic tank through directional spool(J) of flow
amplifier(6).
・ When the above operation is completed, the machine turns to the left.

5-4
3) RIGHT TURN

LH RH

6 CL CR

L R
J

EF

T
PP
D K 21MPa

HP LS HT

L 5 R

MCV RCV Lever

P T LS

Brake system Fan drive


motor
2 1 A

Return line
24
Return line

25
26 27 Return line
23

7707SE04

・ When the steering wheel is turned to the right, the spool(G) within steering unit(5) connected with
steering column shaft is pushed to the right direction.
・ The oil discharged from the pump(A) flows into HP port of flow amplifier(6).
・ The delivered oil passes through the main orifice of steering unit(5), through the priority valve spool
(D) of flow amplifier(6). The position of priority spool(D) is determined when the pressure
difference between front and rear of main orifice is balanced with control spring(K) force.
・ The oil supplied through the directional spool(J) from the steering unit(5) is combined with the direct
oil from the priority valve spool(D) in the amplifier spool(M). The amplified oil flows into the small
chamber of the right steering cylinder and large chamber of the left steering cylinder respectively.
・ Oil returned from left and right cylinder returns to hydraulic tank through directional spool(J) of flow
amplifier(6).
・ When the above operation is completed, the machine turns to the right.

5-5
3. FLOW AMPLIFIER
1) STRUCTURE

21 7 38 4 9C 21

16
T

HT

2 2
24
28
CR CL
34 34
23
L HP R
1 P 29
9A 1

27 13,14

1 1

8 41
40 35
10

11,12

37
22
P
9B HP EF 30
LS
15 PP 16
2
2
31
42 6 19 20 5 36 (770-7) 5-6

1 O-ring 12 Spring washer 28 Spring


2 O-ring 13 Screw 29 Spring
4 O-ring 14 Spring washer 30 Spring
5 Washer 15 End cover 31 Throttle check valve
6 Washer 16 End cover 34 Orifice
7 O-ring 19 Relief valve 35 Orifice
8 O-ring 20 Plug 36 Orifice
9A Amplifier valve 21 Shock, suction valve 37 Plug
9B Priority valve 22 Spring seat 38 Plug
9C Directional valve 23 Spring seat 40 Spring
10 Check valve 24 Spring guide 41 Spring
11 Screw 27 Orifice 42 Orifice

5-6
2) OPERATION
(1) Introduction
The flow amplifier contain a directional valve, an amplification stage, a priority valve, a pilot
pressure relief valve and shock and suction valves.
The flow amplifier amplifies the oil flow from the steering unit cylinder ports L or R by an
amplification factor of 8. The amplified oil flow is directed from the flow amplifier ports CL or CR
to the steering cylinder. The amplified flow is proportional to the rate of the steering wheel
rotation. If the oil flow from the pump fails, the flow amplifier cuts off the amplification.
(2) Priority valve
The priority valve is used in load sensing systems where the same pump supplies oil to both
steering system and working hydraulics.
The steering system always has first priority.
The pressure on the LS connection is almost zero during measuring(Steering unit in neutral
position).
(3) Shock valves
The shock valves protect the flow amplifier against shock from external forces on the steering
cylinders. The shock valves in flow amplifier limit the maximum pressure drop from CL to HT and
from CR to HT.
(4) HP-HT ports characteristic
The pilot pressure relief valve protects the steering unit against excess pressure. The pilot
pressure relief valve together with the priority valve limit the maximum steering pressure HP-HT.

5-7
(5) Neutral
9C

T
HT

CR CL

L HP R
P

HP EF LS
PP

42 9B 30

CL CR

L R
L R 9C
Steering unit
P
LS
9A

EF TO MCV
42 T
P T PP
9B 30

HP LS HT

(770-3ATM) 5-8

5-8
In neutral position, the oil passes from the pump across the integrated priority valve(9B) in the flow
amplifier for discharge through the EF port. With the steering unit in neutral, flow through it is blocked
and all flow through the priority valve(9B) in flow amplifier is directed out the EF port to the loader control
valve.
With the engine off, the priority valve spool(9B) is pushed to the left by the spring(30). The passage to
the EF port is blocked while the passage to the P port is open.
When the machine is first started, all pump flow is routed to the steering unit which blocks the flow.
With the flow blocked, the pressure increases.
Steering inlet pressure is supplied through the dynamic orifice(42) in the spool. This causes the priority
valve spool(9B) to shift to the right against the spring(30) and open the EF port.
As long as the steering unit is in neutral, just enough pressure is maintained at the steering unit to keep
the priority valve spool(9B) shifted to the right.
The operating pressure in the loader system has no effect on the operation of the priority valve(9B) of
flow amplifier. With the loader actuated in relief, the priority valve(9B) will not shift until the machine is
steered.
Flow through the priority valve spool(9B) passes from the P port through the orifice(42) and into the LS
port. It flows through the steering unit LS passage which is routed to return when the steering unit is in
neutral. This provides a warm-up circuit for the steering unit to prevent binding of the steering unit due
to oil temperature extremes.
In neutral position, also the directional valve(9C) is in its center position.
This means that knock and impacts from the cylinder are not transmitted to the steering unit. The flow
amplifier is thus of the non-reaction type.

5-9
(6) Mid-turn
9C

T
HT

CR CL

L HP R
P

S
C

N
A
M

HP EF LS
PP

9B 9A

CL CR

L R
L R 9C
Steering unit
P
LS
9A

EF
T
P T PP
9B

HP LS HT

(770-3ATM) 5-10

5-10
If the steering wheel is turned to the left, a LS signal is passed to the priority valve(9B). The priority
valve(9B) is reversed so that more oil is passed across the P port to the steering unit for discharge
through the L port of the flow amplifier.
The directional valve(9C) is reversed through the pressure being transmitted across the boring in the
spool whereby the spool is moved the right.
The opening shall allow connection between the pilot flow and the pressure control/amplifier valve(9A).
The pilot pressure from the orifice in chamber C moves the valve to the left and passage for the pilot
flow therefore is possible out of hole F.
The main flow passes from the priority valve(9B) to the circular channel M. As the amplifier spool is
moved to the left, the passage will now be open across the holes N to the chamber S.
The spool goes to a position so that the pressure in chamber S equals the pressure in chamber C.
The passage is now open for the main flow through the priority valve(9B) across the holes A.
The main flow and pilot flow merge and is passed across the directional valve(9C) to the steering
cylinder through CL port.
The return oil passes across the directional valve(9C) to the hydraulic tank.

5-11
(7) Full turn

T
HT

CR CL

L HP R
P

HP EF LS
PP

9B T 30

CL CR

L R
L R 9C
Steering unit
P
LS

EF
TO MCV
T
P T PP
D

HP LS HT

(770-3ATM) 5-12

5-12
When the machine is steered to a full turn, the frames bottom against the steering stops. To limit
steering system pressure, a relief system is built into the priority valve assembly(9B).
When the frames bottom is stopped, the pressure in the steering cylinders increases. This pressure is
sensed at the LS port. When the pressure in the LS port increases enough to push priority valve
spool(9B) off its seat, oil in the load sensing circuit flows to return through the T port. Load sensing
pressure is limited to the pressure setting of the relief valve.
Pressure to the steering unit(Pilot pressure), which is sensed at the left end of the priority valve
spool(9B) in flow amplifier, continues to increase until it can move the spool to the right against the load
sensing pressure plus spring(30) force. At this time, all oil flows out of the EF port to the loader control
valve.
If the loader attachment is being operated while steering, the loader function will slow until the machine
reaches the steering stops. At that time, the loader cycle speed will increase until the machine is
steered again.

5-13
4. STEERING UNIT
1) STRUCTURE

12 3 32

4 15 5 18,20

22,23

1 5 7 8 9 2 11 13 14 16 17 18,21

(770-3ATM) 5-14

1 Dust seal ring 9 Cross pin 17 End cover


2 Housing, spool, sleeve 11 Shaft 18 Washer
3 Ball 12 Spring set 20 Pin screw
4 Bushing 13 O-ring 21 Screw
5 Lip seal 14 Distributor plate 22 Name plate
7 Bearing assy 15 Gearwheel set 23 Drive screw
8 Ring 16 O-ring 32 Check valve

5-14
2) OPERATION

A Neutral
Steering
B
cylinder

C Anti-cavitation valves

D Load sense port to priority valve

E Gerotor

K System pressure oil


Spool I G Return L Work pressure oil
J H
G M Trapped oil
Steering shaft Sleeve F
Return N Return pressure oil
From priority valve
(770-3ATM) 5-15

The steering unit consists of a spool(I) inside a sleeve(H) within a housing. When steering wheel is not
moving, the steering unit is in the neutral(A) position. In neutral, the spool and sleeve are aligned so
that oil flow through the steering unit is blocked. The steering cylinder(B) are held stationary by trapped
oil in the left and right workports.
When the steering unit is turned to the right, the spool rotates relative to the sleeve, and opens
passages which allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor(E)
causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the steering unit where it is
directed out the right workport to the respective ends of the steering cylinders.
A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces
a small leak into the pressure side of the steering unit. Its purpose is to dampen the initial pressure
surge when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is
closed off.
Return oil flows back in through the left workport through the spool and sleeve assembly to return. The
load sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load sensing
circuit between the steering unit and the priority valve of flow amplifier through the LS port.
When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve,
until the sleeve stops the flow to the gerotor. At this point, the steering unit is back in the neutral
position and will remain there until the steering wheel is moved again.
The steering unit has a variable steering which is proportional to the speed the steering wheel is rotated.
A variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes
approximately seven turn(Variable orifice small) lock to lock versus four turns(Variable orifice large)
when turning the steering wheel quickly.

5-15
5. STEERING CYLINDER
1) STRUCTURE

9,8 3 12 6,5 7 11,10 4 2 1 13 15,14 16 17 19 18 20,21

7707SE05

1 Tube assembly 8 Dust wiper 15 Back up ring


2 Rod assembly 9 Snap ring 16 Piston seal
3 Gland 10 O-ring 17 Wear ring
4 Bushing 11 Back up ring 18 Lock nut
5 Rod seal 12 O-ring 19 Set screw
6 Back up ring 13 Piston 20 Spherical bearing
7 Buffer ring 14 O-ring 21 Retaining ring

2) OPERATION
This machine use to cross connected cylinder for steering operation.
The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper(8) located on
the in side of the gland protects cylinder inner parts from dust. The piston(13) is fastened to the
rod(2) by a nut(18).
The piston uses a single wear ring(17) with a piston seal(16) to seal between the piston and tube.
The gland seals against the tube with two O-rings. The rod is sealed against the gland with a rod
seal(5).

5-16
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS
This procedure is designed so the service man can make a quick check of the steering system using
a minimum amount of diagnostic equipment. If you need additional information, prefer to structure
and function in group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following this sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be give repair required and group location. If
verification is needed, you will be give next best source of information :

・Chapter 2 : Troubleshooting
・Group 3 : Tests and adjustments

5-17
※Hydraulic oil must be at operating temperature for these checks(Refer to page 6-51).
Item Description Service action

Steering unit check Run engine at low idle. OK


Check completed.

A
Turn steering wheel until frames are
at maximum right(A) and then NOT OK
left(B) positions. Go to next check.

B
LOOK : Frames must move
smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not
be required to turn steering wheel.
NOTE : It is normal for steering to
drift from stops when steering
wheel is released.

Steering system leakage Turn steering wheel rapidly until OK


check frames are against stop. Check completed.
Heat hydraulic oil to Left Right
Hold approximately 2kg on steering NOT OK
operating temperature.
wheel. Do steering system leakage
Run engine at high idle.
test in group 3 to isolate
Count steering wheel revolutions
the leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 7rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm does
not mean steering will be affected.

Priority valve(In flow Park machine on a hard surface. OK


amplifier) low pressure Check completed.
Hold brake pedal down.
check NOT OK
Run engine at high idle.
Do priority valve pressure
Steer machine to the right and left test in group 3.
as far as possible.
LOOK : Machine must turn at least
half way to the right and left stops.

Priority valve(In flow Steer to steering stop and release OK


amplifier) high pressure steering wheel. Check completed.
check Roll bucket back and hold over NOT OK
relief and observe engine rpm. Priority pressure is set too
Run engine at high idle. high. Do priority valve
Turn steering wheel to steering stop
pressure test in group 3.
and hold, observe engine rpm.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm.

5-18
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1)
Step 2. Operational checks(In this group)
Step 3. Troubleshooting
Step 4. Tests and adjustments(See group 3)

Problem Cause Remedy

No steering Low oil level Add recommended oil.


Failed steering pump Remove and inspect return filter for metal
pump particles.
Failed main pump drive Do main pump flow test.
Remove and inspect priority valve spool.
Stuck priority valve spool
Remove and inspect spring.
Broken priority valve spring
Do priority valve relief cartridge leakage test
Relief valve in priority valve stuck open. in group 3.

No hydraulic functions Shorted boom lower solenoid valve ground Disconnect wires from solenoid valve and
steering normal wire or wrong ground wire connected to check operation of hydraulics.
solenoid.
Boom lower solenoid valve stuck in Remove and inspect solenoid valve.
actuated position
Faulty or misadjusted pilot supply unit Do pilot supply unit test in group 3.
valve
Stuck open system relief valve Replace relief valve.
Locked safety valve Unlock safety valve.
Plugged pilot line filter Inspect and replace.
Failed hydraulic pump Remove and inspect the pump.
Low secodary pressure of RCV Check the pressure and replace if
necessary.

5-19
Problem Cause Remedy

Slow or hard steering Too much friction in the mechanical parts of Lubricate bearings and joints of steering
the machine column or repair if necessary.
Check steering column installation.
Cold oil Warm the hydraulic oil.
Low priority valve pressure setting Do priority valve pressure test in group 3.
Clean or replace cartridge in bottom of
priority valve.
Worn hydraulic pump Do hydraulic pump performance check .
Sticking priority valve spool Remove and inspect.
Broken priority valve spring Remove and inspect.
Pinched or restricted LS line Inspect line. Do priority valve LS port flow
test in group 5.

Constant steering to Air in system Check for foamy oil.


maintain straight travel
Leakage in steering system Do steering system leakage check.
Worn steering unit Do steering system leakage check.
Do steering unit neutral leakage test in
group 3.
Leaf spring without spring force or broken Replace leaf springs.
Spring in double shock valve broken Replace shock valve.
Gear wheel set worn Replace gear wheel set.
Cylinder seized or piston seals worn Replace defects parts.

Slow steering wheel Leakage in steering unit gerotor Do steering system leakage check.
movement will not cause
Worn steering unit gerotor Do steering leakage check.
any frame movement

Steering wheel can be Leakage in steering system Do steering system leakage check.
turned with frames
against steering stop

Steering wheel turns with Broken steering column or splined coupling Remove and inspect.
no resistance and causes
Lack of oil in steering unit
no frame movement
Start engine and check steering operation.
Leakage in steering system
Do steering system leakage test in group 3.

5-20
Problem Cause Remedy

Erratic steering Air in oil Check for foamy oil.


Low oil level Add recommended oil.
Sticking priority valve spool Remove and inspect spool.
Loose cylinder piston Remove rod to inspect piston.
Damaged steering unit Remove and inspect.

Spongy or soft steering Air in oil Check for foamy oil.


Low oil level Add recommended oil.

Free play at steering Loose steering wheel nut Tighten.


wheel
Worn or damaged splines on steering Inspect.
column or unit

Steering unit binding or Binding in steering column or misalignment Inspect.


steering wheel does not of column
immediately return to
High return pressure Check for a pinched or damaged return
neutral when released
line.
Contamination in steering unit Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
Large particles of contamination in steering Inspect hydraulic filter for contamination.
unit Repair cause of contamination. Flush
hydraulic system.

Steering unit locks up ★ Thermal shock Do priority valve LS port flow test in group
5. This oil flow provides a warm -up flow to
steering unit when not using the steering.
Repair or replace steering unit.
Worn or damaged steering unit

Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit

Steering wheel turns by Lines connected to wrong port Reconnect lines.


itself

Vibration in steering High priority valve setting Do priority valve pressure test in group 3.
system or hoses jump

★ Thermal stock is caused by a large temperature differential(Approx. 30° C, 50°


F) between the steering
valve and hydraulic oil. If the steering is not operated for a long period of time and the orifice in the
bottom of the priority valve spool is plugged, the steering valve may bind up when the steering is operated
if the hydraulic oil is hot enough.

5-21
Problem Cause Remedy

Neutral position of Steering column and steering unit out of Align the steering column with steering unit.
steering wheel cannot be line
Adjust the play and, if necessary, shorten
obtained, i.e. there is a
Too little or no play between steering the splines journal.
tendency towards
column and steering unit input shaft
"motoring" Contact the nearest service shop.
Pinching between inner and outer spools

"Motoring" effect. Leaf springs are stuck or broken and have Replace leaf springs.
The steering wheel can therefore reduced spring force
turn on its own.
Inner and outer spools pinch, possibly due Clean steering unit or contact the nearest
to dirt service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder and
steering unit too high
Oil is needed in the tank Fill with clean oil and bleed the system.
Steering cylinder worn Replace or repair cylinder.
Gear wheel set worn Replace gear wheel set.
Spacer across cardan shaft forgotten Install spacer.

5-22
Problem Cause Remedy

Backlash Cardan shaft fork worn or broken Replace cardan shaft.


Leaf springs without spring force or broken Replace leaf springs.
Worn splines on the steering column Replace steering column.

Jerky steering LS port orifice missing Inspect orifice.


Orifice in top end of priority valve spool Disassemble and inspect.
missing

"Shimmy" effect. The Air in the steering cylinder Bleed cylinder.


steered wheels vibrate. Find and remove the reason for air
(Rough tread on tires collection.
gives vibrations)
Mechanical connections or wheel bearings Replace worn parts.
worn
High priority valve setting pressure Set pressure as regular value.

Steering wheel can be One or both shock valves are leaky or are Clean or replace defective of missing
turned slowly in one or missing in flow amplifier valves.
both directions without
the steered wheels
turning.

Steering is too slow and Insufficient oil supply to steering unit, pump Replace pump or increase number of
heavy when trying to turn defective or number of revolutions too low revolutions.
quickly.
Relief valve setting too low Adjust valve to correct setting.
Relief valve sticking owing to dirt Clean the valve.
Spool in priority valve sticking owing to dirt. Clean the valve, check that spool moves
easily without spring.
Too weak spring in priority valve Replace spring by a stronger.

"Kick back" in steering Fault in the system Contact authorized man or shop.
wheel from system. Kicks
from wheels.

5-23
Problem Cause Remedy

Heavy kick-back in Wrong setting of cardan shaft and gear- Correct setting as shown in service manual.
steering wheel in both wheel set
directions.

Turning the steering wheel Hydraulic hoses for the steering cylinders Connect lines to correct ports.
activates the steered have been switched around
wheels opposite.

Hard point when starting Spring force in priority valve too weak Replace spring by a stronger.
to turn the steering wheel
Air in LS and / or PP pipes Bleed LS and PP pipes.
Clogged orifices in LS or PP side in priority Clean orifices in spool and in connecting
valve plugs for LS and PP.
Oil is too thick(Cold) Let motor run until oil is warm.

Too little steering force Pump pressure too low Correct pump pressure.
(Possibly to one side
Too little steering cylinder Fit a larger cylinder
only).
Piston rod area of the differential cylinder Fit cylinder with thinner piston rod or 2
too large compared with piston diameter differential cylinders

Leakage at either input Shaft defective Replace shaft seal, see


shaft, end cover, gear-
Screws loose Service manual
wheel set, housing or top
part. Washers or O-rings defective Tighten screws
Torque 3-3.5kgf・m or steering unit(3-3.5
kgf・m).

5-24
Problem Cause Remedy

Amplification too large Dirty, leaky or missing check valve(10). Clean or replace check valve.
Clean and check that the piston moves
Piston(9A) sticks in the open position.
easily.

Amplification too small Piston(9A) sticks in the closed position. Clean and check that the piston moves
easily.
Piston(9A) incorrectly installed Rotate the piston 180°on its axis.

Heavy turning of steering Dirty orifices(34) in directional valve. Clean or replace orifice.
wheel and slow increase
Dirty orifices(35) in the combi-valve spool. Clean or replace orifice.
of amplification
Dirty orifice(27) in housing. Clean or replace orifice.
Dirty orifice(36) in LS port. Clean or replace orifice.
Dirty orifice in throttle / check valve(31) in Clean or replace throttle/check valve.
PP port.
Dirty orifice(42) in priority valve. Clean or replace orifice.

No end stop in one or One or both shock valves(21) set too low. Setting takes a long time without special
both directions equipment. Contact the nearest service
shop.
Missing end stop plate(23) for directional Fit end stop plates.
valve.

"Hard" point when Air in LS and/or PP pipes. Bleed pipes.


starting to turn the
Spring(30) force in the built in priority valve Check or replace of necessary.
steering wheel.
too weak.
Orifices in respectively LS or PP ports Take out and clean orifices.
blocked.

No pressure build-up LS pressure limitation valve(19) adjusted Remove plug and set to specified pressure.
too low
Take out spool set and turn the inner spool
Spool and sleeve in steering unit put 180°in the outer sleeve.(See Group 4)
together incorrectly
Install new ball.
Emergency control ball in steering unit Repair or replace pump.
missing
Pump does not run or is defective

5-25
GROUP 3 TESTS AND ADJUSTMENTS

1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY


※ Service equipment and tool.
・Portable filter caddy
・Two 3658mm(12ft) × 1" I.D. 100R1
hoses with 3/4 M NPT ends
・Quick disconnect fittings
・Discharge wand
・Various size fittings and hoses
※ Brake system uses oil from hydraulic oil
tank. Flush all lines in the steering
system.
Disassemble and clean major components
for steering system.
Steering components may fail if steering
system is not cleaned after hydraulic oil
tank contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Clean
filter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank
of fill the specified oil to hydraulic oil
tank through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filter hole so end is as far away from
drain port as possible to obtain a through
cleaning of oil.

5-26
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is circulated
through filter a minimum of four times.
※ Hydraulic oil tank capacity 200ℓ ℓ
(52.8U.S. gal).
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10)Check oil level in hydraulic oil tank ; Add oil
if necessary.

5-27
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
・ Service equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
connect to a straight section of D
injection line within 100mm(4in) of C
pump. Finger tighten only-do not over
tighten.
B : Black clip(-). Connect to main frame. A
C : Red clip(+). Connect to transducer.
D : Tachometer readout. Install cable.
(770-3ATM) 5-30

2) DIGITAL THERMOMETER INSTALLATION


・ Service equipment and tools
Digital thermometer
A : Temperature probe.
Fasten to a bare metal line using a A
tie band. Wrap with shop towel. B
B : Cable. C
C : Digital thermometer.

(770-3ATM) 5-30

3) DISPLAY MONITOR TACHOMETER


The display monitor tachometer is accurate
enough for test work.

7707SE06

5-28
3. STEERING SYSTEM RESTRICTION TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9°F)
Engine speed High idle
Maximum pressure 2.1MPa(21bar,300psi)
at flow amplifier
・ GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA HP

・ This test will check for restrictions in the


steering system which can cause
overheating of hydraulic oil.
1) Install temperature reader.
(See temperature reader installation Fitting
procedure in this group).
2) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure at
page 6-46). Steering pump
3) Connect fitting and install gauge.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
4) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the
flow amplifier, inspect flow amplifier for a
priority valve spool. Make sure orifice plugs
installed in ends of priority valve spool.
Check for plugged orifice in flow amplifier 7707SE18
LS port.

5-29
4. STEERING UNIT LEAKAGE TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9°
F)
Engine speed High idle
Maximum leakage 7.5ℓ/min(2gpm) Cap fitting
・ GAUGE AND TOOL
T
Temperature reader L
R
Measuring container(Approx. 20ℓ)
Stop watch
1) Install frame locking bar to prevent machine
from turning.
2) Install temperature reader.
(See temperature reader installation
procedure in this group).
3) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure at
page 6-46).
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2kgf・m of force.
Measure oil flow from return hose for 1
minute.
6) Leakage is greater than specifications,
Safety lock bar
repair or replace steering unit.

7707SE08

5-30
5. FLOW AMPLIFIER PRESSURE TEST
・ SPECIFICATION
Relief valve
Oil temperature 45±5° C(113±9°F)
Engine speed High idle
Oil pressure 20.1~21.1MPa
(205~215bar, 2900~3100psi)
・ GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
Temperature reader
1) Connect gauge to test port.
2) Install temperature reader(See installation
procedure in this group).
3) Install frame locking bar.
4) Heat hydraulic oil to specifications(See
hydraulic oil warm up procedure at page
6-46).
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N(5lb force) pressure on wheel with
Test port
frames locked.
※ If steering wheel is turned slowly, it will
continue to with the frames locked.
This will give an incorrect pressure
reading.
If steering wheel continues to turn
rapidly with the frames locked, steering
system leakage is indicated.
6) Read pressure gauge. This is the flow
amplifier relief pressure.
7) If pressure in not to specification, turn
adjusting screw in relief cartridge using a
hex head wrench to adjust pressure.
Safety lock bar
If pressure cannot be adjusted to
specification, disassemble and inspect flow 7707SE07

amplifier.

5-31
6. FLOW AMPLIFIER LS PORT FLOW TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9° F)
Engine speed Low idle
LS port flow(Approx.) 1ℓ/min(0.3 gpm)
・ GAUGE AND TOOL
Temperature reader
Measuring container EF LS B
Stop watch HP

Flow amplifier LS port flow test will check


PP
for a plugged or missing orifice in the
bottom of the priority valve spool. A plugg- A
ed orifice will block warm up flow to the
steering unit which can cause thermal
shock(See for an explanation of thermal
shock page5-21).
A missing orifice can cause the pump to be
loaded to high pressure at all times causing
overheating.
1) Install temperature reader(See temperature
reader installation procedure in this group.)
2) Heat hydraulic oil to specifications(See
hydraulic oil warm up procedure at page
6-46).
3) Disconnect line from LS port and install
plug(A).
4) Connect line(B) to flow amplifier.
5) Start engine and run at specification.
6) Measure flow from LS port for 1 minute.
If flow is low, low steering system neutral
pressure or a plugged orifice in bottom
priority valve spool is indicated.
If flow is high, remove priority valve spool
and inspect for a missing orifice.
Do hydraulic system restriction test in this
group. 7707SE19

5-32
7. FLOW AMPLIFIER RELIEF CARTRIDGE
LEAKAGE TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9° F) A
Engine speed High idle
Maximum leakage 1mℓ/min(16 drops per min)
・ GAUGE AND TOOL T
Temperature reader
B
Measuring container
Stop watch
1) Install temperature reader.
(See temperature reader installation
procedure in this group).
2) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure at C
page 6-46).
3) Install plug(A) in HT port.
Disconnect line from T port on flow
amplifier. Install plug(B) in line.
4) Connect line(C) to flow amplifier.
5) Start engine and run at specification.
6) Measure oil leakage from T port.
7) If leakage is more than specification, 7707SE20

disassemble and inspect cartridge for


damage or debris.

5-33
GROUP 4 DISASSEMBLY AND ASSEMBLY

1. FLOW AMPLIFIER
1) STRUCTURE

20
5

19

38
6
9 4
A

21 36

21 23
7 2 25
26 7 2829
24
16 34
14 15 12 11
13 27 9C
41 31 2
9A 34
3 24
12 1 35 28
11 29
23
9A 22
13
8 14
30 1
10 9B
40
A 42
37

(770-3ATM) 5-36

1 O-ring 12 Spring washer 28 Spring


2 O-ring 13 Screw 29 Spring
3 O-ring 14 Spring washer 30 Spring
4 O-ring 15 End cover 31 Throttle check valve
5 Washer 16 End cover 34 Orifice
6 Washer 19 Relief valve 35 Orifice
7 O-ring 20 Plug 36 Orifice
8 O-ring 21 Shock, suction valve 37 Plug
9 Housing 22 Spring seat 38 Plug
9A Amplifier valve 23 Spring seat 40 Spring
9B Priority valve 24 Spring guide 41 Spring
9C Directional valve 26 Name plate 42 Orifice
10 Check valve 27 Orifice
11 Screw

5-34
2) TOOLS
・ Guide screws : M8×1.0
・ Hook : Wire

(770-3ATM) FA001

・ Hexagon keys : 4, 5, 6, 8 and 10mm


・ Ratchet for socket spanners
・ Hex socket for external : 13, 17 & 19mm
・ Hex socket for internal : 8 & 10mm
・ Multigrip pliers
・ Ring spanner : 13mm
・ Screwdrivers : 3 and 10mm
・ Steel Mandrels : 3, 5 and 8mm
・ Torque wrench : 12.2kgf・m(88lbf・ft)
(770-3ATM) FA002
・ Magnetic rod

3) DISASSEMBLY
(1) Disassembly counter pressure valve
① Unscrew plug with O-ring(Hexagon
socket for 8mm internal hexagon).

(770-3ATM) FA003

② Take out small spring(hook).

(770-3ATM) FA004

5-35
③ Take out ball(magnetic rod).

(770-3ATM) FA005

④ Take out piston.

(770-3ATM) FA006

⑤ Take out spring.

(770-3ATM) FA007

⑥ Counter pressure valve shown disassem-


bled.

(770-3ATM) FA008

5-36
⑦ Counter pressure valve with orifice
shown disassembled.

(770-3ATM) FA009

(2) Removing pressure relief valve


① Unscrew plug with washer(Hexagon
socket for 8mm internal hexagon).

(770-3ATM) FA010

② Screw pressure relief valve out(10mm


hexagon key).

(770-3ATM) FA011

③ Take out washer(Magnetic rod).

(770-3ATM) FA012

5-37
(3) Disassembly pressure relief valve
① Hold cartridge(Multigrip pliers) and screw
the adjustment screw out(5mm hexagon
key).

(770-3ATM) FA013

② Pressure relief valve shown disassembled.

(770-3ATM) FA014

(4) Removing end cover at PP-connection


① Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.

(770-3ATM) FA015

② Remove end cover.

(770-3ATM) FA016

5-38
③ Remove stop and 2 springs.

(770-3ATM) FA017

④ Remove spring.

(770-3ATM) FA018

③ Remove plate and 6 O-rings.

(770-3ATM) FA019

④ Remove spring guide.

(770-3ATM) FA020

5-39
(5) Removing end cover at LS-connection
① Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.

(770-3ATM) FA021

② Remove end cover.

(770-3ATM) FA022

③ Remove stop and 2 springs.

(770-3ATM) FA023

④ Remove stop and spring.

(770-3ATM) FA024

5-40
⑤ Remove plate and 4 O-rings.

(770-3ATM) FA025

⑥ Remove spring guide.

(770-3ATM) FA026

(6) Removing spools


① Remove directional spool.

(770-3ATM) FA027

② Remove amplifier spool.

(770-3ATM) FA028

5-41
③ Remove priority valve spool.

(770-3ATM) FA029

(7) Removing orifices and throttle check


valve
① Unscrew orifice in LS-connection with
6mm hexagon key.

(770-3ATM) FA030

② Unscrew throttle check valve in PP-


connection with 6mm hexagon key.

(770-3ATM) FA031

③ Unscrew orifice in housing with 4 mm


hexagon key.

(770-3ATM) FA032

5-42
(8) Removing shock valves
① Remove shock valve with screwdriver
and hexagon key.

(770-3ATM) FA033

(9) Overview of disassembled parts


① Housing and end cover with accessories.

(770-3ATM) FA034

② Spool with accessories.

(770-3ATM) FA035

(10) Disassembly of directional spool


① Unscrew orifice with 4mm hexagon key.
Use a mandrel.

(770-3ATM) FA036

5-43
② Directional spool shown disassembled.

(770-3ATM) FA037

(11) Disassembly of priority valve spool


① Unscrew plug or throttle check valve with
8mm hexagon key.

(770-3ATM) FA038

② Priority valve spool with plug for external


PP shown disassembled.

(770-3ATM) FA039

③ Priority valve spool with throttle check


valve for internal PP shown disassembled.

(770-3ATM) FA040

5-44
(12) Disassembly of amplifier spool
① Carefully remove the spring ring from the
recess with 3mm screwdriver.
※ Avoid damage to the spring ring.

(770-3ATM) FA041

② Carefully guide the spring ring back.

(770-3ATM) FA042

③ Carefully take the spring ring from the


recess and guide it back with 3mm
screwdriver.
※ Avoid damage to the spring ring.

(770-3ATM) FA043

④ Press pin out gently with finger.

(770-3ATM) FA044

5-45
⑤ Take out plug.

(770-3ATM) FA045

⑥ Take out spring.

(770-3ATM) FA046

⑦ Take out pin 3mm screwdriver.

(770-3ATM) FA047

⑧ Take out inner spool.

(770-3ATM) FA048

5-46
⑨ Unscrew check valve with hexagon
socket for 17mm external hexagon and
mandrel in the pin hole.
※ Avoid damaging the spool surface.

(770-3ATM) FA049

⑩ Unscrew orifice out of plug with 4mm


hexagon key. Use a mandrel.

(770-3ATM) FA050

⑪ Amplifier spool shown disassembled.

(770-3ATM) FA051

(13) Disassembly of check valve


① Unscrew plug with 4mm hexagon key and
hexagon socket for 17mm external
hexagon.

(770-3ATM) FA052

5-47
② Check valve shown disassembled.

(770-3ATM) FA053

(14) Disassembly of shock valve / suction


valve
① Unscrew locknut with hexagon socket for
13mm external hexagon. Use a mandrel.
※ When readjusting shock valve hold
locknut with 13mm ring spanner.

(770-3ATM) FA054

② Take out disc and spring.

(770-3ATM) FA055

③ Take off housing.

(770-3ATM) FA056

5-48
④ Unscrew pilot valve with hexagon socket
for 19mm external hexagon. Use a
mandrel.

(770-3ATM) FA057

⑤ Take out pilot valve and spring.

(770-3ATM) FA058

⑥ Take out spool.

(770-3ATM) FA059

⑦ Unscrew adjustment screw and take out


spring and ball.

(770-3ATM) FA060

5-49
⑧ Shock valve / suction valve shown
disassembled.

(770-3ATM) FA061

※ Cleaning
Clean all parts carefully with low aromatic
kerosene.
※ Inspection and replacement
Replace all gaskets and sealing washers.
Check all other parts carefully and
replace if necessary.
※ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.

5-50
4) ASSEMBLY
(1) Assembly of shock valve / suction
valve
① Guide spring with cone into housing.

(770-3ATM) FA062

② Fit adjustment screw.

(770-3ATM) FA063

③ Fit spool.

(770-3ATM) FA064

④ Fit spring.

(770-3ATM) FA065

5-51
⑤ Fit pilot valve.
Remember O-ring.

(770-3ATM) FA066

⑥ Tighten with torque wrench for 19mm


external hexagon. Use a mandrel.
・Tightening torque : 2 ± 0.5kgf・m
(14.5 ± 3.6lbf・ft)

(770-3ATM) FA067

⑦ Fit housing.

(770-3ATM) FA068

⑧ Fit spring.

(770-3ATM) FA069

5-52
⑨ Fit disc.

(770-3ATM) FA070

⑩ Fit locknut.
・Tightening torque : 1.5 ± 0.2kgf・m
(10.8 ± 1.4lbf・ft)

(770-3ATM) FA071

(2) Assembly of check valve


① Fit ball, spring and plug.
・Tightening torque : 0.5 ± 0.1kgf・m
(3.6 ± 0.7lbf・ft)

(770-3ATM) FA072

(3) Assembly of amplifier spool


① Fit orifice in plug.
・Tightening torque : 0.5 ± 0.1kgf・m
(3.6 ± 0.7lbf・ft)

(770-3ATM) FA073

5-53
② Fit check valve.
・Tightening torque : 2 ± 0.3kgf・m
(14.5 ± 2.2lbf・ft)
※ Avoid damaging spool surface.
Remember O-ring.

(770-3ATM) FA074

③ Place inner spool in the correct position.

(770-3ATM) FA075

④ Guide inner spool in.

(770-3ATM) FA076

⑤ Fit pin.

(770-3ATM) FA077

5-54
⑥ Push spring ring into position. Place
spring ring into the recess with ends
facing away from pin holes.

(770-3ATM) FA078

⑦ Fit spring.

(770-3ATM) FA079

⑧ Fit plug.

(770-3ATM) FA080

⑨ Fit pin.

(770-3ATM) FA081

5-55
⑩ Push spring ring into position. Place
spring ring into the recess with ends
facing away from pin holes.

(770-3ATM) FA082

(4) Assembly of priority valve spool


① Fit plug or throttle check valve.
External PP : Plug.
Internal PP : Throttle check valve.
・Tightening torque : 1 ± 0.3kgf・m
(7.2 ± 2.2lbf・ft)

(770-3ATM) FA083

(5) Assembly of directional spool


① Screw in orifice.
・Tightening torque : 0.5 ± 0.1kgf・m
(3.6 ± 0.7lbf・ft)

(770-3ATM) FA084

(6) Installation of orifice and throttle check


valve
① Fit orifice in housing.
・Tightening torque : 0.5 ± 0.1kgf・m
(3.6 ± 0.7lbf・ft)

(770-3ATM) FA085

5-56
② Fit orifice in LS - connection.
・Tightening torque : 1 ± 0.3kgf・m
(7.2 ± 2.2lbf・ft)

(770-3ATM) FA086

③ Fit throttle check valve in PP -


connection.
・Tightening torque : 1 ± 0.3kgf・m
(7.2 ± 2.2lbf・ft)

(770-3ATM) FA087

※ Comments on flow amplifiers with internal PP :


1. 1/4 BSP. F in PP - connection.
Fit washer and plug.
・Tightening torque : 4.1 ± 0.3kgf・m
(29.7 ± 2.2lbf・ft)
2. 7/16 - 20 UNF in PP - connection.
Fit O-ring and plug.
・Tightening torque : 1.5 ± 0.5kgf・m
(10.8 ± 3.6lbf・ft)

(7) Installation of shock valves


① Guide shock valve in and secure it by
hand.
Remember O-ring.

(770-3ATM) FA088

5-57
(8) Assembly of pressure relief valve
① Guide adjustment screw, spring and cone
up into the cartridge.

(770-3ATM) FA089

② Screw the adjustment screw so far in that


the 10mm hexagon key fully engages.

(770-3ATM) FA090

(9) Installation of pressure relief valve


① Let the washer drop into the hole.

(770-3ATM) FA091

② Fit pressure relief valve.


・Tightening torque : 3.1 ± 0.3kgf・m
(22.4 ± 2.2lbf・ft)

(770-3ATM) FA092

5-58
③ Fit plug with washer.
・Tightening torque : 6 ± 0.5kgf・m
(44.1 ± 3.6lbf・ft)

(770-3ATM) FA093

(10) Installation of back pressure valve


① First fit spring in piston with vaseline.
Fit assembled piston and spring.

(770-3ATM) FA094

② Let the ball drop down.

(770-3ATM) FA095

③ Fit spring in plug with vaseline.


Fit assembled plug and spring.
Remember O-ring.
・Tightening torque : 2.6 ± 0.3kgf・m
(18.8 ± 2.2lbf・ft)

(770-3ATM) FA096

5-59
(11) Installation of spools
① Fit directional spool.
Fit priority valve spool.
※ Spring control must be placed in correct
position against LS - connection.

(770-3ATM) FA097

② Fit spring.
※ Spring must be by the LS - connection.

(770-3ATM) FA098

③ Fit amplifier spool.


※ The orifice must be placed in correct
position against LS - connection.

(770-3ATM) FA099

(12) Installation of end cover at PP -


connection
① Fit spring with vaseline on amplifier spool.
※ The spring must be fitted at the PP -
connection.

(770-3ATM) FA100

5-60
② Fit spring guide with vaseline.

(770-3ATM) FA101

③ Fit large and small springs with vaseline.

(770-3ATM) FA102

④ Fit guide screws.

(770-3ATM) FA103

⑤ Fit 4 large and 2 small O-rings.

(770-3ATM) FA104

5-61
⑥ Guide plate in.

(770-3ATM) FA105

⑦ Fit stop(Thickness : 5mm) in end cover


with vaseline.

(770-3ATM) FA106

⑧ Guide end cover in.

(770-3ATM) FA107

⑨ Fit screw with spring washer.

(770-3ATM) FA108

5-62
⑩ Fit screws with spring washer.
・Tightening torque : 2.6 ± 0.5kgf・m
(18.8 ± 3.6lbf・ft)
・Tightening torque : 8.2 ± 1kgf・m
for large screw (59.3 ± 7.2lbf・ft)

(770-3ATM) FA109

(13) Installation of end cover at LS -


connection
① Fit guide screws.
Fit remote control with vaseline.

(770-3ATM) FA110

② Fit large and small springs with vaseline.

(770-3ATM) FA111

③ Guide in plate with 4 O-rings.

(770-3ATM) FA112

5-63
④ Fit stop for priority valve spool (thickness :
8mm) with vaseline.

(770-3ATM) FA113

⑤ Fit stop for directional spool(Thickness :


5mm) with vaseline.

(770-3ATM) FA114

⑥ Guide in end cover.

(770-3ATM) FA115

⑦ Fit large screw with spring washer.

(770-3ATM) FA116

5-64
⑧ Fit screws with spring washers.
・Tightening torque : 2.6 ± 0.5kgf・m
(18.8 ± 3.6lbf・ft)
・Tightening torque : 8.2 ± 1kgf・m
for large screw (59.3 ± 7.2lbf・ft)

(770-3ATM) FA117

⑨ Fit plastic plugs.

(770-3ATM) FA118

This completes assembly.

5-65
2. STEERING VALVE
1) STRUCTURE

7707SE21

1 Dust seal ring 9 Cross pin 16 O-ring


2 Housing, Spool, sleeve 11 Shaft 17 End cover
3 Ball 12 Spring set 18 Washer
4 Bushing 13 O-ring 20 Pin screw
5 Lip seal 14 Distributor plate 21 Screw
7 Bearing assy 15 Gearwheel set 32 Check valve
8 Ring

5-66
2) TOOLS
(1) Holding tool.

(770-3ATM) 5-69(1)

(2) Assembly tool for O-ring and kin-ring.

(770-3ATM) 5-69(2)

(3) Assembly tool for lip seal.

(770-3ATM) 5-69(3)

(4) Assembly tool for cardan shaft.

(770-3ATM) 5-69(4)

5-67
(5) Assembly tool for dust seal.

(770-3ATM) 5-70(1)

(6) Torque wrench 0~7.1kgf・m


(0~54.4lbf・ft)
13mm socket spanner
6, 8mm and 12mm hexagon sockets
12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon socket spanners
Plastic hammer
(770-3ATM) 5-70(2)
Tweezers

5-68
3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS
(1) Hydraulic connections

L: Left port
R: Right port
T: Tank
TLPR P: Pump

(770-3ATM) 5-71

(2) Tightening torque


Max. tightening torque [ kgf・m(lbf・ft) ]
Screwed
connection With cutting With copper With aluminum
edge washer washer With O - ring

1/4 BSP.F 4.1(29.7) 2.0(14.5) 3.1(22.4) -


3/8 BSP.F 6.1(44.1) 2.0(14.5) 5.1(36.9) -
1/2 BSP.F 10.2(73.8) 3.1(22.4) 8.2(59.3) -
7/16-20 UNF - - - 2.0(14.5)
3/4-16 UNF - - - 6.1(44.1)
M 12×1.5 4.1(29.7) 2.0(14.5) 3.1(22.4) 2.0(14.5)
M 18×1.5 7.1(51.4) 2.0(14.5) 5.1(36.9) 5.1(36.9)
M 22×1.5 10.2(73.8) 3.1(22.4) 8.2(59.3) 7.1(51.4)

5-69
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).

(770-3ATM) 5-72(1)

(2) Remove the end cover, sideways.

(770-3ATM) 5-72(2)

(3) Lift the gearwheel set(With spacer if fitted)


off the unit.
Take out the two O-rings.

(770-3ATM) 5-72(3)

(4) Remove cardan shaft.

(770-3ATM) 5-72(4)

5-70
(5) Remove distributor plate.

(770-3ATM) 5-73(1)

(6) Screw out the threaded bush over the


check valve.

(770-3ATM) 5-73(2)

(7) Remove O-ring.

(770-3ATM) 5-73(3)

(8) Take care to keep the cross pin in the


sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and needle
bearing will be pushed out of the housing
together.

(770-3ATM) 5-73(4)

5-71
(9) Take ring, bearing races and needle
bearing from sleeve and spool. The outer
(Thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.

(770-3ATM) 5-74(1)

(10) Press out the cross pin. Use the special


screw from the end cover.

(770-3ATM) 5-74(2)

※ A small mark has been made with a


pumice stone on both spool and sleeve
close to one of the slots for the neutral
position springs(See drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.

(770-3ATM) 5-74(3)

(11) Carefully press the spool out of the sleeve.

(770-3ATM) 5-74(4)

5-72
(12) Press the neutral position springs out of
their slots in the spool.

(770-3ATM) 5-75(1)

(13) Remove dust seal and O-ring.

(770-3ATM) 5-75(2)

(14) The steering unit is now completely


disassembled.

(770-3ATM) 5-75(3)

※ Cleaning
Clean all parts carefully in Shellsol K or
the like.
※ Inspection and replacement
Replace all seals and washers. Check all
parts carefully and make any
replacements necessary.
※ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.

5-73
5) ASSEMBLY
(1) Assemble spool and sleeve.
※ When assembling spool and sleeve only
one of two possible ways of positioning
the spring slots is correct. There are
three slots in the spool and three holes in
the sleeve in the end of the spool / sleeve
opposite to the end with spring slots.
Place the slots and holes opposite each (770-3ATM) 5-76(1)
other so that parts of the holes in the
sleeve are visible through the slots in the
spool.

(2) Place the two flat neutral position springs


in the slot.
Place the curved springs between the flat
ones and press them into place (see
assembly pattern).

(770-3ATM) 5-76(2)

※ Assembly pattern.
・ Weak springs (Blue)
2 - off flat, blue : Part no. 150-0748
2 - off curved, blue : Part no. 150-0749
・ Blue set
Spare set : Part no. 150-4265

(770-3ATM) 5-76(3)

(3) Line up the spring set.

(770-3ATM) 5-76(4)

5-74
(4) Guide the spool into the sleeve. Make
sure that spool and sleeve are placed
correctly in relation to each other(See page
3-76, No.(1)).

(770-3ATM) 5-77(1)

(5) Press the springs together and push the


neutral position springs into place in the
sleeve.

(770-3ATM) 5-77(2)

(6) Line up the springs and center them.

(770-3ATM) 5-77(3)

(7) Guide the ring down over the sleeve.


※ The ring should be able to rotate free of
the springs.

(770-3ATM) 5-77(4)

5-75
(8) Fit the cross pin into the spool / sleeve.

(770-3ATM) 5-78(1)

(9) Fit bearing races and needle bearing as


shown on below drawing.

(770-3ATM) 5-78(2)

※ Assembly pattern for standard bearings


1
1 Outer bearing race 2
2 Needle bearing 3
3 Inner bearing race
4 Spool
5 Sleeve 4

5
(770-3ATM) 5-78(3)

Installation instruction for O-ring


(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.

(770-3ATM) 5-78(4)

5-76
(11) Grease O-ring with hydraulic oil and place
them on the tool.

(770-3ATM) 5-79(1)

(770-3ATM) 5-79(2)

(12) Hold the outer part of the assembly tool in


the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.

(770-3ATM) 5-79(3)

(13) Press and turn the O-ring into position in


the housing.

(770-3ATM) 5-79(4)

5-77
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.

(770-3ATM) 5-80(1)

Installation instructions for lip seal


(15) Lubricate the lip seal with hydraulic oil and
place it on the assembly tool.

(770-3ATM) 5-80(2)

(770-3ATM) 5-80(3)

(16) Guide the assembly tool right to the


bottom.

(770-3ATM) 5-80(4)

5-78
(17) Press and turn the lip seal into place in the
housing.

(770-3ATM) 5-81(1)

(18) With a light turning movement, guide the


spool and sleeve into the bore.
※ Fit the spool set holding the cross pin
horizontal.

(770-3ATM) 5-81(2)

(19) The spool set will push out the assembly


tool guide. The O-ring are now in
position.

(770-3ATM) 5-81(3)

(20) Turn the steering unit until the bore is


vertical again. Put the check valve ball
into the hole indicated by the arrow.

(770-3ATM) 5-81(4)

5-79
(21) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.

(770-3ATM) 5-82(1)

(22) Grease the O-ring with mineral oil approx.


viscosity 500 cSt at 20°
C.

(770-3ATM) 5-82(2)

(23) Place the distributor plate so that the


channel holes match the holes in the
housing.

(770-3ATM) 5-82(3)

(24) Guide the cardan shaft down into the bore


so that the slot is parallel with the
connection flange.

(770-3ATM) 5-82(4)

5-80
(25) Place the cardan shaft as shown - so that
it is held in position by the mounting fork.

(770-3ATM) 5-83(1)

(26) Grease the two O-rings with mineral oil


approx. viscosity 500 cSt at 20° C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.

(770-3ATM) 5-83(2)

(27) Important
Fit the gearwheel(Rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.

(770-3ATM) 5-83(3)

(28) Fit the spacer, if any.

(770-3ATM) 5-83(4)

5-81
(29) Place the end cover in position.

(770-3ATM) 5-84(1)

(30) Fit the special screw with washer and


place it in the hole shown.

(770-3ATM) 5-84(2)

(31) Fit the six screws with washers and insert


them. Cross-tighten all the screws and
the rolled pin.
・Tightening torque : 3.1 ± 0.6kgf・m
(22.4 ± 4.3lbf・ft)

(770-3ATM) 5-84(3)

(32) Place the dust seal ring in the housing.

(770-3ATM) 5-84(4)

5-82
(33) Fit the dust seal ring in the housing.

(770-3ATM) 5-85(1)

(34) Press the plastic plugs into the connection


ports.
※ Do not use a hammer!

(770-3ATM) 5-85(2)

5-83
5. STEERING CYLINDER
1) STRUCTURE

9,8 3 12 6,5 7 11,10 4 2 1 13 15,14 16 17 19 18 20,21

7707SE05

1 Tube assembly 8 Dust wiper 15 Back up ring


2 Rod assembly 9 Snap ring 16 Piston seal
3 Gland 10 O-ring 17 Wear ring
4 Bushing 11 Back up ring 18 Piston nut
5 Rod seal 12 O-ring 19 Set serew
6 Back up ring 13 Piston 20 Spherical bearing
7 Buffer ring 14 O-ring 21 Retaining ring

5-84
2) TOOLS AND TIGHTENING TORQUE
(1) Tools

Tool name B Remark

L-wrench 5 B

17
Spanner
32

Wrench For gland


(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques

(2) Tightening torque

Torque
Part name Item Size
kgf・m lbf・ft
Gland 3 M105×3 70±7 506±51
Piston 13 M 40×2 50±5 362±36
Piston nut 18 M 40×2 75±8 542±58
Set screw 19 M 10×1.5 5.4±0.5 39±3.6

5-85
5. STEERING CYLINDER
1) STRUCTURE

9,8 3 12 6,5 7 11,10 4 2 1 13 15,14 16 17 19 18 20,21

7707SE05

1 Tube assembly 8 Dust wiper 15 Back up ring


2 Rod assembly 9 Snap ring 16 Piston seal
3 Gland 10 O-ring 17 Wear ring
4 Bushing 11 Back up ring 18 Piston nut
5 Rod seal 12 O-ring 19 Set serew
6 Back up ring 13 Piston 20 Spherical bearing
7 Buffer ring 14 O-ring 21 Retaining ring

5-84
2) TOOLS AND TIGHTENING TORQUE
(1) Tools

Tool name B Remark

L-wrench 5 B

17
Spanner
32

Wrench For gland


(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques

(2) Tightening torque

Torque
Part name Item Size
kgf・m lbf・ft
Gland 3 M105×3 70±7 506±51
Piston 13 M 40×2 50±5 362±36
Piston nut 18 M 40×2 75±8 542±58
Set screw 19 M 10×1.5 5.4±0.5 39±3.6

5-85
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
① Hold the clevis section of the tube in a
vise.
※ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.

② Pull out piston rod(2) about 200mm


(7.8in). Because the piston rod is rather
heavy, finish extending it with air pressure 200mm
after the oil draining operation.

2
(770-3ATM) 5-88(1)

③ Loosen and remove the gland(3).


※ Cover the extracted piston rod(2) with rag
Wrench
to prevent it from being accidentally
damaged during operation.

3
2
(770-3ATM) 5-88(2)

④ Draw out gland(3) and piston rod (2)


assembly together from cylinder tube(1).
※ Since the piston rod assembly is heavy in Lift 1
this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
out. However, when piston rod(2) has
3 2
been drawn out to approximately two
thirds of its length, lift it in its center to Pull straight Oil pan
draw it completely. sideways
(770-3ATM) 5-88(3)

5-86
Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or
a rope.

⑤ Place the removed piston rod assembly


on a wooden V-block that is set level.
Piston rod assy
※ Cover a V-block with soft rag.

Wooden block
(770-3ATM) 5-89(1)

(2) Remove piston and gland assembly


① Remove the set screw(19). 15,14 16 17 13 19 18
② Remove the piston nut(18).
③ Remove piston assembly(13), back up
ring(15) and O-ring(14).

7707SE09

③ Remove the gland(3) assembly from Lift with a crane


piston rod(2).
Plastic
※ If it is too heavy to move, move it by hammer 9,
8,98 6,
6,75 7
5 4
striking the flanged part of gland(3) with
a plastic hammer. Pull straight
※ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the
lip of rod bushing(4) and packing 3 2 (770-3ATM) 5-89(3)
(5,6,7,8,9) by the threads of piston
rod(2).

5-87
(3) Disassemble the piston assembly
① Remove wear ring(17). 16 17
Remove and piston seal(16).
※ Exercise care in this operation not to
damage the grooves.

7707SE10

(4) Disassemble gland assembly


9,8 12 6,
7,65 75 11,10 4
① Remove back up ring(11), and O-ring
(10).
② Remove O-ring (12).
③ Remove snap ring(9) and dust wiper(8).
④ Remove back up ring(6), rod seal(5) and
buffer ring(7).
※ Exercise care in this operation not to
damage the grooves.
(770-3ATM) 5-90(2)
※ Do not remove seal and ring, if does not
damaged.

5-88
4) ASSEMBLY
(1) Assemble gland assembly
※ Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland(3) with
hydraulic oil.
3

(770-3ATM) 5-91(1)

② Coat dust wiper(8) with grease and fit Press here


(Straight down)
dust wiper(8) to the bottom of the hole of
Metal
dust wiper.
At this time, press a pad metal to the 8
metal ring of dust seal.
③ Fit snap ring(9) to the stop face.

(770-3ATM) 5-91(2)

④ Fit back up ring(6) and rod seal(5), and


buffer ring(7) to corresponding grooves,
in that order.
※ Coat each packing with hydraulic oil
Wrong Right
before fitting it.
※ Insert the backup ring until onside of it is
inserted into groove.

(770-3ATM) 5-91(3)

※ Rod seal(5) has its own fitting direction.


Therefore, confirm it before fitting them. Push bar
※ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
56

(770-3ATM) 5-91(4)

5-89
⑤ Fit back up ring(11) to gland (3).
※ Put the backup ring in the warm water of 4
30~50° C.
10
⑥ Fit O-ring(10) to gland(3).
11
3
12

(770-3ATM) 5-92(1)

(2) Assemble piston assembly


※ Check for scratches or rough surfaces.
① If found smooth with an oil stone.
13
Coat the outer face of piston(13) with
hydraulic oil.

(770-3ATM) 5-92(2)

② Fit piston seal(16) to piston


※ Put the piston seal in the warm water of 16
60~100° C for more than 5 minutes.
※ After assembling the piston seal, press its
outer diameter to fit in.

(770-3ATM) 5-92(3)

③ Fit wear ring(17) to piston(13).


④ Fit back up ring(15) and O-ring(14) to 14 15 17 13
piston(13).

7707SE11

5-90
(3) Install piston and gland assembly
① Fix the piston rod assembly to the work Gland assembly
bench. Piston rod
② Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
③ Insert gland assembly to piston rod(2).

(770-3ATM) 5-93(1)

④ Fit piston assembly to piston rod.


Piston assembly
Piston rod

(770-3ATM) 5-93(2)

⑤ Tighten piston nut(18) to piston rod(2).


・Tightening torque : 75±8kgf・m 2 19 18
(542±58lbf・ft)
Tighten set screw(19) to piston nut(18).
・Tightening torque : 5.4±0.5kgf・m
(39±3.6lbf・ft)

7707SE12

5-91
(4) Overall assemble
Fix with a bar
① Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it
and fix the assembly by passing a bar Lift
through the clevis pin hole to lock the
assembly.
Straight
② Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
(770-3ATM) 5-94(1)
crane.
※ Be careful not to damage piston seal by
thread of cylinder tube.
③ Match the bolts holes in the cylinder head
flange to the tapped holes in the cylinder Tube
tube assembly and tighten socket bolts to
a specified torque. Piston rod
※ Refer to the table of tightening torque.
Wrench

Gland
(770-3ATM) 5-94(2)

5-92
6. CENTER PIVOT PIN
1) CONSTRUCTION
Figure shows the construction of the center pivot pin assembly. This assembly serves to connect
the front frame with the rear frame; two sets of assemblies are provided, one each for the upper and
lower parts. The numbers in parentheses following the parts name denote the item numbers
shown in the figure in the disassembly and assembly procedures.

14,15 7 6 21

9
13 12

18
2
1
4,15 3,4 20

20
19
1
3,4
9 8

16,17

21 10 18 14,15

UPPER LOWER

7707SE13

1 Bearing 9 Plate 16 Shim(0.1T)


2 Cover 10 Pin 17 Shim(0.5T)
3 Shim(0.1T) 12 Seal 18 Bushing
4 Shim(0.5T) 13 Seal 19 Cover
6 Pin 14 Hexagon bolt 20 Front frame
7 Collar 15 Hardened washer 21 Rear frame
8 Collar

5-93
2) DISASSEMBLY
After supporting the front frame and the
rear frame as horizontally as possible using
wood blocks and jacks, disassemble as
follows: In order to facilitate the
disassembly/assembly of the center pivot
pins, remove the drive shaft, hydraulic line
and steering cylinder first.
(1) Maintain the horizontal level of front
frame(20) and rear frame(21), and then
14
remove hexagon bolt(14) and plate(9). 9

(2) Take out upper pin(10) to the downside


using a metal punch.
20

21

10
7707SE14

(3) Maintain the front frame horizontal level,


remove hexagon bolts(14) and then 21
6
remove the plate(9) and shims(16,17).
(4) Take out lower pin(6) to the upside using
a metal punch carefully.
20
(5) Jack up or lifting the front frame(20) 8
slightly, the collar(8) protrudes over the
rear frame. 9
Remove the collar(8). 16,17
14
(6) Lift the frame by passing the slinging wire 7707SE15
rope at four positions of front frame, in
order to separate it from the rear frame.
(7) Support the front frame safely.

5-94
(8) Remove bolt(14) and then take out
cover(2) and shims(3,4). 14 13 2

(9) Take out dust seal(13) from the cover(2). 3,4

(10) Remove the bearing(1), and dust


seal(13).
1

13
7707SE16

(11) Remove bolt(14) and then take out 12 7


cover(19) and shims(3,4).
1
(12) Take out the dust seal(12) from the
cover(19).
(13) Remove the bearing(1), collar(7) and dust
seal(12). 3,4

19 12 14
7707SE17

3) INSPECTION
(1) Check the bearing sliding surface for excessive wear, scorching or scratches; replace if
necessary.
(2) Replace all dust seals(12,13) with new ones.
(3) Grind any pins(6, 10) dented with an oilstone or replace any pins abrasive excessively.
(4) Check inside cover(2, 19) and collar(7, 8) for dents or scratches; if any damage is found, correct
with a grinder or replace.
(5) The serviceable limit of pins and bushings is shown in the table below.
Unit : mm

Std Serviceable limit


Item No. Name dimension Remedy
Outer dia Inner dia Clearance
6, 10 Pin 89.5
1 Tapered roller bearing 90 90.5 0.8 Replace
7, 8 Collar 90.5
12, 13 Dust seal When removed Replace

5-95
4) ASSEMBLY
Assemble the center pivot group by reversing the order of disassembly while paying close attention
to the following.
(1) Put the dust seal(12,13) into cover(2, 19) and front frame(20).
※ Apply grease to the lip of the dust seal. Insert the dust seal so that the dust seal lip faces out and
punch four places on the outer circumference of the seal to lock it.
(2) Lower the temperature of the lower bearing cup to -75 5°C (-103 9°F ) and install it to front
frame until it contacts the bottom of the frame.
(3) Coat lightly with oil and install lower bearing in bore in front frame. Coat lightly with oil and install
upper bearing in bore in upper front frame.
(4) Position the upper cover(2) and hold in place with bolt(14). At this time, adjust shims(3,4) to press
the shoulder of bearing(1) against retainer.
Shim thickness : 0.1mm, 0.5mm
(5) Apply grease to lower collar(8) and insert it to the lower of roller bearing.
(6) After setting the bearing so that its upper surface is horizontal, tighten the bolt.
After tightening, confirm that tapered roller bearing moves lightly ; if does not move smoothly, add
shims(3,4).
Tightening Torque : 25.4~34.2kgf m(184~247lbf ft)
(7) Move the front frame and join it to the rear frame so that match the pin hole at the center.
(8) Apply grease to pin(10), bushing(18) and insert it into tapered roller bearing(1).
(9) Apply grease to lower collar(8) and insert it to the lower of roller bearing through rear frame(21).
(10) Apply grease to pin(6) and insert it into tapered roller bearing(1).
(11) Position the plate(9) and hold in place with bolt(14).
Tightening Torque : 25.4~34.2kgf m(184~247lbf ft)
Apply locktite #242.
(12) Before tightening bolt(14), adjust shims(16,17) in order to control the clearance between the
plate(9) and rear frame(21).
Shim thickness : 0.1mm, 0.5mm
Tightening Torque : 9.8~15.8kgf m(70.9~114lbf ft)
Apply Locktite #242.

5-96
5) TROUBLESHOOTING

Trouble Probable cause Remedy

Shock is felt when steering Capscrew for fixing steering valve is loose Retighten
Faulty center pivot pin mounting bolts Retighten
Center pivot pins have worn out Readjust or replace
Faulty hydraulic system See hydraulic system
Shock is felt when moving Fault fixing of connecting capscrews Retighten
backward or forward
Center pins have worn out Readjust or replace
Bearings of support unit have worn out Retighten
Drive shaft damaged See drive system
Faulty transmission See transmission system

5-97
SECTION 6 WORK EQUIPMENT

Group 1 Structure and Function 6-1


Group 2 Operational Checks and Troubleshooting 6-35
Group 3 Tests and Adjustments 6-46
Group 4 Disassembly and Assembly 6-62
SECTION 6 WORK EQUIPMENT
GROUP 1 STRUCTURE AND FUNCTION

1. HYDRAULIC SYSTEM OUTLINE


The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow
from the first(Steering) pump.
The loader system components are :
・Main pump
・Main control valve
・Bucket cylinder
・Boom cylinders
・Pilot supply unit
・Remote control valve(Pilot control valve)
・Safety valve
The pilot unit supply consists of the pressure reducing valve, relief valve and accumulator.
Flow from the main hydraulic pump not used by the steering system leaves the flow amplifier EF port.
It flows to the inlet port plate of a mono block type main control valve.
The main control valve is a tandem version spool type, open center valve which routes flow to the
boom, bucket or auxiliary cylinders(Not shown) when the respective spools are shifted.
Flow from the steering pump is routed to the pilot supply unit where the steering pump outlet pressure
is reduced to pilot circuit pressure. The pilot supply unit flow to the remote control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.

6-1
2. HYDRAULIC CIRCUIT

9 10 11 4 T P
FRONT REAR
B.D/F B.U IN OUT

LH RH LH RH

17 1 3 4 2 1.1 2.1

20
BL1 BR1 BL2 BR2
6 CL CR

8
T1 P1 T2 P2
L R 3 L1 L2 T

16 15
EF
3B 14 B
3A
T

7 B1 A1 B2 A2
PP
21MPa
P3A
Boom up Boom down
P3B
A
16 24MPa
HP LS HT 2B

2A
18
A3 L 5 R
P2A P2B F2
PS T1
Dump Roll back
13
1B 24MPa 24MPa
B 1A
F1
PS1 P1A P1B
12 U
19 24MPa 24MPa
P T 21MPa 4.5MPa
P
T
P T LS
21 3MPa P2
P1

2 1

24

25
T P
26 27
23
C

22

7707WE01

1 Main pump 10 Bucket cylinder 19 Pressure switch


2 Brake & fan pump 11 Boom cylinder 20 Pressure switch
3 Main control valve 12 Pilot supply unit 21 Line filter
4 Remote control valve 13 Line filter 22 Fan drive motor
5 Steering unit 14 Safety valve 23 Oil cooler
6 Flow amplifier 15 Accumulator 24 Air breather
7 Cut off valve 16 Accumulator 25 Hydraulic tank
8 Brake valve 17 Pressure switch 26 Return filter
9 Steering cylinder 18 Pressure switch 27 Bypass valve

6-2
3. WORK EQUIPMENT HYDRAULIC CIRCUIT

10 11 4 T P

B.D/F B.U IN OUT

LH RH

1 3 4 2 1.1 2.1

3 L1 L2 T

3B 14 B
3A
P3A P3B
Boom up Boom down A

2B 24MPa

2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa

1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port
3MPa P2
P1
Steering system
Brake system
2 1
Return line

24

25
T P
26 27
23
C

22 7707WE02

1 Main pump 11 Boom cylinder 24 Air breather


2 Brake & fan pump 12 Pilot supply unit 25 Hydraulic tank
3 Main control valve 13 Line filter 26 Return filter
4 Remote control valve 14 Safety valve 27 Bypass valve
10 Bucket cylinder 23 Oil cooler

6-3
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION

10 11 4 T P

B.D/F B.U IN OUT

LH RH

1 3 4 2 1.1 2.1

3 L1 L2 T

3B 14 B
3A
P3A P3B
Boom Boom down A
up
2B 24MPa

2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa

1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port
3MPa P2
P1
Steering system
Brake system
2 1
Return line

24

25
T P
26 27
23
C

22 7707WE03

・ When the RCV lever(4) is pulled back, the boom spool on the second block is moved to raise
position by pilot oil pressure from port 3 of RCV.
・ The oil from main pump(1) flows into main control valve(3) and then goes to the large chamber of
boom cylinder(11) by pushing the load check valve of the boom spool through center bypass circuit
of the bucket spool.
・ The oil from the small chamber of boom cylinder(11) returns to hydraulic oil tank(25) through the
boom spool at the same time.
・ When this happens, the boom goes up.

6-4
.2) WHEN THE RCV LEVER IS IN THE LOWER POSITION

10 11 4 T P

B.D/F B.U IN OUT

LH RH

1 3 4 2 1.1 2.1

3 L1 L2 T

3B
14 B
3A
P3A P3B
Boom up Boom down A

2B 24MPa

2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa

1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port
3MPa P2
P1
Steering system
Brake system
2 1
Return line

24

25
T P
26 27
23
C

22
7707WE04

・ When the RCV lever(4) is pushed forward, the boom spool on the second block is moved to lower
position by pilot pressure from port 5 of RCV.
・ The oil from main pump(1) flows into main control valve and then goes to small chamber of boom
cylinder(11) by pushing the load check valve of the boom spool through center bypass circuit of the
bucket spool.
・ The oil returned from large chamber of boom cylinder(11) returns to hydraulic tank(25) through the
boom spool at the same time.
・ When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
boom down speed.

6-5
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION

10 11 4 T P

B.D/F B.U IN OUT

LH RH

1 3 4 2 1.1 2.1

3 L1 L2 T

A A

3B
14 B
3A
P3A P3B
Boom up Boom down A

2B 24MPa

2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa

1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port
3MPa P2
P1
Steering system
Brake system
2 1
Return line

24

25
T P
26 27
23
C

22 7707WE05

Float is achieved by opening 2 large capacity check valves(A) fitted into the bolt on float check
block. These check valves connect each of the boom service ports(3A, 3B) to the tank gallery.
Opening of these valves is controlled by pilot pressure from the hydraulic pilot control valve(4).
As the hydraulic control lever is selected in the power down direction the pressure at the spool pilot
end can on the main valve increases and at some point the spool starts to move progressively
through its stroke. This pilot pressure is also connected, internally within the valve, onto a separate
pilot spool which controls the opening and closing of the pilot check valves(A). As the pilot pressure
operates the main spool up to its maximum stroke the pilot spool then selects at some pressure
beyond that and the check valves open, operating a separate connection between the large
chamber and small chamber ports and tank.

6-6
Subsequent deselection of the control lever allows the pilot spool to deselect, the check valves
close, followed by the main spool returning to neutral, all with minimal hysteresis.
On a four position spool, when selecting the spool in one direction, it has to control both power
down and float. This means that the spool stroke for the power down part of the stroke is limited
and so the metering length is shortened, giving limited control on the service.
Because float is achieved by separate check valves, the whole of the spool selection in that
direction can be used for power down and so the metering performance can be maximized.
Because the float is achieved by opening two large capacity check valves, the ability of the valve to
‘make up’ any cavitation during power down is greatly improved over that of a standard 4 position
spool. The original benchmark of no dead time(cavitation in the boom cylinder small chamber)
while floating down from full lift height at mid engine speed, has been surpassed. The achievement
that has been measured with this product is that there is less than 1 second dead time when
floating down from full height at low idle.

6-7
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION
10 11 4 T P

B.D/F B.U IN OUT

LH RH

1 3 4 2 1.1 2.1

3 L1 L2 T

3B 14 B
3A
P3A P3B
Boom up Boom down A

2B 24MPa

2A Roll back

P2A P2B F2
Dump
13
1B 24MPa 24MPa

1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port
3MPa P2
P1
Steering system
Brake system
2 1
Return line

24

25
T P
26 27
23
C

22 7707WE06

・ If the RCV lever(4) is pushed right, the bucket spool on the first block is moved to dump position by
pilot oil pressure from port 2 of RCV.
・ The oil from main pump(1) flows into main control valve(3) and then goes to the small chamber of
bucket cylinder(10) by pushing the load check valve of the bucket spool.
・ The oil at the large chamber of bucket cylinder(10) returns to hydraulic tank(25) through the bucket
spool.
・ When this happens, the bucket is dumped.
・ When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
bucket dump speed.

6-8
5) WHEN THE RCV LEVER IS IN THE ROLL BACK(RETRACT) POSITION

10 11 4 T P

B.D/F B.U IN OUT

LH RH

1 3 4 2 1.1 2.1

3 L1 L2 T

3B 14 B
3A
P3A P3B
Boom up Boom down A

2B 24MPa

2A Roll back

P2A P2B F2
Dump
13
1B 24MPa 24MPa

1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port
3MPa P2
P1
Steering system
Brake system
2 1
Return line

24

25
T P
26 27
23
C

22 7707WE07

・ If the RCV lever(4) is pulled left, the bucket spool on the first block is moved to roll back position by
pilot oil pressure from port 4 of RCV.
・ The oil from main pump(1) flows into main control valve(3) and then goes to the large chamber of
bucket cylinder by pushing the load check valve of the bucket spool.
・ The oil at the chamber of bucket cylinder(10) returns to hydraulic tank(25) through the bucket spool.
・ When this happens, the bucket roll back.
・ When the rolling speed of bucket is faster, the return oil from the small chamber of bucket cylinder
combines with the oil from the pump, and flows into the large chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
bucket rolling speed.

6-9
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION

10 11 4 T P

B.D/F B.U IN OUT

LH RH

1 3 4 2 1.1 2.1

3 L1 L2 T

3B 14 B
3A
P3A P3B
Boom up Boom down A

2B 24MPa

2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa

1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port
3MPa P2
P1
Steering system
Brake system
2 1
Return line

24

25
T P
26 27
23
C

22
7707WE08

・ The oil from main pump(1) flows into main control valve(3).
・ In this time, the bucket spool, the boom spool and the boom float spool are in neutral position, then
the oil supplied to main control valve(3) returns into hydraulic tank(25) through center bypass circuit
of each spool.
・ In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.

6-10
3. MAIN PUMP OPERATION
1) STRUCTURE

35 36 37,38 39

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19

33 34 32 31 30 29 28 25 24 27 26 23 22 21 20
7707WE09

1 End cap 14 Section seal 28 Dowel pin


2 Section seal 15 Section seal 29 Dowel pin
3 Section seal 16 Retaining ring 30 Rotor assembly
4 Back up ring 17 Ball bearing 31 Vane holdout pin
5 Pressure port plate 19 Shaft 32 Vane
6 Camring 20 Shaft seal 33 Dowel pin
7 Rear port plate 21 Round section ring 34 Section seal
8 Bushing 22 Mounting cap 35 Screw
9 Rear port plate 23 Pressure port plate 36 Screw
10 Camring 24 Rotor assembly 37 Screw
11 Dowel pin 25 Vane 38 Lock washer
12 Vane holdout pin 26 Section seal 39 Screw
13 Back up ring 27 Housing

6-11
2) DESCRIPTION
The main vane pump consist of six basic components : end cap(2), P2 section unitlzed cartridge(4)
consisting of ; rotor, vanes, vane holdout pins, cam ring, port plate, and pressure plate, center,
housing(5), P1 section unitlzed cartridge(6) consisting of ; rotor, vanes, vane holdout pins, cam ring,
port plate, pressure plate, shaft(11) and bearing and mounting cap(14).
The main vane pump features the use of unitized pumping cartridge for both the P1 and P2 pump
section.
The unitized cartridge assemblies are pretested and provide for ease of disassembly and assembly
in the event it becomes necessary or desirable to make repairs, overhaul or revise the flow delivery.

P1 section

P2 section

14
11
6
5
4
2

7707WE10

3) OPERATION
The pumping operation of this unit(each cartridge) is obtained by providing a fixed interior cam
surface and a rotating inner member(rotor) containing vanes which held in contact with the inner
cam surface. As the rotor is rotated by the drive shaft, the vanes are urged outward against the
outward sloping cam surface, forming a cavity at the inlet ports of the port plates. Atmospheric
pressure and suction created by the expanding cavity between the rotating vanes fill the inlet cavity
with fluid.
As the rotation continues and the vanes that had previously moved outward and now have fluid
trapped between them and the port plates, follow the inward slope of the cam which decreases the
cavity containing the trapped fluid and discharges the fluid at system pressure through the pressure
port openings in the port plates.
The rotating portion of the unitized cartridges feature the use of pressure actuated vanes which are
urged against the cam ring by pins located in the bottom of each rotor vane slot. Initial force to
bring the vanes in contact with the cam ring contour during start up is provided by centrifugal force.
When pumping operation starts and pressure is established, fluid under pressure fills the pin cavity
through the feed holes.
The feed holes open to the pressure port twice every revolution. All other times they are closed off
by the port plate. This pressure under the pin provides the force necessary to keep the vanes in
contact with the cam contour.
When operating the pump at the maximum outlet pressure, the pump shaft rotation should not be
allowed to fall below 600rpm in order to maintain proper vane to cam ring contact. The inlet or
suction flow for both the P1 cartridge and P2 cartridge feeds through a common 3 port in the center
housing, through the large ports of each port plate for each cartridge and through the center hole in
the suction zone of each cam ring.

6-12
4. REMOTE CONTROL VALVE
1) STRUCTURE

4,3,1
4 1
10 3 2 12
30
11

2
33 30

4,3,1 14 32
40
15
40
4 1 42
20 3 2

22
21
23 4 1

3 2
25

26

45

7707WE11

1 Handle 14 Shim set 26 Bushing kit


3 Lever kit 15 Joint 30 Plunger kit
4 Bellows 20 Flange 32 Regulating unit
5 Nut 21 Solenoid complete 33 Regulating unit
10 Bracket 22 Plunger kit 40 Spring set
11 Detent kit 23 Plunger guide 42 Prefeel point kit
12 Plunger kit 25 Electric bracket 45 Plug set

6-13
2) OPERATION

T P

B.D/F B.U IN OUT

1 34 2
HYDRAULIC CIRCUIT
(3 Electromagnetic locks)

Electromagnetic lock 9

10

11 5

4
12
(1) Hydraulic functional principle 3
Pilot devices with end position locks operate as 2
7
direct operated pressure reducing valves.
They basically comprise of control lever(1), four T 8
x
P
pressure reducing valves, housing(6) and locks.
Each pressure reducing valve comprises of a
6
control spool(2), a control spring(3), a return
spring(4) a plunger(5).
At rest, control lever(1) is held in its neutral position Port 4 Port 2
by return springs(4). Ports(1, 2, 3, 4) are connected 7707WE12

to tank port T via drilling(8).


When control lever(1) is deflected, plunger(5) is pressed against return spring(4) and control
spring(3).
Control spring(3) initially moves control spool(2) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P via
drilling(8). The control phase starts as soon as control spool(2) finds its balance between the
force from control spring(3) and the force, which results from the hydraulic pressure in the relevant
port(ports 1, 2, 3 or 4).
Due to the interaction between control spool(2) and control spring(3) the pressure in the relevant
port is proportional to the stroke of plunger(5) and hence to the position of control lever(1).
This pressure control which is dependent on the position of the control lever and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valves and high response valves for hydraulic pumps.
A rubber bellows(9) protects the mechanical components in the housing from contamination.

6-14
(2) End position lock
Only those control ports, for which it is necessary to hold the control lever in a deflected position
are equipped with end position locks.
Electromagnetic lock
An additional spring(7), which is fitted below an additional plate(12) warns, by means of an
increased force, which is required for compressing this spring, that the plunger(5) and the control
lever(1) have almost reached their end position.
When this threshold is overcome, a ring(10) contacts the solenoid armature(11); if the solenoid is
energized, then control lever(1) is held in its end position by magnetic force.
This lock is released automatically when the solenoid is deenergized.

6-15
5. MAIN CONTROL VALVE
1) STRUCTURE

10 17
7 9
7

11

12
16
13

10
6

14

17

5
7
8

2 15

1 4

6
2

5 12
7707WE30

1 Housing group 10 Pilot valve assembly


2 Main relief valve assembly 11 Pilot operated float check block assembly
3 Double acting spool(Bucket) 12 Adaptor & check valve
4 Double acting spool(Boom) 13 Shuttle valve assembly
5 Bucket spool centering 14 Anti-cavitation check valve assembly
6 Boom spool centering 15 1/4˝ BSPP plug
7 Combined overload & anti-cavitation assembly 16 Check valve assembly
8 Back pressure valve 17 Pilot valve assembly
9 Check valve assembly

6-16
STRUCTURE

P3A 3A 3B P3B

P2A 2A 2B P2B

L1 L2 T

3B

3A
P3A P3B
Boom up Boom down

2B 24MPa

2A
P2A P2B
Dump Roll back

1B 24MPa 24MPa

1A
P1A P1B

24MPa 24MPa
21MPa
P

7707WE71

Port Port name Port size

P From main pump 1-1/4″SAE split flange


T To hydraulic tank 2″SAE split flange
2A, 2B To bucket cylinder port 1-1/2″split flange
3A, 3B To boom cylinder port 1-1/2″split flange
P3A, P3B Boom pilot port PF 3/8″fitting
P2A, P2B Bucket pilot port 9/16″-18 UNF

6-17
2) BOOM SECTION OPERATION
(1) Spool in neutral

L1 L2 T

LH RH

3B

3A
P3B
P3A
Boom up Boom down

2B 24MPa

2A
P2B
P2A
Dump Roll back

24MPa 24MPa

3A 3B Boom spool

P3A P3B

Main relief valve

7707WE72

If the remote control valve is not operated, the oil supplied from the pump port passes through the
neutral passage to the low pressure passage at the outlet section, and then returns to the tank port.

6-18
(2) Boom raise position

L1 L2 T

LH RH

3B

3A
P3A P3B
Boom up

2B 24MPa

2A
P2B
P2A
Dump Roll back

24MPa 24MPa

3A 3B

P3A P3B

7707WE73

When the pilot pressure from remote control valve is supplied to the pilot port(P3A), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump flow into boom cylinder port(3A).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the
neutral passage.
The return oil from cylinder port(3B) flows into the tank via the low pressure passage.

6-19
(3) Boom lower position

L1 L2 T

LH RH

3B

3A
P3B
P3A
Boom down

2B 24MPa

2A
P2B
P2A
Dump Roll back

24MPa 24MPa

3A 3B

P3A P3B

7707WE74

When the pilot pressure from remote control valve is supplied to the pilot port(P3B), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump flow into boom cylinder port(3B).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the
neutral passage.
The return oil from cylinder port(3A) flows into the tank via the low pressure passage.
※ Boom float position : Refer to page 6-6.

6-20
3) BUCKET SECTION OPERATION
(1) Spool in neutral

L1 L2 T

3B

3A
P3B
P3A
Boom up Boom down

2B 24MPa

2A
P2B
P2A
Dump Roll back

24MPa 24MPa

P2A P2B

Bucket spool

Main relief valve


2A 2B
7707WE75

If the remote control valve is not operated, the oil supplied from the pump port passage through the
neutral passage to the low pressure passage at the outlet section, and then return to the tank port.

6-21
(2) Retract (Roll back) position

L1 L2 T

3B

3A
P3B
P3A
Boom up Boom down

2B 24MPa

2A
P2B
P2A
Roll back

24MPa 24MPa

P2A P2B

2A 2B

7707WE77

When the pilot pressure from remote control valve is supplied to the pilot port(P2B), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump flow into bucket cylinder port(2B).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the
neutral passage.
The return oil from cylinder port(2A) flows into the tank via the low pressure passage.

6-22
(3) Dump position

L1 L2 T

3B

3A
P3A P3B
Boom up Boom down

2B 24MPa

2A
P2A
P2B
Dump

24MPa 24MPa

P2A P2B

2A 2B

7707WE76

When the pilot pressure from remote control valve is supplied to the pilot port(P2A), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the flow into boom cylinder port(2A).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the
neutral passage.
The return oil from cylinder port(2B) flows into the tank via the low pressure passage.

6-23
6. PILOT OIL SUPPLY UNIT
1) STRUCTURE

5
1

P
2
U

T
6

P1 2
PILOT SUPPLY UNIT

3MPa Port Port name Port size


U
P2 From main pump 3/4-16UNF
P1 Pluging 3/4-16UNF
4.5MPa
U Supply to RCV lever 9/16-18UNF

P2 T T To hydraulic tank 9/16-18UNF


HYDRAULIC CIRCUIT 7803AWE49

1 Manifold complete 4 Accumulator


2 Reducing valve 5 Gasket
3 Seal kit 6 Relife valve

(2) OPERATION
The pilot supply manifold reduces the pressure from the high pressure circuit to a low pressure circuit
in order to supply the remote control valve.
The accumulator satisfies short term peak power demands and is a source of emergency power in
case of main circuit pressure failures.
The unit consists of the housing, the accumulator(4), the relief valve(6), the check valve and the
reducing valve(2).
The flow path is from the high pressure circuit through port P2 to the pressure reducing valve(2). The
pressure is reduced in the reducing valve(2) and oil passes the check valve into the accumulator(4)
and to the port U, which is connected with the remote control valve.
The pressure relief valve(6) protects the pilot circuit in case of the reducing valve(2) failures or
external increase of pressure.

6-24
7. BOOM AND BUCKET CYLINDER
The boom cylinders are two unit and the bucket cylinder is one unit. They use a bolt on rod guide.
The piston(12) threads on to the rod(2) and is retained by a nut(17, 16) and set screw(18, 17).
The piston seals against the tube(1) with piston seal(15, 14). Two wear rings(16, 15) are located on
each side of the piston seal.
The gland(3, the rod guide) seals against the tube with an O-ring(10). The cylinder thread seals
against the rod with a lip type buffer ring(7) and a rod seal(5). A dust wiper(8) cleans the rod when it
is retracted.
1) BOOM CYLINDER

8,9 5,6 19 3 7 10,11 4 2 1 13,14 15 16 12 17 18 26,27

20 23,24 28 21 25 22,23

(770-3ATM) 6-30

1 Tube assy 11 Back up ring 21 Pipe assy


2 Rod assy 12 Piston 22 Bolt
3 Gland 13 O-ring 23 Spring washer
4 Bushing 14 Back up ring 24 Bolt
5 Rod seal 15 Piston seal 25 O-ring
6 Back up ring 16 Wear ring 26 Bushing
7 Buffer ring 17 Piston nut 27 Dust seal
8 Dust wiper 18 Set screw 28 Clamp
9 Snap ring 19 Bolt
10 O-ring 20 Pipe assy

6-25
2) BUCKET CYLINDER

27,25 22 21 18 23,24 19 20 26,27

9,8 6,5 7 3 11,10 4 2 1 12 13 14 15 17 16

7707WE13

1 Tube assy 10 O-ring 19 Pipe assy


2 Rod assy 11 Back up ring 20 Pipe assy
3 Gland 12 Piston 21 Bolt
4 Bushing 13 O-ring 22 O-ring
5 Rod seal 14 Piston seal 23 Bolt
6 Back up ring 15 Wear ring 24 Spring washer
7 Buffer ring 16 Piston nut 25 Bushing
8 Dust wiper 17 Set screw 26 Bushing
9 Snap ring 18 Bolt 27 Dust seal

6-26
8. HYDRAULIC OIL TANK
1) STRUCTURE
・ The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders.
In the return circuit, the oil from various parts merges.
・ A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the
hydraulic tank(1).
・ If the hydraulic return oil filter becomes clogged, return filter bypass valve(6) acts to allow the oil to
return directly to the hydraulic tank(1). This prevents damage to the hydraulic filter(5). The
bypass valve(6) is also actuated when negative pressure is generated in the circuit.

4,10,11 13 7 5

14 15 12 1 9 2 8
7707WE19

1 Hydraulic tank wa 9 Bolt


2 Pipe wa 10 Retaining ring
3 Sight gauge 11 Strainer
4 Air breather 12 Cover
5 Element assembly 13 Cover
6 By pass valve 14 O-ring
7 Spring 15 Bolt
8 O-ring

6-27
2) RETURN OIL FILTER BYPASS VALVE
(1) When the filter is clogged
Bypass valve(1) is opened and the oil
returns directly to the tank without passing 1
through the filter.
・Bypass valve set pressure : 1.36kg/cm2
(19.3psi)

From MCV
770-3ATM (6-33)

6-28
3) AIR BREATHER
The air breather is equipped with the
capacity to perform three functions Air breather
simultaneously-as an air filter, breathing
Element
valve, and as a lubrication opening. Retaining ring
Strainer
(1) Preventing negative pressure inside
the tank
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens,
the difference in pressure between the
tank and the outside atmospheric
pressure opens the poppet in the
breather, and air from the outside is let
into the tank or prevent negative pressure.
(2) Preventing excessive pressure inside
the tank
When the hydraulic cylinder is being used,
the oil level in the hydraulic system
increases and as temperature rises. If
the hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank. 7707WE66

6-29
9. ACCUMULATOR
The accumulator is installed at the pilot oil
supply unit. When the boom is left the raised
position, and the control levers are operated
with the engine stopped the pressure of the
compressed nitrogen gas inside the
accumulator sends pilot pressure to the
1
control valve to actuate it and allow the boom
2
and bucket to come down under their own
3
weight.
Type of gas Nitrogen gas(N2)
Volume of gas 0.75ℓ(0.2 U.S.gal)
Charging pressure of gas 16kg/cm2(228psi)
Max actuating pressure 128kg/cm2(1820psi)
1 Diaphragm
2 Closure button
3 Steel pressure vessel
7803AWE56

6-30
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:

・Chapter 2 : Troubleshooting
・Group 3 : Tests and adjustments

6-31
※ Hydraulic oil must be at operating temperature for these checks(Refer to page 6-50).
Item Description Service action

Hydraulic system warm- Hold a hydraulic function over OK


up procedure relief to heat oil.(Don't keep relief Check completed.
condition over 5 seconds at a
Run engine at high idle.
time)
Refer to page 6-46.
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
operating temperature.
FEEL : Hydraulic reservoir must
be uncomfortable to hold your
hand against.
(approximately 45 ~55°C)
Hydraulic pump With bucket flat on ground, OK
performance check actuate boom raise. Time how Check completed.
Heat hydraulic oil to long it takes to raise boom to full
NOT OK
operating temperature. height.
Go to priority valve(in flow
Run engine at high idle.
LOOK : Boom must raise to full amplifier) high pressure
height in less than 7 seconds. check at page 5-31.
IF OK
Do steering system
leakage check at page
5-30.
IF OK
Do main hydraulic pump
flow test at page 6-47.
Control valve lift check With bucket partially dumped, OK
Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control Repair lift checks in
lever(RCV lever) to boom lower loader control valve.
position.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.

6-32
Item Description Service action

Bucket rollback circuit Position bucket at a 45°angle OK


relief valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit Raise front of machine which OK
relief valve low pressure bucket at 45°angle. Go to next check.
check
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 6-48.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
machine.
Run engine at low idle. NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
pressure test in group 3.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
Boom cylinder and Set the boom and bucket OK
bucket cylinder drift horizontal, then stop the engine. Check complete.
check
Stop the engine, wait for 5 NOT OK
Heat hydraulic oil to minutes, then start measuring. Go to next check.
operating temperature.
B
Measure the amount the lift and
dump cylinder rods retract during
15 minutes.(Unloaded bucket)
A
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
Boom cylinder must drift less than
40mm
Bucket cylinder must drift less
than 40mm

6-33
Item Description Service action

Boom cylinder leakage Dump bucket until teeth or cutting OK


check edge is perpendicular to the Drift is approximately the
ground. same between first and
Heat hydraulic oil to
operating temperature. Raise boom until cutting edge is second measurement.
about 1m(3ft) above ground. Repair loader control
Stop engine. Measure drift from valve or circuit relief valve.
tooth or cutting edge to ground for
NOT OK
1 minute.
If drift is considerably less
Wait 10 minutes. on second measurement,
Measure drift from tooth or cutting repair cylinder.
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1m(3ft) off OK
check ground with bucket level. Drift is approximately the
Heat hydraulic oil to Stop engine. Place a support same between first and
under boom. second measurement.
operating temperature.
Measure drift from tooth or cutting Repair loader control
edge to ground for 1 minute. valve or circuit relief valve
Wait 10 minutes. at page 6-48.
Measure drift from tooth or cutting NOT OK
edge to ground for 1 minute. Drift is considerably less
on second measurement.
LOOK : Compare the drift rates
between the first measurement Repair cylinder.
and the second measurement.
Check valve of safety Put bucket level and position OK
valve leakage check about 1.2m(4ft) above ground. Check complete.
Heat hydraulic oil to Place a piece of tape on cylinder NOT OK
operating temperature. rod at least 51mm(2in) from rod Check or replace safety
guide. valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Pilot control valve Stop engine. Turn key switch to OK
OFF position. Check completed.
(RCV lever) check
Move control lever to all positions
and then release. NOT OK
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.

6-34
Item Description Service action

Bucket leveler Position bucket fully dumped just OK


(Positioner) check above ground level. Check complete.
Run engine at low idle. Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release. in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
Run engine at low idle. detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Maximum cycle time
Heat hydraulic oil to Boom raise Bucket flat on ground to full height. 6.2sec
operating temperature.
Boom lower(Foat) Full height to level ground. 3.3sec
Run engine at high idle.
Bucket dump Boom at full height. 2.0sec
Bucket rollback Boom at full height. 2.5sec
Steering(No. of Frame stop to frame stop. 3.0sec(4.5 turns)
turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.

6-35
※ MEASURING BOOM AND BUCKET CYCLE TIME
1. MEASUREMENT CONDITION
・Coolant temperature : Inside operating range
・Steering position : Neutral
・Hydraulic temperature : 40~50°C
・Bucket : Unloaded
・Engine speed : High idling

2. MEASURING TOOL
・Stop watch(1EA)

3. MEASURING PROCEDURE
1) LIFTING TIME OF BOOM Lifting time of boom
Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure
the time taken for bucket to reach the
maximum height of the boom.

7707WE16

2) LOWERING TIME OF BOOM


Set the bucket horizontal with the boom at Lowering time of boom
the maximum height, lower the bucket and
measure the taken for the bucket to reach
the lowest position on the ground.

7707WE17

3) DUMPING TIME OF BUCKET


Raise the boom to the maximum height and Dumping time of bucket
Rollback time of bucket
measure the time taken for the bucket to
move from the maximum tilt back position
to the maximum dump position
4) ROLL BACK TIME OF BUCKET
Raise the boom to the maximum height and
measure the time taken for the bucket to
reach the maximum tilt back position. 7707WE18

6-36
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to
least likely, more difficult to verify. Remember the following steps when troubleshooting a
problem :

Step 1. Operational check out procedure (see section 1)


Step 2. Operational checks (see group 2)
Step 3. Troubleshooting
Step 4. Tests and adjustments (see group 3)

Problem Cause Remedy

Noisy hydraulic pump Low oil supply or wrong viscosity Fill reservoir with recommended oil.
Plugged or pinched suction line Clean or replace line.
Air in oil Check for foamy oil. Tighten
connections.
Replace O-rings and or lines.
Plugged suction strainer Inspect and clean strainer in reservoir.
Loose or missing hydraulic line clamps Tighten or replace clamps.
Hydraulic lines in contract with frame Inspect and repair.
Worn or damaged pump Do hydraulic pump performance check
in group 2. Do hydraulic pump flow test
in group 3.

No or Slow hydraulic Failed or worn hydrualic pump Do performance check.


functions
Cold oil Warm oil up.
Slow engine speed Adjust engine speed control linkage.
Check high idle speed.
Suction line air leak Check for foamy oil.
Low oil supply Add recommended oil.
Wrong oil viscosity Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 2.
valve
Blocked or damaged line Inspect lines.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit group 3.
Faulty pilot control valve(RCV) Do pilot control valve(RCV) pressure
test in group 3.
Binding loader control valve(MCV) Inspect valve.
spool
Faulty flow amplifier Check priority valve, orifice of flow
amplifier specification

6-37
Problem Cause Remedy
No steering or hydraulic Low oil level Add recommended oil.
function
Failed hydraulic pump Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive Remove main hydraulic pump and
inspect drive gear.

No hydraulic functions Failed hydraulic pump Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed line filter Remove and inspect line filter for RCV.
Faulty safety valve Safety valve leakage test or ON, OFF
function test.
Stuck open port relief valve Replace relief valve.

Boom float function Low pilot control pressure Do pressure reducing valve pressure
does not work test in group 3.
Faulty pilot control valve(RCV) Replace relief valve.
Loader control valve(MCV) spool Do pressure reducing valve pressure
binding in bore test in group 3.

One hydraulic function Faulty pilot control valve(RCV) Do pilot control valve pressure test.
does not work.
Inspect and repair valve.
Stuck open port relief valve Replace relief valve.
Oil leaking past cylinder packings Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Loader control valve(MCV) spool stuck Inspect and repair valve.
in bore

Low hydraulic power Leakage within work circuit Do cylinder drift check in group 2.
Low system relief valve(main relief Do loader system and port relief valve
valve) setting pressure test in group 3.
Low port relief valve setting Do loader system and port relief valve
pressure test in group 3.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit group 3.
Leaking system relief valve Remove and inspect valve.
Worn hydraulic pump Do hydraulic pump performance check
in group 2.
Faulty pilot control valve Do pilot control valve pressure test in
group 3.

6-38
Problem Cause Remedy

Function drifts down Leaking cylinders Do cylinder leakage checks in group 2.


Leaking seals in circuit relief valve(port Inspect seals. Replace relief valve.
relief valve) or valve stuck open
Leaking loader control valve Repair or replace valve section.

Boom drifts up Leakage in boom down spool Remove and inspect boom down spool.

Boom down does not Safety valve not operated Operate valve.
work(Engine off)
Stuck pilot control valve Inspect.
Faulty line filter Remove and inspect filter.
Accumulation not operated. Inspect.
MCV spool stuck Inspect and repair valve.

Oil overheats Low oil viscosity in hot weather Use recommended oil.
Excessive load Reduce load.
Holding hydraulic system over relief Reduce load.
Leakage in work circuit Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler Inspect and clean oil cooler.
Internally plugged oil cooler Do hydraulic oil cooler restriction test in
group 3.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting pressure test in group 3.
Restriction in oil lines or loader Inspect for dented or kinked lines.
valve(MCV)
Do hydraulic system restriction test in
group 3.
Pinched or restricted priority valve of Run engine at low idle. Steer machine
flow amplifier "LS" line back and forth. If engine load
decreases while steering, a restricted
"LS" line or priority valve of flow
amplifier malfunction is indicated.
Do priority valve of flow amplifier
"LS" port flow test in group 3.
Malfunctioning flow amplifier Do hydraulic system restriction test in
group 3.
Leaking system main relief valve Remove and inspect valve and seals.
Worn hydraulic pump(internal leakage) Do hydraulic pump performance check
in group 2.

Function drops before Stuck open lift check valve Do control valve lift check in group 2.
raising when valve is
activated

6-39
Problem Cause Remedy

Hydraulic oil foams Low oil level Add recommended oil.


Wrong oil Change to recommended oil.
Water in oil Change oil.
Loose or faulty suction lines (air leak in Tighten or install new lines.
system)

Remote control valve Leaking plunger seals Remove, inspect and replace plunger
(RCV) leaking seals.

※ Followings are general precautions for the hydraulic system and equipment.
1) Every structure has its limit of strength and durability. The relief valve is installed to limit the
pressure on the hydraulic equipment and protect various parts of the wheel loader from possible
damage. Therefore, never change the preset pressure of the relief valve unless absolutely
necessary.
2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of
dust and / or other particles in the hydraulic circuit might cause wear and/or damage, resulting in
unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.
Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and
replace the element as necessary.
3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it
analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling
until the oil temperature has become the normal operating temperature. Since the replacement
period varies depending on operating conditions, refer to Operator's Manual and change oil.
4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in
the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and
clean the hydraulic tank. Change the hydraulic oil entirely.
5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely,
flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate
internal damage to the equipment. In such a case, check carefully before flushing, and repair or
replace as required.
6) To add and/or change the hydraulic oil, always use recommended oil.(Refer to the list of
recommended oils and lubricants at page 1-21, Recommended lubricants.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.

6-40
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.

6-41
GROUP 3 TESTS AND ADJUSTMENTS

1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY


※ Service equipment and tool
・Portable filter caddy
・Two 4000mm × 1in 100R1 Hoses
・Quick disconnect fittings.
・Discharge wand
・Various size fittings.
※ Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake, pilot,
steering system and cut off system.
Disassemble and clean major
components for brake and steering
system. Remove and clean pilot caps
from main control valve.
Brake and steering components may fail
if brake and steering system is not
cleaned after hydraulic oil tank
contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank
of fill the specified oil to hydraulic oil
tank through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.

6 -42
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is
circulated through filter a minimum of four
times.
※ Hydraulic oil tank capacity : 200ℓ(52.8U.S.
gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
Clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in reservoir; Add oil if
necessary.

6 -43
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
boom control lever at hold, then stop the
engine.
Be careful lest work equipment fall
down. Boom
Put the hydraulic safety lock lever in the
LOCK position.

Proximate switch
7707WE20

2) Loosen nuts and bolts then tighten them


after adjusting the plate or proximate switch Bolt
so that it comes in contact with the center of Nut
the probe of the proximate switch.
Boom

Plate
7707WE21

3) Loosen the nuts so that a clearance


between the plate and the probe of the
proximate switch are maximum 6mm. Max 6mm

Boom

7707WE22

4) Start the engine. Position the bucket on


Neutral
the ground. Then lift the bucket to a
desired height by using the control lever
and release the hand. Detent position
Confirm the lever automatically returns to
the neutral position and the boom(the
bucket) stop at the adjusted position.

7707WE23

6 -44
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
・Service equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
connect to a straight section of injection D
line within 100mm(4in) of pump. Finger C
Tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable.
(770-3ATM) 6-49

2) DIGITAL THERMOMETER INSTALLATION


・Service equipment and tools
Digital thermometer
A : Temperature probe.
A
Fasten to a bare metal line using a tie
band. Wrap with shop towel.
B : Cable. B C
C : Digital thermometer.

(770-3ATM) 6-49

3) DISPLAY MONITOR TACHOMETER


The display monitor tachometer is accurate
enough for test work.

7707SE06

6 -45
4. HYDRAULIC OIL WARM UP PROCEDURE
1) Install temperature reader(See temperature
reader installation procedure in this group).
2) Run engine at high idle.
3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to
distribute warm oil.
5) Heat oil to test specification(Approx. 50°
C).

6 -46
5. MAIN HYDRAULIC PUMP FLOW TEST
SPECIFICATION
Oil temperature 45 5 C(113 9 F)
Engine speed 2200 25rpm
Test pressure 200 10bar(2845psi)
Maximum pump flow 431 /min(114gpm)
FLOW METER GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
Temperature reader
1) Make test connections.
Flow meter
2) Install temperature reader.
(See temperature reader installation To MCV
procedure in this group)
3) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure in this
group)
Hyd tank
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump. 7707WE24

6 -47
6. LOADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
・ SPECIFICATION
Oil temperature (40~50°
C)

Relief valve Engine speed Relief pressure


U D
210±5kg/cm2 R
System(M) High
(2987±70psi)

Boom 240±5kg/cm2
Low
raise(U) (3414±70psi)

Bucket 240±5kg/cm2
Low
rollback(R) (3414±70psi) M

Bucket 240±5kg/cm2
Low
dump(D) (3414±70psi)

・ Gauge and tool


Gauge 0~35MPa(0~350bar, 0~5000psi)
M : System(Main) relief valve
R : Bucket rollback relief
D : Bucket dump relief
U : Boom raise relief
1) Install fitting and pressure gauge to test port
in pump delivery line.
2) Install temperature reader.
(See temperature reader installation
procedure in this group)
Main pump
3) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure in this
group)
4) To check the system relief(M), run engine at
high idle. Lower boom to bottomed
position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve(M) and adjust to specification.
7707WE68

6 -48
※ Do not adjust the system relief valve
above 250kg/cm2 (3560psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
and boom raise, adjust the system relief
valve to 250kg/cm2 (3560psi).
Run engine to maintain 800 ~ 850rpm when
hydraulic function is activated over relief.
Activate the function to be checked with the
cylinder bottomed. Read the pressure
gauge.
If pressure is not to specification cycle relief
valve over relief 10 times to flush.
Read pressure gauge again. Turn screw
to adjust valve to specification.
※ Do not work machine with system relief
adjusted above specification or
structural damage may occur.
6) Adjust system relief valve to specification.

6 -49
7. HYDRAULIC SYSTEM RESTRICTION TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9°F)
Engine speed High idle
Maximum pressure 2MPa(20bar, 285psi) at
flow amplifier
Maximum pressure at main control valve
1MPa(10bar, 145psi) EF port
・ GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
1) Install temperature reader. Flow amplifier
(See temperature reader installation
procedure in this group)
2) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure in this
group)
3) Connect fitting and gauge to flow amplifier.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader
functions or test gauge may be damaged.
5) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the
loader control valve, check for a kinked,
dented or obstructed hydraulic line. Check
loader control valve for a binding spool.
If pressure is more than specification at the
steering unit, inspect neutral condition of
the steering unit and flow amplifier for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve
"LS" port and dynamic signal orifice on flow
7707WE69
amplifier body.

6 -50
8. LOADER CYLINDER DRIFT TEST
・ SPECIFICATION A
Oil temperature 45±5°
C(113±9°
F)
Boom horizontal
Bucket horizontal
Bucket unloaded
Item Standard value B

Retraction of boom
40mm A : Retraction of bucket cylinder rod
cylinder rod
B : Retraction of boom cylinder rod
Retraction of bucket
40mm
cylinder rod

・ GAUGE AND TOOL


Stop watch
Temperature reader
Put the safety lock lever in the lock
position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
(770-3ATM) 6-55(1)
cylinder rods retract during 15 minutes.

6 -51
9. BOOM AND BUCKET CYLINDER LEAKAGE
TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9°
F)
Engine speed Low idle
Maximum leakage 15 mℓ/min(1/2 oz/min)
・ GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
2) Heat hydraulic oil to specifications(See
hydraulic oil warm up procedure in this
group).
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
※ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at slow idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
loader control valve or circuit relief valve. (770-3ATM) 6-56

6 -52
10. PILOT CONTROL VALVE PRESSURE TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9° F)
Engine speed Low idle
Begin metering 1/4" of lever travel
Pressure in detent :
Boom float detent 1.9MPa(19bar)
Pressure at feel position :
Boom power down 19~22bar
Boom raise 19~22bar
Bucket rollback 19~22bar
Bucket dump 19~22bar
・ GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi)
As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to
approximately 5.8bar at 1/4in. travel. The
pressure should then increase smoothly to
the specification at the FEEL position(Or
3/4 lever travel), and then jump up about
430psi as the lever is moved into detent.
This test will determine if adequate pilot
pressure is available to move the loader
control valve spools.
※ The FEEL position is when lever is
moved to feel the ramp of the detent
before lever passes into detent position.
1) Lower boom to ground.
2) Connect gauge to the pilot pressure port(A)
of function to be checked.
3) Install temperature reader(See temperature
reader installation procedure in this group).
4) Heat hydraulic oil to specification(See
hydraulic oil warm up procedure in this
group). 7707WE67

6 -53
5) Run engine at specification. Activate
function to be checked and record pressure
reading.
※ If boom raise or bucket rollback FEEL
positions are not operation due to boom
or bucket position, plug boom float
detent wires into bucket leveler solenoid
or boom height kickout solenoid. This
will provide a feel position on the control
lever.

6 -54
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9° F)
Engine speed Low idle and stop
Pilot pressure setting
30~35bar(430~500psi)
Relief valve setting pressure 45bar
・ Accumulator precharging pressure 16bar
GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi)
The pilot supply unit consist of the pressure
reducing valve, the relief valve and an
accumulator. This regulates pressure to
the pilot control circuit.
U

1) Connect gauge to test port on the screw T P2

coupling.
2) Install temperature reader(See temperature
reader installation procedure in this group).
3) Heat hydraulic oil to specification(See
hydraulic oil warm up procedure in this
group).
4) Run engine at low idle for 1 minute and
stop engine, wait for 5 minutes. Then start
measuring.
5) If pressure in not within specifications,
replace valve.
7707WE26

6 -55
12. CYCLE TIME TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9°
F)
Engine speed High idle

Function Operating conditions Maximum cycle time(seconds)

Boom raise Bucket flat on ground to full height 6.2


Boom lower(float) Full height to ground level 3.3
Bucket dump Boom at full height 2.0
Bucket rollback Boom at full height 2.5
Steering(Number of turns) Frame stop to stop 3.0(4.5 turns)

Hydraulic pump performance cycle time.

Function Operating conditions Maximum cycle time(seconds)


Bucket flat on ground to full height
Boom raise 8.0
while holding steering over relief

6 -56
13. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and
forth several times, and clean all over the
upper surface of the hydraulic oil tank.
2) Remove the bolts(1) and take out the filter
case cover(2) and O-ring(3).
1
3) Remove the spring(4) and bypass valve(5).
2
4) Remove the filter element(6) from the tank.
3
5) Check the element and the filter case 4
bottom for debris. Excessive amounts of
5
brass and steel particles can indicate a
failed hydraulic pump or a pump failure in 6
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
※ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be
replaced every 250 operating hours or
more often. When the filter element is
replaced, please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-
ring with new one if damaged.sa
7707WE27

6 -57
GROUP 4 DISASSEMBLY AND ASSEMBLY

1. MAIN PUMP
1) STRUCTURE

P2 CARTRIDGE

27
34 39
35 1

20 26
17 21 22
16 21
P1 CARTRIDGE 19
8

7707WE28

1 End cap 22 Mounting cap


2 Bushing 26 Section seal
16 Internal snap ring 27 Center housing
17 Ball bearing 34 Section seal
19 Splined shaft 35 Cap screw
20 Shaft seal 39 Cap screw
21 Internal snap ring

6 -58
STRUCTURE(2/2)

37
36 28
38
29

7
9

11

6
10

32
25
30
24
31
12
33
5 11

23
4
3
13
2
14

15

P2 CARTRIDGE P1 CARTRIDGE
7707WE29

2 Section seal 12 Vane holdout pin 29 Lock pin


3 Section seal 13 Back up ring 30 Rotor assembly
4 Back up ring 14 Section seal 31 Vane holdout pin
5 Pressure port plate 15 Section seal 32 Vane
6 Camring 23 Pressure port plate 33 Dowel pin
7 Rear port plate 24 Rotor assembly 36 Screw
9 Rear port plate 25 Vane 37 Screw
10 Camring 28 Lock pin 38 Lock washer
11 Dowel pin

6 -59
2) GENERAL INSTRUCTION
(1) Preliminary
※ Any servicing work done on main pump is to be done in a clean environment to prevent potential
contamination by foreign particles.
※ Appropriate tools and equipment are required in order to insure proper disassembly and
reassembly in suitable conditions. In case of repetitive service, a specific working bench is
recommended.
※ To prevent oil leakage and body tilting during assembly, housing bolts are to be tightened as per
the following pattern !

1 3 3 1

5 6

7 4
4 2 2
7803AWE05

(2) Parts
※ Parts must be kept clean at all time. If cleaning is needed, solvent is to be used. It is needed to
check and oil the inner parts before assembly.
※ In case of replacement of parts with mulitiple numbers, such as vanes and holdout pins, all the
parts are to be changed.
① Vanes
The faces and edges should be free of scratch from contamination. Vanes should move
smoothly in the rotor slots, without excessive clearance. Edges may be stoned with a fine lndia
stone to remove burrs.
② Vane holdout pins :
Holdout pins should have no matting marks.

Vane

Rotor
Pin
7803AWE50

③ Rotor :
Side surfaces and vane slots should be free of scratches. Side feeds, vane slots and holdout pin
orifices should be free of any contamination. Serration(driving splines) should not be deformed
by the shaft.

7803AWE51

6 -60
④ Camring :
No scratches or vane shock marks(waves) should be seen. Visual axial waves on new camring
are from grinding process and therefore normal.

7803ASE06

⑤ Port plates :
Faces should not be scratched. No cavitation/aeration/fretting corrosion marks should be seen.
When there, the bronze bushing should be clean, with no abnormal wear sign.
Bi-directional cartridges use same port plates for CW and CCW rotation. Unit-directional
cartridges require different port plates.

7803ASE08

⑥ Seals :
・ All oil seals must be cleaned, with no wear or cutting mark. When servicing a pump from field
operation, it is highly recommended to change all seals. All seals are to be greased lightly
before assembly.
・ Use seal driver tool to install shaft seal, and protective cone to install shaft assembly.
・ Backup rings(1) on pressure plates are to be replaced, anytime a cartridge is taken out of a
pump. Backup rings are to be installed as follow, behind the square seal :

Back up ring Seal

7803ASE07

⑦ Shaft :
・ Key-way should be clean and not worn on the sides by excessive torque. No fretting corrosion
due to poor coupling should be visible. On spline shaft, splines should not be deformed.
・ No axial scratch should be on the sealing area(1). The shaft seal lip contact line may be visible,
but should not be a groove. Bronze-bushing contact area(2) should be clean and cylindrical,
without scratch marks.

6 -61
2 4 1

7803ASE10

・ Ball bearing(3) should turn freely and snap ring(4) should be in place. Some shaft assemblies
have 2 snap rings, before and after the ball bearing.
※ Never insert a snap ring from shaft seal side, to avoid scratching the sealing surface.
※ Use protective cone to install shaft assembly. If not available, make sure not to damaged the
shaft seal lips.
(3) Pre start check and priming.
① Before operating the pump again, the following points are to be checked :
・ Pump rotation is as per electric motor or engine.
・ All fittings are properly connected and tight. No oil-leak and/or air intake being allowed.
・ If any, valve on suction line is to be fully opened.
② When electric motor or engine is started up, the pump should prime immediately. However,
depending on installation and amount of air in the discharge lines, priming may take a few
seconds.
③ In case priming does not occur within 15 seconds, equipment should be switched off at once.
・ Then :
・ Manually fill the pump housing with fluid.
・ Bleed off air that may be trapped in the pump.
・ Check air bleed-off valves.
・ Start rotation in a jogging manner until a prime is picked up.

6 -62
3) DISASSEMBLY
(1) Install the pump on the table.
※ Two bolts will help to unscrew the 4 pump
bolts.
(2) Unscrew the bolts.

7707WE31

(3) Remove the end cap (P2 cartridge will


come with it).
※ Cartridge : Be careful as some items
could fall if the retaining cartridge bolts are
totally loose or broken.
※ The seal(34) usually stays in the rear cap.
34

7707WE32

6 -63
(4) Disassemble the P2 cartridge/end cap
with an extractor.
※ If you want to continue the pump disasse-
mbly(P1 & shaft), go to page 6-65.
※ If you want to reassemble the P2 cartrid-
ge, go to page 6-66.

7707WE33

(5) Put two screws in the housing and flip the


pump (housing + P1 assy).

7707WE34

(6) Remove the bolts.

7707WE35

6 -64
(7) Remove the front cap.
※ P1 cartridge will come with the front cap /
shaft assembly.

7707WE36

(8) Disassemble the P1 cartridge / front cap


with an extractor.

7707WE37

A : Remove the retaining ring


B : Extract the shaft / bearing assembly. A
※ Take a protection cone to prevent seal
damage.
If you don’t, change the shaft seal.
※ If not new, the shaft seal should be
replaced.
※ If the shaft Ø is bigger than the shaft seal B
Ø, please contact HYUNDAI.

7707WE38

6 -65
(9) The pump is now disassembled.

Housing End cap Cartridge P2 Cartridge P1

Retaining ring Shaft assy Front cap Shaft seal


7707WE39

4) ASSEMBLY
(1) Fit the cartridge P1 into the housing.

7707WE40

(2) Check if the dowel pin is in its position in


the housing by trying to rotate the
cartridge.
※ If the cartridge does rotate, the dowel pin
is not in the hole.
Take the cartridge out and try again.

7707WE41

6 -66
A : Protective cone on the shaft assembly.
B : Shaft assembly + protective cone into the
front cap. Slightly rotate the shaft to avoid C
the shaft seal lip(s) to be deteriorated.
C: Retaining ring into the front cap.
ö To avoid damaging the shaft seal do not
forget to put a protective cone on the B
shaft.
ö Push on the external bearing cage.

7707WE42

(3) Assemble the front cap assy on the


housing & cartridge assy.
ö Position the shaft / front cap assy only if
the cartridge is well positioned, dowel pin
in the housing dowel pin hole.
ö Put some grease on the seals to prevent
them from moving.

7707WE43

6 -67
① Always check if the shaft rotates freely.
If not, disassemble and go back to the 19.1Kgf.m(138lbf.ft)
previous step.
② Check the porting configuration.
③ Tighten the 4 bolts.

1 4
Step by step to
avoid damaging
the seals.
3 2

④ Always check if the shaft rotates freely.


If not, disassemble and go back to the
previous step.
6.9Kgf.m(50lbf.ft)

7707WE44

(4) Fit the cartridge(P2) into the housing.


(5) Check if the dowel pin is in its position in the
housing by trying to rotate the cartridge.
※ If the cartridge does rotate, the dowel pin is
not in the hole. Take the cartridge out and
try again.

7707WE45

6 -68
(6) Assemble the end cap on the housing assy.
※ Position the shaft / front cap assy only if the
cartridge is well positioned, dowel pin in the
housing dowel pin hole.
※ Put some grease on the seals to prevent
them from moving.
※ Always check if the shaft rotates freely.
If not, disassemble and go back to the
previous step.

7707WE46

(7) Final assembly


① Always check if the shaft rotates freely.
If not, disassemble and go back to the
previous step.
② Check the porting configuration.
③ Tighten the 4 or 7 bolts.

1 4 1 4

6 7

3 2
3 2 5

④ Step by step to avoid damaging the seals.


・Tightening torque
Mounting cap : 19.1kgf・m(138lbf・ft)
End cap : 6.9kgf・m(50lbf・ft)
⑤ Always check if the shaft rotates freely.
If not, disassemble and go back to the
previous step.

7707WE47

6 -69
2. MAIN CONTROL VALVE
1) STRUCTURE

10 17
7 9
7

11

12
16
13

10
6

14

17

5
7
8

2 15
4.2kgf.m(30.4lbf.ft)

Spool to be assembled with


identification groove at the
1 B port end

6
2

Spool to be assembled with


identification groove at the
B port end
5 12

7707WE50

1 Housing group 10 Pilot valve assembly


2 Main relief valve assembly 11 Pilot operated float check block assembly
3 Double acting spool(Bucket) 12 Adaptor & check valve
4 Double acting spool(Boom) 13 Shuttle valve assembly
5 Bucket spool centering 14 Anti-cavitation check valve assembly
6 Boom spool centering 15 1/4˝ BSPP plug
7 Combined overload & anti-cavitation assembly 16 Check valve assembly
8 Back pressure valve 17 Pilot valve assembly
9 Check valve assembly

6 -70
2) DISASSEMBLY AND ASSEMBLY
※ Ensure that the machine is in a safe condition with no suspended loads or trapped pressure within
the system before removing any pipework or component.
Servicing must only be carried out by trained personel.
(1) MAIN RELIFE VALVE(Item 2)
① Removal
Unscrew both the pilot assembly and the plug from both ends of the relief valve. The main stage
assembly must be driven or pressed out in the direction of the pilot assembly using a soft drift.
② Refitting
Lubricate sleeve and assemble by pressing into housing until detent ring(12) locates on housing.
Fit the pilot assembly and end cap.
③ Adjusting
The main relief valve must be adjusted to the required setting when the machine is recommissioned.
Adjustment is made by first unscrewing the adjuster(1) until there is no load on the pilot spring(10).
Select a machine service to its end stop.
Screw in the adjuster until the correct pressure setting is measured at the valve inlet, account must
be taken for the effect of back pressure on the measured setting.

8
1
16
3 15.5kgf.m(112lbf.ft)

14
10
5
Pil
ot 7
as
sy

9
12
17
4
6
Ma 15
in 13
sta 11
ge 14
as
sy 2

15.5kgf.m(112lbf.ft) 7707WE51

1 Adjusting screw 7 Sleeve 13 O-ring


2 Plug cap 8 Lock nut 14 O-ring
3 Cap 9 Spring 15 O-ring
4 Seat 10 Spring 16 O-ring
5 Poppet 11 Detent ring 17 Orifice wire
6 Plunger 12 Detent ring

6 -71
(2) DOUBLE ACTING SPOOL(Item 3, 4) 4
Control spools are not replaceable as they 3
2
are individually sized to suit the housing.
Bucket spool
When removing and refitting spools ensure
that they are refitted into the correct bore 1
and correctly orientated as shown by the
identification groove location on the valve 2
3
assembly drawing. 4
1 Spool 3 Spring
2 Plunger 4 O-ring

Boom spool
7707WE52

(3) BUCKET SPOOL CENTERING(Item 5)


Remove 4 retaining screws(8) from the spring centring end. Remove the cover(1) and withdraw the
spring pack and spool from the valve.
Hold the spool in a suitable soft clamp being careful not to damage the spool surface or bend the
spool. Remove the spool caps from the spool. The replacement assembly is supplied with the spring
set to the correct load. Refit the spool caps to the specified torque using Loctite 542 or similar
medium strength oil tolerant thread locking product.

8
3.1kgf.m(22.4lb.ft)

2
3
6

10
1 5
3.1kgf.m(22.4lb.ft)
6
9
7
16
4

12
9 15
9.7kgf.m(70.2lb.ft)
17

9.7kgf.m(70.2lb.ft)

7707WE53

1 Cover 6 Spring retainer 12 Spool cap


2 Cap screw 7 Seal retainer 15 Cover
3 Washer 8 Cap screw 16 O-ring
4 Spool cap 9 O-ring 17 Cap screw
5 Spring 10 Shim(0.020, 0.010, 0.005, 0.002inch)

6 -72
(4) BOOM SPOOL CENTERING(Item 6)
Remove 4 retaining screws(8) from the spring centering end. Remove the cover(1) and withdraw the
spring pack and spool from the valve.
Hold the spool in a suitable soft clamp being careful not to damage the spool surface or bend the
spool. Remove the spool caps from the spool. The replacement assembly is supplied with the spring
set to the correct load. Refit the spool caps to the specified torque using loctite 542 or similar medium
strength oil tolerant thread locking product.

16
15
17
2
6
8
10,11,13
1
3
6
3.1kgf.m(22.4lbf. ft) 9
7
18
5 4

12
17
15
9.7kgf.m(70.2lbf. ft) 16

9.7kgf.m(70.2lbf. ft)

9
19
14
7707WE54

1 Cover 8 Cap screw 14 Cover


2 Cap screw 9 O-ring 15 O-ring
3 Washer 10 Shim(0.020inch, 2EA) 16 Plug
4 Spool cap 11 Shim(0.005inch, 2EA) 17 Back up ring
5 Spring 12 Spool cap 18 O-ring
6 Spring retainer 13 Shim(0.005inch, 1EA) 19 Cap screw
7 Seal retainer

6 -73
(5) COMBINED OVERLOAD AND ANTI-CAVITATION(Item 7)
This is a non servicable item and a replacement unit factory set to the correct setting should be fitted.
Inspect seat in valve housing for damage before refitting.

10
5 3
12
6
9
15 14
13
10
9.7kgf.m(70.2lbf.ft)
2
4
8
11
8.7kgf.m(62.9lbf.ft)
1
7

3.1kgf.m(22.4lbf.ft)

7707WE55

1 Adjusting screw 6 Pilot pin 11 O-ring


2 Pilot housing 7 Thin nut 12 Composite piston seal
3 A/C housing 8 Pilot spring 13 Composite piston seal
4 Pilot poppet 9 Spring 14 A/C check and main housing
5 Main plunger 10 O-ring 15 Return spring

(6) BACK PRESSURE VALVE(Item 8)


This assembly is retained by screws(5)
when replacing the check valve(2) ensure
that it is free to slide in the housing before 1
refitting the blanking plate.
2
4
3 5

0.51kgf.m(3.7lbf.ft)

1 Blanking plate 4 O-ring


2 Check valve 5 Socket screw
3 Spring
7707WE56

6 -74
(7) CHECK VALVE ASSEMBLY(Item 9, 16)
This is a non servicable item and a
7
replacement unit should be fitted. 1
Ensure that orifice in check valve(1) is clear
6
when refitting. Inspect seat in float check
5
block for damage before refitting. 4
8
1 Float check valve 6 Spring
2
2 Housing 7 Composite piston seal
4 O-ring 8 O-ring
5 Back up ring
7.6kgf.m(55lbf.ft)

7707WE57

(8) PILOT VALVE ASSEMBLY(Item 10)


The replacement of this item requires that the float check block is first removed from the valve.
This is a non servicable item and a replacement unit should be fitted.
The logic spool is individually sized to the housing bore in item 12.
Replacement assemblies are supplied factory set.

15

12

11
10
7
9
6
8
5
3
4
17 2
16
1

7707WE58

1 Socket set screw 6 Back up ring 11 O-ring


2 Lock nut 7 Back up ring 12 Logic seat and spool
3 Spring body 8 O-ring 15 Plug
4 Spring 9 O-ring 16 O-ring
5 Spring retainer 10 O-ring 17 Spring guide

6 -75
(9) PILOT OPERATED FLOAT CHECK BLOCK ASSEMBLY(Item 11)
Remove the three retaining screws(2) and
lift the block from the main housing. 2 3
Do not slide the block accross the face as
this may damage the sealing face and 1 3
seals. 78
8 7

6
3 3
4 5

1 Float check block 5 O-ring


2 Cap head screw 6 Plug
3 Plug 7 O-ring
4 O-ring 8 Plug
7707WE59

(10) ADAPTER+ORIFICE SCREW+CHECK VALVE(Item 12)

3
4
2
1

1 Adapter
2 Socket set screw
3 Check valve
4 O-ring
7707WE60

(10) SHUTTLE VALVE ASSEMBLY(Item 13)


0.51kgf.m(3.7lbf.ft)
This is non servicable item and a
replacement unit should be fitted.
Inspect seat in float check block for damage
before refitting. 2
3

1 Seat
2 Metric ball
3 O-ring
7707WE61

6 -76
(12) A/C CHECK VALVE ASSEMBLY(Item 14)
This is a non servicable item and a
replacement unit should be fitted. Inspect
seat in float check block for damage before 4
refitting. 2
3
1 Body 4 Piston seal 5
2 Check valve 5 O-ring
3 Spring 1
7707WE62

(13) PILOT VALVE ASSEMBLY(Item 17)


The replacement of this item requires that the float check block is first removed from the valve.
This is a non servicable item and a replacement unit should be fitted. The logic spool is individually
sized to the housing bore in item 12.
Replacement assemblies are supplied factory set.

13

12
0.51kgf.m(3.7lbf.ft)
11
10 4.6kgf.m(33.2lbf.ft)
7
9
68 16
5
4
15
14

16
3
1
2
7707WE63

1 Socket set screw 7 Back up ring 12 Logic seat and spool


2 Hexagon nut 8 O-ring 13 Plug
3 Spring body 9 O-ring 14 O-ring
4 Spring 10 O-ring 15 Spring guide
5 Spring retainer 11 O-ring 16 Plug
6 Back up ring

6 -77
3. REMOTE CONTROL VALVE
1) STRUCTURE

2
1

3-1
3-2
Locite 262
3-3

5
11-1
11-2 12-1
4,3,1 12-2
4 1
10 3 2
30
11-3 12-3
11-4 12-4
2
33 30
11-5
11-6
4,3,1 14 32
40
15

40
4 1
20-1 42
20 3 2

22
21
23 4 1

3 2
25

26

7707WE64

1 Handle 11-4 Cardan 21 Solenoid


2 Push button 11-5 Armature 22 Intermediary plunger kit
3-1 Locking pin 11-6 Spring ring 23 Intermediary plunger guide
3-2 Bent lever 12-1 Counter nut 25 Electric bracket
3-3 Nut 12-2 Spring ring 26 Bushing
4 Rubber boot 12-3 Switch plate screw 30 Plunger kit
5 Locking nut 12-4 Press screw 32 Regulation unit
10 Cardan bracket 14 Shims(0.1, 0.2, 0.5mm) 33 Regulation unit
11-1 Self-locking nut 15 Cardan 40 Return spring
11-2 Washer 20 Flange 42 Prefeeling point kit
11-3 Washer

6 -78
2) DISASSEMBLY AND ASSEMBLY
(1) PUSH BUTTEN
The remote control valve does not need to be removed from the machine to perfom this operation.
Remove worn pushbutton using a small screwdriver.
The installation of new elements is performed without any special tools; the parts are simply
pressed into place.
(2) RUBBER BOOT
① Remove the remote control valve from the machine or free the valve by unscrewing the 4 screws
fixing the plate in order to release the electrical cable.
・Assembly
Torque : 1.02kgf・m(7.4lbf・ft)
Hold the remote control valve using a vice or a vice-grip wrench(clamp onto the body).
※ The pilot unit does not need to be removed from the machine to release the cable. However, it is
recommended to lift the control unit by undoing the 4 fixing screws on the arm rest.
※ It is unnecessary to remove the units with no electrical functions.
② Lift and turn the boot inside out.
③ Remove the grommet(7) from its emplacement to free the cable.
④ Loosen the handle mounting nut(3-3) using a 19mm open-end wrench.
・Assembly : torque 4.08kgf・m(29.5lbf・ft)
⑤ Unscrew and remove the handle(1).
・Assembly
- Add loctite 262 onto the lever thread
- Torque : 4.08kgf・m(29.5lbf・ft)
⑥ Replace the faulty rubber boot(4) with a new one.
⑦ Replace the handle(1) following the disassembly instructions in reverse order.
(3) HANDLE
① Clamp the threaded section of the lever(3-2) in a vice fitted with V-shaped vice clamp.
② Remove the pin(3-1) using a 5mm pin driver.
③ Replace the lever(3-2) onto the new handle(1) and secure it with the pin(3-1) using a 5mm pin
driver.
※ Respect the position of the curved lever to ensure that the handle is correctly oriented as
indicated by the machine’s technical specifications.
④ Replace the nut(3-3) on the threaded section and replace the boot(4).

6 -79
(4) DETENT CARDAN BRACKET KIT
※ Remove the 2 grommets(20-1) from the W
flange (20).
V
※ Place centering sleeves V & W to avoid
damaging the cardan knuckles while
loosening the nuts.
※ Unscrew the locking nut(5) using a
23mm open-end wrench.
・Assembly : Torque 4.08±0.4kgf・m
(29.5±2.9lbf・ft)
① Unscrew the self-locking nut(11-1) using Before loosening the nuts

a 13mm open-end wrench.


・Assembly W
- Torque 1.02kgf・m(7.4lbf・ft)
- Place centering sleeves(V-W) to avoid
damaging the cardan knuckles while
screwing the nuts.
② Remove : - Friction washer(11-2) V
- Friction washer(11-3)
- Cardan/armature assembly
7707WE65
(11-4 ~ 11-6)

(5) NON-DETENT PLUNGER KIT


① Unscrew the self-locking nut(12-1) using a 13mm open-end wrench.
・Reassembly : - Torque 1.02kgf・m(7.4lbf・ft)
- Place centering sleeves(V-W) to avoid damaging the cardan knuckles while
screwing the nuts.
② Undo the snap ring(12-2) using a flat-end screwdriver.
③ Remove the screw assembly(12-3, 12-4)
(6) CARDAN
① Remove the centering sleeves V & W.
② Remove the cardan bracket(10) and the shims(14).
③ Unscrew the cardan(15) using a 17mm open-end wrench.
・Reassembly : - Ungrease the cardan threads
- Add loctite 262 onto the cardan threads(both end)
- Torque 4.08kgf・m(29.5lbf・ft)
(7) SOLENOID AND CONNECTOR
※ It is advised to mount the connector onto the solenoid cable once the remote control valve is
assembled.
① Remove the flange(20) and the electrical bracket(25),
② Remove the protecting bushes(26) from the electrical bracket(25).
③ Undo the solenoid(21) from the electric bracket(25).
④ Replace the solenoid.
※ Clean the polar face using a piece of cloth and pay attention not to hit them.
⑤ Assembly : Place the solenoid cable in its emplacement on the electric bracket before fitting the
protection bushes.

6 -80
(8) INTERMEDIARY PLUNGER KIT
① Undo the intermediary plunger guide(23).
② Remove and replace the intermediary plunger kit assembly(22).
(9) GUIDE / PLUNGER AND REGULATION UNIT
※ Beware of the plungers that might jump out due to the spring return.
① Remove : - Guide/plunger assembly(30).
- Regulation unit(32/33).
- Return spring(40).
- Pre-feeling point kit(42).
② The remote control valve is now totally disassembled.
Assemble in reverse order following the torque specification.

6 -81
SECTION 7 ELECTRICAL SYSTEM

Group 1 Component Location 7-1


Group 2 Electrical Circuit 7-3
Group 3 Monitoring System 7-22
Group 4 Electrical Component Specification 7-38
Group 5 Connectors 7-45
Group 6 Troubleshooting 7-59
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION

1. LOCATION 1

1
2
8
9 Cab roof

LH SIDE 10 14
11 15
3 12 16
4 13 17
5 18
6
7

A
19
20

7707EL02

1 Buzzer stop switch 8 Radio & cassete 15 Main light switch


2 Beacon switch(option) 9 Aircon & heater switch 16 Work lamp switch
3 Horn button 10 Starting switch 17 Auto select switch
4 Multi function switch 11 Rear wiper/washer switch 18 Clutch cut off switch
5 Cluster 12 Ride control switch(option) 19 Cigar lighter
6 Gear selector lever 13 Pump motor switch(option) 20 12V socket
7 Kick down switch 14 Parking brake switch

7-1
2. LOCATION 2

1 2 3 4 5

6
7

16

15
8 14
13
9 10 11 12

7707EL02-1

1 Proximity switch 7 Front turn lamp 12 Back up buzzer


2 Proximity switch 8 Start relay 13 Number plate lamp
3 Horn 9 Fuel sender 14 Master switch
4 Work lamp 10 Battery 15 Rear combi lamp
5 Switch panel 11 Rear combi lamp 16 Work lamp
6 Head lamp

7-2
GROUP 2 ELECTRICAL CIRCUIT

7707EL00

7-3
BUZZER STOP SW BEACON LAMP SW INLET M/ACT MODE(D/FOOT) RESISTOR RELAY(HI) RELAY(M2)
TEMP M/ACT MODE(VENT)

2
8
7

2
9

8
7

9
CN-23
C13 1.25 W 1 3 M 7 1 M 4 2 7
3 M 7 1 M 4 2 7 BLOWER

3
3
FRONT WORK LAMP

1
1
ROTARY LAMP
DOOR SW

1 Lo 1

4 Hi 4
3 ML 2
2 MH 3
C11 1.25 L 2 5 5

M
2
2

4
M

5
6
7

5
6
7
1
2
3
4

1
2
3
4

5
6
7
5
6
7
1
2
3
4
1
2
3
4
10 10

10 10
SPEAKER,LH

5 5

7 6

5 5

7 6

CS-55
CS-23
CS-34

CS-1
CL-3

1
2
1
CL-7

1
2
3

4
2
3
CL-5

CL-6

21 GW

23 WR
16 BW

15 WB
1

3
1

9
3

4
9

22 BG
18 BG

9A GB

9B GB
2

8
2

19 GL

25 YB
1

17 LR

24 LB
R14B 1.25 RW 1 Lo

20 Y

20A Y

YBr
YW
CN-24

LG

YW
BG
6B RY

RY
29 YB

32 2B
R13A 1.25 V 2 Hi

33 R

36 L
C12 1.25 OR 1

36 L
G02 1.25 B 3 E

36A
2

33A
C10 1.25 GY

26
35
27

6A
28

35
R51 1.25 G 4 C

C08B 1.25 GY

C08A 1.25 GY

C09C 1.25 Or
C03B 1.25 Or

C03A 1.25 Or

C08 1.25 GY
4 HEAD LIGHT,LH SPEAKER,RH

C09 1.25 Or
B
L

C07 1.25 G

G23 1.25 B

G13 1.25 B
G12 1.25 B

G11 1.25 B
3 G09 1.25 B

G22 1.25
2 CL-24

C06 1.25
R09 1.25 Or
1 R06 1.25 LW G03 1.25 B 1
G02 1.25 B G
CN-18 R52 1.25 L 2
CN-27
COMBI,LH
C13 1.25 W 1 S.L+
C01 1.25 G 2 ACC
1 R04 1.25 OrW CN-20
C05 1.25 R 3 ILL+
2 R03 1.25 Y G04 1.25 B 1
C12 1.25 OR 4 S.R+
3 R02 1.25 BOr R05A 1.25 V 2 CN-11 NO. DESTINATION
G03 1.25 B 5 ILL- 1,2 BR
4 R01 1.25 W 1 1 GND(CONTROLLER)
HORN C11 1.25 L 6 S.L- 32 2B
5 G27 1.25 B 2 2 GND(BLOWER)
C02A 1.25 Y 7 B+ 6 RY
6 CN-25 3 3 FUSE(IG)
C10 1.25 GY 8 S.R- 3,4 RW
CN-17 G12 1.25 B 1 CN-5 4 4 FUSE(Battery)
G04 1.25 B 9 GND 33 2R
R05B 1.25 V 2 5 5 FUSE(Battery)
1 FUSE BOX 1 C01 1.25 G CASSETTE RADIO 30 LW
2 6 6 DPS(COMPRESSOR)
2 31 LY
3 7 7 CONDENSOR FAN
3 FUSE BOX C02 1.25 Y 5 G
CN-8 CL-4 8 8 ILLUMINATION
4 WORK LAMP F. RY 4 C03 1.25 Or CL-1
1 CONTROLLER 1 R01 1.25 W R14A 1.25 RW 1 Lo 2 AIR CON
5 5 C02B 1.25 Y
2 CONTROLLER 2 R02 1.25 BOr R13B 1.25 V 2 Hi
6 GND 6 G01 1.25 B C09A 1.25 Or 1
3 FUSE BOX 3 R03 1.25 Y G11 1.25 B 3 E
7

WB 15
BW 16
LR 17
BG 18
GL 19
Y 20
GW21
BG 22
WR23
LB 24
YB 25
LG 26
YBr27
BG 28
YB 29
LW 30
LY 31
7 C05 1.25 R

1
2
3
4
5
6

BrR 8
GB 9
4 RELAY 4 R04 1.25 OrW R53 1.25 W 4 C SWITCH ILL. G06 1.25 B B

RW
RW
8 8 G10 1.25 B

BR
BR

RY
GND

1.25LgB 9
1.25G 8
5 HORN RY 5 R05 1.25 V HEAD LIGHT,RH ROOM LAMP

G
6 9 CONTROLLER 9 C06 1.25 L
6 RIDE CONT.SW R06 1.25 LW
7 10 GND 10 G21 1.25 B
7 BUCKET RY R07 1.25 G CL-25

10
11
12
13
14
15
16
17
18

10
11
12
13
14
11 C07 1.25 G CL-30

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
DUCT SENSOR(GND) 9
8 R08 1.25 Br G13 1.25 B 1 11 FUSE BOX
8 BOOM UP RY 12 C02C 1.25 Y 2
12

MODE M/ACT(FOOT)
TEMP MOTOR ACT(+)

BLOWER RELAY(M1)
BLOWER RELAY(M2)

COMPRESSOR(DPS)
BLOWER RELAY(LO)
2

TEMP MOTOR ACT(-)

MODE M/ACT(PBR)
9 R09 1.25 Or R50 1.25 Or

MODE M/ACT(DEF)
9 RIDE CONT.RY

BLOWER RELAY(HI)
TEMP M/ACT(PBR)
INLET MOTOR(REC)

DUCT SENSOR(+)
MOTOR ACT(REF)

CONDENSER FAN
INLET MOTOR(FRE)

MODE M/ACT(M+)
13 13 C09B 1.25 Or 1

MODE M/ACT(M-)

1
2
10 10 COMBI,RH 14

ILLUMINATION
11 G08 1.25 B 14 G05 1.25 B B
11 GND

BATTERY(+)
BATTERY(+)
15 15
12

POWER IG
12

CN-10 CN-100 DUCT

GND
GND
1 FUSE BOX 1 R10 1.25 R R10A 1.25 R 1 B SENSOR

NC

NC
NC
NC
NC
NC
2 2 G16 1.25 B 3 E
3 GND AC-11
3 G05 1.25 B R08 1.25 Br 4 S AC & HEATER CONTROLLER
18

1 2 3 4 5 6 7 8 9 10 1112 13 14 15161718
4 GND 4 G60 1.25 B BOOM KICK OUT
5 17 C44 1.25 Y CONDENSER FAN
GND 5 G18 1.25 B
6 16 C43 1.25 LW COMPRESSOR(DPS)
6
7
8
ILL. SW (FUSE)
ILL. SW (FUSE)
7
8
R51
R53
1.25
1.25
G
W R10B 1.25 R
CN-101
1 B
15
14
13
C42
C41
C40
1.25
1.25
1.25
YW
BOr
YW
BLOWER RELAY(HI)
BLOWER RELAY(M2)
BLOWER RELAY(M1)
AIR CONDITIONER HARNESS
9 MULTI FUNCTION SW 9 R13 1.25 V G17 1.25 B 3 E
10 MULTI FUNCTION SW 12 C39 1.25 LW BLOWER RELAY(LO)
10 R14 1.25 RW R07 1.25 G 4 S
11 MULTI FUNCTION SW 11 C38 1.25 Y MODE M/ACT(PBR)
11 R52 1.25 L BUCKET LEVELER
12 MULTI FUNCTION SW 10 C37 1.25 LW MODE M/ACT(M-)
12 R50 1.25 Or
9 C36 1.25 WOr MODE M/ACT(M+)
8 C35 1.25 BW MODE M/ACT(FOOT)
7 C34 1.25 GY MODE M/ACT(DEF)
C33 1.25 Y MOTOR ACT(REF) B G32
6 1
5 C32 1.25 G TEMP M/ACT(PBR) OR 18A
2
4 C31 1.25 BOr TEMP MOTOR ACT(-) CN-137
3 C30 1.25 L TEMP MOTOR ACT(+) RIDE CONTROL SOLENOID
2 C29 1.25 BW INLET MOTOR(FRE) FROM BATT RY
1 C28 1.25 WOr INLET MOTOR(REC)
AC-1
M
FRONT HARNESS AC-22
B G31

1 2 3 4 5 6 7 8 9 10 11 121314
14 NC 1 MOTOR RY
13 NC OR 18
2
12 NC CN-136
11 NC CONT VALVE SOLENOID CD-40
10 NC CN-17 5A B
2 Pa
9 C27 1.25 GW DUCT SENSOR(GND) CD-41 Y 1 3 BR
1 1
8 C26 1.25 BW DUCT SENSOR(+) OR 18 OR 2
Pa 1 2
7 NC 2 OR 17 BR 3 STR PUMP PS
3
6 C25 1.25 R POWER IG L 4 CD-39
4
5 C24 1.25 G ILLUMINATION BOOM DOWN B 5 5 B
5 2 Pa
4 C23 1.25 RW BATTERY(+) 4 L
6 1
3 C22 1.25 RW BATTERY(+)

B G31
W 17A
OR 17
2 C21 1.25 BrW GND MAIN PUMP PS
1 C20 1.25 BrW GND
CN-12 AC-2

CN-18
1
1 2 3 4
2 E16 1.25 W
3 E13 1.25 G
4 E12 1.25 L
5
6
E11
E10
1.25 Or
1.25 W(tw) CAB HARNESS
7
8
E14
E17
1.25 B(tw)
1.25 W
F21 3.0 W
F22 5.0 R
1
2
RIDE CONTROL HARNESS EMERGENCY HARNESS
9 CN-60
10 E18 1.25 LW
11 MASTER SW
12 E15 1.25 BW CR-1
13 E09 1.25 L R4 B G
R1
14 E07 1.25 VOr F23C 1.25 L
15 G79 1.25 B
R2 R3 BATTERY CS-0
BATT. RY
12
11 E06 1.25 G TO STARTER
CN-92
10 F23B 1.25 L 2
9 E08 1.25 W EF20A 1.25 RW 1 E18 0.85 LW A VEHICLE KEY SW INPUT
8 EF20B 1.25 RW DO-3 TO PREHEATER RY E16D 0.85 W B BATT. 24V
7 E05 1.25 R E16B 0.85 W C BATT. 24V
6 E16C 0.85 W D BATT. 24V
5 E19 1.25 V F23A 1.25 L 2 E17A 0.85 W M BATT. 24V
4 G78 1.25 B 1 E17B 0.85 W S BATT. 24V
SPF23

3 E03 shield DO-2 G01 0.85 B E BATT. GROUND


G02 0.85 B F BATT. GROUND SENSOR CONNECTOR 50P
2 E02 1.25 G(sh)
1 E01 1.25 V(sh) F23 1.25 L 2 G03 0.85 B H BATT. GROUND 22 LIFT PUMP
G04 0.85 B P BATT. GROUND M 1 11 LIFT PUMP
CN-4 F12 1.25 V 1 LIFT PUMP
DO-1 G05 0.85 B W BATT. GROUND 2
CL-23 N FAN CLUTCH
F14B 1.25 Br 1 E19 0.85 V J FUEL WARMER C 46 ACCUMULATOR PRESS
G08 1.25 B G17 1.25 B 2 D 35 FUEL TEMP
CN-99 A

CAPS FUEL PUMP


WORK LAMP,RH
CN-1 G02 1.25 B E01B 0.85 V A A B
1 F21 3.0 W E02B 0.85 G B 1 21 CAPS FRONT P/P SOL-
2 F22 5.0 R CL-22 C 2 31 CAPS FRONT P/P SOL+
B
F14A 1.25 Br 1 3 25 CAPS REAR P/P SOL+
GND GND
CN-2 G19 1.25 B 2 4 15 CAPS REAR P/P SOL-
1 CONTROLLER SPF14 CN-94 2 6 MAIN V/V OUTPUT+
1 E01 1.25 V(sh) WORK LAMP,LH
2 CONTROLLER 2 E02 1.25 G(sh) EARTH2 EARTH1 E01A 0.85 V A 1 7 MAIN V/V RETURN-
3 CONTROLLER 3 E03 shield E02A 0.85 G B 3 36 INJ.CONTV/V+
4 CONTROLLER 4 CN-75 E03 Shield C 4 14 RETURN
5 CONTROLLER 5 F10 1.25 V(sh) F10 1.25 V(sh) 2
6 FUSE BOX 6 F09 1.25 G(sh) F09 1.25 G(sh) 1 A 8 ENG.SPEED 5V
GND CN-93 ENGINE
7 CONTROLLER 7 F11 shield F11 shield ESS C 17 ENG.SPEED SIG.
FAN CLUTCH SPEED SENSOR
8 CONTROLLER 8 SHIELD 10 B 18 ENG.SPEED RETURN
9 PREHEATER RY. 9 E09 1.25 L EARTH4 E22 0.85 V 40 WIF
10 AIR-CON RY. 10 E08 1.25 W E15A 0.85 BW 20 ENG RETURN A 10 ENG.POSITION 5V
ENGINE C
11 SAFETY RY. 11 E05 1.25 R CD-1 E14 0.85 B(tw) 19 THROTTLE POSITION RETURN EPS 9 ENG.POSITION SIG.
POSITION SENSOR
12 CONTROLLER 12 F08 1.25 WOr F08 1.25 WOr E13 0.85 G 25 OFF IDLE SW B 19 ENG.POSITION RETURN
1
13 CONTROLLER 13 F07 1.25 GrW G03 1.25 B 2 E12 0.85 L 26 ON IDLE SW
14 FUEL WARMER RY. 14 E07 1.25 VOr E11 0.85 Or 29 THROTTLE POSITION +5V 5V A
TEMP SENSOR(HYD) OIL
15 AIR-CON ASSY 15 F06 1.25 Y E10 0.85 W(tw) 30 THROTTLE POSITION SIG. PRESS SIG C 33 OIL PESS SIG.
31 COLD START AID RTN B
CN-3 E09 0.85 L 41 COLD START AID
1 FUSE BOX 1 F53 1.25 W CD-10 CN-12 5V A
BOOST
2 MULTI FUNCTION SW. 2 F52 1.25 L F07 1.25 GrW 1 1 SIG C 45 BOOST PRESS SIG.
Pa PRESS
3 PREHEATER RY. 3 E06 1.25 G G05 1.25 B 2 FUSE BOX 2 E16 1.25 W RTN B
4 CONTROLLER 4 EF20 1.25 RW 3 PEDAL 3 E13 0.85 G E22 0.85 V A
AIR FILTER FUEL FILTER
5 PRESS SW. 5 F13 1.25 Br 4 PEDAL 4 E12 0.85 L E15B 1.25 B/W B Pa 5V A
6 START KEY 5 5 AMBIENT SIG C 32 AMBIENT AIR PRESS SIG
6 F12 1.25 V PEDAL E11 0.85 Or CD-35 PRESS
7 BACK-UP RY 7 F03 1.25 Y CN-29 6 PEDAL 6 E10 0.85 W(tw) RTN B
8 CONTROLLER 8 F04 1.25 OrW F06 1.25 Y 2 PA 7 PEDAL 7 E14 0.85 B(tw)
9 FUSE BOX 8 FUSE BOX 8 E17 1.25 W CN-28 C B 23 COOLANT TEMP SIG.
9 E18 1.25 LW F05 1.25 LW 1 COOLANT TEMP
10 WORK LAMP RY. 10 F14 1.25 Br 9 9 E08 1.25 W 1 A
R/DRY
11 MULTI FUNCTION SW. 11 F50 1.25 Or 10 FUSE BOX 10 E18 0.85 LW
12 FUSE BOX 12 F51 1.25 G 11 11 C B 34 INTAKE AIR TEMP SIG
AIR COMP AIR TEMP
13 FUSE BOX 13 E17 1.25 W CL-21 12 PEDAL 12 E15 0.85 BW A
14 FUSE BOX 14 E16 1.25 W F53A 1.25 W S 13 PREHEATER RY. 13 E09 0.85 L CN-96
15 FUEL WARMER RY 15 E19 1.25 V G71 1.25 B E 14 FUEL WARMER RY. 14 E07 1.25 VOr E07 1.25 VOr 2 C 49 COOLANT LEVEL 5V
T16 1.25 R 1 15 15 G13 1.25 B B
OUTPUT SPEED NUMBER PLATE LAMP 1
T17 1.25 Br 2 D 27 COOLANT LEVEL HIGH
SENSOR FUEL WARMER A 37 COOLANT LEVEL LOW
CN-14 T18 1.25 L 3 CD-2
1 PEDAL 1 E13 1.25 G G72 1.25 B 1 CN-4
CD-51 TO BATT RELAY
2 PEDAL 2 E12 1.25 L F04 1.25 OrW 2 1 CONTROLLER 1 E01 0.85 V(sh) CN-92
3 PEDAL 3 E11 1.25 Or T13B 1.25 B(tw) 2 INTERN.GEAR 2 CONTROLLER 2 E02 0.85 G(sh) A 5 IG 24V
FUEL SENDER
4 PEDAL 4 E10 1.25 W(tw) T11 1.25 W(tw) 1 PICK-UP 3 CONTROLLER 3 E03 Shield B 39 24V BATT.(+)
CR-24
5 PEDAL 5 E14 1.25 B(tw) CN-65 4 4 C 40 24V BATT.(+)
CD-50
6 6 G73 1.25 B 5 FUEL WARMER RY. 5 E19 0.85 V E06 1.25 G D 50 24V BATT.(+)
1
7 PEDAL 7 E15 1.25 BW T13C 1.25 B(tw) 2 TURBIN F03 1.25 Y 2 6 6 M 38 24V BATT.(+)
8 TCU 8 T13C 1.25 B(tw) T10 1.25 W(tw) 1 PICK-UP 7 SAFETY RY. 7 E05 1.25 R S
BACK BUZZER 8 HEATER RELAY E 20 BATT.(-)
9 TCU 9 T13B 1.25 B(tw) CD-27
CONTROLLER/BATT.RY 8 E20 1.25 RW PREHEATER
10 AIR-CON RY. 10 F05 1.25 LW 9 AIR-CON RY. 9 E08 1.25 W F 28 BATT.(-)
11 TCU 11 T13A 1.25 B(tw) T13A 1.25 B(tw) 2 CL-16 10 10 H 29 BATT.(-)
ENGINE
12 TCU 12 T10 1.25 W(tw) T12 1.25 W(tw) 1 PICK-UP F51 1.25 G 4 C 11 PREHEATER RY. 11 E06 1.25 G P 30 BATT.(-)
12 12 STARTER W
13 TCU 13 T11 1.25 W(tw) CD-17 F50 1.25 Or 3 T
14 TCU 14 T12 1.25 W(tw) G74 1.25 B CR-23 M J 01 FUEL HEATER
2 E M
15 15 T38 1.25 WOr 1 F13A 1.25 Br G11 1.25 B 1 O 42 EXHAUST BRAKE ENABLE
FILTER 1 S
T09C 1.25 BOr 2 Pa
COMBI LAMP,RH
E05 1.25 R 2
B+
M A 2 J1939(+)
CN-6 B
CD-52 START RY B 12 J1939(-)
1 TCU 1 T16 1.25 R CN-45
2 C 44 SHIELD

15 R
TCU 2 T17 1.25 Br
3 TCU 3 T18 1.25 L CD-15 CL-15 CN-94
4 4 T45 1.25 BOr 1 F53B 1.25 W 4 C CN-74
(CONVERTER) A
5 TCU 5 T05 1.25 LW T09B 1.25 BOr 2 F52 1.25 L 3 T B+ G
6 TCU B
6 T19 1.25 YW G75 1.25 B 2 E 3
7 TEMP SENSOR
TCU 7 T07 1.25 W F13B 1.25 Br 1 S E20 1.25 RW I
8 U
TCU 8 T21 1.25 Or GND
9 TCU 9 T08 1.25 WOr COMBI LAMP,LH ALT
10
11
TCU
TCU
10
11
T09
T06
1.25
1.25
BOr
G SPT09 16
GEARBOX

ENGINE HARNESS ENGINE HARNESS(CUMMINS)


12 TCU 12 T04 1.25 V T09A 1.25 BOr 9 VMGA2
13
14
TCU
TCU
13
14
T20
T38
1.25
1.25
Gr
WOr
T08 1.25
T07 1.25
WOr
W
8
7
TEMP
VPS1(+)
FRAME HARNESS
15 TCU 15 T45 1.25 BOr T06 1.25 G 6 Y6 GND
T05 1.25 LW 5 Y5
T04 1.25 V 4 Y4
EARTH3
T21 1.25 Or 3 Y3
T20 1.25 Gr 2 Y2
T19 1.25 YW 1 Y1
CN-112
TRANSMISSION

7707EL01

7-4
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.2) Illumination switch [CS-39(1)] Switch ON, 1st step
[CS-39(7)] All switch indicator lamp ON
[CS-39(5)] Fuse box(27) I/conn [CN-3(12)] RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-10(7)] LH Head lamp ON [CL-3(4)]
I/conn [CN-12(10)] Cluster [CN-51(17)] All cluster gauge and
LCD lamp ON
Hazard switch indicator lamp ON
Fuse box(28) I/conn [CN-3(1) Number plate lamp ON [CL-21(S)]
LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-10(8)] RH Head lamp ON [CL-4(4)]
2) CHECK POINT
Engine Key switch Check point Voltage

① - GND (Switch input)


② - GND (Switch output)
OFF ON 20~25V
③ - GND (To light)
④ - GND (To cluster)
※ GND : Ground

7-5
ILLUMINATION CIRCUIT

FUSE BOX
BEACON LAMP 20A
1
M17 12.5 OrW ILL.LAMP 10A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4

24
TCU 10A
25
CLUSTER 10A
26
RF51 1.25 G ILL,F/L,R/R 5A
27
RF53 1.25 W ILL.F/R,R/L 5A
28

CN-36

LH HEAD LIGHT
1 Lo
2 Hi
G02 1.25 B
3 E
R51 1.25 G
4 C
2 1 CL-3
2 3
ILL & HEAD LAMP SW 3
G19 0.85 B
9 10 10 C05B 0.85 R
4 RH HEAD LIGHT
9 5 1 Lo
4 8 6 2 Hi
2 C05C 0.85 R RF51D 1.25 G R51 1.25 G G11 1.25 B
7 7 3 E
7 RF53D 1.25 W R53 1.25 W R53 1.25 W
1 6 8 4 C
5 M02 1.25 BrW
5 9 CL-4
4 10
3
NUMBERPLATE LAMP
3 11 F53A 1.25 W
II I 0

2 S
M17 12.5 OrW 12
1 CN-10 E
CS-39 CL-21
RF53C 1.25 W R53 1.25 W 3
1
1 2 RH COMBI
3 F51 1.25 G
4 C
4
3 T
5 G74 1.25 B
2 E
6
ALL SWITCH INDICATOR LAMP ON 1 S
7
CL-16
8
9 3
10 LH COMBI
F53B 1.25 W
11 4 C
RF 51C 1.25 G
12 3 T
G75 1.25 B
13 2 E
14 1 S
CN-3 CL-15

CLUSTER
12 20 TX-PC
11 19 GND
RF51A 0.85 G RF51E 0.5 G
10 17 ILL.
9 16 T/M ERROR
8 15 SERIAL-L
14 SERIAL-H
7
4 6
12 GND
11 GND
5 10 RX-PC
4 9 FWE
3 8 N.C
7 WORK LAMP
2
10 10 RF51F 0.5 G

6 HIGH BEAM
1 5 RH TURN
CN-12 4 LH.TURN
3 24V PER.
2 24V IG
1 24V IG
CS-41

CN-51
9
8
6 7
6
5 5
4
3
2
1
8
2
7
1
9

HAZARD SW

7707EL03

7-6
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.3) Head light switch [CS-39(4)] Light switch ON, 2nd step [CS-39(2)]
I/conn [CN-7(7)] Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-7(6)] I/conn [CN-10(10)]
LH Head light low beam ON [CL-3(1)]
RH Head light low beam ON [CL-4(1)]
Multi function switch DOWN [CS-11(6)] I/conn [CN-7(5)] I/conn [CN-10(9)]
LH Head light high beam ON [CL-3(2)]
RH Head light high beam ON [CL-4(2)]
I/conn [CN-12(7)]
Cluster high beam pilot lamp ON [CN-51(6)]
2) CHECK POINT
Engine Key switch Check point Voltage

① - GND (Switch input)


② - GND (Switch output)
③ - GND (Multi function input)
④ - GND (Multi function output)
OFF ON 20~25V
⑤ - GND (Multi function output)
⑥ - GND (Low beam)
⑦ - GND (High beam)
⑧ - GND (Passing B+)
※ GND : Ground

7-7
HEAD LIGHT CIRCUIT

FUSE BOX
BEACON LAMP 20A
1
ILL.LAMP 10A
2
M15 1.25 YW HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4

24
TCU 10A
25
CLUSTER 10A
26
ILL,F/L,R/R 5A
27
ILL.F/R,R/L 5A
28

CN-36

LH HEAD LIGHT
R14B 1.25 RW
1 Lo
R13A 1.25 V
2 Hi
G02 1.25 B
3 E
ILL & HEAD LAMP SW 1
4 C
2
9 10 10 1
9 3 CL-3
4 8 4 G60 1.25 B
2 RH HEAD LIGHT
7 5 R14A 1.25 RW
1 Lo
7 1 6 6 7 R13B 1.25 V
2 Hi
5 5 7 G11 1.25 B
M15B 1.25 YW 3 E
4 8
R13 1.25 V 4 C
3 9
M41 1.25 W R14 0.85 RW
II I 0

2 10 CL-4
1 11
CS-39 12
CN-10
2 6

CLUSTER
CN-7

20 TX-PC
10
11
12
13
14
1
2
3
4
5
6
7
8
9

19 GND
17 ILL.
16 T/M ERROR
15 SERIAL-L
14 SERIAL-H
12 12 GND
11 11 GND
10 10 RX-PC
9 FWE
9 8 N.C
R13B 1.25 V 8 R13B 0.5 Br 7 WORK LAMP
7 6 HIGH BEAM
6 5 RH TURN
5
4 LH.TURN
M15A 1.25 YW

3 24V PER.
4
R14 0.85 RW

24V IG
R13A 1.25 V

2
4
M41 1.25 W

3 1 24V IG
4 2 CN-51
3 1
5 8 CN-12
CS-11

5
8

4
7

3
2
1

BWG 4
W6
Hi

C
Lo
Hi

B+

C
F

R
L
O

R
L
7 Y Lo

2 BW
8 WB

3 BG
5B

MULTI FUNCTION SW

7707EL04

7-8
3. WORK LIGHT SWITCH
1) OPERATING FLOW
※ Illumination switch : ON position
(1) Work lamp switch ON (1st step)
ILL & head lamp switch [CS-39(7)] work lamp switch [CS-20(1)]
(5) Front work lamp relay [CR-3(2)→(4)] I/conn [CN-5(4) LH Front work lamp
ON [CL-6(2)]
RH Front work lamp
ON [CN-5(2)]
(7) I/conn [CN-12(8)] Cluster [CN-51(7)] Work light pilot lamp ON
(9) Work lamp switch indicate lamp ON
(2) Work lamp switch (2nd step)
Work lamp switch [CS-20(4)→(2)] Rear work lamp relay [CR-6(2)→(4)]
I/conn [CN-3(10)] LH Rear work lamp ON [CL-22(1)]
RH Rear work lamp ON [CN-23(1)]
2) CHECK POINT

Engine Key switch Check point Voltage

① - GND (Work lamp power input)


② - GND (Work lamp power output)
OFF ON 20~25V
③ - GND (Front work lamp)
④ - GND (Rear work lamp)
※ GND : Ground

7-9
WORK LIGHT SWITCH

FUSE BOX
BEACON LAMP 20A
1
M17 1.25 OrW ILL.LAMP 10A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
6
CIGAR 20A
7
SWITCH 10A
8
F/R WIPER 20A
9
M10 1.25 Gr WORK LAMP 30A
10
OPTION 10A
11

CN-36

2
3
1 1
2 FRONT WORK
FR WORK LAMP RY 3 LAMP,LH
C03 1.25 Or C03 1.25 Or C03A 1.25 Or
3 4 4 4 2
M51 0.85 W G11 1.25 B
3 5 G01 1.25 B 1
M10A 1.25 Gr 6 CL-6
2
G21 1.25 B 7 3
1 2 1 FRONT WORK
8
CR-3 LAMP,RH
9 C03B 1.25 Or
2
10 G12 1.25 B
11 1
12 CL-5
13
14
15
CN-5
2
RR WORK LAMP RY
F14 1.25 Br 1
3 4 4
M52 0.85 L 2
3
M10B 1.25 Gr 3 4
2 REAR WORK
4 LAMP,LH
G22 1.25 B F14A 1.25 Br
1 2 1 5
1
CR-6 6 G19 1.25 B
7 2
1 8 CL-22
WORK LAMP SW 9 F14 1.25 Br
G13 0.85 B 10
9 10 10
9 C05F 0.85 R 11 4
4 8 12 REAR WORK
2 M59 0.85 Y 13 LAMP,RH
7 F14B 1.25 Br
14 1
7 1 6 G17 1.25 B
M51 0.85 W 15 2
5 5
C05G 0.85 R CN-3 CL-23
4
3
M52 0.85 L
II I 0

2 CLUSTER
1 C05H 0.85 R 20 TX-PC
CS-20 19 GND
17 ILL.
CS-39
16 T/M ERROR
15 SERIAL-L
9 10 10 14 SERIAL-H
9 12 12 GND
4 8 11 GND
2 C05C 0.85 R 11
7 10 RX-PC
10 9 FWE
7 1 6 9
5 M59 0.5 Y 8 N.C
5 WORK LAMP
8 7
4 7 6 HIGH BEAM
3 6 5 RH TURN
II I 0

2 4 LH.TURN
M17 1.25 OrW 5 3 24V PER.
1
4 2 24V IG
ILL & HEAD LAMP SW : ON(1st step) 3 1 24V IG
2 CN-51
1
CN-12

7707EL05

7-10
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(R4 terminal) Fusible link [CN-60(1)]
I/conn [CN-1(1)] Fuse box (No.15) Start switch [CS-2(1)]
※ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector has an output signal which is activated whenever the shift lever is in the neutral
position. This signal can be used to control a relay and prevent engine from starting whenever the
shift lever is not in the neutral position.
(1) When start key switch is in ON position
Start switch ON Start switch [CS-2(2)] I/conn [CN-3(6)] Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)] Fuse box [No.23] Fuse box (No.22)
I/conn [CN-3(9)] I/conn [CN-12(10)] ECM[CN-92(A)]
(2) When start key switch is in START position
Start switch START [CS-2(5)] Start safety relay [CR-5(30)] Start safety relay [CR-5(87)]
I/conn [CN-2(11)] [CN-4(7)] Start relay [CR-23(2)]
Starter(Terminal B+ and M connector of start motor)

2) CHECK POINT
Engine Key switch Check point Voltage

① - GND (Battery B+)


② - GND (Fusible link)
③ - GND (Start key B terminal)
④ - GND (Start key BR terminal)
⑤ - GND (I/conn CN-3(6))
Running ON 20~25V
⑥ - GND (Start key ST terminal)
⑦ - GND (Start safety relay output)
⑧ - GND (Controller)
⑨ - GND (Start key ACC terminal)
※ GND : Ground
※ ECM : Electronic control module

7-11
STARTING CIRCUIT

CONTROL UNIT CONTROLLER

HYD TEMP SENDER


CLUTCH CUT-OFF PS

SPEEDMETER SIG.

RIDE CONT. AUTO


COOLANT SIG
SAFETY RY

BUZZER STOP
WIPER RY
STEERING RY

ALT LEVEL
FUEL SENSOR

TACHO SENSOR+
PREHEATER

SERIAL-H

WASH SIG
NEUTRAL SIG

CAN-H
AUTO SEL.TCU
REMOTE FAN(+)

CAN-L
REMOTE FAN(-)

CLUTCH CUT-OFF SW
STEERING PS

STEERING P/P PS
ENG OIL PS

RIDE CONT. ON
WIPER INT SIG

PARKING SIG
SERIAL-L

GND
BUZZER

AUTO SEL.SW

BRAKE PS
TAHCO SENSOR -

AIR FILTER
IG 24V
VMGA2

ADM5

VPE2
AIP6
AIP4
AIP1

ED1
ED5
ED2
ED9
ED6
EF4
VPI
45
46
51
55
56
57
62
63
64
65
66
67
68

23
35
34

24
36

31

26
25
32
33

27

21
20
30
29
28

22

17
19

11
18

16

12

10
13
15
14

1
2
FUSE BOX

3
6
8

4
5
7
9
CN-52

T37 0.85 W
A 14
VM OUTPUT SIGNAL K CN-58

T37B 0.85 W

EF20 0.85 RW
RADIO/ROOM LAMP 5A
VP F B N D B 15
ED 1 2 3 4 1 2 3 4 1 2 3 4 C M04 1.25 Or START KEY 30A
AD1 B1 D
8 TCU 10A
16

AD2 B2 17
CN-121 ECM 10A
AD3 B3 18
AD4 V CLUSTER 10A
19

M01 1.25 WOr


AD5 R A 1 AC & HEATER 10A
SAFETY RY 20
AD6 AS B 2 M43 1.25 R
AD7 C 3 30 SPARE 10A
21
T37A 0.85 W 85
86 87a 87
T37C 0.85 W
A AD3 D 4 ECM 5A
E05 0.85 R 22
B AD2 CN-122 5 87 RCV 10A
6 M21 0.85 L 23
C AD1 85 CONTROLLER 10A

E18 0.85 LW
7 24
X1
D AD7(KD) 87a 30 86 TCU 10A
8
A ED1(VP) 9
7 CR-5 CLUSTER 10A
25

26
D AD6 10 ILL,F/L,R/R 5A
B AD4 27
11
ILL.F/R,R/L 5A
C AD5 12 28
X2
13
14 CN-36
F21 3.0 W
CN-13
BATTERY MASTER SW
BATT RY
R4 B G
F23C 1.25 L R1

G79 1.25 B
R3
R2 CS-0
CR-1
F22 5.0 R
1
2 2
F21 3.0 W
1 1
CN-1 CN-60
F23B 1.25 L
2
EF20A 1.25 RW
1
2
DO-3 STARTER
F23A 1.25 L
2 B+
EF20 0.85 RW

G12 1.25 B
1
1 DO-2
2 F23 1.25 L
2 M
5 F12 1.25 V CN-45
3 1
EF20 1.25 RW
4 DO-1 START RY
5
G15 1.25 B
6 1
E05 1.25 R
M01 1.25 WOr

M04B 1.25 Or
F12 0.85 V

7 2
9 4
M43 1.25 R

8 9 CR-23
E18 0.85 LW
9 10
6 3 10 11 1 1
11 12 2 2 CN-92
E18 0.85 LW
CS-2

12 13 3 3 A VEHICLE KEY SW INPUT


5
4

1
6

2
3

14 B BATT. 24V
13 4 4 C BATT. 24V
B 14 15
0, I 5 5 D BATT. 24V
1

15 M BATT. 24V
CN-12 6 6 S BATT. 24V
CN-3 7 7 E BATT. GROUND
H 0 I II
8 8 F BATT. GROUND
4
6
5

3
2

C ST ACC BR
H H BATT. GROUND
9 9
P BATT. GROUND
START SWITCH 10 10 W BATT. GROUND
E05 0.85 R
11 11 N FAN CLUTCH
12 12 J FUEL WARMER

CN-4 ECM
CN-2

7707EL06

7-12
5. ENGINE STOP CIRCUIT
1) OPERATING FLOW
Start key OFF [CS-2(3)] Fuse box (No.20) I/conn [CN-2(8)] I/conn [CN-4(9)]
Engine stop solenoid OFF (CN-79)
2) CHECK POINT
Engine Key switch Check point Voltage

⑨ - GND (Start key IG terminal)


OFF OFF 0V
⑩ - GND (Engine stop solenoid)
※ GND : Ground

3) WIRING DIAGRAM - See page 7-12.

7-13
6. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74(I)] I/conn [CN-4(8)] I/conn [CN-3(4)] Controller [CN-58(25)]
Cluster charge warning lamp ON
(2) Charging flow
Alternator Starter [CN-45(B+)] Battery relay [CR-1]
Battery(+) terminal Charging
I/conn [CN-60(1),(2)] I/conn [CN-1(1),(2)] Fuse box

2) CHECK POINT
Engine Key switch Check point Voltage

① - GND (Battery)
② - GND (Battery relay)
③ - GND (ALT B+)
Running ON 20~28V
④ - GND (ALT I)
⑤ - GND (Controller)
⑥ - GND (Fuse box)
※ GND : Ground

7-14
CHARGING CIRCUIT

CONTROLLER FUSE BOX


BEACON LAMP 20A

HYD TEMP SENDER


CLUTCH CUT-OFF PS

SPEEDMETER SIG.

RIDE CONT. AUTO


COOLANT SIG
SAFETY RY

BUZZER STOP
WIPER RY
STEERING RY

ALT LEVEL
FUEL SENSOR

TACHO SENSOR+
PREHEATER

SERIAL-H

WASH SIG
NEUTRAL SIG

CAN-H
AUTO SEL.TCU
REMOTE FAN(+)

CAN-L
REMOTE FAN(-)

STEERING PS

CLUTCH CUT-OFF SW

STEERING P/P PS
ENG OIL PS

RIDE CONT. ON
WIPER INT SIG

PARKING SIG
SERIAL-L

GND
BUZZER

AUTO SEL.SW

BRAKE PS
TAHCO SENSOR -

AIR FILTER
IG 24V
1
ILL.LAMP 10A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
6 6
CIGAR 20A

23
35
34

24
36

31

26
25
32
33

27

21
20
30
29
28

22

17
19

11
18

16

12

10
13
15
14

1
2
3
6
8

4
5
7
9
7
SWITCH 10A
CN-58 8 F22 5.0 R

EF20 0.85 RW
F/R WIPER 20A 2 2
9 F21 3.0 W
WORK LAMP 30A
1 1
5 OPTION 10A
10
CN-1 CN-60
11
CASSETTE/BUZZER 5A
12
PREHEATER 30A
13
TURN LAMP 20A
14
RADIO/ROOM LAMP 5A
15
START KEY 30A
16
TCU 10A
17
ECM 10A
18
CLUSTER 10A
19
AC & HEATER 10A
20
SPARE 10A
21
ECM 5A
22
RCV 10A
23
1
CONTROLLER 10A BATTERY MASTER SW
24 BATT RY
TCU 10A R4 B G
25
CLUSTER 10A
26
ILL. F/L,R/R 5A R3
27 CS-0
ILL. F/R,R/L 5A
28 CR-1

CN-36 2

STARTER
M
1
2
3 B+ M
4 3 CN-45

15 R
1 5 ALTERNATOR
2 6
B+ G
3 7
EF20 0.85 RW EF20 1.25 RW E20 1.25 RW 3
4 8 I
U
5 9 GND
6 10 CN-74
7 11 4
8 12
9 CN-4
10
11
12
13
14
CN-3

7707EL07

7-15
7. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.8) Parking switch OFF [CS-17(6) (8)] Parking solenoid ON (Activated)
Parking brake released (By hydraulic pressure)
(2) Parking ON
Fuse box (No.8) Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
[CS-17(5) (7)] T/M control unit [CN-52(21)]
T/M declutch
(3) Declutch ON
Fuse box (No.8) Clutch cut-off switch ON Clutch cut-off switch [CS-42(5) (1)]
Controller [CN-58(10) (29)] Service brake applied Service brake pressure switch
ON [CD-5] T/M control unit [CN-52(66)] Declutch
2) CHECK POINT
Engine Key switch Check point Voltage

① - GND (Parking switch input)


② - GND (Parking switch output)
③ - GND (Parking switch input)
Running ON ④ - GND (Parking switch output) 20~25V
⑤ - GND (Parking solenoid)
⑥ - GND (Pressure switch clutch cut-off)
※ GND : Ground

7-16
ELECTRIC PARKING, DECLUTCH CIRCUIT

CONTROL UNIT CONTROLLER

CLUTCH CUT-OFF PS
SERIAL-L

RIDE CONT. AUTO


SAFETY RY

BUZZER STOP
WIPER RY
STEERING RY

FUEL SENSOR
PREHEATER

WASH SIG
NEUTRAL SIG

CLUTCH CUT-OFF SW

STEERING P/P PS
TACHO +

RIDE CONT. ON
WIPER INT SIG

PARKING SIG
SERIAL-H

AUTO SEL.SW

BRAKE PS
CANF-H

CANF-T
CANF-L

VPE2
VPE1
ED10

ED11
VGS

ED5
ED2
ED9
ED6
ED3

ED7
EF1

64
65
66
67
68
19
20
21
22
23
25
26
27
28
29
36 35 34 33 32 31 30 29 28 11 10 9 8 7 6 5 4 3 2 1

CN-52 CN-58

M31 0.85 GrW


T26 0.85 YW

M34 0.85 ROr

M26 0.85 Gr
T36 0.85 WOr
FUSE BOX[CN-36(2)]

9 10 10
9
4 8
2 C05C 0.85 R
7
7 1 6
5 5
4
3
II I 0

2
M17 1.25 OrW
1
ILL & HEAD LAMP SW : ON(1st step) FUSE BOX
BEACON LAMP 20A
1
ILL.LAMP 10A
4 2 1 2
HEAD LAMP 20A
3
PARKING SW BACK/STOP LAMP 10A
G17 0.85 B 4
HORN/CONVERTER 30A
9 10 10 C05K 0.85 R 5
9 AIR-CON/HEATER 20A
M44 0.85 L 6
8 CIGAR 20A
8 T26 0.85 YW 7
6 7
2 M09E 0.85 W M09 0.85 W SWITCH 10A
6 8
7 M09F 1.25 W F/R WIPER 20A
5 5 9
1
4 CN-36
3
2
1
CS-17
3

CLUTCH CUT-OFF SW
G09 0.85 B
9 10 10 M09C 0.85 C
9
8

T36 0.85 WOr


M34 0.85 ROr
8
M26 0.85 Gr
G27 0.85 B

6 7
2
G28 0.85 B
M44 0.85 L

6
7 M09C 0.85 W 6
1
5 5 5
4
CD-26

CD-5
2
1

1
2
2

M31 0.85 GrW 1 2


1
CN-71

CS-42
Pa

Pa

PARK PARK PS CLUTCH


SOLENOID CUT-OFF

7707EL08

7-17
8. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.9) Wiper relay [CR-4(30) (87a)] I/conn [CN-13(9)]
Front wiper motor [CN-21(1)]
Wiper relay Lo [CR-26(86), (87)]
I/conn [CN-7(8)] Multi function switch [CS-12(6)]
Rear wiper & washer switch [CS-3(1)]
Rear wiper motor [CN-102(1)]
(1) Front washer switch ON
① Washer switch ON [CS-12(6) (2)] Washer tank [CN-22(2)] Washer operating
Controller [CN-58(5) (33)] Front wiper relay Lo
[CR-26(87) (30)] I/conn [CN-13(13)]
Front wiper motor [CN-21(5)] Wiper motor operating(Low)
(2) Front wiper switch ON
① INT position
Wiper switch ON [CS-12(6) (1)] I/conn [CN-7(13)] Controller [CN-58(8) (33)]
Wiper relay Lo [CR-26(87) (30)] I/conn [CN-13(13)] Front wiper motor [CN-21(5)]
Front wiper motor intermittently operating
② Lo position
Wiper switch ON [CS-12(6) (4)] Wiper relay Lo [CR-26(87a) (30)] I/conn [CN-13(13)]
Front wiper motor [CN-21(5)] Front wiper motor operating (Low)
③ Hi position
Wiper switch ON [CS-12(6) (3)] Wiper relay Hi [CR-4(30) (87)] I/conn [CN-13(12)]
Front wiper motor [CN-21(4)] Front wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Switch OFF Fuse box (No.9) Wiper relay Hi [CR-4(30) (87a)] I/conn [CN-13(9)]
Front wiper motor [CN-21(1) (2)] Multi function switch [CS-12(5) (4)]
Wiper relay Lo [CR-26(87a) (30)] I/conn [CN-13(13)] Front wiper motor [CN-21(5)]
Wiper motor stop
(4) Rear wiper and washer switch
① Wiper switch ON(1st step)
Wiper switch ON [CS-3(1) (6)] Rear wiper motor [CN-102(5)] Rear wiper motor operating
② Washer switch ON(2nd step)
Washer switch ON [CS-3(1) (3)] Rear washer tank [CN-103(2)] Washer operating

7-18
2) CHECK POINT

Engine Key switch Check point Voltage

① - GND (Front wiper switch power input)


② - GND (Rear wiper switch power input)
③ - GND (Wiper relay power input)
④ - GND (Front wiper motor Lo power input)
⑤ - GND (Front wiper motor High power input)
Stop ON 20~25V
⑥ - GND (Wiper relay power input)
⑦ - GND (Front washer power output)
⑧ - GND (Rear washer power output)
⑨ - GND (Front wiper motor power output)
⑩ - GND (Rear wiper motor power output)
※ GND : Ground

7-19
CS-3
G11 0.85 B
9 10 10
9
M54 0.85 W
3 8
7 6 5 Lo M
8 M55 0.85 Or M55 0.85 Or
6 6 5 4 Hi
1 4
5 G55 1.25 B
3 1B

10
4 M54 0.85 W

0,I
M56 0.85 L 2 2Pf
WIPER AND WASHER CIRCUIT

3 M14B 1.25 L
REAR WIPER

1 3E
2 CN-102
M14C 1.25 L

II I 0

REAR WIPER & WASHER SW


1

8
2
36 NEUTRAL SIG
35 SAFETY RY
34 PREHEATER
M22 0.85 Gr
33 WIPER RY
32 STEERING RY
CONTROLLER

31 SERIAL-H
CN-22
G54 1.25 B 30 SERIAL-L
M 1
M27B 0.85 R 29 CLUTCH CUT-OFF PS
2 28 FUEL SENSOR

FRONT WASHER
27 HYD TEMP SENDER
26 COOLANT SIG
CN-103
G53 1.25 B 25 ALT LEVEL
M 1
M56A 0.85 L 24 REMOTE FAN(-)
2
23 REMOTE FAN(+)
22 GND
21 BUZZER

REAR WASHER
20 SPEEDMETER SIG.
19 CAN-L
18 CAN-H
17 AUTO SEL.TCU
16 TAHCO -
15 STEERING PS
14 ENG OIL PS
13 AIR FILTER
12 IG 24V
11 AUTO SEL.SW
10 CLUTCH CUT-OFF SW
8 9 TACHO +
M30 0.85 Y
Hi 7 8 WIPER INT SIG
F Lo
6 7 RIDE CONT. ON
L 6 RIDE CONT. AUTO
O 5 M27 0.85 R
R 5 WASH SIG
4
5B 4 BUZZER STOP
B+ 3
3 STEERING P/P PS
2 2 PARKING SIG

7-20
1 1
CN-58

BRAKE PS

MULTI FUNCTION SWITCH


CS-11
8 WB

7 Y Lo W6
Hi
2 BW L
BWG 4
3 BG C
R
II
1
9

I
0
6
J 0 G 5
CS-12 7
II BVi 3 M14D 1.25 L
6 8
I L 4
5 9
M39 0.85 G
4 10
J BY 1 M38 0.85 Br
3 11
C RW 6 M27A 0.85 R
2 12
W Gr 2 M30 0.85 Y
1 13
14
HO Y CN-7
CS-5
7
M14 1.25 L

1
2
M40 0.85 VOr

3
4
CIGAR
SWITCH
ILL.LAMP

5
FUSE BOX

F/R WIPER

6
HEAD LAMP

WORK LAMP

7
BEACON LAMP

CN-21 8 M45C 0.85 W


AIR-CON/HEATER
BACK/STOP LAMP

3E 1 9
HORN/CONVERTER

2Pf 2 10 G51 1.25 B


1B 3 11
10A
10A
10A

30A
20A

20A

30A
20A
20A
20A

M49 0.85 G
4 12
2
1

M46 0.85 R
7
3

9
8
4

6
5

10

4 Hi 5 13
CN-36

FRONT WIPER

M
5 Lo 6 14
CN-13
5
6

M38 0.85 Br
M22 0.85 Gr

M14A 0.85 L

4
M39 0.85 G

M45B 0.85 W
M45 0.85 W

G25 1.25 B
M49 0.85 G
M45A 0.85 W
M46 0.85 R

3
85
87
86
30

85
87
86
30
87a

CR-4
87a
CR-26

30 86
30 86

87a 87 85
87a 87 85
WIPER RY LO

WIPER RY HI

7707EL09
HAZARD, TURN AND ROTARY CIRCUIT

COMBI LAMP LH
1 4 C 1
F52 1.25 L F52 1.25 L
2 3 T 2
G75 1.25 B
3 2 E 3
1 S ROTARY LAMP
4 4
CL-15 C08 1.25 GY
5 5 FUSE BOX
G13 1.25 B
6 6 C07 1.25 G BEACON LAMP 20A
1
7 7 CL-7 ILL. LAMP 10A
8 8 2
HEAD LAMP 20A
9 COMBI LAMP RH 9 3
BACK/STOP LAMP 10A
10 4 C 10 4
RF50C 0.85 Or F50 1.25 Or HORN/CONVERTER 30A
11 3 T 11 5
G74 1.25 B
12 2 E 12 AIR-CON/HEATER 20A
6
13 1 S
13 CIGAR 20A
14 CL-16 7
14 SWITCH 10A
CN-3 8
15 F/R WIPER 20A
CN-5 9
WORK LAMP 30A
10
OPTION 10A
11
CASSETTE/BUZZER 5A
12
PREHEATER 30A
13
TURN LAMP 20A
14
RADIO/ROOM LAMP 5A
15
START KEY 30A
FLASHER UNIT 16
M42 1.25 BrW TCU 10A
1 L 17
M11 1.25 R ECM 10A
2 B G 18
G62 1.25 B CLUSTER 10A
3 E 19

CN-7
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CR-11 AC & HEATER 10A
20

CN-36
CLUSTER
20 TX-PC
19 GND
17 ILL.
16 T/M ERROR
15 SERIAL-L
14 SERIAL-H
12 GND
11 GND
10 RX-PC
9 FWE
8 N.C
7 WORK LAMP
RF50A 0.5 Or 6 HIGH BEAM
5 RH TURN
4 LH.TURN
RF52A 0.5 L 3 24V PER.
2 24V IG
M42A 1.25 BrW

1 24V IG
RF50 0.85 Or

1
RF50 0.85 L

CN-51
2
3
4
5 LH TURN,FR
G03 1.25 B

CS-12
CS-11

CS-5
6 1
R52 1.25 L

6
5
4
3
2
1
8
7
6
5
4
3
2
1

7 2
M42C 1.25 BrW
M42B 1.25 BrW

RF50D 0.85 Or

C08A 1.25 GY

8
C08B 1.25 GY
RF52D 0.85 L

CL-24
BWG 4
G53 0.85 B

C07 1.25 G
G23 1.25 B

RW 6
9
W6

BVi 3
L 4
G 5

BY 1

Gr 2
10 RH TURN,FR

Y
R52 0.85 L G13 1.25 B
11 1
RF50 0.85 Or R50 1.25 Or

HO
12 2

W
II
I
Hi

C
J 0

J
C

CN-10 CL-25
0
II
CS-41

I
CS-23

Lo
10 10

10
9
8
7
6
5
4
3
2
1

9
8
7
6
5
4
3
2
1

Hi

B+
F
10
5
6

R
L
O

R
L
7 Y Lo
8 WB

2 BW

3 BG
5B
9

8
2
7
1

8
2
7
1

HAZARD SWITCH BEACON LAMP SWITCH MULTI FUNCTION SWITCH

7707EL11

7-21
3.MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case
of abnormal machine operation or conditions for the appropriate operation and inspection.
 Gauges : Indicate operating status of the machine.
 Warning lamp : Indicate abnormality of the machine.
 Pilot lamp : Indicate operating status of the machine.
ö The monitor installed on this machine does not entirely guarantee the condition of the
machine. Daily inspection should be performed according to chapter 6, MAINTENANCE.
ö When the monitor provides a warning immediately check the problem, and perform the
required action.
ÿCluster(Machine serial no. ; -#0816)

Warning lamp High beam pilot lamp


Work light pilot lamp Right turning pilot lamp
Left turning pilot lamp Parking brake warning lamp
Preheater warning lamp Hyd oil temp warning lamp
Brake fail warning lamp Clutch cut off pilot lamp
Steering warning lamp Battery charging warning lamp
(Emergency) Fuel low level warning lamp
Steering warning lamp Seat belt warning lamp
(Primary)
Air cleaner warning lamp
Engine overheat
warning lamp T/M error warning lamp
Engine oil pressure
warning lamp

20 30
10 10 20 40 M MENU
Menu switch
0 0 30
50 BACK Back switch
mph
Km/h
NEXT Next switch
SE
E
L
C
Select switch

Hyd oil temp gauge


T/M oil temperature gauge LCD display
Battery volt meter Speedometer77073CD02
Engine coolant temperature gauge Fuel gauge

7-21
ÿCluster(Machine serial no. ; #0817-)

Warning lamp High beam pilot lamp


Work light pilot lamp Right turning pilot lamp
Left turning pilot lamp Parking brake warning lamp
Preheater warning lamp Hyd oil temp warning lamp
Brake fail warning lamp Clutch cut off pilot lamp
Steering warning lamp Battery charging warning lamp
(Emergency) Fuel low level warning lamp
Steering warning lamp Seat belt warning lamp
(Primary)
Air cleaner warning lamp
Engine overheat
warning lamp T/M error warning lamp
Engine oil pressure
warning lamp

LCD
mph
Km/h

Select(Enter) key

Right
Hyd oil temp gauge Escape key
T/M oil temperature gauge Main/Menu key
Battery volt meter Speedometer
Engine coolant temperature gauge Fuel gauge

77073CD02-1

1) SPEEDOMETER
(1) The speedometer displays the speed of machine in mph and
km/h.

77073CD03

7-22
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the indicator moves E point, refuel as soon as
possible to avoid running out of fuel.
ö If the gauge indicates below E point even though the
machine is on the normal condition, check the electric device
77073CD04 as that can be caused by the poor connection of electricity or
sensor.

3) ENGINE COOLANT TEMPERATURE GAUGE


(1) This indicates the temperature of coolant.
Red
ÂRed range : Above 104ÁC (219ÁF )
(2) Keep idling engine at low speed until the indicator is in the
operating range.

Operating
(3) If the indicator is in the red range, turn OFF the engine, check the
range 77073CD05 radiator and engine.

4) TRANSMISSION OIL TEMPERATURE GAUGE


(1) This range indicates the temperature of transmission oil.
Red
ÂRed range : Above 107ÁC (225ÁF )
(2) Keep idling engine at low speed until the indicator is in the
operating range.

Operating
(3) If the indicator is in the red range, it means the transmission is
range 77073CD06 overheated. Be careful that the indicator does not move into the
red range.

5) BATTERY VOLT METER


(1) This gauge indicates the voltage in the charging system when
the engine is running.
(2) If the indicator is below 24V(Yellow range), it means that the
electricity is being discharged. If the indicator is above 30V(Red
range), an unusually high voltage may damage the alternator.
Check the charging system in both cases.
77073CD07

7-23
6) HYD OIL TEMPERATURE GAUGE
(1) This range indicates the temperature of hydraulic oil.
Red
ÂRed range : Above 105ÁC (221ÁF )
(2) Keep idling engine at low speed until the indicator is in the
operating range.

Operating
(3) If the indicator is in the red range, reduce the load on the system.
range 77073CD08 If the gauge stays in the red range, stop the machine and check
the cause of the problem.

7) WARNING LAMP
(1) When all warning lamp or fault codes are being displayed, this
warning lamp will flash.
(2) When this warning lamp flashes, machine must be checked or
serviced as soon as possible.

77073CD09

8) DIRECTION PILOT LAMP


(1) This lamp flashes when the signal indicator lever is moved.

77073CD10

9) WORK LIGHT PILOT LAMP


(1) This lamp lights ON when work lamp switch is pressed.

77073CD11

10) HIGH BEAM PILOT LAMP


(1) This lamp works when the illuminating direction is upward.
(2) This lamp comes ON when the dimmer switch is operated, e.g.,
when passing another vehicle.

77073CD12

7-24
11) PARKING BRAKE WARNING LAMP
(1) When the parking brake is actuated, the lamp lights ON.
ö Check the lamp is OFF before driving.

77073CD13

12) PREHEATER WARNING LAMP


(1) This lamp lights ON when start switch is turned clockwise to the
ON position. Light will turn off after approximately 15~45
seconds, depending on engine temperature, indicating that
preheating is completed.
(2) When the lamp goes out the operator should start cranking the
77073CD14 engine.

13) CLUTCH CUT OFF PILOT LAMP


(1) When the clutch cut off switch is pressed, the lamp lights ON.

77073CD65

14) BRAKE FAIL WARNING LAMP


(1) The lamp lights ON when the oil pressure of service brake drops
below the normal range.
(2) When the lamp is ON, stop the engine and check for its cause.
ö Do not operate until any problems are corrected.

77073CD16

15) ENGINE OVERHEAT WARNING LAMP


(1) This lamp is turned ON when the temperature of cooling water is
over the normal temperature(104ÁC, 219ÁF)
(2) Check the cooling system when the lamp is ON.

77073CD17

7-25
16) ENGINE OIL PRESSURE WARNING LAMP
(1) This lamp is comes ON after starting the engine because of the
low oil pressure.
(2) If the lamp comes ON during engine operation, shut OFF engine
immediately. Check oil level.

77073CD18

17) TRANSMISSION ERROR WARNING LAMP


(1) This lamp lights ON and the LCD display show the error codes when
an error occurs in the transmission.
(2) Immediately pull the machine to a convenient stop. Stop the
engine. Investigate the cause.
ö Consult a HYUNDAI dealer to investigate the cause.
77073CD19
ö Do not operate until the cause has been corrected.

18) AIR CLEANER WARNING LAMP


(1) This lamp operates by the vacuum caused inside when the filter
of air cleaner is clogged.
(2) Check the filter and clean or replace it when the lamp is ON.

77073CD20

19) HYD OIL TEMPERATURE WARNING LAMP


(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105ÁC(221ÁF).
(2) Check the hydraulic oil level when the lamp is turned ON.
(3) Check for debris between oil cooler and radiator.

77073CD21

20) BATTERY CHARGING WARNING LAMP


(1) This lamp is ON when key ON, it is turned OFF after starting the
engine.
(2) Check the battery charging circuit when this lamp comes ON,
during engine operation.

77073CD22

7-26
21) FUEL LOW LEVEL WARNING LAMP
(1) Fill the fuel immediately when the lamp is turned ON.

77073CD23

22) SEAT BELT WARNING LAMP


(1) This lamp lights ON for the first five seconds after starting the
machine.

77073CD24

23) STEERING WARNING LAMP(Option)


(1) Primary
This lamp indicates that the primary steering has failed. When
the indicators come on and the action alarm sounds, steer the
machine immediately to a convenient location and stop the
machine. Stop the engine and investigate the cause.
ö Do not operate the machine until the cause has been
77073CD66
corrected.

(2) Emergency
This lamp indicates the emergency steering system is active.
ö Immediately pull the machine to a convenient stop and
stop the engine.
ö The emergency steering system can be manually tested.
77073CD15
Refer to page 7-36-4.

7-27
24) LCD(Machine serial no. ; -#0816)
Cluster 1( ) LCD
1 2( ) MENU
M 2 - Display main menu
MENU

- Return to the normal display


BACK
3
3( ) BACK
4
NEXT
Return to the previous menu
5
SELECT
4( ) NEXT
Move to the next selection
5( ) SELECT
77073CD72
Activate the currently chosen item

(1) Normal display

TYPE 1 TYPE 2

1
c
a e 3
2 d
b

6 4

5
77073CD73

No Symbol Meaning Remark

Forward, reverse, neutral LCD type 1, Display during AEB mode


F, R, N Forward, reverse, neutral LCD type 2, Display during AEB mode
1
1, 2, 3, 4 Actual gear -
P Parking brake mode active -
a Wiper motor intermittently operating -
2 When operating intermittently, it
b -
shows an operating time interval.
c, d Up and down shifting c : Forward, d : Reverse
3 Automatic mode
e Pre-selected gear -
HOUR

4 Hour meter Display the total operation hours of the machine


COOLANT
5 C Engine coolant temperature Display in accordance with selected items
AUT Ride control mode active Ride control switch AUTO position,see page7-36-4
6 ON Ride control mode active Ride control switch ON position,see page7-36-4
(Option)
OFF Ride control mode turn off Ride control switch MIDDLE position,see page7-36-4
ö Both type1 and type2 are LCD modes and they can be changed each other by operator’s selection.

7-28
(2) Display map

Normal Main menu Sub menu Activate item


Press MENU Press ACCESSORY Press ACCESSORY
M
ACCESSORY JOB TIMER JOB TIMER
CLOCK STOP WATCH ON
USER ODOMETER OFF
ADJUSTMENT LIGHT CONT
DIAGNOSTICS RESET

Previous Press Previous Press Previous Press


menu menu menu
77073CD74

Main group Sub group Meaning Display on LCD


Accessory ÂMeasure the various job time. JOB HOUR

Job timer
ÂPress : Display ON, OFF or RESET
ÂMeasures time in seconds.
Stop watch -
ÂPress : Start. Press again : Stop.
LATEST-DIS
Latest ÂDistance until recent times. Km
Odometer TOTAL-DIS
Total ÂTotal distance. Km

ÂControl of LCD display luminosity.


Light control -
ÂBrightness control : , .
Clock ÂWhen 12H or 24H is selected, the current
Time set hour appears.
 , : input, : setting.
PM
Clock ON/OFF Â : Clock display ON or OFF.

1
ÂAlarm setting. It is possible to set 3 alarms.
Alarm 2
ÂStop alarming : or buzzer stop switch.
3
User
ÂRaise the idle rpm to 1200rpm automatically
Alternate idle -
to warm up the engine.
Mode 1 ÂAutomatic travelling speed is applied from 1st
(1st-4th) to 4th gear. -
Auto 1/2
Mode 2 ÂAutomatic travelling speed is applied from
(2nd-4th) 2nd to 4th gear. -
Mode 1 ÂPress button once : Shift down, press button
(Down/Up) again ; shift up. -
Quick
shift Mode 2 ÂPress button every time : Shift to lower gear
(Down) respectively. -
Auto ÂON : Transmission auto condition.
Select ÂOFF : Transmission semi-auto condition.
Aux-sw
Clutch ÂON : Clutch cut-off is activated. -
Cut-off ÂOFF : Clutch cut-off is cancelled.

7-29
Main group Sub group Meaning Display on LCD display
Adjustment Unit ÂChoose between metric and inch unit display.
TOTAL-DIS TOTAL-DIS

Km Mile

Wiper ÂWhen using the intermittent function of wiper


Intermittence motor, it regulates operation time.
ÂRegulate idle rpm.
Alternate RPM ÂPress , : Adjust idle rpm increments -
(or decrement) by 25rpm.

Pulse ÂPress : Modification. -


ÂIt controls the disk interval of the transmission,
AEB -
automatically.
ÂEnglish : Display in English.
ENG/KOR -
ÂKorean : Display in Korean.
ÂType 1 : Indicate with the symbol.
Display 1/2 ÂType 2 : Indicate with a letter. ,
Diagnostics Fault ÂError code display.
-
Code ÂRefer to page 7-31.
Machine ÂHydraulic temperature and battery voltage HYD BATT-VOLT

Monitor display. C V
ÂPress : Display ON or OFF.
Fault ÂError code display.
-
Code ÂConsult a Hyundai dealer to error code.
Engine
ÂEngine coolant temperature display. COOLANT

Monitor C
ÂPress : Display ON or OFF.

Fault ÂError code display.


ÂConsult a Hyundai dealer to error code. -
Transmis- Code
sion Transmission oil temperature display. OIL TEMP

Monitor ÂPress : Display ON or OFF. F

(3) Machine fault code


When selecting the fault code menu, it shows all of the fault codes which mean abnormal
conditions of present time.

Press ö To go out from fault explanation window,


press button.
030 Er : 030 (Press , to go out to first menu.)
050 ö No error will be indicated in case that
025 there’s no fault.
046
Fuel level sensor open
or short to power

77073CD60

7-30
Description Code Meaning Remark

010 Power input voltage low Below 18V


011 Power input voltage high Above 38V
Electrical 012 Alternator voltage low Below 5V
system 013 Alternator voltage high Above 36V
014 Buzzer circuit open or short to ground
015 Buzzer circuit short to power
Hydraulic 020 Hydraulic oil temperature sensor open or short to power
system 021 Hydraulic oil temperature sensor short to ground
030 Fuel level sensor open or short to power
Engine 031 Fuel level sensor short to ground
system 034 Cooling fan driving valve open or short to ground
035 Cooling fan driving valve short to power
050 Auto select switch supply power open or short to power
051 Auto select switch supply power short to ground
T/M system
052 Clutch cutoff supply power open or short to power
053 Clutch cutoff supply power short to ground
Steering 060 Emergency steering relay open or short to ground Option
system 061 Emergency steering relay short to power Option
070 MCU communication error
Communication 071 TCU communication error
072 ECM communication error
MCU : Machine control unit TCU : Transmission control unit ECM : Engine control module

7-31
LCD(Machine serial no. ; #0817-)
1 LCD
2( ) Right
Move to the next selection
1
3( ) Select(Enter)
Activate the currently chosen item
2 4( ) Escape
3 Return to the previous menu
4 5( ) Main, Menu
5 - Display menu
7707A3CD04-1
- Return to the main display

(1) Main display

2
TYPE 1 TYPE 2
1
4
c
a
3 e 5
b
d
7
6

8 9
7707A3CD10-1

No Symbol Meaning Remark


Job timer, Odometer, Hydraulic temperature, Battery
1 Job Time 1.26h Monitoring information
voltage, Coolant temperature, T/M oil temperature.
2 AUTO
State information Ride state(option), Warming up
a When operating intermittently, it shows an operating time interval
3 Wiper display
b Wiper motor intermittently operating
Forward, reverse, neutral LCD type 1
F, R, N Forward, reverse, neutral LCD type 2
4 Actual gear display
1, 2, 3, 4 Actual gear
P Parking brake mode active
c, d Up and down shifting c: Forward, d: Reverse
5 Select gear display Automatic mode
e Pre-selected gear
Fault
6 71 Fault code display Fault code state display
7 0 RPM Engine rpm display Now engine rpm state display
8 11.0Hr Hour meter display Hour meter state display
9 PM 12:05 Timer & alarm display Now time & alarm state display
ö Both type1 and type2 are LCD modes and they can be changed each other by operator’s selection.
(Adjustment/Display, see page 7-34)

7-32
(2) Display map

Main Menu Sub menu Activate item

7707A3CD11-1

Main group Sub group Meaning Display on LCD


Accessory ÂMeasure the various job time.
Job timer Job Time 1.26h
ÂPress : Display ON, OFF or RESET
ÂMeasures time in seconds.
Stop watch -
ÂPress : Start. Press again : Stop.

Latest ÂDistance until recent times. Latest 20.5 Km


Odometer
Total ÂTotal distance. Total 30.5 Km

ÂControl of LCD display luminosity.


Light control -
ÂBrightness control : .
Clock ÂWhen 12H or 24H is selected, the current
Time set hour appears.
 : input, : setting. PM 22:05
Clock ON/OFF Â : Clock display ON or OFF.

1
ÂAlarm setting. It is possible to set 3 alarms.
Alarm 2
ÂStop alarming :
3
User ON
Alternate ÂRaise the idle rpm to 1200rpm automatically
idle to warm up the engine. -
OFF
Mode 1 ÂAutomatic travelling speed is applied from 1st
(1st-4th) to 4th gear. -
Auto
select Mode 2 ÂAutomatic travelling speed is applied from
(2nd-4th) 2nd to 4th gear. -
Mode 1 ÂPress button once : Shift down, press button
(Down/Up) again ; shift up. -
Quick
shift Mode 2 ÂPress button every time : Shift to lower gear
(Down only) respectively. -
Auto ÂON : Transmission auto condition.
select ÂOFF : Transmission semi-auto condition.
Aux-sw
Clutch ÂON : Clutch cut-off is activated. -
cut-off ÂOFF : Clutch cut-off is cancelled.

7-33
Main group Sub group Meaning Display on LCD
Adjustment MKS Total 50.7 Km
Unit ÂChoose between metric and inch unit display.
ENG Total 31.5 Mile
Wiper ÂWhen using the intermittent function of wiper
Intermittence motor, it regulates operation time.
ÂRegulate idle rpm.
Alternate RPM ÂPress : Adjust idle rpm increments -
(or decrement) by 25rpm.

Pulse ÂPress : Modification. -


ÂIt controls the disk interval of the transmission,
AEB automatically.
ÂIt is set at the factory, so there's no need to
Model -
change.
ÂEnglish : Display in English.
ENG/KOR -
ÂKorean : Display in Korean.
ÂType 1 : Indicate with the symbol.
Display 1/2 ÂType 2 : Indicate with a letter. ,

Diagnostics Fault ÂError code display.


-
code ÂRefer to page 7-35.
Machine ÂHydraulic temperature and battery voltage HYD temp 100.6 C
Monitor display. Bat Volt 27.5 V
ÂPress : Display ON or OFF.
Fault ÂError code display. -
code ÂConsult a Hyundai dealer to error code.
Engine
ÂEngine coolant temperature display.
Monitor Coolant Temp 57.6 C
ÂPress : Display ON or OFF.

Fault ÂError code display.


-
Transmis- code ÂConsult a Hyundai dealer to error code.
sion Transmission oil temperature display.
Monitor ÂPress : Display ON or OFF.
Oil Temp 37.6 C

Version ÂDisplay the controller(MCU) and cluster version. -

7-34
(3) Machine fault code
When selecting the fault code menu, it shows all of the fault codes which mean abnormal
conditions of present time.

3 's FAULT 71
34 71 72 TCU Communication Error

7707A3CD36-1

ö To go out from fault explanation window, press button.


(Press , to go out to main.)
ö No error will be indicated in case that there’s no fault.

Description Code Meaning Remark

010 Power input voltage low Below 18V


011 Power input voltage high Above 38V
Electrical 012 Alternator voltage low Below 5V
system 013 Alternator voltage high Above 36V
014 Buzzer circuit open or short to ground
015 Buzzer circuit short to power
Hydraulic 020 Hydraulic oil temperature sensor open or short to power
system 021 Hydraulic oil temperature sensor short to ground
030 Fuel level sensor open or short to power
Engine 031 Fuel level sensor short to ground
system 034 Cooling fan driving valve open or short to ground
035 Cooling fan driving valve short to power
050 Auto select switch supply power open or short to power
051 Auto select switch supply power short to ground
T/M system
052 Clutch cutoff supply power open or short to power
053 Clutch cutoff supply power short to ground
Steering 060 Emergency steering relay open or short to ground Option
system 061 Emergency steering relay short to power Option
070 MCU communication error
Communication 071 TCU communication error
072 ECM communication error
MCU : Machine control unit TCU : Transmission control unit ECM : Engine control module

7-35
(4) Transmission warning

Symbol Meaning Remarks

LF, LR Limp home gear -


F/R/Ā/Ă flashing Direction F or R selected while turbine
speed is too high, CAUTION gear will -
engage if turbine speed drops
Oil temperature too low, no gear available Warm up engine / transmission
WS Warning sump temperature Changes between actual gear/direction
while driving, in neutral only displayed if no
fault is detected
WT Warning torque converter temperature Changes between actual gear/direction
while driving, in neutral only displayed if no
fault is detected
WE Warning high engine speed Changes between actual gear/direction
while driving, in neutral only displayed if no
fault is detected

7-36
2. SWITCHES

Beacon switch(option)
Buzzer stop switch

Starting switch Parking brake switch


Front Rear wiper/washer switch Main light switch
Ride control switch(option) Work lamp switch
LH SIDE Pump motor switch(option) Auto select switch
Clutch cut off switch
Kick down switch

A
Horn button
Multi function switch
Hazard switch
Kick down switch

77073CD29

1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
 (OFF) : None of electrical circuits activate.
 (ON) : All the systems of machine operate.
 (START) : Use when starting the engine.
Release key immediately after starting.
ö Key must be in the ON position with engine running maintain
77073CD41
electrical and hydraulic function and prevent serious machine
damage.

7-36-1
2) HAZARD SWITCH
(1) Use for parking, or roading machine.
OFF
ö If the switch is left ON for a long time, the battery may be
ON
discharged.

77073CD42

3) CLUTCH CUT OFF SWITCH


(1) This switch is pressed, it will cut off the clutch when brake operates.
ö Be careful not to use this switch when driving on a slope.
(2) When the switch failure occurs, it will be able to operate a clutch off
function from LCD.
ö Refer to page 7-29,33.
77073CD43

4) PARKING BRAKE SWITCH


(1) This switch is pressed, the parking brake will start to operate and the
gauge panel warning lamp will comes ON.
ö When operating the gear selector lever, be sure to release the
parking brake. If the machine is operated with the parking
brake engaged, the brake will overheat and may cause the
brake system to go out of order.
77073CD44

5) MAIN LIGHT SWITCH


(1) This switch use to operates the clearance lamp and head light by
two step.
ÂFirst step : Clearance lamp and cluster illumination lamp comes
ON. Also, all indicator lamp of switches come ON.
ÂSecond step : Head light comes ON.

77073CD45

6) WORK LAMP SWITCH


(1) This switch use to operates the front and rear work lamps by two
step.
ÂFirst step : Front work lamp located on the cab comes ON.
ÂSecond step : Rear work lamp located on the cowl comes ON.

77073CD46

7-36-2
7) REAR WIPER AND WASHER SWITCH
(1) The switch use to operates the rear wiper and washer by two step.
ÂFirst step : The rear wiper operates.
ÂSecond step : The washer liquid is sprayed and the rear wiper is
operated only while pressing. If release the switch,
return to the first step position.

77073CD47

8) BUZZER STOP SWITCH


(1) The red lamp on the cluster lights ON and the buzzer sounds when
the machine has a problem.
In this case, if the switch is pressed, the buzzer will be stopped. Be
sure to check machine for problems.
(2) Wait until the lamp is turned OFF, if the red lamp lights ON after the
77073CD48 buzzer stopped.
If not, stop engine and check the system which the lamp is ON.

9) AUTO SELECT SWITCH


(1) Manual mode(Η Η)
Press the top of the switch for the manual mode of the autoshift
function. The operator selects the desired speed and the desired
direction in the manual mode with the gear selector lever.
(2) Automatic mode(Θ)
77073CD49 Press the bottom of the switch for the autoshift function in the
automatic mode. Press the bottom of the switch prior to shifting the
transmission into forward or reverse in order to activate the autoshift
function.
ö The operator can select two kinds of automatic modes.
Ĉ4th, 2ndĈ4th)
(1stĈ
ö When the switch failure occurs, it will be able to operate a auto
select function from LCD.
ö Refer to page 7-29,33.

10) BEACON SWITCH (Option)


(1) This switch turns ON the rotary light on the cab.

77073CD50

7-36-3
11) RIDE CONTROL SWITCH (Option)
(1) AUTO position
Push in the top of the ride control switch in order to turn on the
automatic ride control. The automatic ride control automatically
turns on when the travel speed exceeds a preset speed of
approximately 9.5km/h. The automatic ride control automatically
77073CD51 shuts off during low speed 8km/h travel mode.
(2) ON position
Push in the bottom of the ride control switch in order to turn on the
system for ride control regardless speed. The ride control will
smooth the ride of the machine during travel.

77073CD51-1

(3) MIDDLE position


Push the ride control switch to the middle position in order to turn off
the system for the ride control.

77073CD51-2

12) PUMP MOTOR SWITCH (option)


(1) The emergency steering system can be manually tested. Push the
pump motor switch in order to determine if the emergency steering
and the emergency steering lamp are functional.
(2) When the switch is pushed, the emergency steering pump motor will
run. The emergency steering lamp will light. If the emergency
77073CD52 steering lamp does not light, do not operate the machine.

13) HORN BUTTON


(1) If you press the button on the top of the multifunction switch, the
Horn button
horn will sound.

73033CD28A

14) CAB LAMP SWITCH


(1) This switch turns ON the cab room lamp.

73033CD24

7-36-4
15) KICK DOWN SWITCH
Kick down switch (1) Manual mode
It is effective 2nd speed to 1st speed only and recover to 2nd speed
quickly when push the switch one more time.
(2) Automatic mode
Η Mode 1(Down/Up)
It shifts down quickly from current gear to one step lower speed by
77073CD108
pushing the switch and recover to original speed quickly when push
the switch one more time.
Θ Mode 2(Down)
It shifts down from current gear to one step lower speed when push
the switch every time.
ö Refer to page 7-29,33.

16) MULTI FUNCTION SWITCH


O J Ɇ ɇ (1) Front wiper and washer switch
Η When the switch is in J position, the wiper moves intermittently.
Θ When placed in Ɇ or ɇ position, the wiper moves continuously.
Ι If you push the grip of the lever, washer liquid will be sprayed and
the wiper will be activated 2-3 times.
73033CD29
ö Check the quantity of washer liquid in the tank. If the level of
the washer liquid is LOW, add the washer liquid (In cold, winter
days) or water. The capacity of the tank is 1 liter.

Up (2) Dimmer switch


Η This switch is used to turn the head lights direction.
M
Θ Switch positions
Down ÂUp : To flash for passing
ÂMiddle : Head lights low beam ON
73033CD30 ÂDown : Head lights high beam ON
Ι If you release the switch when it's in up position, the switch will
return to middle.

Left turning (3) Turning switch


Η This switch is used to warn or signal the turning direction of the
machine to other vehicles or equipment.
Θ Push the lever up for turning left, pull the lever down for turning
Right turning right.
73033CD31

7-36-5
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION

Part name Symbol Specifications Check

※ Check specific gravity


12V × 200Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging

Rated load : ※ Check coil resistance


24V Normal : About 50Ω
Battery relay 100A(Continuity) ※ Check contact
1000A(30seconds) Normal : ∞Ω
CR-1

※ Check disconnection
2 Normal : 0Ω
Fusible link 1 24V 60A (Connect ring terminal and
CN-60 check resistance between
terminal 1 and 2)

H BR ACC ST C ※ Check contact


23 56
H 0 I II 4 OFF : ∞Ω(For each
terminal)
0, I
Start key 1
B - ON : 0Ω(For terminal 1-3)
1 2 3 4 5 6 ∞Ω(For terminal 1-5)
START : 0Ω(For terminal 1-3
CS-2
and 1-5)

1
Pa
2 ※ Check contact
Pressure switch N.C TYPE Normal : 0Ω(CLOSE)
CD-3 CD-26
CD-39 CD-41

1
※ Check contact
Pressure switch 2 Pa N.O TYPE
Normal : ∞Ω(OPEN)
CD-4 CD-40
CD-5 CD-52

7-38
Part name Symbol Specifications Check

1 ※ Check resistance
Solenoid valve 2 24V 1A Normal : 15~25Ω
(For terminal 1-2)
CN-137

Pa Pressure :
Air cleaner ※ Check contact
pressure switch 635mmH2O
Normal : ∞Ω
(N.O TYPE)
CD-10

2 ※ Check LED lamp


Parking
1 24V 1.2A ※ Check Resistance
solenoid
About 24Ω
CN-71

1
※ Check resistance
Reed switch :
Fuel sender 2 Full : About 30Ω
Magnetic type
CD-2 Low level : About 300Ω

1 2 1

2 ※ Check resistance
3 Normal : About 200Ω
Relay 4 4 3 24V 20A (For terminal 1-3)
(4pin)
AC RY(H1)
CR-2 ACAC
CR-26 RY(H2)
RY1 : ∞Ω
CR-35
CR-5 CR-42
CR-30CR-3
AC RY2 (For terminal 2-4)
CR-6 CR-7 CR-46
CR-2

※ Check resistance
30
86
87a 87 85 Normal : About 160Ω
87 (For terminal 2-6)
Relay 85 24V 20A : 0Ω
(5pin) 87a 30 86
(For terminal 1-3)
CR-4 CR-5 CR-26 : ∞Ω
CR-30 CR-40 CR-41
(For terminal 1-3)

7-39
Part name Symbol Specifications Check

1 B
3 E
Proximate
4 S 24V 400mA
switch
CN-100 CN-101

1 ※ Check resistance
Hydraulic
2 Normal : ∞Ω
temperature
105°C over : 0Ω
CD-1

※ Check contact
Normal : 1.12Ω
1 Lo 1 (For terminal 2-4)
2 MH 3
Aircon resistor ML 2
: 2.07Ω
3
4 Hi 4 (For terminal 3-4)
: 3.17Ω
(For terminal 4-1)

1
※ Check resistance
Speaker 2 4Ω 20W
Normal : 50Ω
CN-23(LH)
CN-24(RH)

10 9 8 7 6 5 4 3 2 1
10 6 5
※ Check contact
OFF : ∞Ω
Switch
24V 8A (for terminal 1-5, 2-6)
(Locking type) 9 8 2 7 1
: 0Ω
CS-17 CS-23
CS-23 CS-34
CS-42
CS-41 CS-42
CS-21 CS-41 CS-51
CS-54 (for terminal 5-7, 6-8)

10 9 8 7 6 5 4 3 2 1

Switch 10 4 1 ※ Check contact


(Non-locking 24V 8A OFF : ∞Ω
type) 9 2 75 (for terminal 2-4, 1-7)
CS-3 CS-34 CS-39

7-40
Part name Symbol Specifications Check

1 Work lamp
Work lamp, 24V 70W
2
Room lamp, ※ Check disconnection
CL-1 CL-6 Number plate lamp
Number plate CL-1 CL-6 CL-22
CL-22 Normal : A fewΩ
CL-5
CL-5 CL-21
CL-21CL-23
CL-23 Room lamp
lamp
CL-24 CL-25 CL-30 24V 10W

M 24V 70W ※ Check disconnection


Beacon lamp
(H1 TYPE) Normal : A fewΩ
CL-7

24V A
24V
DC/DC GND B ※24V (A-B)
12V 3A
Converter 12V 12V (B-C)
12V C

※ Check operation
22-28V 2A
Horn Supply power(24V) to each
110dB
CN-20 CN-25 terminal and connect ground

2 PA
1 ※ Check contact
Receiver dryer 24V 2.5A
Normal : ∞Ω
CN-29

1 S.L+
2 ACC
3 N.C
4 S.R+ ※ Check resistance
5 N.C
Cassette radio 6 S.L- 24V 20W+20W Power ON : 4Ω+4Ω
7 B+
8 S.R- (for terminal 1-6, 4-8)
9 N.C

CN-27

7-41
Part name Symbol Specifications Check

24V 0.5A
Back up buzzer -
110dB
CN-65

M 1 ※ Check contact
Washer pump 2 24V 2.5A Normal : 26.4 Ω
(for terminal 1-2)
CN-103 CN-22
1 2 3 4 5 6

24V 1.5A
Hi
Wiper motor E M Lo
2-speed -
Auto parking
CN-102 CN-21

B
A
Cigar lighter 24V 5A -
1

CL-2

B+ G
3
I ※ Check voltage
Alternator U 20V 60A
GND Normal : 24~28V
CN-74

Delco Remy
Starter ※ Operating or not
B+ M 28MT 24V

CN-45

7-42
Part name Symbol Specifications Check

1
Aircon ※ Check contact
24V 79W
compressor Normal : 13.4Ω
CN-28

2 ※ Check contact
Start relay 1 24V 200A
Normal : 11.3Ω
CR-23

M 1 24V 9A
Blower -
2 2900±150rpm

※ Check resistance
1 Normal : 0 Ω
1°C OFF
Duct sensor (for terminal 1-2),
2 4°C ON
the atmosphere temp:
over 4°C

※ Check resistance
Door switch 24V 2W
Normal : About 5MΩ
CS-1 CS-55

3 E
G 24V
2 B
Flasher unit 85 ~ 190 C/M -
1 L
50dB
CR-11

7-43
Part name Symbol Specifications Check

1 Lo
2 Hi 24V 75W/70W
(H4 TYPE) ※ Check disconnection
Head lamp 3 E
24V 4W Normal : A few Ω
4 C (T4W)
CL-3 CL-4

4 C
24V 5W
3 T
(R5W)
Combi lamp 2 E -
1 S
2×24V 21W
(P21W)
CL-15 CL-16

1
24V 21W
Turn lamp 2 -
(P21W)
CL-24 CL-25

Continuous
capacity :
Master switch 180Amp -
Push in capacity :
1000Amp

2
24V 200mA
Warning buzzer 1 -
90±5dB(ℓm)
CN-26

1 ※ Check contact
5 BL- BL+ 1
2
6 BK- BK+ 2 Normal : 80~90Ω
3
7 FL- FL+ 3
4 (For terminal 1-5, 2-6
Joy stick lever -
5 3-7, )
6
4 8
7 : ∞Ω
8 CN-114 (For terminal 4-8)

7-44
GROUP 5 CONNECTORS

1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 58 2 I/conn(Frame harness-Main harness) S813-030200 S813-130200
CN-2 AMP 15 I/conn(Frame harness-Main harness) 2-85262-1 368301-1
CN-3 AMP 15 I/conn(Frame harness-Main harness) 2-85262-1 368301-1
CN-4 SWP 12 I/conn(Frame harness-Engine harness) S816-012002 S816-112002
CN-5 AMP 15 I/conn(Cab harness-Main harness) 2-85262-1 368301-1
CN-6 AMP 15 I/conn(Frame harness-Main harness) 2-85262-1 368301-1
CN-8 SWP 12 I/conn(Front harness-Main harness) S816-012002 S816-112002
CN-10 SWP 12 I/conn(Front harness-Main harness) S816-012002 S816-112002
CN-11 DEUTSCH 8 I/conn(Main harness-Aircon harness) DT06-8S -
CN-12 AMP 15 I/conn(Frame harness-Engine harness) 2-85262-1 368301-1
CN-14 AMP 15 I/conn(Frame harness-Main harness) 2-85262-1 368301-1
CN-20 Molex 2 Horn 36825-0212 -
HW090
CN-21 sealed 6 Front wiper motor 6189-01330 -
CN-22 SWP 2 Front washer tank S814-002000 -
CN-23 YAZAK1 2 Speaker(LH) 7123-1520 -
CN-24 YAZAK1 2 Speaker(RH) 7123-1520 -
CN-25 Molex 2 Horn 36825-0212 -
CN-26 250 2 Warning buzzer S810-002202 -
CN-27 PA 9 Cassette and radio S811-009003 -
CN-28 - 1 Comp(Air-con) NMWP01F-B -
CN-29 KET 2 Receiver drier MG640795 -
CN-36 - - Fuse box 24L1-04100 -
CN-45 Ring term - Starter S820-414000 -
CN-51 - 13 Cluster 172498-1 -
CN-52 AMP 68 T/M Control unit 962175 -
CN-53 - 6 Diagnostic - 1-408705-0
CN-58 Econo seal 36
III Controller 344111-1 -
CN-60 58 2 Fusible link - S813-130200
CN-65 Shur 1 Back up buzzer S822-014000 -
CN-71 J 2 Parking solenoid DT06-2S -
CN-74 Ring term - Alternator S820-105000 -
CN-75 AMP 2 Fan clutch 85202-1 -
CN-83 MWP 2 Aircon fan PH805-02028 -
CN-96 PACKARD 2 Fuel heater 1530-0027 -

7-45
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-100 Autonics - Boom kick out 21L6-20020 -
CN-101 Autonics - Bucket leveler 21L6-20020 -
HW090
CN-102 sealed 6 Rear wiper motor 6189-01330 -
CN-103 SWP 2 Rear washer tank S814-002000 -
CN-110 - 2 Joy stick 1-480698-0 -
CN-114 - 6 Joy stick 1-480704-0 -
CN-121 PACKARD 4 Gear shift lever - 1201-0974
CN-122 PACKARD 4 Gear shift lever 1201-5797 -
CN-136 - 2 Ride control valve DT06-2S-P012 -
CN-137 - 2 Ride control solenoid DT06-2S-P012 -
CN-138 DEUTSCH 3 DC/DC Converter DT06-3S -
CN-139 DEUTSCH 2 12V socket - DT04-2P
CN-144 J 6 Pedal S816-006002 -
Relay
CR-1 Ring term - Battery relay S820-104000 -
CR-2 250 4 Horn relay S810-004202 -
CR-3 250 4 Front work lamp relay S810-004202 -
CR-4 250 6 Wiper relay S810-006202 -
CR-5 250 2 Safety relay S810-006202 -
CR-6 250 4 Rear work lamp relay S810-004202 -
CR-7 250 4 Aircon relay S810-004202 -
CR-11 250 3 Flasher unit S810-003702 -
CR-23 J 2 Start relay S814-102001 -
CR-24 - 1 Preheater relay S822-014000 -
CR-30 250 4 Back-up relay S810-004202 -
CR-35 250 4 Ride control relay S810-004202
CR-42 250 4 Preheater relay S810-004202 -
CR-46 250 4 Fuel warmer relay S810-004202 -
Switch -
CS-1 - 1 Door switch S822-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-3 SWF 10 Rear wiper switch 593757 -
CS-5 Shur 1 Horn switch S822-014000 -
CS-11 SWP 8 Multi function switch S814-008000 -
CS-12 SWP 6 Multi function switch S814-006000 -
CS-17 SWF 10 Parking switch 593757 -
CS-20 SWF 10 Work lamp switch 593757 -

7-46
Connector No. of Connector part No.
Type Destination
number pin Female Male
CS-23 SWF 10 Beacon switch 593757 -
CS-34 SWF 10 Buzzer stop switch 593757 -
CS-39 SWF 10 Illumination and head lamp switch 593757 -
CS-41 SWF 10 Hazard switch 593757 -
CS-42 SWF 10 Clutch cut off switch 593757 -
CS-50 SWF 10 Ride control switch 593757 -
CS-51 SWF 10 Auto/manual switch 593757 -
CS-53 SWF 10 Steering pump switch 593757 -
Light
CL-1 - 2 Room lamp MG610392 -
CL-2 250 3 Cigar lighter S810-003202 -
CL-3 SWP 4 Head light(LH) S814-004000 -
CL-4 SWP 4 Head light(RH) S814-004000 -
CL-5 SWP 2 Work light(LH) S814-002000 -
CL-6 SWP 2 Work light(RH) S814-002000 -
CL-7 250 1 Beacon lamp S810-001202 -
CL-15 SWP 4 Combi lamp(RR, LH) S814-004000 -
CL-16 SWP 4 Combi lamp(RR, RH) S814-004000 -
CL-21 - 1 Numberplate lamp 170183-2 -
CL-22 DEUTSCH 2 Work light(LH) DT04-2P -
CL-23 DEUTSCH 2 Work light(RH) - DT04-2P
CL-24 SWP 2 Turn lamp(LH) S814-002000 -
CL-25 SWP 2 Turn lamp(RH) S814-002000 -
Sensor, sender
CD-1 AMP 2 Hyduaulic oil temo sendor 85202-1 -
CD-2 SWP 2 Fuel sendor S814-002000 -
CD-3 Rubber cap - Brake fail pressure switch 21EA-003100 -
CD-4 Rubber cap - Stop lamp pressure switch 21EA-003100 -
CD-5 Rubber cap - Clutch cut off pressure switch 21EA-003100 -
CD-10 Ring term 2 Air cleaner switch S820-105000 -
CD-15 AMP 2 Converter sensor 85202-1 -
CD-17 AMP 2 Engine pick-up sensor 85202-1 -
CD-26 Rubber cap - Parking pressure switch 21EA-003100 -
CD-27 AMP - Turbin pick up sensor 85202-1 -
CD-35 PACKARD 2 Fuel fiter 1204-0753 -
CD-39 Rubber cap - Steering pressure switch 21EA-00310 -

7-47
Connector No. of Connector part No.
Type Destination
number pin Female Male
CD-40 Rubber cap 2 Steering pump pressure switch 21EA-00310 -
CD-51 - 3 Output speed sensor 282087 -
CD-52 AMP 2 Oil filter 282080 -

7-48
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

1 1

S813-030100 S813-130100

1 2
1 2

S813-030200 S813-130200

7-49
2) PA TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

2 5 1 3

1 3 2 5
S811-005002 S811-105002

3 7 1 4

1 4 3 7
S811-007002 S811-107002

4 9
1 5

1 5
4 9
S811-009002 S811-109002

5 11 1 6

11

1 6 5 11
S811-011002 S811-111002

7-50
No. of
Receptacle connector(Female) Plug connector(Male)
pin

6 13 1 7

13

1 7 6 13
S811-013002 S811-113002

1 9
8 17

17

1 9 8 17
S811-017002 S811-117002

10 21 1 11

21

1 11 10 21
S811-021002 S811-121002

7-51
3) J TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

1 1

2 2
S816-002001 S816-102001

2 3 1

3 1 2
S816-003001 S816-103001

7-52
4) SWP TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

1 1

S814-001000 S814-101000

2 1

1 2
S814-002000 S814-102000

3 1

2 1 23

S814-003000 S814-103000

2 4 1 3

1 3 2 4
S814-004000 S814-104000

7-53
No. of
Receptacle connector(Female) Plug connector(Male)
pin

3 6 1 4

3 6
1 4
S814-006000 S814-106000

4 8 1 5

4 8
1 5
S814-008000 S814-108000

4 12 1 9

12

4 12
1 9

S814-012000 S814-112000

3 14 11
1

14

1 11 3 14
S814-014000 S814-114000

7-54
5) CN TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin

1 1

S810-001202 S810-101202

2 2

1 1

S810-002202 S810-102202

3 2

1 2 1 3

S810-003202 S810-103202

2 4 1 4

1 3 2 3

S810-004202 S810-104202

7-55
No. of
Receptacle connector(Female) Plug connector(Male)
pin
3 6 1 4

1 4 3 6
S810-006202 S810-106202

4 8 1 5

1 5 4 8
S810-008202 S810-108202

7-56
6) ITT SWF CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)

2
10

1 10

9
SWF593757

7) HW090 SEALED CONNECTOR


No. of
pin Receptacle connector(Female) Plug connector(Male)

6 3

4
6

6189-0133

8) MWP02F-B CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)

2 1

2
PH805-02028

7-57
9) AMP ECONOSEAL CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)

1
12

1
24 13

36
36
13 25 12
24
25
36
344111-1 344108-1

7-58
GROUP 6 TROUBLESHOOTING

1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.26 is not blown out and ON/OFF of bulb.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace
Check voltage
YES
between CN-51
(1, 2) and chassis

NO Disconnection in Repair or replace


wiring harness or (After clean)
Check voltage
poor contact
between CN-12
(1) and chassis between
CN-51(1, 2) and
CN-12(1)

NO
Disconnection in Repair or replace
wiring harness or (After clean)
poor contact
between CN-12(1)
and fuse No.26

CLUSTER
1
FUSE
2 1
NO.26
CN-51
CN-12

Check voltage
YES 20 ~ 30V
NO 0V 7707EL22

7-59
2. WHEN BATTERY LAMP LIGHTS UP(Engine is started)
・Before carrying out below procedure, check all the related connectors are properly inserted.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective controller Replace
Check voltage
YES
between CN-58
(25) and chassis
NO Disconnection in Repair or replace
Voltage : 27.5~30V wiring harness or (After clean)
poor contact
Check voltage between CN-58
YES between CN-3(4)
(25) and CN-3(4)
and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact
between CN-4(8) between CN-4(8)
NO
Check voltage and chassis and CN-3(4)
between
alternator terminal Disconnection in Repair or replace
"I" and chassis NO
wiring harness or (After clean)
Voltage : 26~30V poor contact
Starting switch : ON
between CN-4(8)
and alternator
terminal " I "

Defective alternator Replace


NO

CONTROLLER

ALTERNATOR
25 4 8 " I " TERMINAL
CN-3 CN-4
CN-58

Check valtage
YES 20 ~ 30V
NO 0V 7707EL23

7-60
3. WHEN PARKING SOLENOID DOES NOT WORK
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.8 is not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective parking Replace
Check voltage brake solenoid
between CN-71
(2) and chassis YES
Defective parking
Check voltage
Starting switch : ON switch
Parking switch : ON-OFF NO
between CS-17
Voltage : 20~30V (6) and chassis
Disconnection in
Voltage : 20~30V NO
wiring harness or
poor contact
between CS-17(6)
and Fuse No.8

PARKING SWITCH
8 2
1
5
CN-71
6
CS-17 FUSE

No.8

7707EL24

7-61
4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.17(T/M controller) and No.8 are not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective T/M Replace
controller

Check voltage YES


Disconnection in Repair or replace
between CN-52
wiring harness or (After clean)
(21) and chassis
poor contact
Starting switch : ON Check voltage between CN-52
Parking switch : ON between CS-17
Voltage : 20~30V NO (21) and CS-17(7)
(7) and chassis
YES
Voltage : 20~30V Defective switch Replace
Parking switch : ON Check voltage
between CS-17
NO
(5) and chassis
Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.8

PARKING SWITCH
FUSE
6
5 No.8
7
CS-17 21

CN-52

Check resistance
YES MAX 1Ω
7707EL25
NO MIN 1MΩ

7-62
5. MACHINE DOES NOT TRAVEL
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.17(Transmission controller) is not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.
・Wiring diagram : See page 7-17.
Cause Remedy
YES
Defective clutch Replace
cut-off switch
Check resistance
YES
between CD-5
and chassis

NO Is there continuity Defective T/M Replace


between CN-52 NO
(66) and chassis? controller

NO
Defective T/M Replace
Is voltage between
controller
CN-52(21) and
chassis 20-28V? YES
Defective parking Replace
Starting switch : ON
Parking switch : OFF
switch
Clutch cut-off Is there continuity
switch : ON between CS-17(7)
YES
and chassis?

Disconnection Repair or replace


NO
wiring harness or (After clean)
poor contact
between CN-52
(21) and CS-17(7)

Check resistance
YES MAX 1Ω
NO MIN 1MΩ

7-63
6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.9 is not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.
CONTROLLER

HYD TEMP SENDER


CLUTCH CUT-OFF PS
SERIAL-L

SPEEDMETER SIG.

RIDE CONT. AUTO


COOLANT SIG
SAFETY RY

BUZZER STOP
WIPER RY
STEERING RY

ALT LEVEL
FUEL SENSOR
PREHEATER

WASH SIG
NEUTRAL SIG

CAN-H
AUTO SEL.TCU
REMOTE FAN(+)

CAN-L
REMOTE FAN(-)

STEERING PS

CLUTCH CUT-OFF SW

STEERING P/P PS
ENG OIL PS

TACHO +

RIDE CONT. ON
WIPER INT SIG

PARKING SIG
SERIAL-H

GND
BUZZER

AUTO SEL.SW

BRAKE PS
TAHCO -

AIR FILTER
IG 24V
Cause Remedy FUSE BOX
BEACON LAMP 20A
YES ILL.LAMP 10A
1

Check voltage Defective front Replace 2


HEAD LAMP 20A

23
35
34

24
36

31

26
32

25
33

27

21
20
30
29
28

22

17
19

11
18

16

12

10
13
15
14

1
2
3
6
8

4
5
7
9
YES between front wiper motor BACK/STOP LAMP 10A
3

M30 0.85 Y

M27 0.85 R
CN-58

M22 0.85 Gr
wiper motor and HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
chassis Poor connection of Replace 6

Check voltage Voltage : 20~30V


NO CIGAR 20A

YES chassis SWITCH 10A


7

between CN-21(5) Starting switch : ON F/R WIPER


8
M14 1.25 L 20A
Wiper switch : 1st 9
and chassis WORK LAMP 30A
10

CN-36
Voltage : 20~30V
Starting switch : ON Disconnection in Repair or replace WIPER RY LO
Check voltage Wiper switch : 1st NO M46 0.85 R
30
YES between CS-12 wiring harness or (After clean) M45A 0.85 W
86
87a 87 85
M45 0.85 W
(4), CN-7(10) and poor contact M22 0.85 Gr
87
85
chassis between CN-7(10) M39 0.85 G
87a 30 86
CR-26
Voltage : 20~30V and CN-21(5),
Starting switch : ON
Wiper switch : OFF CN-13(5)
WIPER RY HI
M14A 0.85 L
30
Defective wiper Repair or replace M38 0.85 Br 87a 87 85
NO M49 0.85 G
86
switch or (After clean) G25 1.25 B
87
85
Check voltage disconnection in M45B 0.85 W
87a 30 86

CS-12(6) wiring harness or CR-4

poor contact
Voltage : 20~30V between CS-12(4)
Starting switch : ON

M27A 0.85 R
M14D 1.25 L
and CN-7(10).

M38 0.85 Br
M39 0.85 G

M30 0.85 Y
Wiper switch : 1st
YES
Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact
between CN-7(8) between CS-7(8)

CN-7
10
11
12
13
14
6
7

9
8

M45C 0.85 W
NO

M49 0.85 G
M46 0.85 R
G51 1.25 B
and chassis. and fuse No.9

Discomection in Repair or replace

CS-11

CS-12

CS-5
NO

6
5
4
3
2
1
8
7
6
5
4
3
2
1

CN-13
wiring harness or (After clean)

10
11
12
13
14
1
2
3
4
5
6
7
8
9
BWG 4
poor contact

RW 6
W6

BVi 3
L 4
G 5

BY 1

Gr 2

Y
M40 0.85 VOr
between CS-12(6)

HO
W
II
and CN-7(8).

I
Hi

C
J 0

J
C

CN-21
1
2
3

5
4

6
0
II
I
Lo
Hi

5 Lo
4 Hi
3E
B+

2Pf
1B
F

R
L
O

R
L

M
7 Y Lo
8 WB

2 BW

3 BG
MULTI FUNCTION SWITCH 5B FRONT WIPER

7707EL26

7-64
7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
・Before carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.16 is not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
FUSE BOX
YES
Defective cable Repair or replace RADIO/ROOM LAMP 5A
14

Check voltage (After clean)


15
YES assembly M04 1.25 Or START KEY 30A
16
between CN-60(2) TCU 10A
17
and chassis ECM 10A
18
Short circuit or Replace CLUSTER 10A
19
Voltage : 20~30V NO AC & HEATER 10A
Check voltage defect of fusible SPARE 10A
20
YES 21
between CR-1 link or defective ECM 5A
22
RCV 10A
(R1) and chassis 23
battery relay CONTROLLER 10A
24
Voltage : 20~30V TCU 10A
25
CLUSTER 10A
26
Disconnection in Replace ILL,F/L,R/R 5A
27
NO ILL.F/R,R/L 5A
Check voltage wiring harness or 28

YES between CS-2 CN-36


(1)[and CS-2(2)] poor contact F21 3.0 W

and chassis between CS-2(2) - BATTERY MASTER SW


BATT RY
Voltage : 20~30V R4 B G

CN-3(6)-CR-1 F23C 1.25 L R1

G79 1.25 B TO STARTER


(R1) R2
R3
CS-0
CR-1
F22 5.0 R
2 2
F21 3.0 W
Disconnection in Replace 1 1
Check voltage NO CN-1 CN-60
wiring harness or
and specific
gravity of battery poor contact
between fuse No.
Specific gravity : MIN 1.28
Voltage : MIN 24V 16 and CS-2(1) or
1
F23 1.25 L
defect of start 2 2
3 F12 1.25 V
1
switch 4 DO-1
5
6

M04B 1.25 Or
Repair or replace

F12 0.85 V
Battery capacity 7
NO 8
too low (After clean) 9
10
11

CS-2
12

5
4

1
6

2
3
13
B 14
0, I

1
15
CN-3
H 0 I II

4
6
5

3
2
H
C ST ACC BR
START SWITCH

7707EL27

7-65
8. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
・Before carrying out below procedure, check all the related connectors are properly inserted, and the
fuse No.10 is not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified. FUSE BOX
BEACON LAMP 20A
1
M17 1.25 OrW ILL.LAMP 10A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
Cause Remedy AIR-CON/HEATER 20A
6
YES CIGAR 20A
Defective lamp Replace SWITCH
7
Check voltage 10A
8
YES between each F/R WIPER 20A
9
M10 1.25 Gr WORK LAMP 30A
lamp and chassis OPTION
10
Disconnection in Repair or replace 10A
11
NO
Voltage : 20~30V wiring harness or (After clean) CN-36
Check voltage Starting switch : ON poor contact
YES between CN-5(4), between CL-6(2),
CN-3(10) and CL-5(2), CL-22(1),
chassis CL-23(1) and CN-
Voltage : 20~30V 5(4), CN-3(10). 1
Starting switch : ON 2 FRONT WORK
FR WORK LAMP RY 3 LAMP,LH
C03A 1.25 Or
Check voltage Disconnection in Repair or replace 3 4 4
C03 1.25 Or
4
C03 1.25 Or
2
M51 0.85 W G11 1.25 B
YES between CR-3(4), NO 3 5 G01 1.25 B 1
wiring harness or (After clean) 2
M10A 1.25 Gr 6 CL-6
CR-6(4) and poor contact 1 2 1
G21 1.25 B 7
FRONT WORK
8
chassis between CN-5(4) -
CR-3 9 C03B 1.25 Or
LAMP,RH
2
10 G12 1.25 B
Voltage : 20~30V 1
Starting switch : ON
CR-3(4) and CN- 11
CL-5
12
3(10) - CR-6(4) 13
Check voltage 14
15
between CR- Defective work Replace relay CN-5
3(2), CR-6(2) and NO
lamp relay
chassis RR WORK LAMP RY
F14 1.25 Br 1
YES 3 4 4 2
Voltage : 20~30V Disconnection in Repair or replace 3
M52 0.85 L
3
Starting switch : ON M10B 1.25 Gr REAR WORK
2
wiring harness or (After clean) G22 1.25 B
4
5 F14A 1.25 Br
LAMP,LH
1 2 1 1
Check voltage poor contact CR-6 6 G19 1.25 B
2
7
between CR-3(2), 8 CL-22
between fuse No.
NO CR-6(2) and fuse WORK LAMP SW
G13 0.85 B
9 F14 1.25 Br
10 and chassis 9 10 10
10
No.10 9 C05F 0.85 R 11
4 8 12 REAR WORK
Voltage : 20~30V 2 M59 0.85 Y 13 F14B 1.25 Br
LAMP,RH
7
Starting switch : ON 14 1
Short circuit of fuse Replace 7 1 6
15
G17 1.25 B
2
NO 5 5 M51 0.85 W
C05G 0.85 R CN-3 CL-23
4
3
M52 0.85 L

II I 0
2 CLUSTER
1 C05H 0.85 R 20 TX-PC
CS-20 19 GND
17 ILL.
CS-39
16 T/M ERROR
15 SERIAL-L
9 10 10 14 SERIAL-H
9 12 12 GND
4 8 11 GND
2 C05C 0.85 R 11
7 10 RX-PC
10 9 FWE
7 1 6 9
5 M59 0.5 Y 8 N.C
5 WORK LAMP
8 7
4 7 6 HIGH BEAM
3 6 5 RH TURN

II I 0
2 4 LH.TURN
M17 1.25 OrW 5 3 24V PER.
1
4 2 24V IG
ILL & HEAD LAMP SW : ON(1st step) 3 1 24V IG
2 CN-51
1
CN-12

7707EL28

7-66
9. WHEN ENGINE DOES NOT START
・Check supply of the power at engine stop solenoid while starting switch is ON. CONTROL UNIT
・Before carrying out below procedure, check all the related connectors are properly inserted.
・After checking, connect the disconnected connectors again immediately unless other wise specified.

VMGA2

ADM5
・Check forward reverse switch at neutral position.

VPE2
AIP6
AIP4
AIP1

ED1
ED5
ED2
ED9
ED6
EF4
VPI
45
46
51
55
56
57
62
63
64
65
66
67
68
FUSE BOX
Cause Remedy CN-52

T37 0.85 W
A 14
VM OUTPUT SIGNAL K RADIO/ROOM LAMP 5A
YES VP F B N D B 15
Defective battery Check engine ED 1 2 3 4 1 2 3 4 1 2 3 4 C START KEY 30A
16
AD1 B1 D TCU 10A
system charge or AD2 B2 CN-121 ECM 10A
17
AD3 B3 18
replace (after AD4 V CLUSTER 10A
19

M01 1.25 WOr


1
checking specific AD5 R A
SAFETY RY AC & HEATER 10A
20
AD6 AS B 2 M43 1.25 R
gravity of battery) AD7 C 3 30 SPARE 10A
21
85
YES A AD3 D 4
T37C 0.85 W
86 87a 87 ECM 5A
Check voltage Defective magnet Replace CN-122 5 E05 0.85 R
87 RCV 10A
22

Check operation YES between starter of start motor


B AD2
C AD1 6 M21 0.85 L
85 CONTROLLER 10A
23

7 24
of start motor magnet coil and X1
D AD7(KD)
8
87a 30 86 TCU 10A
25
CR-5
chassis Defective start Replace
A ED1(VP) 9 CLUSTER 10A
26
Starting switch : start NO D AD6 10 ILL,F/L,R/R 5A
Starting switch : start relay B AD4 11 27
ILL.F/R,R/L 5A
C AD5 12 28
X2
13
YES CN-36
ⓐ 14
CN-13
Check operation Check voltage
NO of starter relay YES
between CR-5
(87) and chassis
Starting switch : start
Disconnection in Replace
Starting switch : OFF NO
wiring harness or
Check operation poor contact
of start safety between CN-2(11)
NO
relay and CR-5(87)
Check switch : neutral YES
Defective relay Replace
Check voltage
between CR-5 STARTER
NO TO BATT
(86) and chassis B+

Starting switch : OFF NO



M
YES CN-45
Defective start Replace

M01 1.25 WOr

M04B 1.25 Or
M43 1.25 R

F12 0.85 V
Check voltage relay START RY
G15 1.25 B
ⓐ between CR-23 1
E05 1.25 R
1
2 2
(2) and chassis

CS-2
3 CR-23

5
4

1
6

2
3
Disconnection in Repair or replace 4
Voltage : 20~30V NO B
Starting switch : ON wiring harness or 0, I 5 1

1
6 2
poor contact
7 3
between CN-2(11) H 0 I II
8 4

4
6
5

3
2
-CN-4(7)-CR-23(2)
H
C ST ACC BR 9 5
START SWITCH 10 6
E05 0.85 R
YES 11 7
Disconnection in Repair or replace 12 8
wiring harness or CN-2 9
10
Check voltage poor contact 11
ⓑ between CN-13 between CN-13(4) 12
(4) and chassis and CR-5(86) CN-4

Starting switch : OFF


Defective DW-3 Replace 7707EL29
NO

7-67

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